EKT730-EKT750

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
23 Tools and Aids
26 Troubleshooting
30 Air Cleaner/Intake
32 Electronic Fuel Injection (EFI) System
58 Governor System
59 Lubrication System
61 Electrical System
67 Starter System
69 Emission Compliant Systems
70 Disassembly/Inspection and Service
86 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 WARNING

Explosive Fuel can cause Hot Parts can cause High Pressure Fluids can
fires and severe burns. severe burns. puncture skin and cause
Do not fill fuel tank while Do not touch engine severe injury or death.
engine is hot or running. while operating or just Do not work on fuel
after stopping. system without proper
Gasoline is extremely flammable training or safety
and its vapors can explode if Never operate engine with heat equipment.
ignited. Store gasoline only in shields or guards removed.
approved containers, in well Fluid puncture injuries are highly
ventilated, unoccupied buildings, toxic and hazardous. If an injury
away from sparks or flames. WARNING
occurs, seek immediate medical
Spilled fuel could ignite if it comes Cleaning Solvents can attention.
in contact with hot parts or sparks cause severe injury or
from ignition. Never use gasoline death.
as a cleaning agent. WARNING
Use only in well
ventilated areas away Explosive Fuel can
WARNING from ignition sources. cause fires and severe
burns.
Rotating Parts can cause Carburetor cleaners and solvents
severe injury. are extremely flammable. Follow Fuel system ALWAYS
cleaner manufacturer’s warnings remains under HIGH
Stay away while engine PRESSURE.
is in operation. and instructions on its proper and
safe use. Never use gasoline as a
Keep hands, feet, hair, and cleaning agent. Wrap a shop towel completely
clothing away from all moving around fuel pump module
parts to prevent injury. Never connector. Press release button(s)
operate engine with covers, CAUTION and slowly pull connector away
shrouds, or guards removed. from fuel pump module allowing
Electrical Shock can shop towel to absorb any residual
cause injury. fuel in high pressure fuel line. Any
WARNING Do not touch wires while spilled fuel must be completely
engine is running. wiped up immediately.
Carbon Monoxide can
cause severe nausea,
fainting or death. CAUTION
Avoid inhaling exhaust Damaging Crankshaft
fumes. and Flywheel can cause
Engine exhaust gases contain personal injury.
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled. Using improper procedures can
lead to broken fragments. Broken
WARNING fragments could be thrown from
engine. Always observe and use
Accidental Starts can precautions and procedures when
cause severe injury or installing flywheel.
death.
Disconnect and ground CAUTION
spark plug lead(s) before
servicing. Failure to utilize or
reassemble debris
Before working on engine or screen as designed could
equipment, disable engine as result in debris screen
follows: 1) Disconnect spark plug failure and serious
lead(s). 2) Disconnect negative (–) personal injury.
battery cable from battery.

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 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
Disconnect and ground spark plug lead(s) negative (–) battery cable from battery.
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

Every 25 Hours¹
● Service/replace precleaner. Air Cleaner/Intake
● Replace LPAC element (if not equipped with precleaner). Air Cleaner/Intake

Every 50 Hours¹
● Replace LPAC element (if equipped with precleaner). Air Cleaner/Intake
● Replace high performance air cleaner element (if not equipped with precleaner). Air Cleaner/Intake

Every 75 Hours¹
● Replace high performance air cleaner element (if equipped with precleaner). Air Cleaner/Intake
● Replace PRO performance air cleaner element (if not equipped with precleaner). Air Cleaner/Intake

Every 100 Hours¹

● Replace PRO performance air cleaner element (if equipped with precleaner). Air Cleaner/Intake
● Change oil and filter. Lubrication System
● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake

Every 100 Hours

● Check that all fasteners are in place and components are properly secured. Reassembly

Every 200 Hours¹

● Replace unique EFI fuel filter.

Every 500 Hours²

● Have valve lash checked/adjusted. Reassembly

Every 500 Hours

● Replace spark plugs and set gap. Electrical System
¹ Perform these procedures more frequently under severe, dusty, dirty conditions.
² Have a Kohler authorized dealer perform this service.

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).

32 690 12 Rev. -- KohlerEngines.com 3

Maintenance

OIL RECOMMENDATIONS STORAGE

We recommend use of Kohler oils for best performance. If engine will be out of service for 2 months or more
Other high-quality detergent oils (including synthetic) follow procedure below.
of API (American Petroleum Institute) service class SJ 1. Add Kohler PRO Series fuel treatment or equivalent
or higher are acceptable. Select viscosity based on to fuel tank. Run engine 2-3 minutes to get stabilized
air temperature at time of operation as shown in table fuel into fuel system (failures due to untreated fuel
below. are not warrantable).
2. Change oil while engine is still warm from operation.
10W-30 Remove spark plug(s) and pour about 1 oz. of
engine oil into cylinder(s). Replace spark plug(s) and
crank engine slowly to distribute oil.
SAE 30
3. Disconnect negative (–) battery cable.
5W-30 4. Store engine in a clean, dry place.
°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.

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 Specifications

Engine Dimensions with Low Profile Air Cleaner-Flywheel Side

D
C

I
F K
D
G J
H

A 140.4 mm (5.53 in.) B 423.0 mm (16.65 in.) C 147.4 mm (5.80 in.) D 89.8 mm (3.54 in.)
Oil Fill and Dipstick Fuel Line
E 50.1 mm (1.97 in.) F G H 154.4 mm (6.08 in.)
(Yellow) Connection Point
7.0 mm (0.28 in.) 45.3 mm (1.78 in.)
I Mounting Hole "A" J K 317.9 mm (12.52 in.) L
Center of Gravity Center of Gravity

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Specifications

Engine Dimensions with Low Profile Air Cleaner-Oil Filter Side

A J
B
I

C
H
G
D
E F D

355.1 mm (13.98 in.) 329.1 mm (12.96 in.) 159.4 mm (6.28 in.) Engine Mounting
A Air Cleaner B C D
Top of Air Cleaner Center of Gravity Surface
Removal
134.0 mm (5.28 in.)
80.3 mm (3.16 in.) 51.2 mm (2.02 in.)
E F Mounting Hole "A" G H Spark Plug
Oil Filter Oil Filter Center Line
380.7 mm (14.99 in.)
I 340.9 mm (13.42 in.) J Optional Fixed Guard

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 Specifications

Engine Dimensions with Low Profile or High Performance Air Cleaner-Engine Mounting Surface (PTO End)

A
B B C
D

F H

G
T

S
J
I

R K

N
Q O
K K M
P
L

48.1 mm (1.89 in.)

A 334.3 mm (13.16 in.) B 72.8 mm (2.87 in.) C 94.3 mm (3.71 in.) D Evap Connection
Point
4 X 5/16-18
UNC-2B in. 268.3 mm (10.56 in.)
50.0 mm (1.97 in.)
E 16.5 mm F 30° G H Evap Connection
Exhaust Port #2
(0.649 in.) Deep Point
No Studs
18.0 mm (0.71 in.)
I 242.1 mm (9.53 in.) J 104.0 mm (4.10 in.) K 89.8 mm (3.54 in.) L Oil Filter
Removal
248.1 mm (9.77 in.)
M 116.8 mm (4.60 in.) N Mounting Hole "A" O Rotation Direction P Starter Stud
4 X 9.005 mm
(0.355 in.) 312.0 mm (12.28 in.)
37 mm (1.46 in.) 93.1 mm (3.66 in.) Throttle and 50.0 mm (1.97 in.)
Q R S T
Deep on a Ø Starter Stud Choke Cable Exhaust Port #1
254 mm (10.0 in.) Mounting Surface
B.C.

32 690 12 Rev. -- KohlerEngines.com 7

Specifications

Engine Dimensions with Low Profile, High Performance, or PRO Performance Air Cleaner-Starter Side

G
F
A

B D

C E

55.8 mm (2.20 in.)

A B 13.0 mm (0.51 in.) C Mounting Hole "A" D 40.8 mm (1.61 in.)
Starter Stud
154.0 mm (6.06 in.)
Engine Mounting 72.0 mm (2.83 in.) 92.0 mm (3.62 in.)
E F G H Spark Plug Center
Surface Exhaust Port #2 Exhaust Port #1
Line

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 Specifications

Engine Dimensions with Low Profile, High Performance, or PRO Performance Air Cleaner-Valve Cover Side

B
E
D

C
Engine Mounting
A 87.6 mm (3.45 in.) B C 152.9 mm (6.02 in.) D 4.4 mm (0.17 in.)
Surface
E Mounting Hole "A" F 39.8 mm (1.57 in.)

32 690 12 Rev. -- KohlerEngines.com 9

Specifications

Engine Dimensions with High Performance Air Cleaner-Flywheel Side

C
B

I K
E C
G J
H
F

A 423.0 mm (16.65 in.) B 147.4 mm (5.80 in.) C 89.8 mm (3.54 in.) D 50.1 mm (1.97 in.)
Oil Fill and Dipstick Fuel Line Connection
E F G Mounting Hole "A" H 154.4 mm (6.08 in.)
(Yellow) Point
8.0 mm (0.31 in.) 44.3 mm (1.74 in.)
I 134.4 mm (5.29 in.) J K 317.9 mm (12.52 in.) L
Center of Gravity Center of Gravity

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 Specifications

Engine Dimensions with High Performance Air Cleaner-Oil Filter Side

J
A I
B

C
H

D E
F
D

389.5 mm (15.33 in.) 164.5 mm (6.48 in.)

354.6 mm (13.96 in.) Engine Mounting
A Air Cleaner B C Center of D
Top of Air Cleaner Surface
Removal Gravity
134.0 mm (5.28 in.)
80.3 mm (3.16 in.) 51.2 mm (2.02 in.)
E F Mounting Hole "A" G H Spark Plug
Oil Filter Oil Filter Center Line
380.7 mm (14.99 in.)
I 340.9 mm (13.42 in.) J Optional Fixed Guard

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Specifications

Engine Dimensions with PRO Performance Air Cleaner-Flywheel Side

C
B

E
G K
F C J
H
I

A 424.7 mm (16.72 in.) B 147.4 mm (5.80 in.) C 89.8 mm (3.54 in.) D 50.1 mm (1.97 in.)
Oil Fill and Dipstick Fuel Line Connection
E F G 140.4 mm (5.53 in.) H Mounting Hole "A"
(Yellow) Point
8.1 mm (0.32 in.) 46.1 mm (1.81 in.)
I 154.4 mm (6.08 in.) J K 317.9 mm (12.52 in.) L
Center of Gravity Center of Gravity

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 Specifications

Engine Dimensions with PRO Performance Air Cleaner-Oil Filter Side

C L
K

E J

I
F
G
H F

272.5 mm (10.73 in.) 458.7 mm (18.06 in.) 398.7 mm (15.70 in.) 265.9 mm (10.47 in.)
A Evap Connection B Air Cleaner C Top of Air D Evap Connection
Point Removal Cleaner Point
166.4 mm (6.55 in.) Engine Mounting 80.3 mm (3.16 in.)
E F G H Mounting Hole "A"
Center of Gravity Surface Oil Filter
134.0 mm (5.28 in.)
51.2 mm (2.02 in.) 380.7 mm (14.99 in.)
I J Spark Plug Center K 340.9 mm (13.42 in.) L
Oil Filter Optional Fixed Guard
Line

32 690 12 Rev. -- KohlerEngines.com 13

Specifications

Engine Dimensions with PRO Performance Air Cleaner-Engine Mounting Surface (PTO End)

A
B B C

E
E

F
R

Q
G
H

P I

L
O M
I I K
N
J
4 X 5/16-18
UNC-2B in.
A 334.3 mm (13.16 in.) B 72.8 mm (2.87 in.) C 94.3 mm (3.71 in.) D 16.5 mm
(0.649 in.) Deep
No Studs
50.0 mm (1.97 in.)
E 30° F G 104.0 mm (4.10 in.) H 242.1 mm (9.53 in.)
Exhaust Port #2
18.0 mm (0.71 in.)
I 89.8 mm (3.54 in.) J K 116.8 mm (4.60 in.) L Mounting Hole "A"
Oil Filter Removal
4 X 9.005 mm
(0.355 in.) 37 mm
248.1 mm (9.77 in.) (1.46 in.) Deep on 93.1 mm (3.66 in.)
M Rotation Direction N O P
Starter Stud aØ Starter Stud
254 mm (10.0 in.)
B.C.
312.0 mm (12.28 in.)
Throttle and 50.0 mm (1.97 in.)
Q Choke Cable R Exhaust Port #1
Mounting
Surface

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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 . . . . . . . . . . . . . . . . . . . . . EKT730
EFI 7500 Series Engine

Numerical Designation
Specification . . . . . . . . . . . . . . . EKT730-0001
Serial . . . . . . . . . . . . . . . . . . . . . 4723500328
Year Manufactured Code Factory Code
Code Year
47 2017
48 2018
49 2019

GENERAL SPECIFICATIONS3,4 EKT730 EKT740 EKT745 EKT750

Bore 83 mm (3.27 in.)
Stroke 67 mm (2.64 in.) 69 mm (2.7 in.)
Displacement 725 cc (44 cu. in.) 747 cc (46 cu. in.)
Oil Capacity (refill) 1.9 L (2.0 U.S. qt.)
Maximum Angle of Operation (@ full oil level)5 25°

TORQUE SEQUENCES EKT730 EKT740 EKT745 EKT750

(Refer to Torque Specifications for torque values).
Backing Plate Fasteners 4
3
1 2

Breather Cover Fasteners

1&5
3

4 2

3
Values are in Metric units. Values in parentheses are English equivalents.
4
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.
5
Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.

32 690 12 Rev. -- KohlerEngines.com 15

Specifications

TORQUE SEQUENCES EKT730 EKT740 EKT745 EKT750

(Refer to Torque Specifications for torque values).
Cylinder Head Bolt Fasteners 4 2 2 4

1 3 3 1

#1 #2
Intake Manifold Mounting Fasteners
4 3

2 1

Oil Pan Fasteners 1

3
10
5
8

9
2 4
Valve Cover Fasteners
1&5 3

4 2

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 Specifications

TORQUE SPECIFICATIONS3,6 EKT730 EKT740 EKT745 EKT750

Backing Plate (torque sequence on page 15)

Fastener 7.3 N·m (65 in. lb.)
Dipstick Tube Fastener 3.4 N·m (30 in. lb.)

Baffle and Sheet Metal into Aluminum

M5 Thread Forming Fasteners 8.5 N·m (75 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
M6 Thread Forming Fasteners 10.7 N·m (95 in. lb.) into new hole
7.3 N·m (65 in. lb.) into used hole

Blower Housing and Sheet Metal

M3 HI-LO Screw 2.3 N·m (20 in. lb.)
M4 HI-LO Screw 2.8 N·m (25 in. lb.)
M5 Fasteners 6.2 N·m (55 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
M6 Fasteners 10.7 N·m (95 in. lb.) into new hole
7.3 N·m (65 in. lb.) into used hole

Connecting Rod
Cap Fastener (torque in increments) 13.6 N·m (120 in. lb.)

Crankcase
Breather Assembly
Breather Reed Cover Stud 6.2 N·m (55 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
Breather Reed Cover Hex Nut
1.3 N·m (12 in. lb.)
Breather Cover Fasteners (torque sequence
on page 15) 6.2 N·m (55 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
Engine Temperature Sensor Fastener 11.9 N·m (105 in. lb.)
Oil Drain Plug 13.6 N·m (10 ft. lb.)

Cylinder Head (torque sequence on page 16)

Head Bolt Fastener (torque in 2 increments) first to 22.6 N·m (200 in. lb.)
finally to 41.8 N·m (370 in. lb.)
Rocker Arm Stud 11.3 N·m (100 in. lb.)
Rocker Arm Adjuster Set Screw 7.9 N·m (70 in. lb.)

Flywheel
Retaining Screw 74.5 N·m (55 ft. lb.)

Fuel Pump
Module Baffle Fastener 11.9 N·m (105 in. lb.) into new hole
7.8 N·m (69 in. lb.) into used hole
Module Fastener 9.2 N·m (81 in. lb.)
Pulse Pump Fastener to Blower Housing 2.8 N·m (25 in. lb.)

Governor
Lever Nut 6.8 N·m (60 in. lb.)

3
Values are in Metric units. Values in parentheses are English equivalents.
6
Lubricate threads with engine oil prior to assembly.
32 690 12 Rev. -- KohlerEngines.com 17
Specifications

TORQUE SPECIFICATIONS3,6 EKT730 EKT740 EKT745 EKT750

Ignition
Spark Plug 27 N·m (20 ft. lb.)
Coil Fastener 10.2 N·m (90 in. lb.)
Electronic Control Unit (ECU) Fastener 6.2 N·m (55 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
Rectifier-Regulator Fastener 3.4 N·m (30 in. lb.)
Crankshaft Position Sensor to Bracket Screw 11.3 N·m (100 in. lb.)
Crankshaft Position Sensor Bracket to Crankcase 8.3 N·m (73 in. lb.)
Screw

Intake Manifold (torque sequence on page 16)

Mounting Fastener 10.5 N·m (93 in. lb.)
Temperature/Manifold Absolute Pressure (TMAP) 7.3 N·m (65 in. lb.)
Sensor Fastener
Air Cleaner Base to Throttle Body Nut 6.8 N·m (60 in. lb.)
Fuel Injector Cap Fastener 7.3 N·m (65 in. lb.)
Ground Wire Fastener 7.3 N·m (65 in. lb.)

Muffler
M8 Hex Nuts 24.4 N·m (216 in. lb.)
5/16-18 Capscrew 16.9 N·m (150 in. lb.)
Bracket Screw 9.9 N·m (88 in. lb.)
Oxygen Sensor smaller 14 mm (9/16 in.) wrench size 18 N·m (159 in. lb.)
Oxygen Sensor larger 22 mm (7/8 in.) wrench size 50.1 N·m (37 ft. lb.)

Oil Pan (torque sequence on page 16)

Fastener 25.7 N·m (227 in. lb.)

Oil Pump
Screw (no torque sequence) 9.9 N·m (88 in. lb.)

Oil Sentry™
Pressure Switch 4.5 N·m (40 in. lb.)

Speed Control Bracket

Fastener 10.7 N·m (95 in. lb.) into new holes
7.3 N·m (65 in. lb.) into used holes

Starter Assembly
Mounting Screw 23.8 N·m (211 in. lb.)

Stator
Mounting Screw 8.8 N·m (78 in. lb.)

Valve Cover (torque sequence on page 16)

Fastener (stamped steel cover) 13.6 N·m (120 in. lb.)

3
Values are in Metric units. Values in parentheses are English equivalents.
6
Lubricate threads with engine oil prior to assembly.
18 KohlerEngines.com 32 690 12 Rev. --
 Specifications

CLEARANCE SPECIFICATIONS3 EKT730 EKT740 EKT745 EKT750

Camshaft
End Play 0.06/0.40 mm (0.0024/0.0157 in.)
Running Clearance 0.040/0.077 mm (0.0016/0.0030 in.)
Bore I.D.
New 20.000/20.025 mm (0.7874/0.7884 in.)
Max. Wear Limit 20.038 mm (0.7889 in.)
Bearing Surface O.D.
New 19.948/19.960 mm (0.7854/0.7858 in.)
Max. Wear Limit 19.945 mm (0.7852 in.)

Connecting Rod
Connecting Rod-to-Crankpin Running Clearance
New 0.037/0.083 mm (0.0015/0.0033 in.)
Max. Wear Limit 0.098 mm (0.0039 in.)
Connecting Rod-to-Crankpin Side Clearance 0.261/0.67 mm (0.0102/0.0264 in.)
Connecting Rod-to-Piston Pin Running Clearance 0.013/0.032 mm (0.0005/0.0013 in.)
Piston Pin End I.D.
New 17.013/17.027 mm (0.6698/0.6704 in.)
Max. Wear Limit 17.040 mm (0.6709 in.)

Crankcase
Governor Cross Shaft Bore I.D.
New 8.025/8.075 mm (0.3159/0.3179 in.)
Max. Wear Limit 8.088 mm (0.3184 in.)

Crankshaft
End Play (free) 0.075/0.595 mm (0.0030/0.023 in.)
Bore (in crankcase)
New 40.974/40.987 mm (1.6131/1.6137 in.)
Max. Wear Limit 41.000 mm (1.6142 in.)
Bore (in oil pan)
New 40.974/41.000 mm (1.6457/1.6142 in.)
Crankshaft Bore (in oil pan)-to-Crankshaft
Running Clearance
New 0.039/0.087 mm (0.0015/0.0034 in.)
Flywheel End Main Bearing Journal
O.D. - New 40.913/40.935 mm (1.6107/1.6116 in.)
O.D. - Max. Wear Limit 40.840 mm (1.608 in.)
Max. Taper 0.022 mm (0.0009 in.)
Max. Out-of-Round 0.025 mm (0.0010 in.)
Oil Pan End Main Bearing Journal
O.D. - New 40.913/40.935 mm (1.6107/1.6116 in.)
O.D. - Max. Wear Limit 40.840 mm (1.608 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 35.950/35.974 mm (1.4154/1.4163 in.)
O.D. - Max. Wear Limit 35.950 mm (1.4154 in.)
Max. Taper 0.018 mm (0.0007 in.)
Max. Out-of-Round 0.025 mm (0.0010 in.)
T.I.R.
PTO End, Crank in Engine 0.279 mm (0.0110 in.)
Entire Crank, in V-Blocks 0.200 mm (0.0079 in.)

3
Values are in Metric units. Values in parentheses are English equivalents.
32 690 12 Rev. -- KohlerEngines.com 19
Specifications

CLEARANCE SPECIFICATIONS3 EKT730 EKT740 EKT745 EKT750

Cylinder Bore
Bore I.D.
New 83.006/83.031 mm (3.2679/3.2689 in.)
Max. Wear Limit 83.069 mm (3.2704 in.)
Max. Out-of-Round 0.120 mm (0.0047 in.)
Max. Taper 0.050 mm (0.0020 in.)

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

Governor
Cross Shaft End Play 0.25/3.15 mm (0.010/0.124 in.)
Governor Cross Shaft-to-Crankcase Running
Clearance 0.025/0.126 mm (0.0009/0.0049 in.)
Cross Shaft O.D.
New 7.949/8.000 mm (0.3129/0.3149 in.)
Max. Wear Limit 7.936 mm (0.3124 in.)
Governor Gear Shaft-to-Governor Running 0.050/0.210 mm (0.0020/0.0083 in.)
Clearance
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.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.)
Pin Bore I.D.
New 17.006/17.012 mm (0.6695/0.6698 in.)
Max. Wear Limit 17.025 mm (0.6703 in.)
Pin O.D.
New 16.995/17.000 mm (0.6691/0.6693 in.)
Max. Wear Limit 16.994 mm (0.6691 in.)
Top Compression Ring-to-Groove Side Clearance 0.030/0.070 mm (0.001/0.0026 in.)
Middle Compression Ring-to-Groove Side 0.030/0.070 mm (0.001/0.0026 in.)
Clearance
Oil Control Ring-to-Groove Side Clearance 0.060/0.190 mm (0.0022/0.0073 in.)
Top Compression Ring End Gap
New Bore 0.189/0.277 mm (0.0074/0.0109 in.)
Used Bore (Max.) 0.531 mm (0.0209 in.)
Middle Compression Ring End Gap
New Bore 1.519/1.797 mm (0.0598/0.0708 in.)
Used Bore (Max.) 2.051 mm (0.0808 in.)
Thrust Face O.D.7
New 82.978 mm (3.2668 in.)
Max. Wear Limit 82.833 mm (3.2611 in.)
Piston Thrust Face-to-Cylinder Bore7 Running
Clearance
New 0.019/0.062 mm (0.0007/0.0024 in.)

3
Values are in Metric units. Values in parentheses are English equivalents.
7
Measure 6 mm (0.2362 in.) above bottom of piston skirt at right angles to piston pin.
20 KohlerEngines.com 32 690 12 Rev. --
 Specifications

CLEARANCE SPECIFICATIONS3 EKT730 EKT740 EKT745 EKT750

Valves and Valve Tappets

Clearance 0.101/0.152 mm (0.0040/0.0060 in.)
Valve Tappet to Crankcase Running Clearance 0.013/0.073 mm (0.0005/0.0029 in.)
Intake Valve Stem-to-Valve Guide Running 0.040/0.0780 mm (0.0016/0.0031 in.)
Clearance
Exhaust Valve Stem-to-Valve Guide Running 0.052/0.090 mm (0.0020/0.0035 in.)
Clearance
Intake Valve Guide I.D.
New 7.040/7.060 mm (0.2772/0.2780 in.)
Max. Wear Limit 7.140 mm (0.2811 in.)
Exhaust Valve Guide I.D.
New 7.040/7.060 mm (0.2772/0.2780 in.)
Max. Wear Limit 7.160 mm (0.2819 in.)
Valve Guide Reamer Size
Standard 7.050 mm (0.2776 in.)
0.25 mm O.S. 7.300 mm (0.2874 in.)
Intake Valve Minimum Lift 8.500 mm (0.3346 in.)
Exhaust Valve Minimum Lift 8.500 mm (0.3346 in.)
Nominal Valve Face Angle 45°

3
Values are in Metric units. Values in parentheses are English equivalents.
32 690 12 Rev. -- KohlerEngines.com 21
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

22 KohlerEngines.com 32 690 12 Rev. --

 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.
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.
Cylinder Leakdown Tester Kohler 25 761 05-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 (Domestic) 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
Cylinder Leakdown Tester Kohler 25 761 05-S
Oil Pressure Test Kit Kohler 25 761 06-S
Rectifier-Regulator Tester (120 V AC/60Hz) Kohler 25 761 20-S
Dealer Tool Kit (International) Kohler 25 761 42-S
Complete kit of Kohler required tools.
Components of 25 761 42-S
Ignition System Tester Kohler 25 455 01-S
Cylinder Leakdown Tester Kohler 25 761 05-S
Oil Pressure Test Kit Kohler 25 761 06-S
Rectifier-Regulator Tester (240 V AC/50Hz) Kohler 25 761 41-S
Digital Vacuum/Pressure Tester Design Technology Inc.
For checking crankcase vacuum. DTI-721-01
Individual component available: Design Technology Inc.
Rubber Adapter Plug DTI-721-10
Electronic Fuel Injection (EFI) Diagnostic Software Kohler 25 761 23-S
For Laptop or Desktop PC.
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
Schrader 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
Flywheel Puller SE Tools KLR-82408
For properly removing flywheel from engine.

32 690 12 Rev. -- KohlerEngines.com 23

Tools and Aids

TOOLS
Description Source/Part No.
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.
Hydraulic Valve Lifter Tool Kohler 25 761 38-S
For removing and installing hydraulic lifters.
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
Offset Wrench (K and M Series) Kohler 52 455 04-S
For removing and reinstalling cylinder barrel retaining nuts.
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
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 (GE/Novaguard G661) Kohler 25 357 11-S
Dielectric Grease Loctite® 51360
Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-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™, 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

24 KohlerEngines.com 32 690 12 Rev. --

 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.

32 690 12 Rev. -- KohlerEngines.com 25

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 EFI 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 fuses. ● Faulty electric starter or solenoid.
● Clogged fuel line or fuel filter. ● Faulty key switch or ignition switch.
● Empty fuel tank. ● Interlock switch is engaged or faulty.
● Faulty ignition coil(s). ● Loose wires or connections that intermittently ground
● Faulty spark plug(s). ignition kill circuit.
● Fuel pump malfunction-vacuum hose clogged or ● Pawls not engaging in drive cup (Recoil Start).
leaking. ● Seized internal engine components.
● Fuel shut-off valve closed.
● Insufficient voltage to electronic control unit. Engine Runs But Misses
● Interlock switch is engaged or faulty. ● Fuel system issue (Fuel Injectors).
● Key switch or kill switch in OFF position. ● Engine overheated.
● Low oil level. ● Faulty spark plug(s).
● Quality of fuel (dirt, water, stale, mixture). ● Ignition module(s) faulty.
● Spark plug lead(s) disconnected. ● Incorrect crankshaft position sensor air gap.
● Interlock switch is engaged or faulty.
Engine Starts But Does Not Keep Running ● Loose wires or connections that intermittently ground
● Faulty cylinder head gasket. ignition kill circuit.
● Faulty or misadjusted throttle controls. ● Quality of fuel (dirt, water, stale, mixture).
● Fuel pump malfunction-vacuum hose clogged or ● Spark plug lead(s) disconnected.
leaking. ● Spark plug lead boot loose on plug.
● Intake system leak. ● Spark plug lead loose.
● Loose wires or connections that intermittently ground
ignition kill circuit. Engine Will Not Idle
● Quality of fuel (dirt, water, stale, mixture). ● Engine overheated.
● Restricted fuel tank cap vent. ● Faulty spark plug(s).
● Idle speed adjusting screw improperly set.
Engine Starts Hard ● Inadequate fuel supply.
● Clogged fuel line or fuel filter. ● Low compression.
● Engine overheated. ● Quality of fuel (dirt, water, stale, mixture).
● Faulty ACR mechanism (Recoil Start). ● Restricted fuel tank cap vent.
● Faulty spark plug(s).
● Flywheel key sheared. Engine Overheats
● Fuel pump malfunction-vacuum hose clogged or ● Cooling fan broken.
leaking. ● Excessive engine load.
● Interlock switch is engaged or faulty. ● High crankcase oil level.
● Loose wires or connections that intermittently ground ● Lean fuel mixture.
ignition kill circuit. ● Low crankcase oil level.
● Low compression. ● Cooling system components clogged or restricted.
● Quality of fuel (dirt, water, stale, mixture).
● Weak spark. Engine Knocks
● Excessive engine load.
● Hydraulic lifter malfunction or incorrect valve lash
adjustment.
● Incorrect oil viscosity/type.
● Internal wear or damage.
● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture).
● Loose/worn pulley/clutch on crankshaft PTO.

26 KohlerEngines.com 32 690 12 Rev. --

 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 throttle body throat for dirt. Dirt in throat is
further indication that air cleaner was not functioning
● Breather reed broken. properly.
● Clogged, broken, or inoperative crankcase breather. ● Check if oil level is within operating range on dipstick.
● Loose or improperly torqued fasteners. If it is above, sniff for gasoline odor.
● Piston blow by, or leaky valves. ● Check condition of oil. Drain oil into a container; it
● Restricted exhaust. should flow freely. Check for metal chips and other
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.

32 690 12 Rev. -- KohlerEngines.com 27

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. Stay away while engine is in operation.

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
Level in engine side should be a minimum of pressure.
10.2 cm (4 in.) above level in open side. Digital tester–depress test button on top of tester.
If level in engine side is less than specified (low/no Crankcase vacuum should be a minimum of 10.2 cm
vacuum), or level in engine side is lower than level in (4 in.) of water. If reading is below specification, or if
open side (pressure), check for conditions in table pressure is present, check table below for possible
below. causes and conclusions.
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.

28 KohlerEngines.com 32 690 12 Rev. --

 Troubleshooting

COMPRESSION TEST
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 battery is fully charged, unplug ECU, and throttle is wide open during test.
Compression should be at least 160 psi and should not vary more than 15% between cylinders.
Some models (recoil start) may be 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.

32 690 12 Rev. -- KohlerEngines.com 29

Air Cleaner/Intake

AIR CLEANER PRO Performance Air Cleaner Components

These systems are CARB/EPA certified and components
should not be altered or modified in any way.
Low-Profile Air Cleaner (LPAC) Components
A
A
B

E D
E
B

E
C C

A Air Cleaner Cover B Paper Element

C Precleaner D Air Cleaner Base
D E Bail

NOTE: Operating engine with loose or damaged air

cleaner components could cause premature
wear and failure. Replace all bent or damaged
A Air Cleaner Cover B Paper Element components.
C Precleaner D Air Cleaner Base
NOTE: Paper element cannot be blown out with
Air Cleaner Cover compressed air.
E Lever
Rotate air cleaner cover levers outward to unlock cover;
remove air cleaner cover.
High Performance Air Cleaner Components or
A Move bails on air cleaner cover up; remove latches from
cover; remove cover.
Precleaner (if equipped)
1. Remove precleaner from paper element.
B E 2. Replace or wash precleaner in warm water with
detergent. Rinse and allow to air dry.
3. Lightly oil precleaner with new engine oil; squeeze
out excess oil.
4. Reinstall precleaner over paper element.
C
Paper Element
1. Separate precleaner from element; service
precleaner and replace paper element.
D 2. Install precleaner over new paper element and install
on base.
Position air cleaner cover with levers outward over air
cleaner; turn levers inward to lock.
A Air Cleaner Cover B Paper Element
or
C Precleaner D Air Cleaner Base
Reinstall cover; place latches onto cover; pull down bails
Air Cleaner Cover to secure cover.
E Lever

30 KohlerEngines.com 32 690 12 Rev. --

 Air Cleaner/Intake

Air Cleaner Base BREATHER TUBE

Disassembly/Reassembly Ensure both ends of breather tube are properly
If air cleaner base requires removal, proceed as follows: connected.
1. Remove mounting screws for fuel pump (if AIR COOLING
equipped), and blower housing.
WARNING
2. Raise or remove blower housing for access to air
cleaner base. Hot Parts can cause severe burns.
3. Remove air cleaner components from base. Do not touch engine while operating or just
after stopping.
4. Remove nuts securing air cleaner base onto
mounting studs. Never operate engine with heat shields or guards
5. Disconnect breather hose from air cleaner base, removed.
then remove base and gasket. Proper cooling is essential. To prevent over heating,
6. Reverse procedure to reassemble components. clean screens, cooling fins, and other external surfaces
Torque nuts to 6.8 N·m (60 in. lb.). Torque blower of engine. Avoid spraying water at wiring harness or any
housing screws 6.2 N·m (55 in. lb.) into new holes or electrical components. Refer to Maintenance Schedule.
4.0 N·m (35 in. lb.) into used holes, and front HI-LO
screws to 2.8 N·m (25 in. lb.).

32 690 12 Rev. -- KohlerEngines.com 31

EFI SYSTEM

A lift fuel pump is used to move fuel from tank through

WARNING an in-line fuel filter and fuel line. Fuel is then pumped
Explosive Fuel can cause fires and severe to fuel pump module. Fuel pump module regulates
burns. fuel pressure to a system operating pressure of 39 psi.
Fuel is delivered from fuel pump module through high
Do not fill fuel tank while engine is hot or pressure fuel line into injectors, which inject fuel into
running. intake ports. ECU controls amount of fuel by varying
Gasoline is extremely flammable and its vapors can length of time that injectors are on. This can range
explode if ignited. Store gasoline only in approved from 2 to over 12 milliseconds depending on fuel
containers, in well ventilated, unoccupied buildings, requirements. Controlled injection of fuel occurs every
away from sparks or flames. Spilled fuel could ignite if it other crankshaft revolution, or once for each 4-stroke
comes in contact with hot parts or sparks from ignition. cycle. When intake valve opens, air/fuel mixture is drawn
Never use gasoline as a cleaning agent. into combustion chamber, where it is compressed,
ignited, and burned.
Typical electronic fuel injection (EFI) system and related ECU controls amount of fuel being injected and ignition
components include: timing by monitoring primary sensor signals for engine
● Fuel pump module and lift pump. temperature, speed (RPM), and throttle position (load).
● Fuel filter. These primary signals are compared to preprogrammed
● High pressure fuel line. maps in ECU computer chip, and ECU adjusts fuel
● Fuel line(s). delivery to match mapped values. After engine reaches
● Fuel injectors. operating temperature, an exhaust gas oxygen sensor
● Throttle body/intake manifold. provides feedback to ECU based upon amount of
● Electronic control unit (ECU). unused oxygen in exhaust, indicating whether fuel
● Ignition coils. mixture being delivered is rich or lean. Based upon this
● Engine temperature sensor. feedback, ECU further adjusts fuel input to re-establish
● Throttle position sensor (TPS). ideal air/fuel ratio. This operating mode is referred to as
● Crankshaft position sensor. closed loop operation. EFI system operates closed loop
● Oxygen sensor. when all three of following conditions are met:
● Temperature/Manifold Absolute Pressure (TMAP) ● Engine temperature is greater than 45°C (113°F).
sensor. ● Oxygen sensor has warmed sufficiently to provide a
● Wire harness assembly & affiliated wiring. signal (minimum 400°C, 752°F).
● 30 Amp fuse (charging system). ● Engine operation is at a steady state (not starting,
● 10 Amp fuse (ignition switch). warming up, accelerating, etc.).
● 10 Amp fuse (battery power).
● Malfunction indicator light (MIL) - optional.
During closed loop operation ECU has ability to readjust
temporary and learned adaptive controls, providing
FUEL RECOMMENDATIONS compensation for changes in overall engine condition
Refer to Maintenance. and operating environment, so it will be able to maintain
FUEL LINE ideal air/fuel ratio. This system requires a minimum
Low permeation fuel line must be installed on all Kohler engine temperature of 50°-60°C (122°-140°F) to properly
Co. engines to maintain EPA and CARB regulatory adapt. These adaptive values are maintained as long as
compliance. ECU is not reset.
OPERATION During certain operating periods such as cold starts,
NOTE: When performing voltage or continuity tests, warm up, acceleration, high load, etc., a richer air/fuel
avoid putting excessive pressure on or against ratio is required and system operates in an open loop
connector pins. Flat pin probes are mode. In open loop operation oxygen sensor output is
recommended for testing to avoid spreading or used to ensure engine is running rich, and controlling
bending terminals. adjustments are based on primary sensor signals and
programmed maps only. This system operates open
EFI system is designed to provide peak engine loop whenever three conditions for closed loop operation
performance with optimum fuel efficiency and lowest (above) are not being met.
possible emissions. Ignition and injection functions
are electronically controlled, monitored and continually ECU is brain or central processing computer of entire
corrected during operation to maintain ideal air/fuel ratio. EFI system. During operation, sensors continuously
gather data which is relayed through wiring harness
Central component of system is Electronic Control Unit to input circuits within ECU. Signals to ECU include:
(ECU) which manages system operation, determining ignition (on/off), crankshaft position and speed (RPM),
best combination of fuel mixture and ignition timing for throttle position, engine temperature, intake air
current operating conditions. temperature, exhaust oxygen levels, manifold absolute
pressure, and battery voltage.

32 KohlerEngines.com 32 690 12 Rev. --

 EFI SYSTEM

ECU compares input signals to programmed maps in Crankshaft position sensor is essential to engine
its memory to determine appropriate fuel and spark operation; constantly monitoring rotation and speed
requirements for immediate operating conditions. ECU (RPM) of crankshaft. There are 23 consecutive teeth
then sends output signals to set injector duration and cast into flywheel. One tooth is missing and is used to
ignition timing. reference crankshaft position for ECU.
ECU continually performs a diagnostic check of itself, When ignition is turned ON, ECU captures and records
each of sensors, and system performance. If a fault battery voltage. During engine start (cranking) voltage
is detected, ECU can turn on a Malfunction Indicator drops 2+ volts. When ECU receives voltage drop input,
Light (MIL) (if equipped) on equipment control panel, it then looks for a signal from crankshaft position sensor.
store fault code in its fault memory, and go into a default During rotation, an AC voltage pulse is created within
operating mode. Depending on significance or severity sensor for each passing tooth. ECU calculates engine
of fault, normal operation may continue. A technician can speed from time interval between consecutive pulses.
access stored fault code using a blink code diagnosis Gap from missing tooth creates an interrupted input
flashed out through MIL. An optional computer software signal, corresponding to specific crankshaft position near
diagnostic program is also available, see Tools and Aids. BDC for cylinder #1. This signal serves as a reference
ECU requires a minimum of 6.0 volts to operate. for control of ignition timing by ECU. Synchronization of
inductive speed pickup and crankshaft position takes
To prevent engine over-speed and possible failure, a place during first two revolutions each time engine is
rev-limiting feature is programmed into ECU. If maximum started. Sensor must be properly connected at all times.
RPM limit (4500) is exceeded, ECU suppresses injection If sensor becomes disconnected for any reason, engine
signals, cutting off fuel flow. This process repeats itself in will quit running.
rapid succession, limiting operation to preset maximum.
Throttle position sensor (TPS) is used to indicate throttle
Wiring harness used in EFI system connects electrical plate angle to ECU. Since throttle (by way of governor)
components, providing current and ground paths for reacts to engine load, angle of throttle plate is directly
system to operate. All input and output signaling occurs related to load on engine.
through two special all weather connectors that attach
and lock to ECU. Connectors are Black and Grey and Mounted on throttle body and operated directly off end
keyed differently to prevent being attached to ECU of throttle shaft, TPS works as a potentiometer, varying
incorrectly. voltage signal to ECU in direct correlation to angle
of throttle plate. This signal, along with other sensor
Condition of wiring, connectors, and terminal signals, is processed by ECU and compared to internal
connections is essential to system function and preprogrammed maps to determine required fuel and
performance. Corrosion, moisture, and poor connections ignition settings for amount of load.
are as likely cause of operating problems and system
errors as an actual component. Refer to Electrical Correct position of TPS is established and set at factory.
System for additional information. Do not loosen TPS or alter mounting position unless
absolutely required by fault code diagnosis. If TPS
EFI system is a 12 VDC negative ground system, is loosened or repositioned, appropriate TPS Learn
designed to operate down to a minimum of 6.0 volts. Procedure must be performed to re-establish baseline
If system voltage drops below this level, operation relationship between ECU and TPS.
of voltage sensitive components such as ECU, fuel
pump, ignition coils, and injectors will be intermittent Engine temperature sensor is used by system to
or disrupted, causing erratic operation or hard starting. help determine fuel requirements for starting (a cold
A fully charged, 12 volt battery with a minimum of 350 engine needs more fuel than one at or near operating
cold cranking amps is important in maintaining steady temperature).
and reliable system operation. Battery condition and Mounted on crankcase behind fuel pump module
state of charge should always be checked first when baffle, it has a temperature-sensitive resistor that
troubleshooting an operational problem. monitors surface temperature. Resistance changes
Keep in mind that EFI-related problems are often caused with temperature, altering voltage sent to ECU. Using
by wiring harness or connections. Even small amounts a table stored in its memory, ECU correlates voltage
of corrosion or oxidation on terminals can interfere with drop to a specific temperature. Using fuel delivery maps,
milliamp currents used in system operation. ECU then knows how much fuel is required for starting/
running at that temperature.
Cleaning connectors and grounds will solve problems
in many cases. In an emergency situation, simply Temperature/Manifold Absolute Pressure (TMAP) sensor
disconnecting and reconnecting connectors may clean is an integrated sensor that checks both intake air
up contacts enough to restore operation, at least temperature and manifold absolute pressure.
temporarily. Intake Air Temperature control is a thermally sensitive
If a fault code indicates a problem with an electrical resistor that exhibits a change in electrical resistance
component, disconnect ECU connector and test for with a change in its temperature. When sensor is cold,
continuity between component connector terminals and resistance of sensor is high. As sensor warms up,
corresponding terminals in ECU connector using an resistance drops and voltage signal increases. From
ohmmeter. Little or no resistance should be measured, voltage signal, ECU can determine temperature of intake
indicating that wiring of that particular circuit is OK. air.

32 690 12 Rev. -- KohlerEngines.com 33

EFI SYSTEM

Purpose of sensing air temperature is to help ECU Injectors have sequential fueling that open and close
calculate air density. Higher air temperature less dense once every other crankshaft revolution. Amount of fuel
air becomes. As air becomes less dense ECU knows injected is controlled by ECU and determined by length
that it needs to lessen fuel flow to achieve correct air/fuel of time valve needle is held open, also referred to as
ratio. If fuel ratio was not changed engine would become injection duration or pulse width. Time injector is open
rich, possibly losing power and consuming more fuel. (milliseconds) may vary in duration depending on speed
Manifold Absolute Pressure check provides immediate and load requirements of engine.
manifold pressure information to ECU. TMAP sensor A high-voltage, solid-state, battery ignition system is
measures difference in pressure between outside used with EFI system. ECU controls ignition output and
atmosphere and vacuum level inside intake manifold timing through transistorized control of primary current
and monitors pressure in manifold as primary means delivered to coils. Based on input from crankshaft
of detecting load. Data is used to calculate air density position sensor, ECU determines correct firing point
and determine engine's mass air flow rate, which in turn for speed at which engine is running. At proper instant,
determines required ideal fueling. TMAP also stores it interrupts flow of primary current in coil, causing
instant barometric pressure reading when key is turned electromagnetic flux field to collapse. Flux collapse
ON. induces an instantaneous high voltage in coil secondary
Oxygen sensor functions like a small battery, generating which is strong enough to bridge gap on spark plug.
a voltage signal to ECU based upon difference in oxygen Each coil fires every other revolution.
content between exhaust gas and ambient air, or a These EFI engines are equipped with a 15 amp charging
generated electrical reference current. system to accommodate combined electrical demands
Tip of sensor, protruding into exhaust gas, is hollow. of ignition system and specific application. Charging
Outer portion of tip is surrounded by exhaust gas, with system troubleshooting information is provided in
inner portion exposed to ambient air, or a reference Electrical System.
voltage current. When oxygen concentration on one An electric fuel pump module and a lift pump are used
side of tip is different than that of other side, a voltage to transfer fuel in EFI system. Pumping action within lift
signal up to 1.0 volt is generated and sent to ECU. pump is created by oscillation of positive and negative
Voltage signal tells ECU if engine is straying from pressures within crankcase through a hose. Internal
ideal fuel mixture, and ECU then adjusts injector pulse check valves prevent fuel from going backward through
accordingly. pump. Fuel pump module receives fuel from lift pump,
Oxygen sensor functions after being heated to a increases and regulates pressure for fuel injectors.
minimum of 400°C (752°F). A heater inside sensor heats Fuel pump module is rated for a minimum output of 13.5
electrode to optimum temperature in about 10 seconds. liters per hour and regulated at 270 kilopascals (39 psi).
Oxygen sensor receives ground through wire, eliminating When key switch is turned ON and all safety switch
need for proper grounding through muffler. If problems requirements are met, ECU activates fuel pump module
indicate a bad oxygen sensor, check all connections and for about six seconds (prime process), which pressurizes
wire harness. Oxygen sensor can also be contaminated system for start-up. If key switch is not promptly turned
by leaded fuel, certain RTV and/or other silicone to start position, engine fails to start, or engine is
compounds, fuel injector cleaners, etc. Use only those stopped with key switch ON (as in case of an accident),
products indicated as O2 Sensor Safe. ECU switches off pump preventing continued delivery
Fuel injectors mount into intake manifold, and high of fuel. In this situation, MIL will go on, but it will go back
pressure fuel line attaches to them at top end. off after 4 cranking revolutions if system function is OK.
Replaceable O-rings on both ends of injector prevent Once engine is running, fuel pump remains on.
external fuel leakage and also insulate it from heat and Precision components inside fuel pump module are not
vibration. A special clip connects each injector to high serviceable. DO NOT attempt to open fuel pump module.
pressure fuel line and holds it in place. O-rings and Damage to components will result and warranty will be
retaining clip must be replaced any time fuel injector is void. Because fuel pump module is not serviceable,
separated from its normal mounting position. engines are equipped with a special 10-micron EFI fuel
When key switch is on, fuel pump module will pressurize filter to prevent harmful contamination from entering
high pressure fuel line to 39 psi, and voltage is present module.
at injector. At proper instant, ECU completes ground If there are two filters in system, one before lift pump
circuit, energizing injector. Valve needle in injector will be a standard 51-75 micron filter, and one after lift
is opened electromagnetically, and pressure in high pump will be special 10-micron filter. Be sure to use an
pressure fuel line forces fuel down through inside. approved 10-micron filter for replacement.
Director plate at tip of injector contains a series of
calibrated openings which directs fuel into manifold in a
cone-shaped spray pattern.

34 KohlerEngines.com 32 690 12 Rev. --

 EFI SYSTEM

High pressure fuel line is an assembly of hoses, injector IMPORTANT NOTES!

caps and a fuel connector to fuel pump module. High ● Cleanliness is essential and must be maintained at all
pressure fuel line feeds fuel to top of injectors through times when servicing or working on EFI system. Dirt,
injector caps. Caps are fastened to intake manifold and even in small quantities, can cause significant
injectors are locked into place. A small retaining clip problems.
provides a secondary lock.
High pressure fuel line is serviced as a complete ● Clean any joint or fitting with parts cleaning solvent
assembly to prevent tampering and safety hazards. before opening to prevent dirt from entering system.
Components are not individually serviceable.
Vent hose assembly is intended to vent fuel vapor out of ● Always depressurize fuel system through fuel
fuel pump module and direct fuel vapor into throttle body. connector on fuel pump module before disconnecting
All EFI engines are equipped with an engine mounted or servicing any fuel system components.
purge port. This capped purge port can be used by OEM
to vent fuel tanks or used in conjunction with a carbon ● Never attempt to service any fuel system component
canister kit for Tier III evaporative emissions compliance. while engine is running or ignition switch is ON.
Purge port connects to vent hose assembly and directs
all fuel vapor into throttle body. If purge port remains ● Do not use compressed air if system is open. Cover
unused, port must remain capped to prevent dirt from any parts removed and wrap any open joints with
entering engine. plastic if they will remain open for any length of time.
New parts should be removed from their protective
EFI engines have no carburetor, so throttle function packaging just prior to installation.
(regulate incoming combustion airflow) is achieved with
a throttle valve in a separate throttle body attached to ● Avoid direct water or spray contact with system
intake manifold. Throttle body/intake manifold provides components.
mounting for fuel injectors, throttle position sensor,
TMAP sensor, high pressure fuel line, idle speed screw, ● Do not disconnect or reconnect ECU wiring harness
and air cleaner assembly. connector or any individual components with ignition
Idle speed is only adjustment that may be performed on on. This can send a damaging voltage spike through
EFI system. Standard idle speed setting for EFI engines ECU.
is 1500 RPM, but certain applications might require
a different setting. Check equipment manufacturer’s ● Do not allow battery cables to touch opposing
recommendation. terminals. When connecting battery cables attach
positive (+) cable to positive (+) battery terminal first,
For starting and warm up, ECU will adjust fuel and followed by negative (-) cable to negative (-) battery
ignition timing, based upon ambient temperature, engine terminal.
temperature, and loads present. In cold conditions,
idle speed will probably be different than normal for a ● Never start engine when cables are loose or poorly
few moments. Under other conditions, idle speed may connected to battery terminals.
actually start lower than normal, but gradually increase
to established setting as operation continues. Do not ● Never disconnect battery while engine is running.
attempt to circumvent this warm up period, or readjust
idle speed during this time. Engine must be completely ● Never use a quick battery charger to start engine.
warmed up, in closed loop operating mode for accurate
idle adjustment. ● Do not charge battery with key switch ON.

● Always disconnect negative (-) battery cable before

charging battery, and also unplug harness from ECU
before performing any welding on equipment.

32 690 12 Rev. -- KohlerEngines.com 35

EFI SYSTEM

ELECTRICAL COMPONENTS Grey Connector Side

Electronic Control Unit (ECU) Pin # Description
Pinout of ECU 1 Not Used
Black Connector Side 2 Not Used
Pin # Function 3 Malfunction Indicator Light (MIL) Ground
1 Ignition Coil #1 Ground 4 Not Used
2 Battery Ground 5 Not Used
3 Diagnostic Communication Line 6 Not Used
4 Speed Sensor input 7 Not Used
5 Fuel Injector Output #1 Ground 8 Not Used
6 Fuel Injector Output #2 Ground 9 Battery Ground
7 Oxygen Sensor Heater 10 Ignition Coil #2 Ground
8 Intake Air Temperature (TMAP) sensor input 11 Not Used
9 Fuel Pump Ground 12 Not Used
10 Ground for TPS, TMAP, O2 and
Engine Temperature Sensors
13 Not Used
14 Safety Switch Ground
Manifold Absolute Pressure (TMAP) sensor 15 Not Used
11 input
16 ECU
12 Throttle Position Sensor (TPS) input 17 Fuel Pump Control (+12V)
13 Speed Sensor Ground 18 Not Used
14 Engine Temperature Sensor input
15 Ignition Switch (Switched +12V)
16 Power for TPS and TMAP Sensors (+5V)
17 Oxygen Sensor (O2) input
18 Battery Power (Permanent +12V)

ECU
BLACK CONNECTOR SIDE GREY CONNECTOR SIDE

Pinout of ECU

36 KohlerEngines.com 32 690 12 Rev. --

 EFI SYSTEM

Never attempt to disassemble ECU. It is sealed to TPS Learn Procedure

prevent damage to internal components. Warranty is 1. Turn idle screw clockwise one full turn prior to key/
void if case is opened or tampered with in any way. ignition ON after ECU Reset.
All operating and control functions within ECU are 2. Start engine, run at low idle until engine is warm.
preset. No internal servicing or readjustment may 3. Idle speed must be above 1500 RPM. If below 1500
be performed. If a problem is encountered, and you RPM, turn idle screw up to 1700 RPM and then shut
determine ECU to be faulty, contact your source of down engine and perform ECU Reset again.
supply.
4. Restart engine, adjust idle speed down to 1500
ECU pins and/or connectors are coated at factory with RPM. Allow engine to dwell at 1500 RPM for about 3
a thin layer of electrical grease to prevent fretting and seconds.
corrosion. Do not attempt to remove grease from ECU
pins and/or connectors. 5. After this, adjust idle speed to final specified speed
setting.
Relationship between ECU and throttle position sensor
(TPS) is very critical to proper system operation. If 6. Turn key/ignition OFF and count to 10 seconds.
TPS or ECU is changed, or mounting position of TPS Learn procedure is complete.
is altered, appropriate TPS Learn Procedure must be
performed to restore synchronization.
Any service to ECU, TPS/Throttle Body (including idle
speed increase over 300 RPM), or fuel pump module
replacement should include ECU Reset.
This will clear all trouble codes, all closed loop learned
offsets, all max values, and all timers besides permanent
hour meter.
This system will NOT reset when battery is
disconnected!
ECU Reset Procedure
1. Turn key/ignition OFF.
2. Install Red wire jumper from Kohler EFI service kit
on to service port (connect white wire to black wire in
4 way diagnostic port).
3. Turn key/ignition ON, then OFF and count 10
seconds.
4. Turn key/ignition ON, then OFF and count to 10
seconds a second time.
5. Remove Red wire jumper. Turn key/ignition ON, then
OFF and count to 10 seconds a third time. ECU is
reset.
A TPS Learn Procedure must be performed after ECU
Reset.

32 690 12 Rev. -- KohlerEngines.com 37

38
Wiring Diagram
O AJ
F
1 2
N M 3 2 1

6 5 4
T
EFI SYSTEM

B U
I S
Q R AL
P A
H C

1
10
AK
A K J

9
18
W V

1
10
X

M M M K B G

KohlerEngines.com
9
18
G B F B B M B H H D B F H M G M L E L J M
3 4

A B A B A B C A B C 1 2 A B C D A B C 1 2 3 4 1 2

Z AA AB AC AD AE AF AG AH AI

A Red B Red/Black C Red/White D Yellow E Light Green

F Dark Green G Dark Blue H Purple I Pink J Tan
K White L Grey M Black N Stator O Rectifier-Regulator
30A Fuse
P Q Battery R Fuel Pump S 6-Terminal Connector T MIL
(Charging System)
10A Fuse 10A Fuse
U Oil Pressure Switch V W X Black Connector Y Grey Connector
(Ignition Switch) (Battery Power)
Crankshaft Position
Z Fuel Injector #1 AA Fuel Injector #2 AB Ignition Coil #1 AC Ignition Coil #2 AD Sensor
Throttle Position Engine Temperature
AE Oxygen Sensor AF AG TMAP Sensor AH AI Diagnostic Connector
Sensor Sensor
Battery Source (OEM Switched Power (OEM Key Switch (OEM
AJ AK AL
Supplied) Supplied) Supplied)

32 690 12 Rev. --
 EFI SYSTEM

Crankshaft Position Sensor Throttle Position Sensor (TPS)

TPS is a sealed, non-serviceable assembly. If diagnosis
indicates a bad sensor, complete replacement is
necessary. A magnet that sensor detects is separate,
and can be replaced or reused. If a blink code indicates
a problem with TPS, it can be tested as follows:
Diagnostics of sensor: ECU will have electrical faults
captured in fault codes P0122 and P0123. Fault code
P0122 detecting low voltage, open circuit, and P0123 for
high voltage conditions between ECU, wire harness, and
sensor. Tip: when working with any electrical connection,
A sealed, non-serviceable assembly. If fault code P0337 remember to keep connections clean & dry. This is best
is present and engine does not start/run, proceed to step accomplished by cleaning connection thoroughly prior
1. If P0337 is present and engine operates, clear codes to disassembly. Contaminated sensor connections can
and retest. If Fault Code diagnosis indicates a problem cause premature engine faults. Functionally testing
within this area, test and correct as follows. sensor can no longer be done with simple resistance
checks. If either of these two faults is present or a TPS
1. Inspect wiring and connections for damage or fault is suspected, recommended diagnostic test is as
problems. follows:
2. Make sure engine has resistor type spark plugs. If a computer with diagnostic software is available
3. Disconnect Black connector from ECU. Observe throttle percent and raw TPS values through
4. Connect an ohmmeter between #4 and #13 pin diagnostic software. With diagnostic software
terminals. A resistance value of 325-395 Ω at room communicating to ECU and key ON engine not running,
temperature (20°C, 68°F) should be obtained. these values can be observed while throttle is moved
5. If resistance is incorrect, remove blower housing. from closed to full open position. There should be a
smooth and repeatable throttle percent value starting
6. Disconnect crankshaft position sensor connector at closed position reading between 0 (about 6.5%) to
from wiring harness. Test resistance between WOT position reading 93 (100%). If one of these values
terminals. A reading of 325-395 Ω should again be is outside of specified range and output transitions
obtained. in a smooth manner, reset ECU and run test again.
Since there are no longer any wear elements inside
a. If resistance is incorrect, remove screw securing sensor, most likely faults will be in electrical connections
sensor to crankcase and replace sensor. between sensor and wire harness and wire harness to
b. If resistance in step 4 was incorrect, but ECU. With service software communicating to ECU and
resistance of sensor alone was correct, test wire engine not running, a small load or gentle back and forth
harness circuits between sensor connector motion can be applied to connectors or wires just outside
terminals and corresponding pin terminals (#4 connectors to detect a faulty connection.
and #13) in main connector. Correct any If only a volt meter is available
observed problem, reconnect sensor, and
perform step 4 again. Measure voltage supply to sensor from ECU. This
voltage should be 5.00 +/- 0.20 volts. This can be
7. If resistance is correct from step 4, check mounting, measured by gently probing terminals B & C on harness
flywheel teeth (damage, run-out, etc.), and flywheel side with TPS connector removed from TPS and key
key. ON. This will generate a P0122 fault that can be cleared
8. When fault is corrected and engine starts, clear fault with an ECU reset. If voltage is low, battery, harness and
codes following ECU Reset procedure. ECU should be investigated. If supply voltage is good,
plug sensor back into harness. Probe sensor signal
wire with volt meter, terminal A at TPS or pin Black 12 at
ECU. This signal should start between 0.6-1.2 volts at
low idle and grow smoothly as throttle is opened to 4.3-
4.8 volts at full open (WOT). Since there are no longer
any wear elements inside sensor, most likely faults will
be in electrical connections between sensor and wire
harness and wire harness to ECU.

32 690 12 Rev. -- KohlerEngines.com 39

EFI SYSTEM

Replace magnet assembly Engine Temperature Sensor

Magnet Installation
A Magnet Assembly B A Engine Temperature Sensor
Depth
Magnet assembly is captured in a small plastic housing NOTE: Engine temperature sensor resembles a ground
that is press fit to end of throttle shaft. This generally wire.
does not need replacement. If replacement is required, it A sealed, non-serviceable assembly. A faulty sensor
can be replaced as follows: requires a wire harness replacement. If a blink code
1. Remove sensor from throttle body, exposing round indicates a problem with temperature sensor, it can be
magnet assembly. tested as follows:
2. A pair of flat blade screw drivers or a spanner tool 1. Shut off engine and allow it to return to room
can be used to pry this off shaft. Caution should be temperature (25°C, 77°F).
used to avoid damage to machined flat surface that 2. With sensor still connected, check temperature
sensor seals against. Also, make sure throttle blade sensor circuit resistance between Black pin 10 and
is in full open position to avoid driving throttle blade 14 terminals. Value should be 9000-11000 Ω.
into throttle bore causing damage to blade and/or 3. If resistance is out of specifications, replace wire
bore. harness.
3. When replacing magnet assembly, alignment is
critical. There is a D-shaped drive feature on end of Temperature/Manifold Absolute Pressure (TMAP)
shaft and a matching pocket in magnet assembly. Sensor
On outer diameter of magnet assembly is a notch A sealed non-serviceable integrated sensor that checks
that aligns with center of flat feature of D. Align this both intake air temperature and manifold absolute
notch and flat of D feature in shaft and preassemble pressure. Complete replacement is required if it is faulty.
parts. Sensor and wiring harness can be checked as follows.
4. With throttle blade in full open position (WOT), press If a blink code indicates a problem with Intake Air
magnet assembly fully on to throttle shaft. Full Temperature (TMAP) Sensor Circuit (P0112 or P0113), it
insertion can be checked by measuring height from can be tested as follows:
throttle body sensor mounting face to end of magnet
assembly. This should be no more than 8.6 mm 1. Remove TMAP sensor from intake manifold.
(0.338 in.). Installation process requires significant 2. Allow it to reach room temperature (20°C, 68°F).
force, so take care that all parts are aligned. Tapping
magnet assembly on can fracture/damage brittle 3. Unplug Black connector from ECU.
magnet within assembly and throttle body assembly 4. With sensor still connected, check temperature
and is NOT RECOMMENDED. sensor circuit resistance between Black pins 10 and
8. Value should be 1850-2450 Ω.
5. Unplug sensor from wire harness and check sensor
resistance separately across pins. Resistance value
should again be 1850-2450 Ω.
a. If resistance is out of specifications, check local
temperature. Sensor resistance will go down as
temperature is higher. Replace TMAP sensor if
determined to be faulty.
b. If it is within specifications, proceed to Step 6.

40 KohlerEngines.com 32 690 12 Rev. --

 EFI SYSTEM

6. Check circuits (input, ground), from main harness Style 2 (Larger Sensor)
connector to sensor plug for continuity, damage, etc.
Connect one ohmmeter lead to Black pin 8 in main
harness connector (as in step 4). Connect other lead
to terminal #3 in sensor plug. Continuity should be
indicated. Repeat test between Black pin 10 and
terminal #4 in sensor plug.
Pin A
7. Reinstall sensor.
Pin D Pin B
If a blink code indicates a problem with Manifold
Absolute Pressure (TMAP) Sensor Circuit (P0107 or Pin C
P0108), it can be tested as follows:
B
1. Make sure all connections are making proper
contact and are free of dirt and debris. Slide locking
tab out and pull off TMAP connector. Turn key switch
to ON and check with a volt meter by contacting red A
lead to pin 1 and black lead to pin 2. There should
be 5 volts present, indicating ECU and wiring Purple Wire, White Wire,
harness are functioning. Pin A Pin B
Heater + Heater -
2. Check continuity in wire harness. Ohms between Pin
Pin C Black Wire, Sensor Pin D Grey Wire, Sensor
3 at sensor connector and Black pin 11 connector at Output Ground
ECU should be near zero ohms. If no continuity is 22 mm or 7/8 in. 18 mm x 1.5
measured or very high resistance, replace wire A B
Wrench Size Thread Size
harness.
Installation Torque 50.1 N·m (37 ft. lb.)
3. Check to make sure intake manifold is not loose and
TMAP sensor is not loose. Loose parts would allow
a vacuum leak, making TMAP sensor report Cutaway Oxygen Sensor Components (O2)
misleading information to ECU. G
D
a. Tighten all hardware and perform an ECU Reset E F
and a TPS Learn Procedure to see if MIL will
display a fault with sensor again. If MIL finds a A C
fault with TMAP sensor, replace it. B
Oxygen Sensor (O2)
Identify style of sensor to ensure proper testing and
installation torque.
Style 1 (Smaller Sensor)

Pin A Planar Element

A Protection Shield B and Heater
Pin D Pin B Stainless Steel
C Lower Insulator D Housing
Pin C Terminal Connection
E Upper Insulator F to Element
High Temp
G Water Seal
Temperature must be controlled very accurately and gas
A B constituents measured to a high degree of accuracy for
absolute sensor measurements. This requires laboratory
Purple Wire, White Wire, equipment to determine a good or bad sensor in field.
Pin A Pin B Furthermore, as with most devices, intermittent problems
Heater + Heater -
are difficult to diagnose. Still, with a good understanding
Grey Wire, Sensor Black Wire, Sensor of system and sensor, it is possible to diagnose many
Pin C Pin D
Output Ground sensor problems in field.
14 mm or 9/16 in. 12 mm x 1.25
A B
Wrench Size Thread Size
Installation Torque 18 N·m (159 in. lb.)

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EFI SYSTEM

Using diagnostic software connected to ECU is a useful 2. Reconnect sensor and start engine. Run engine at
technique for observing sensor performance. However, sufficient speed to bring sensor and engine up to
user must understand that such software reads a signal operating temperature (engine temperature of 150°F
generated by ECU. If there is an ECU or wiring problem, (66°C) or more displayed by diagnostic software).
readings could be misinterpreted as a sensor problem. Maintained throttle openings of less than 40%
Digital nature of signal to software means that it is not typically display rich biased values of 500 to 1000
reading continuous output of sensor. A voltmeter can mv (0.500 to 1.000 Volts). Maintained throttle
also be used as an effective tool in diagnosing sensors. openings of more than 40% typically display lean
It is advisable to use an electronic meter such as a biased values of 100 to 500 mv (0.100 to 0.500
digital voltmeter. Simple mechanical meters may place Volts). Occasional spikes outside these values is
a heavy electrical load on sensor and cause inaccurate normal. Lack of continuous fluctuation is not an
readings. Since resistance of sensor is highest at indication of a defective sensor.
low temperatures, such meters will cause largest 3. Check engine harness for battery voltage on heater
inaccuracies when sensor is in a cool exhaust. circuit.
Visual Inspection Removal Inspection
NOTE: Perform these visual inspections before using NOTE: Apply anti-seize compound only to threads.
guided troubleshooting provided by diagnostic Anti-seize compound will affect sensor
software to prevent misdiagnosis. performance if it gets into lower shield of
1. Look for a damaged or disconnected sensor-to- sensor.
engine harness connection. 1. If sensor has heavy deposits on lower shield,
2. Look for damage to sensor lead wire or associated engine, oil, or fuel may be source.
engine wiring due to cutting, chaffing or melting on a 2. If heavy carbon deposits are observed, incorrect
hot surface. engine fuel control may be occurring.
3. Disconnect sensor connector and look for corrosion 3. With sensor at room temperature, measure heater
in connector. circuit resistance, purple wire (Pin A) and white wire
4. Try reconnecting sensor and observe if problem has (Pin B).
cleared. Style 1 (Smaller Sensor) resistance should be
5. Correct any problems found during visual check. 16.5-19.5 Ω.
6. Inspect for any exhaust system leaks upstream or Style 2 (Larger Sensor) resistance should be
downstream of oxygen sensor. Confirm oxygen 8.1-11.1 Ω.
sensor is secured to exhaust with appropriate 4. If a damaged sensor is found, identify root cause,
torque. which may be elsewhere in application. Refer to
Style 1 (Smaller Sensor) 18 N·m (159 in. lb.). Troubleshooting-Oxygen Sensor (O2) table.
Style 2 (Larger Sensor) 50.1 N·m (37 ft. lb.). 5. A special "dry to touch" anti-seize compound is
All leaks must be repaired and an ECU/TPS reset applied to all new oxygen sensors at factory. If
must be performed before proceeding with sensor recommended mounting thread sizes are used, this
testing. material provides excellent anti-seize capabilities
and no additional anti-seize is needed. If sensor is
7. Using diagnostic software, document any trouble removed from engine and reinstalled, anti-seize
codes. Determine if historic trouble codes are compound should be reapplied. Use an oxygen
logically related to current fault experienced. If sensor safe type anti-seize compound. It should be
uncertain, clear codes and retest. applied according to directions on label. Torque
Sensor Signal Observation sensor to appropriate torque.
NOTE: Do not cut into or pierce sensor or engine Style 1 (Smaller Sensor) 18 N·m (159 in. lb.).
wiring to make this connection. Sensor
produces a very small signal. Corrosion or Style 2 (Larger Sensor) 50.1 N·m (37 ft. lb.).
damage to wiring could lead to an incorrect
signal because of repairs or contamination to
sensor.
1. With key ON and sensor unplugged, using a digital
voltmeter, observe voltage between Pin C and Pin D
of engine wiring harness. Voltage should read
approximately 5.0 volts. With sensor attached, using
diagnostic software, O2 volts displayed should be
more than 1.0 volt. This voltage is generated by
ECU. If not present, there may be a power and/or
ground supply fault to engine harness or ECU, a
fault of engine harness itself (refer to Visual
Inspection), or a fault of ECU.

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Troubleshooting-Oxygen Sensor (O2)

Condition Possible Cause Conclusion
Continuous low voltage output Shorted sensor or sensor circuit. Replace sensor or replace and
(less than 400mV) observed with Shorted lead wire. properly route wiring.
throttle openings of 40% or more
(lean biased condition). Wiring shorted to ground.
Upstream or downstream exhaust Repair all exhaust leaks and secure
Fault codes P0131, P0171, or leaks observed. sensor to appropriate torque.
P0174 may set.
Air leak at sensor. Style 1 (Smaller Sensor)
18 N·m (159 in. lb.).
Style 2 (Larger Sensor)
50.1 N·m (37 ft. lb.).
Restricted fuel supply. Resolve fuel supply issues from tank
to engine. Test fuel pressure. Perform
repairs necessary.
Misfire A misfire causing incomplete
combustion will result in lean (low
voltage) values.
Lean biased sensor failure. Replace sensor.
Continuous high voltage output Silica poisoning. Replace sensor. Identify and resolve
(600mV or more) observed with root cause.
throttle openings of 40% or less Contaminated gasoline. Purge fuel system and retest.
(rich biased condition).
Wiring shorted to voltage. Replace damaged harness.
Fault codes P0172 or P0132 may Overly rich condition due to unmetered Test fuel pressure. Inspect fuel pump
set. fuel entering combustion chamber. vent and evaporative emissions hoses
for raw fuel flow.
Inspect engine oil for fuel
contamination; drain and refill if
suspect.
Perform repairs as necessary.
Cold engine. Engine temperature Normal operation, or engine operated
below 150°F (66°C) as displayed by in an excessively cold environment.
diagnostic software.
Rich biased sensor failure. Replace sensor.
No activity from sensor. Heater circuit open or shorted. Replace sensor.
Engine keyed ON with sensor Secure and/or confirm sensor
Diagnostic software displays disconnected. connection and clear codes.
1.015 Volts continuously.
Historic codes.
Fault codes P0031 or P0032 may Contaminated gasoline. Purge fuel system and retest.
set.

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EFI SYSTEM

Fuel Injectors 2. Disconnect electrical connector from an injector and

listen for a change in idle performance (only running
on one cylinder) or a change in injector noise or
WARNING vibration.
Explosive Fuel can cause fires and severe If an injector is not operating, it can indicate either a bad
burns. injector, or a wiring/electrical connection problem. Check
Fuel system ALWAYS remains under HIGH as follows:
PRESSURE. 1. Disconnect electrical connector from both injectors.
Plug a 12 volt noid light into one connector.
Wrap a shop towel completely around fuel pump
module connector. Press release button(s) and slowly 2. Make sure all safety switch requirements are met.
pull connector away from fuel pump module allowing Crank engine and check for flashing of noid light.
shop towel to absorb any residual fuel in high pressure Turn key OFF for at least 10 seconds between tests
fuel line. Any spilled fuel must be completely wiped up to allow ECU to go to sleep and reawake. Repeat
immediately. test at other connector.
Details a. If flashing of noid light occurs, use an ohmmeter
(Rx1 scale) and check resistance of each injector
across two terminals. Proper resistance is 11-13
Ω. If injector resistance is incorrect, replace
B A injector.
If injector resistance is correct, visually inspect
connection between connector and injector
terminals. Terminals should be free of corrosion,
wear, or dirt. If a problem is found, clean/repair/
replace as needed.
b. If no noid light flashing occurs, reattach
connectors to both injectors. Disconnect black
connector from ECU. Use an ohmmeter (Rx1
C scale) and check injector circuit resistance
D between black pins 5 and 15 for injector #1, and
pins 6 and 15 for injector #2. Proper resistance
E should be 11-13 Ω for each. If circuit resistance is
incorrect, check all electrical connections,
connectors, and wiring harness leads for issues.
F G
If circuit resistance is found to be correct, injector
H I circuit is inactive (no noid light operation) due to
other problems within system. Test and inspect
A Electrical Connection B Upper O-ring for proper system operating voltage and
C Solenoid Winding D Armature appropriate grounds. Correct or repair any
problem found.
E Valve Housing F Valve Seat
Injector leakage is very unlikely, but in those rare
G Valve End H Lower O-ring instances it can be internal (past tip of valve needle),
I Director Plate or external (weeping around injector O-rings). Loss
NOTE: Do not apply voltage to fuel injector(s). of system pressure from leakage can cause hot
Excessive voltage will burn out injector(s). Do restart problems and longer cranking times. Refer to
not ground injector(s) with ignition ON. Disassembly for removal of injector.
Injector(s) will open/turn on if system is 1. Remove manifold mounting bolts and separate
energized. throttle body/manifold from engine leaving TPS, high
NOTE: When cranking engine with injectors pressure fuel line, injectors and fuel line connections
disconnected, fault codes will be registered in intact. Discard old gaskets.
ECU and will need to be cleared using software 2. Position manifold assembly over an appropriate
fault clear or an ECU Reset and TPS Learn container to capture fuel and turn key switch ON to
Procedure. activate fuel pump and pressurize system. Do not
Injector problems typically fall into three general turn switch to START position.
categories: electrical, leakage, or dirty/clogged. An NOTE: Fuel pump module pins are coated with a thin
electrical problem usually causes one or both of injectors layer of electrical grease to prevent fretting and
to stop functioning. Several methods may be used to corrosion. Do not attempt to remove electrical
check if injectors are operating. grease from fuel pump module pins.
1. With engine running at idle, listen for a buzzing or 3. If either injector exhibits leakage of more than two to
clicking sound. four drops per minute from tip, or shows any sign of
leakage around outer shell, turn ignition switch OFF
and replace injector as follows.

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4. Depressurize fuel system. 1. To check cylinder coil 1 (starter side), disconnect

5. Clean any dirt accumulation from sealing/mounting Black connector from ECU and test between Black
area of faulty injector(s) and disconnect electrical pins 1 and 15. To check cylinder coil 2 (oil filter side),
connector(s). disconnect Grey connector from ECU and test
between Grey pins 10 and 17. Wiring and coil
6. Pull retaining clip off top of injector(s). Remove primary circuits are OK if readings are 0.5-0.8 
screw holding injector(s) from manifold.
2. If reading(s) are not within specified range, check
7. Reverse appropriate procedures to install new and clean connections and retest.
injector(s) and reassemble engine. Use new O-rings
and retaining clips any time an injector is removed 3. If reading(s) are still not within specified range, test
(new replacement injectors include new O-rings and coils separately from main harness as follows:
retaining clips). Lubricate O-rings lightly with clean a. Remove screw retaining coil to housing and
engine oil. Use installation tool provided with O-rings disconnect primary leads connector.
to install new upper O-ring. Place tool into fuel b. Connect an ohmmeter set on Rx1 scale to
injector inlet. Place one side of O-ring into O-ring primary terminals of coil. Primary resistance
groove and roll O-ring over tool onto fuel injector. should be 0.5-0.8 Ω.
Torque screw securing fuel injector caps to 7.3 N·m
(65 in. lb.). An ECU Reset and TPS Learn Procedure c. Connect an ohmmeter set on Rx10K scale
will need to be completed. between spark plug boot terminal and B+ primary
terminal. Secondary resistance should be 6400-
Injector problems due to dirt or clogging are generally 7800 Ω.
unlikely due to design of injectors, high fuel pressure,
and detergent additives in gasoline. d. If secondary resistance is not within specified
range, coil is faulty and needs to be replaced.
Symptoms that could be caused by dirty/clogged
injectors include rough idle, hesitation/stumbling during FUEL COMPONENTS
acceleration, or triggering of fault codes related to fuel
delivery. Injector clogging is usually caused by a buildup WARNING
of deposits on director plate, restricting flow of fuel,
resulting in a poor spray pattern. Some contributing Explosive Fuel can cause fires and severe
factors to injector clogging include higher than normal burns.
operating temperatures, short operating intervals, and Fuel system ALWAYS remains under HIGH
dirty, incorrect, or poor quality fuel. Cleaning of clogged PRESSURE.
injectors is not recommended; they should be replaced.
Additives and higher grades of fuel can be used as a Wrap a shop towel completely around fuel pump
preventative measure if clogging has been a problem. module connector. Press release button(s) and slowly
pull connector away from fuel pump module allowing
Ignition Coils shop towel to absorb any residual fuel in high pressure
If a coil is determined to be faulty, replacement is fuel line. Any spilled fuel must be completely wiped up
necessary. Refer to Electronic Ignition System tests immediately.
and Spark Testing before performing electrical tests
below. An ohmmeter may be used to test wiring and coil Fuel Pump Module (FPM)
windings. FPM is not serviceable and must be replaced if
NOTE: Do not ground primary coil with ignition ON as determined to be faulty. If a FPM problem is suspected,
they may overheat or spark. make certain pump is being activated, all electrical
connections are properly secured and fuses are good. If
NOTE: Always disconnect spark plug lead from spark required, testing of FPM may be conducted.
plug before performing following tests.
1. Relieve fuel pressure at FPM. FPM may need to be
NOTE: If ignition coil(s) are disabled and an ignition loosened or pulled away from engine. Press release
fault is registered, system will automatically button(s) and slowly pull connector away from FPM
disable corresponding fuel injector drive allowing shop towel to absorb any residual fuel in
signal. Fault must be corrected to ignition coil high pressure fuel line. Insert pressure test jumper
and ECU power (switch) must be turned OFF for (from Kohler EFI Service Kit) between high pressure
10 seconds for injector signal to return. This is a fuel line and FPM.
safety measure to prevent bore washing and oil
dilution. 2. Connect black hose of Pressure Tester. Route clear
hose into a portable gasoline container or equipment
Testing fuel tank.
Main purpose of performing ignition coil resistance test 3. Turn on key switch to activate pump and check
is to identify if primary (low voltage) and secondary (high system pressure on gauge. It may take several key
voltage) circuits are shorted to each other or ground. cycles to compress air introduced into system and
Coil resistance readings will vary based on temperature. reach regulated pressure. System pressure of 39 psi
If coil passes spark testing, and primary and secondary ± 3 should be present. Turn key switch OFF and
circuits are not shorted, resistance variations outside depress valve button on tester to relieve system
specified range may be normal due to temperature. pressure.
Using an ohmmeter set on Rx1 scale, check resistance a. If pressure is too high or too low, proceed to
in circuits as follows: troubleshooting.

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EFI SYSTEM

4. If pump did not activate (step 3), confirm that safety system on equipment is not active. One potential cause of
unnecessary FPM replacement may involve measuring voltage at FPM electrical connector. Using a Digital Volt
Ohm Meter (DVOM) will provide a reading near battery voltage, even when ECU is not grounding FPM circuit.
a. Connect a DVOM across terminals in plug, turn on key switch and confirm battery voltage is present during six
second prime process.
b. Test light confirmation: Turn key off. Disconnect DVOM. Connect 12 volt test light across terminals in plug. Key
needs to remain off for a minimum of 30 seconds before proceeding. Turn key on. Confirm test light illuminates
for approximately 6 seconds. After approximately 6 seconds, test light will remain off unless another prime
cycle is initiated.
5. If battery voltage is not present and/or test light does not illuminate, connect red lead of DVOM to red wire of plug
and black lead to a battery ground while key is still ON.
6. If battery voltage is present, turn key switch OFF and connect an ohmmeter between terminals on FPM to check
for continuity. If battery voltage at plug was confirmed, and there was continuity across FPM terminals, reconnect
plug to FPM, making sure you have a good connection. Turn on key switch and listen for FPM to activate.
a. If FPM starts, repeat steps 2 and 3 to verify correct pressure.
b. If FPM still does not operate, replace it.
7. If battery voltage was not present at connector inspect fuse and wiring harness.
High Pressure Fuel Line
High pressure fuel line is mounted to intake manifold. No specific servicing is required unless operating conditions
indicate that it needs replacement. Thoroughly clean area around all joints and relieve any pressure before starting
any disassembly. Detach by removing two mounting screws, wire ties, and injector retaining clips.
Purge Port and Vent Hose Assembly
No specific servicing is required for vent hose assembly or purge port unless operating conditions indicate
replacement is required. All components are serviced individually. Abrasion sleeves on hoses should be reused
or replaced when servicing vent hoses. Please note vent hose routing and replicate after service or component
replacement to prevent pinching or abrasion of vent hoses. Only Kohler replacement parts can be used because fitting
is specific to system and must be maintained. Visit KohlerEngines.com for recommended Kohler replacement parts.
Throttle Body/Intake Manifold Assembly
NOTE: ECU Reset is required if throttle body is replaced.
Throttle body is serviced as an assembly, with throttle shaft, TPS, throttle plate, and idle speed adjusting screw
installed. Throttle shaft rotates on needle bearings (non-serviceable), capped with seals to prevent air leaks.
TROUBLESHOOTING
Troubleshooting Guide
Condition Possible Cause
Fuel pump not running.
Faulty spark plugs.
Old/stale fuel.
Incorrect fuel pressure.
Crankshaft position sensor loose or faulty.
TPS set incorrect (ECU Reset and TPS Learn).
Engine Starts Hard
or Fails to Start TPS faulty.
When Cold.
Engine temp sensor faulty.
Faulty coils.
Low system voltage.
Faulty injectors.
Faulty battery.
Loose or corroded connections.

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 EFI SYSTEM

Troubleshooting Guide
Condition Possible Cause
Faulty spark plugs.
Fuel pump not running.
Fuel pressure low.
Insufficient fuel delivery.
Engine Starts Hard
or Fails to Start TPS set incorrect (ECU Reset and TPS Initialization).
When Hot.
Crankshaft position sensor loose or faulty.
TPS faulty.
Engine temp sensor faulty.
Faulty injectors.
Faulty spark plugs.
Insufficient fuel delivery.
Engine Stalls or TPS set incorrect.
Idles Roughly
(cold or warm). TPS faulty.
Faulty engine temperature sensor.
Faulty injectors.
Fuel injector(s), fuel filter, fuel line, or fuel pick-up dirty/restricted.
Dirty air cleaner.
Engine Misses, Insufficient fuel pressure or fuel delivery.
Hesitates, or Stalls Vacuum (intake air) leak.
Under Load.
Improper governor setting, adjustment or operation.
TPS faulty, mounting problem or TPS Initialization Procedure incorrect.
Bad coil(s), spark plug(s), or wires.
Dirty air filter.
Insufficient fuel delivery.
Basic engine problem exists.
Improper governor adjustment.
Low Power Plugged/restricted exhaust.
Faulty/malfunctioning ignition system.
One injector not working.
TPS faulty or mounting problem.
Throttle plate in throttle body not fully opening to WOT stop (if equipped).

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EFI SYSTEM

Function Test Fault Codes

Example of Diagnostic Display
WARNING
(0)
High Pressure Fluids can puncture skin and
cause severe injury or death. One second pause
Do not work on fuel system without proper (1)
training or safety equipment. Fault
One second pause Code
Fluid puncture injuries are highly toxic and hazardous. 0107
If an injury occurs, seek immediate medical attention. (0)
Function of fuel system is to provide sufficient delivery One second pause
of fuel at system operating pressure of 39 psi ± 3. If an (7)
engine starts hard, or turns over but will not start, it may
indicate a problem with EFI fuel system. A quick test will
verify if system is operating.
Three second pause
1. Disconnect and ground spark plug leads.
2. Complete all safety interlock requirements and crank (6)
engine for approximately 3 seconds.
One second pause
3. Remove spark plugs and check for fuel at tips. End Code 61
(1)
a. If there is fuel at tips of spark plugs fuel pump and
injectors are operating.
b. If there is no fuel at tips of spark plugs, check
following:
1. Make sure fuel tank contains clean, fresh,
proper fuel.
2. Make sure that vent in fuel tank is open.
3. Make sure fuel tank valve (if equipped) is fully
opened.
4. Make sure battery is supplying proper voltage.
5. Check that fuses are good, and that no
electrical or fuel line connections are damaged
or broken.
6. Test fuel pump module operation as described
earlier under Fuel Pump Module (FPM).

Diagnostic Fault Code Summary

Fault Code Connection or Failure Description
0031 Oxygen Sensor Heater Circuit Low Voltage
0032 Oxygen Sensor Heater Circuit High Voltage
0107 Manifold Absolute Pressure (TMAP) Circuit Low Voltage or Open
0108 Manifold Absolute Pressure (TMAP) Circuit High Voltage
0112 Intake Air Temperature (TMAP) Circuit Low Voltage
0113 Intake Air Temperature (TMAP) Circuit High Voltage or Open
0117 Engine Temperature Sensor Circuit Low Voltage
0118 Engine Temperature Sensor Circuit High Voltage or Open
0122 Throttle Position Sensor Circuit Low Voltage or Open
0123 Throttle Position Sensor Circuit High Voltage
0131 Oxygen Sensor 1 Circuit Low Voltage, or Open
0132 Oxygen Sensor 1 Circuit High Voltage
0171 Maximum Adaptation Limit Exceeded
0172 Minimum Adaptation Limit Exceeded
0174 Lean Fuel Condition at High Load (Open Loop)
0201 Injector 1 Circuit Malfunction
0202 Injector 2 Circuit Malfunction

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 EFI SYSTEM

0230 Fuel Pump Module Circuit Low Voltage or Open

0232 Fuel Pump Module Circuit High Voltage
0336 Crankshaft Position Sensor Noisy Signal
0337 Crankshaft Position Sensor No Signal
0351 Cylinder 1 Ignition Coil Malfunction
0352 Cylinder 2 Ignition Coil Malfunction
0562 System Voltage Low
0563 System Voltage High
0650 MIL Circuit Malfunction
61 End of Code Transmission
ECU continuously monitors engine operation against A MIL may not be provided with engine. If equipment
preset performance limits. If operation is outside limits, manufacturer has not added a MIL to equipment, one
ECU activates MIL, if equipped, and stores a diagnostic can be added easily for quick diagnostics. Main engine
code in its fault memory. If component or system to vehicle connection will have a tan wire which is
returns to proper function, ECU will turn off MIL. If MIL ground for MIL. Either incandescent or LED type bulbs
stays illuminated, it warns customer a fault is currently can be used for MIL as long as they do not draw more
happening, and dealer service is required. Upon receipt, than 0.1 amps. Bulb needs to be rated at 1.4 Watts or
dealer technician can access fault code(s) to help less, or needs to have a total resistance of 140 Ω or
determine what portion of system is malfunctioning. more. LEDs typically draw less than 0.03 amps.
Codes are accessed through key switch and displayed Attach +12 volts to positive terminal of bulb and attach
as blinks or flashes of MIL. Access codes as follows: ground terminal of bulb to tan wire.
1. Check that battery voltage is above 11 volts. Diagnostic Code Summary
2. Start with key switch OFF. Code 0031
NOTE: Codes 0031 and 0032 may have been
3. Turn key switch to ON and OFF, then ON and OFF, mistakenly activated by turning key ON with
then ON, leaving it on in third sequence. Do not start oxygen sensor disconnected. If either code
engine. Time between sequences must be less than status is historic, that code may have set during
2.5 seconds. assembly or a previous repair and may not be
4. MIL will blink a series of times. Number of times MIL related to current event. Clear codes and retest
blinks represents a number in blink code. to confirm. If code status is current, refer to
Oxygen Sensor (O2) earlier in this section, to test
5. A sequence of four digits make up a fault code. and troubleshoot.
There is a one (1) second pause between blinks of a
fault code. There is a three (3) second pause Component: Oxygen Sensor Heater
between separate fault codes. After fault code(s) are
blinked a two digit 61 is blinked to indicate program Fault: O2S Heater Circuit Low Voltage
has completed. Condition: System voltage too low, open connection
or faulty sensor.
a. It’s a good idea to write down codes as they
appear, as they may not be in numerical Conclusion: Engine Wiring Harness Related
sequence. ● Pin circuit wiring or connectors.
ECU black pin 7 or broken wire.
b. Code 61 will always be last code displayed,
indicating end of code transmission. If code 61 Oxygen Sensor Related
appears immediately, no other fault codes are ● Sensor connector or wiring problem.
present.
After problem has been corrected, fault codes may Poor system ground from ECU to engine
be cleared by following ECU Reset and TPS Learn or battery to engine.
Procedures.
Diagnostic Fault Code Summary lists fault codes, and
what they correspond to. Diagnostic Code Summary
is a list of individual codes with an explanation of what
triggers them, what symptoms might be expected, and
probable causes.

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Code 0032 Code 0108

NOTE: Codes 0031 and 0032 may have been Component: Manifold Absolute Pressure (TMAP)
mistakenly activated by turning key ON with
oxygen sensor disconnected. If either code Fault: MAP Circuit High Voltage
status is historic, that code may have set during Condition: Intake manifold leak, shorted connection
assembly or a previous repair and may not be or faulty sensor.
related to current event. Clear codes and retest Conclusion: TMAP Sensor Related
to confirm. If code status is current, refer to ● Sensor malfunction.
Oxygen Sensor (O2) earlier in this section, to test ● Vacuum leaks from loose manifold or
and troubleshoot. sensor.
Component: Oxygen Sensor Heater Wire Harness Related
Fault: O2S Heater Circuit High Voltage ● Poor grounding.
Condition: System voltage too high, shorted ● Pin circuit wiring or connectors at Black
connection or faulty sensor. 11.
Conclusion: Oxygen Sensor Related
● Sensor connector or wiring problem. Bad TPS Learn.
● Sensor damaged.
● Pin circuit wiring or connectors at Black Code 0112
7. Component: Intake Air Temperature (TMAP)
Fault: Intake Air Temperature Sensor Circuit
ECU Related Low Voltage
● ECU-to-harness connection problem.
Condition: Shorted connection, faulty sensor or
shorted wire.
Code 0107 Conclusion: TMAP Sensor Related
Component: Manifold Absolute Pressure (TMAP) ● Sensor wiring or connection.
Fault: MAP Circuit Low Voltage or Open
Engine Wiring Harness Related
Condition: Intake manifold leak, open connection or ● Pin circuits Black 10 and Black 8 may
faulty sensor. be damaged or routed near noisy
Conclusion: TMAP Sensor Related signal (coils, alternator, etc.).
● Sensor malfunction. ● ECU-to-harness connection problem.
● Vacuum leaks from loose manifold or
sensor. Code 0113
Component: Intake Air Temperature (TMAP)
Wire Harness Related
● Poor grounding or open circuit. Fault: Intake Air Temperature Sensor Circuit
● Wire harness and connectors loose, High Voltage or Open
damaged or corroded. Condition: Shorted connection, faulty sensor, broken
● Pin circuit wiring or connectors at Black wire or connection.
10, 11 and 16. Conclusion: TMAP Related
● Sensor wiring or connection.
Bad TPS Learn.
Engine Wiring Harness Related
● Pin circuits ECU Black pin 10 and 8
may be damaged.
● ECU-to-harness connection problem or
broken wire.

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 EFI SYSTEM

Code 0117 Code 0122

Component: Engine Temperature Sensor Component: Throttle Position Sensor (TPS)
Fault: Engine Temperature Sensor Circuit Low Fault: TPS Circuit Low Voltage or Open
Voltage Condition: Open connection, broken wire or faulty
Condition: Shorted connection, faulty sensor or sensor.
shorted wire. Conclusion: TPS Related
Conclusion: Temperature Sensor Related ● TPS bad or worn internally.
● Sensor wiring or connection.
Engine Wiring Harness Related
Engine Wiring Harness Related ● Broken or shorted wire in harness.
● Pin circuits Black 10 and Black 14 ECU Black pin 10 to TPS pin 1.
maybe damaged or routed near noisy ECU Black pin 12 to TPS pin 3.
signal (coils, stator, etc.). ECU Black pin 16 to TPS pin 2.
● ECU-to-harness connection problem.
Throttle Body Related
Code 0118 ● Throttle shaft inside TPS worn, broken,
or damaged.
Component: Engine Temperature Sensor ● Throttle plate loose or misaligned.
Fault: Engine Temperature Sensor Circuit High ● Throttle plate bent or damaged
Voltage or Open allowing extra airflow past, or restricting
Condition: Shorted connection, faulty sensor, open movement.
connection or broken wire.
Conclusion: Temperature Sensor Related ECU Related
● Sensor wiring or connection. ● Circuit providing voltage or ground to
TPS damaged.
Engine Wiring Harness Related ● TPS signal input circuit damaged.
● Pin circuits ECU Black pin 10 and 14
may be damaged. Code 0123
● ECU-to-harness connection problem or Component: Throttle Position Sensor (TPS)
broken wire.
Fault: TPS Circuit High Voltage
System Related Condition: Shorted connection or faulty sensor.
● Engine is operating above 176°C Conclusion: TPS Sensor Related
(350°F) temperature sensor limit. ● Sensor connector or wiring.
● Sensor output affected or disrupted by
dirt, grease, oil, wear.
● Sensor loose on throttle body manifold.

Throttle Body Related

● Throttle shaft or bearings worn/
damaged.

Engine Wiring Harness Related

● ECU pins Black 10, 12 and 16
damaged (wiring, connectors).
● ECU pins Black 10, 12 and 16 routed
near noisy electrical signal (coils,
alternator).
● Intermittent 5 volt source from ECU
(pin Black 16).
● ECU-to-harness connection problem.

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EFI SYSTEM

Code 0131 Code 0171

Component: Oxygen Sensor Component: Fuel System
Fault: O2S 1 Circuit Low Voltage Fault: Maximum adaptation limit exceeded
Condition: Open connection, broken wire or faulty Condition: Fuel inlet screen/filter plugged, low
sensor. pressure at high pressure fuel line, TPS
Conclusion: Oxygen Sensor Related malfunction, shorted connection, faulty
● Sensor connector or wiring problem. sensor, low fuel or wrong fuel type.
● Sensor contaminated, corroded or Conclusion: Oxygen Sensor Related
damaged. ● Corrosion or poor connection.
● Poor ground path. ● Sensor contaminated or damaged.
● Pin circuit wiring or connectors. ● Air leak into exhaust.
ECU Black pin 10 or 17. ● Poor ground path.
● Pin circuit wiring or connectors.
TPS Learn Procedure Incorrect ECU Black pin 10 or Black pin 17.
● Lean condition (check oxygen sensor
signal with VOA and see Oxygen TPS Sensor Related
Sensor section). ● Throttle plate position incorrect during
Learn procedure.
Engine wiring harness related such as a ● TPS problem or malfunction.
cut wire, broken or pinched.
Engine Wiring Harness Related
Code 0132 ● Difference in voltage between sensed
Component: Oxygen Sensor voltage and actual sensor voltage.
Fault: O2S 1 Circuit High Voltage ● Problem in wiring harness.
● ECU-to-harness connection problem.
Condition: Shorted connection or faulty sensor.
Conclusion: Oxygen Sensor Related Systems Related
● Sensor connector or wiring problem. ● Ignition (spark plug, plug wire, ignition
● Sensor contaminated or damaged. coil).
● Poor ground path. ● Fuel (fuel type/quality, injector, fuel
● Pin circuit wiring or connectors. pressure too low, fuel pump module or
ECU Black pin 10 or Black pin 17. lift pump).
● Combustion air (air cleaner dirty/
Engine Wiring Harness Related restricted, intake leak, throttle bores).
● Difference in voltage between sensed ● Base engine problem (rings, valves).
voltage and actual sensor voltage. ● Exhaust system leak (muffler, flange,
● Short in wire harness. oxygen sensor mounting boss, etc.).
● Fuel in crankcase oil.

52 KohlerEngines.com 32 690 12 Rev. --

 EFI SYSTEM

Code 0172 Code 0174

Component: Fuel System Component: Fuel System
Fault: Minimum adaptation limit exceeded Fault: Lean fuel condition
Condition: Too high pressure at high pressure fuel Condition: Fuel inlet screen/filter plugged, low
line, TPS malfunction, shorted pressure at high pressure fuel line, TPS
connection, faulty sensor or fuel pump malfunction, shorted connection or faulty
module failure. sensor.
Conclusion: Oxygen Sensor Related Conclusion: TPS Learn Incorrect
● Sensor connector or wiring. ● Lean condition (check oxygen sensor
● Sensor contaminated or damaged. signal with VOA and see Oxygen
● Poor ground path. Sensor).
● Pin circuit wiring or connectors.
ECU Black pin 10 or 17. Engine Wiring Harness Related
● Pin circuit wiring or connectors.
TPS Sensor Related ECU pin Black 10, 12, 16 and 17.
● Throttle plate position incorrect during
Learn procedure. Low Fuel Pressure
● TPS problem or malfunction. ● Plugged filters.
● Bad lift pump.
Engine Wiring Harness Related
● Difference in voltage between sensed Oxygen Sensor Related
voltage and actual sensor voltage. ● Sensor connector or wiring problem.
● Problem in wiring harness. ● Exhaust leak.
● ECU-to-harness connection problem. ● Poor ground.

Systems Related Poor system ground from ECU to engine,

● Ignition (spark plug, plug wire, ignition causing rich running while indicating lean.
coil).
● Fuel (fuel type/quality, injector, fuel Fuel pump module connection. See Fuel
pressure too high, fuel pump module or Components.
lift pump).
● Combustion air (air cleaner dirty/
restricted).
● Base engine problem (rings, valves).
● Fuel in crankcase oil.
● Fuel pump module is over filled.
● Lift pump diaphragm is ruptured.

32 690 12 Rev. -- KohlerEngines.com 53

EFI SYSTEM

Code 0201 Code 0232

Component: Fuel Injector Component: Fuel Pump
Fault: Injector 1 Circuit Malfunction Fault: Circuit High Voltage
Condition: Injector damaged or faulty, shorted or Condition: Shorted connection.
open connection. Conclusion: Fuel Pump Related
Conclusion: Injector Related ● Fuel pump module damaged internally.
● Injector coil shorted or opened.
Charging Output System Too High.
Engine Wiring Harness Related
● Broken or shorted wire in harness. Code 0336
ECU pin Black 5.
● Wiring from Ignition. Component: Crankshaft Position Sensor
Fault: Crankshaft Position Sensor Noisy Signal
ECU Related Condition: Loose sensor, faulty/bad battery, shorted
● Circuit controlling injector #1 damaged. or faulty connection, faulty sensor or
faulty sensor grounding.
Code 0202 Conclusion: Crankshaft Position Sensor Related
Component: Fuel Injector ● Sensor connector or wiring.
Fault: Injector 2 Circuit Malfunction ● Sensor loose.
Condition: Injector damaged or faulty, shorted or Crankshaft Position Sensor Wheel
open connection. Related
Conclusion: Injector Related ● Damaged teeth.
● Injector coil shorted or opened. ● Gap section not registering.

Engine Wiring Harness Related Engine Wiring Harness Related

● Broken or shorted wire in harness. ● Pin circuit wiring or connectors.
ECU pin Black 6. ECU pin Black 4 and Black 13.
● Wiring from Ignition. ● ECU-to-harness connection problem.

ECU Related Ignition System Related

● Circuit controlling injector #2 damaged. ● Non-resistor spark plug(s) used.
● Faulty or disconnected ignition coil or
Code 0230 secondary lead.
Component: Fuel Pump
Fault: Circuit Low Voltage or Open
Condition: Shorted or open connection.
Conclusion: Fuel Pump Related
● Fuel pump module open or shorted
internally.

Engine Wiring Harness related

● Broken or shorted wire in harness.
ECU pin Black 9 or Grey 17.

ECU Related
● ECU is damaged.

54 KohlerEngines.com 32 690 12 Rev. --

 EFI SYSTEM

Code 0337 Code 0352

NOTE: If fault code P0337 is present and engine does Component: Ignition Coil
not start/run, proceed to step 1 of Crankshaft
Position Sensor earlier in this section. If P0337 Fault: Cylinder 2 Ignition Coil Malfunction
is present and engine operates, clear codes and Condition: Broken wire in harness (may not be
retest. visible), shorted connection or faulty
sensor.
Component: Crankshaft Position Sensor
Conclusion: Engine Wiring Harness Related
Fault: Crankshaft Position Sensor No Signal ● Connection to ignition or fuse.
Condition: Loose sensor, open or shorted ● Pin circuit wiring or connectors.
connection (sensor connector or battery ECU pin Grey 10.
connections) or faulty sensor. ● ECU-to-harness connection problem.
Conclusion: Crankshaft Position Sensor Related
● A false fault code P0337 is triggered by Ignition System Related
a voltage drop with key ON and engine ● Incorrect spark plug(s) used.
off. Voltage drop may be caused by a ● Poor connection to spark plug.
poor/inadequate battery connection,
battery charger connected or Code 0562
disconnected, or any event that may
interrupt voltage signal to ECU like a Component: System Voltage
power interruption or heavy load from Fault: System Voltage Low
equipment that results in a recordable Condition: Faulty voltage regulator, bad fuse or
voltage drop. shorted connection.
● Sensor connector or wiring. Conclusion: Corroded Connections
● Sensor loose.
Bad Stator
Crankshaft Position Sensor Wheel
Related Bad Battery
● Damaged teeth. ● Low output charging system.
● Poor magnet in flywheel.
Engine Wiring Harness Related ● Bad or missing fuse.
● Pin circuit wiring or connectors.
ECU pin Black 4 or Black 13.
● ECU-to-harness connection problem. Code 0563
Component: System Voltage
If code is stored in fault history and starts
normally. Clear code, no other service Fault: System Voltage High
required. Condition: Faulty voltage regulator or shorted
connection.
Code 0351 Conclusion: Faulty Rectifier-Regulator
Component: Ignition Coil Bad Stator.
Fault: Cylinder 1 Ignition Coil Malfunction
Condition: Broken wire in harness (may not be Bad Battery.
visible), shorted connection or faulty
sensor. Code 0650
Conclusion: Engine Wiring Harness Related Component: MIL Circuit
● Connection to ignition or fuse. Fault: MIL Circuit Malfunction
● Pin circuit wiring or connectors.
● ECU pin Black 1. Condition: Failure in MIL circuit detected.
● ECU-to-harness connection problem. Conclusion: Bad ECU.

Ignition System Related Bad Connection.

● Incorrect spark plug(s) used.
● Poor connection to spark plug. Broken Wire.
Code 61
Component: End of Code Transmission

32 690 12 Rev. -- KohlerEngines.com 55

EFI SYSTEM

EFI Diagnostic Flow Diagram

START OF TEST
PROCEED TO START OF TEST FOR RETEST

KEY ON

MALFUNCTION NO REFER TO DIAGNOSTIC AID #1

INDICATOR LIGHT SYSTEM POWER
ON

ARE FAULT CODES YES REFER TO

PRESENT? DIAGNOSTIC FAULT CODE SUMMARY

NO CLEAR CODES

DOES ENGINE START? YES MIL GOES OFF? NO REFER TO DIAGNOSTIC AID #3
RUN/ON

YES
NO
OPERATE AT VARIOUS SPEED/
LOAD CONDITIONS

CRANK ENGINE.

PROCEED TO START OF TEST FOR RETEST

DOES MIL GO OFF? REFER TO DIAGNOSTIC
ARE FAULT CODES YES FAULT CODE SUMMARY
PRESENT?
YES
NO
NO CLEAR CODES
KEY OFF AND KEY ON1.
LISTEN FOR FUEL PUMP.
END OF TEST

DOES FUEL PUMP RUN2?

REFER TO DIAGNOSTIC AID #4
CRANKSHAFT POSITION SENSOR

YES NO

REFER TO DIAGNOSTIC AID #5

WHILE CRANKING, CHECK FUEL PUMP
IGNITION SYSTEM

SPARK? NO REFER TO DIAGNOSTIC AID #6

IGNITION SYSTEM

YES

WHILE CRANKING, CHECK

INJECTOR FUEL DELIVERY.

NO REFER TO DIAGNOSTIC AID #7

WET SPARK PLUG? FUEL SYSTEM ELECTRICAL

YES

INSTALL IN-LINE PRESSURE

GAUGE AND KEY ON.

FUEL PRESSURE REFER TO DIAGNOSTIC AID #8

IN SPECIFICATION? NO FUEL SYSTEM

YES REFER TO DIAGNOSTIC AID #9

BASIC ENGINE

1. After turning key to OFF, wait 30 seconds before turning to ON to allow ECU to initiate another prime cycle.
2. Fuel pump module can be heard or a vibration can be felt to establish pump cycle. Fuel pump module will run for one 4-6 second prime cycle
after key switch remains off for a minimum of 30 seconds.

56 KohlerEngines.com 32 690 12 Rev. --

 EFI SYSTEM

Troubleshooting Flow Chart Diagnostic Aid #5 FUEL PUMP

(fuel pump not turning on)
Following a flow chart provides an alternative method
of troubleshooting EFI system. Chart will enable you Condition
to review entire system in about 10-15 minutes. Using ● Inspect fuse(s)
chart, accompanying diagnostic aids (listed chart), and ● Fuel pump circuit problem, pin circuits Black 9 and
any signaled fault codes, you should be able to quickly Grey 17.
locate any problems within system. ● Fuel pump module
Flow Chart Diagnostic Aids
Diagnostic Aid #6 IGNITION SYSTEM
Diagnostic Aid #1 SYSTEM POWER (no spark)
(MIL does not illuminate when key is turned ON) Condition
NOTE: MIL is installed by vehicle OEM. Twelve volt ● Spark plug
supply to bulb will be part of vehicle wire ● Plug wire
harness. Kohler key switch model will have MIL ● Coil
on engine with 12V supply to bulb. ● Coil circuit(s), pin circuits Grey 10 and Black 1.
Conclusion ● ECU grounds
● Battery ● ECU
● Main system fuse ● Vehicle safety interlocks, ground signal on safety wire.
● MIL light bulb burned out
● MIL electrical circuit problem Diagnostic Aid #7 FUEL SYSTEM ELECTRICAL
Pin circuits Grey 3. (no fuel delivery)
● Ignition switch
● Permanent ECU power circuit problem Condition
Pin circuit Black 18. ● No fuel
● Switched ECU power circuit problem ● Air in high pressure fuel line
Pin circuit Black 15. ● Fuel valve shut OFF
● ECU grounds ● Fuel filter/line plugged
● ECU ● Injector circuit(s), pin circuits Black 5 and Black 6
● Injector
Diagnostic Aid #2 FAULT CODES ● ECU grounds
Refer to Diagnostic Fault Code Summary. ● ECU
● Lift pump not working
NOTE: If fault code P0337 is present and engine does
not start/run, proceed to step 1 of Crankshaft
Position Sensor earlier in this section. If P0337 Diagnostic Aid #8 FUEL SYSTEM
is present and engine operates, clear codes and (fuel pressure)
retest. Low Fuel Pressure-Condition
● No fuel
● Fuel filter(s) plugged
Diagnostic Aid #3 RUN/ON ● Fuel supply line plugged
(MIL remains ON while engine is running) ● Lift fuel pump - insufficient fuel supply
NOTE: Either incandescent or LED type bulbs can be ● Fuel pump (lift or module) - internally plugged
used for MIL as long as they do not draw more ● Pressure regulator not functioning properly inside fuel
than 0.1 amps. Bulb needs to be rated at 1.4 pump module.
Watts or less, or needs to have a total resistance
of 140 Ω or more. LEDs typically draw less than Diagnostic Aid #9 BASIC ENGINE
0.03 amps. (cranks but will not run)
Conclusion Condition
● All current fault codes will turn on MIL when engine is ● Refer to basic engine troubleshooting charts within
running. Troubleshooting.

Diagnostic Aid #4 CRANKSHAFT POSITION SENSOR

(MIL does not turn off during cranking)
Condition
● Crankshaft position sensor
● Crankshaft position sensor circuit problem, pin circuits
Black 4 and Black 13.
● Crankshaft position sensor/toothed wheel air gap
● Toothed wheel
● Flywheel key sheared
● ECU

32 690 12 Rev. -- KohlerEngines.com 57

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 oil pan and is driven off gear on camshaft.
Governor Components

J
I
H

G D
A
F C

Inside Engine

C B

E
D

A Governor Lever B Governor Spring C Governor Linkage D Linkage Spring

Locking Tab
E Throttle Lever F Governor Gear Shaft G H Governor Gear
Thrust Washer
I Flyweight J Regulating Pin
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 throttle body.
● 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 throttle body through external throttle linkage. 3. Move governor lever toward throttle body 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. Use 7 mm hex socket on end of cross shaft and
rotating. Force applied by regulating pin against cross rotate shaft counterclockwise (viewed from end) as
shaft tends to close throttle plate. Governor spring far as it will turn, then torque nut to 6.8 N·m (60 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.
58 KohlerEngines.com 32 690 12 Rev. --
 Lubrication System

This engine uses a combination pressure/splash lubrication system, delivering oil under pressure to crankshaft,
connecting rod and main bearing surfaces. Other component areas are splash lubricated.
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 and oil pump.
Lubrication Components

B C

A Oil Fill/Dipstick B Oil Drain Plug C Oil Filter

OIL RECOMMENDATIONS CHANGE OIL AND FILTER

Refer to Maintenance. Change oil while engine is warm.
1. Clean area around oil fill/dipstick. Remove drain plug
CHECK OIL LEVEL and oil fill/dipstick. Allow oil to drain completely.
NOTE: To prevent extensive engine wear or damage, 2. Clean area around oil filter. Place a container under
never run engine with oil level below or above filter to catch any oil and remove filter. Wipe off
operating range indicator on dipstick. mounting surface. Reinstall drain plug. Torque to
Ensure engine is cool and level. Clean oil fill/dipstick 13.6 N·m (10 ft. lb.).
areas of any debris. 3. Place new filter in shallow pan with open end up. Fill
1. Remove dipstick; wipe oil off. with new oil until oil reaches bottom of threads. Allow
2. Reinsert dipstick into tube; press completely down. 2 minutes for oil to be absorbed by filter material.
3. Remove dipstick; check oil level. Level should be at 4. Apply a thin film of clean oil to rubber gasket on new
top of indicator on dipstick. filter.
4. If oil is low on indicator, add oil up to top of indicator 5. Refer to instructions on oil filter for proper
mark. installation.
5. Reinstall and secure dipstick. 6. Fill crankcase with new oil. Level should be at top of
indicator on dipstick.
7. Reinstall oil fill/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.

32 690 12 Rev. -- KohlerEngines.com 59

Lubrication System

OIL SENTRY™ (if equipped) Testing

NOTE: Make sure oil level is checked before each use, Compressed air, a pressure regulator, pressure gauge,
and is maintained up to FULL or F mark on and a continuity tester are required to test switch.
dipstick. This includes engines equipped with
Oil Sentry™. 1. Connect continuity tester across blade terminal and
metal case of switch. With 0 psi pressure applied to
This switch is designed to prevent engine from starting in switch, tester should indicate continuity (switch
a low oil or no oil condition. Oil Sentry™ may not shut closed).
down a running engine before damage occurs. In some
applications this switch may activate a warning signal. 2. Gradually increase pressure to switch. As pressure
Read your equipment manuals for more information. increases through range of 2-5 psi tester should
indicate a change to no continuity (switch open).
Oil Sentry™ pressure switch is installed in oil filter Switch should remain open as pressure is increased
adapter. to 90 psi maximum.
Installation 3. Gradually decrease pressure through range of
2-5 psi. Tester should indicate a change to continuity
1. Apply pipe sealant with Teflon® (Loctite® PST® 592™ (switch closed) down to 0 psi.
Thread Sealant or equivalent) to threads of switch.
4. Replace switch if it does not operate as specified.
2. Install switch into tapped hole in oil filter adapter.
3. Torque switch to 4.5 N·m (40 in. lb.).

60 KohlerEngines.com 32 690 12 Rev. --

 Electrical System

BATTERY CHARGING SYSTEM ● Disconnect rectifier-regulator plug, electronic control

unit (ECU), and/or wiring harness plug before doing
any electric welding on equipment powered by engine.
CAUTION Also, disconnect all other electrical accessories in
Electrical Shock can cause injury. common ground with engine.
Do not touch wires while engine is running. ● Prevent stator (AC) leads from touching or shorting
while engine is running. This could damage stator.
NOTE: Observe following guidelines to avoid damage to
electrical system and components: These engines are equipped with a 15 amp regulated
charging system.
● Make sure battery polarity is correct. A negative (–)
ground system is used.

15 Amp Regulated Charging System

B F
3 2 1 E H
A 6 5 4

D
G

Red (OEM Supplied

A Battery B C 6-Terminal Connector D Purple
Battery Source)
Flywheel Stator
E Fuse F Rectifier-Regulator G Connector Block H Assembly

Stator Battery Size Recommendations

Stator is mounted on crankcase behind flywheel. Follow Temperature Battery Required
procedures in Disassembly/Inspection and Service and Above 32°F (0°C) 300 cca minimum
Reassembly if stator replacement is necessary.
0°F to 32°F (-18°C to 0°C) 300 cca minimum
Rectifier-Regulator -5°F to 0°F (-21°C to -18°C) 300 cca minimum
Rectifier-regulator is mounted on backing shroud -10°F (-23°C) or below 400 cca minimum
assembly. To replace it, disconnect plug and remove
mounting screws. If battery charge is insufficient to turn over engine,
recharge battery.
Battery
Battery Maintenance
A 12-volt battery with 400 cold cranking amps (cca) is
generally recommended for starting in all conditions. A Regular maintenance is necessary to prolong battery
smaller capacity battery is often sufficient if an life.
application is started only in warmer temperatures. Refer
to following table for minimum capacities based on Battery Test
anticipated ambient temperatures. Actual cold cranking To test battery, follow manufacturer's instructions.
requirement depends on engine size, application, and
starting temperatures. Cranking requirements increase
as temperatures decrease and battery capacity shrinks.
Refer to operating instructions of equipment for specific
battery requirements.

32 690 12 Rev. -- KohlerEngines.com 61

Electrical System

FUSES Test Charging System for No Charge to Battery

This engine has 3 blade type automotive fuses.
Replacement fuses must have same rating as blown
fuse. Use fuse chart below to determine correct fuse.
Wire Color Fuse Rating
2 Purple Wires 30-amp Fuse
1 Red Wire w/Black Stripe 10-amp Fuse
1 Red Wire w/White Stripe
2 Red Wires 10-amp Fuse

Fuse Replacement
1. Shut engine off and remove key.
A
2. Locate fuse holders.
3. Remove fuse cover and pull out fuse holder. Inspect
condition of fuse holder. B+ Wire (Purple Wire Covered with Black Heat
A Shrink Tubing)
4. Inspect fuse for a solid fusible link or a broken
fusible link. Replace fuse if fusible link is broken. If 1. With engine off, test and record battery voltage.
you are not sure if fusible link is broken, replace Voltage should be above 12 volts to proceed. With
fuse. voltmeter attached to battery, start engine. Set
engine speed to high RPM position, battery voltage
5. Insert fuse into fuse holder until it is seated properly. should increase (for example: 12.6 volts engine off;
Install fuse cover. 13.4 volts engine running). Actual voltage increase
6. If replacement fuse fails, there is a problem within will differ depending on state of charge in battery.
circuit. Diagnostics are required. Identify which 2. If no voltage increase is seen at battery, turn engine
circuit is affected (see EFI System for electrical off and move voltmeter red lead to purple B+ lead on
schematic) by identifying failed fuse/circuit. Perform rectifier-regulator and black ground meter lead to
troubleshooting procedures appropriate for circuit ground. Recorded battery voltage from step 1 should
fuse that failed. be seen. If battery voltage is not seen, a blown fuse
7. Install fuse holder into fuse cover. or bad connection may be at fault.
Inspect (green 30 amp) charging system fuse for
Troubleshooting Guide blown fuse and/or corroded fuse terminals. Inspect
rectifier-regulator and ensure mounting screws are
15 Amp Battery Charging System secure.
NOTE: Always zero meter on each scale before testing
to ensure accurate readings. Voltage tests 3. If recorded battery voltage is seen, but no increase
should be made with engine running at 3600 while running engine, proceed to step 2 of Test
RPM - no load. Battery must be good and fully Charging System Output, for component diagnostic
charged. testing.
When problems occur in keeping battery charged or 4. If a slight voltage increase is seen, but system
battery charges at too high a rate, problem can usually output may be in question, proceed to step 1 of Test
be found somewhere in charging system or with battery. Charging System Output.

62 KohlerEngines.com 32 690 12 Rev. --

 Electrical System

Test Charging System Output Test Charging System for Battery Continuously
1. Perform test a or b. Charging at High Rate
a. Insert an ammeter in B+ wire (purple wire 1. With engine running at 3600 RPM, measure voltage
covered with black heat shrink tubing) at rectifier- from B+ lead to ground using a DC voltmeter.
regulator connector. With engine running at 3600
RPM and B+ (at terminal on rectifier-regulator) to Condition Conclusion
ground using a DC voltmeter. If voltage is 13.8 Voltage is 14.7 volts or Charging system is OK.
volts or more, place a minimum load of 5 amps less. Battery is unable to hold
(turn on lights if 60 watts or more, or place a 2.5 charge; service or replace.
ohm, 100 watt resistor across battery terminals) Voltage is more than 14.7 Faulty rectifier-regulator;
on battery to reduce voltage. Observe ammeter. volts. replace.
b. If a carbon pile test tool is available, start and run
engine at high speed (3600 RPM optimal), adjust To Test 15 amp Rectifier-Regulators
carbon pile voltage to 12 volts and observe NOTE: When installing rectifier-regulator, take note of
amperage on amp meter. Displayed amperage terminal markings and install plug(s) accordingly.
should be near or at maximum rated system NOTE: Disconnect all electrical connections attached to
output. (Follow tool directions for carbon pile test rectifier-regulator. Testing may be performed
procedures.) with rectifier-regulator mounted or loose. Repeat
applicable test procedure two or three times to
Condition Conclusion determine condition of part.
Charge rate increases Charging system is OK NOTE: A flashing LOW light can also occur as a result
when load is applied. and battery was fully of an inadequate ground lead connection. Make
charged. certain connection location is clean and clamp is
Charge rate does not Test stator and rectifier- secure.
increase when load is regulator (steps 2 and 3). Testing rectifier-regulator may be performed as follows,
applied. using appropriate rectifier-regulator tester.
2. With engine off, remove connector from rectifier- 1. Connect tester ground lead (with spring clamp) to
regulator. Start engine and with engine running at body of rectifier-regulator.
3600 RPM, measure AC voltage across white stator
leads using an AC voltmeter. 2. Connect red lead from tester to middle terminal
labeled B+.
Condition Conclusion 3. Connect black leads from tester to both outer AC
Voltage is 28 volts or Stator is OK. Test rectifier- terminals on rectifier-regulator.
more. regulator. 4. Plug tester into proper AC outlet/power supply for
Voltage is less than 28 Stator is faulty; replace. tester being used. Turn on power switch. POWER
volts. Test stator further using an light should be illuminated and one of four status
ohmmeter (steps 3 and 4). lights may be lit as well. This does not represent
3. With engine stopped, measure resistance across condition of part.
stator leads using an ohmmeter. 5. Press TEST button until a click is heard and then
release. Momentarily one of four status lights will
Condition Conclusion illuminate indicating partial condition of part.
Resistance is 0.1/0.2 Stator is OK. Condition Conclusion
ohms.
OK (green) light comes on Disconnect tester black
Resistance is 0 ohms. Stator is shorted; replace. and stays steady. lead attached to 1 AC
Resistance is infinity Stator is open; replace. terminal and reconnect
ohms. it to other AC terminal.
4. With engine stopped, measure resistance from each Repeat test. If OK (green)
stator lead to ground using an ohmmeter. light comes on again, part
is good and may be used.
Condition Conclusion NOTE: A flashing LOW Rectifier-regulator is faulty
Resistance is infinity ohms Stator is OK (not shorted light can also and should not be used.
(no continuity). to ground). occur as a result
of an inadequate
Resistance (or continuity) Stator leads are shorted to ground lead
measured. ground; replace. connection. Make
certain connection
location is clean
and clamp is
secure.
Other lights come on.

32 690 12 Rev. -- KohlerEngines.com 63

Electrical System

IGNITION SYSTEM Inspection

Spark Plug Inspect each spark plug as it is removed from cylinder
head. Deposits on tip are an indication of general
Component and Details condition of piston rings, valves, and fuel mixture.
Normal and fouled plugs are shown in following photos:
A Normal
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.
C D
Worn
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
by a spark plug that has improper gap or is in poor
condition.
Engine is equipped with following spark plugs:
Gap 0.76 mm (0.030 in.) On a worn plug, center electrode will be rounded and
gap will be greater than specified gap. Replace a worn
Thread Size 14 mm spark plug immediately.
Reach 19.1 mm (3/4 in.)
Hex Size 15.9 mm (5/8 in.) Wet Fouled
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.).
2. Install plug into cylinder head.
3. Torque plug to 27 N·m (20 ft. lb.).

A wet plug is caused by excess fuel or oil in combustion

chamber. Excess fuel could be caused by a restricted
air cleaner, a fuel mixture problem. Oil in combustion
chamber is usually caused by a restricted air cleaner, a
breather problem, worn piston rings, or valve guides.

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 Electrical System

Carbon Fouled Overheated

Chalky, white deposits indicate very high combustion

Soft, sooty, black deposits indicate incomplete temperatures. This condition is usually accompanied
combustion caused by a restricted air cleaner, over rich by excessive gap erosion. Lean fuel mixture settings,
fuel mixture, weak ignition, or poor compression. an intake air leak, or incorrect spark timing are normal
causes for high combustion temperatures.

Troubleshooting Guide
Test Ignition System
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. If Kohler diagnostic software is available, review "Safety System Active" status in Data Display screen. If yes is
displayed, equipment safety circuit is active (seat switch/PTO switch/Safety interlocks, etc.). This must be
corrected prior to continuing testing.
If diagnostic software is not available, 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 1 cylinder is
affected, test ignition coils.

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Electrical System

Test for Spark

NOTE: If 2 ignition system 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 coil 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 550-600 RPM, and observe tester(s) for spark.
3. Repeat spark test on opposite cylinder if cylinders are being tested individually.
Condition Possible Cause Conclusion
1 cylinder is not firing or 1 Wiring, Connections, or Using a DVOM, attach black (-) lead of meter to battery
cylinder has good spark System Power ground, remove primary plug from coil, test voltage at
and other cylinder has no or red wire with black tracer at coil primary connector with
intermittent spark. ignition key ON. Battery voltage should be seen. If no
voltage, check all fuses. Key OFF, perform continuity
test between black primary wire connector and
corresponding terminal connector (ignition coil #1 or
#2) on black or grey ECU connector (see EFI System
Wiring Diagram). If no continuity is found, repair or
replace electrical wiring harness. If continuity is found,
refer to EFI System, Ignition Coil Testing or exchange
ignition coils (side to side) and retest. If problem follows
ignition coil, replace that coil. If problem stays with
cylinder, test circuit (power and ground) for problem
cylinder. Repair/replace as needed. Test ignition coils
and connections. Refer to Test Ignition System (on
previous page).
Tester shows spark but engine Spark Plug(s) Try new spark plug(s).
misses or won’t run on that Flywheel Key Remove flywheel, inspect key, replace key if damaged.
cylinder.
Neither side is firing. Ignition Switch, EFI Test for "Safety System Active" as described in step 1
System, Kill Lead of Test Ignition System (on previous page). Inspect
red 10 amp fuses. Replace fuse if found blown. If fuse
is OK, using a DVOM, attach black (-) lead of meter to
battery ground, key ON, test for voltage at 2 red 10
amp fuses. Battery voltage should be seen on both
sides of fuses. If voltage is found on 1 side of fuse only,
inspect for blown fuse or inspect fuse holder/terminals
for arching or corrosion. If no voltage is seen at any
fuse, further electrical testing inspection is required
(application, key switch, ground connections, etc.)
Recheck position of ignition switch and check for
shorted kill lead.
Both cylinders have good Spark Plug(s) Install new spark plug(s) and retest engine
spark but engine runs poorly performance.
or existing plug condition is Flywheel Key Remove flywheel, inspect key, replace key if damaged.
questionable.

66 KohlerEngines.com 32 690 12 Rev. --

 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 engine develops sufficient speed to disengage starter but does not keep running (a false start), engine
rotation must be allowed to come to a complete stop before attempting to restart engine. 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.
NOTE: Battery must be tested and confirmed acceptable prior to troubleshooting starter system. Follow battery or
OEM battery testing procedures.
Engines in this series use inertia drive starters. Inertia drive starters are not serviceable.
Troubleshooting-Starting Difficulties
Condition Possible Cause Conclusion
Starter does not energize. Battery Check specific gravity of battery and battery state of charge. 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
or Solenoid cranks normally, replace faulty components. Consult with
OEM electrical system service procedures for OEM related
component diagnostics. Perform solenoid test procedure.
Starter energizes but turns Battery Check specific gravity of battery and battery state of charge. If
slowly. low, recharge or replace battery as necessary.
Transmission Make sure clutch or transmission is disengaged or placed
or Engine in neutral. This is especially important on equipment with
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.

INERTIA DRIVE ELECTRIC STARTERS When power is applied to starter, armature rotates. As
armature rotates, drive pinion moves out on drive shaft
splines and into mesh with flywheel ring gear. When
pinion reaches end of drive shaft, it rotates flywheel and
cranks engine.
When engine starts, flywheel rotates faster than starter
armature and drive pinion. This moves drive pinion out
of mesh with ring gear and into retracted position. When
power is removed from starter, armature stops rotating
and drive pinion is held in retracted position by anti-drift
spring.

32 690 12 Rev. -- KohlerEngines.com 67

Starter System

Inertia Drive Starter Tests

NOTE: Please perform following testing as near to conditions during failure.
Before Starting
● Disable ignition system: with key OFF, unplug EFI Electronic Control Unit (ECU) or remove both 10 amp (red)
engine mounted fuses.
● Battery voltage should be tested and must be at 12.4 VDC or higher. Do not proceed if battery voltage is less than
12.4 VDC as battery should be charged.
● Test meter leads before use. (Set meter to Ohms and check for resistance reading of less than 0.5 Ohm.)
● If available, use clamping meter leads to assist with testing.
● Set meter to next highest voltage scale that includes 12 VDC.
● When taking readings, allow meter to stabilize before recording. Reading should stabilize after 3 to 5 seconds. If
reading continues to drop while cranking, stop test and perform a battery load test.

A B C

D D D
+ - + - + -
G H

+ - + - +
E E - F

I J K

Test #1 Test #2 Test #3

A Battery Voltage Test B Voltage Drop Across C Voltage Drop Across D DVOM
(Static) Battery (Cranking) Starter (Cranking)
Touch meter leads Use starter end plate
E Battery F Starter G to actual battery H as test point.
terminals.
I Test #1 Results J Test #2 Results K Test #3 Results
Test 1 Conclusions
• If battery voltage is above 12.4 VDC continue to Test 2.
• If voltage is below 12.4 VDC, charge battery and retest.
• If battery will not hold a charge it should be replaced before continuing test or replacing starter.

Test 2 Conclusions
• If battery cranking voltage is above 9.0 VDC continue to Test 3.
• If battery cranking voltage is below 9.0 VDC you should check battery by using a load tester. Also check for external
engine load.

Test 3 Conclusions
• If difference between test 2 and test 3 is greater than 1 VDC check all positive and negative electrical connections
for corrosion and/or loose fasteners in starter circuit.

68 KohlerEngines.com 32 690 12 Rev. --

 Emission Compliant Systems

EVAPORATIVE EMISSION COMPLIANT SYSTEM

Carbon Canister System

D
A

Roll Over Valve

A Fuel Tank Cap B Fuel Tank C D Carbon Canister
(ROV)
Canister Breather
E F To Throttle Body
Filter
For equipment to be Tier III compliant, it may be fitted with a Kohler supplied canister vapor recovery system, or a
system developed and installed by Original Equipment Manufacturer (OEM). Details on Kohler system are included
below.
Operation Maintenance
Fuel vapors travel from fuel tank through tubing to On Kohler-supplied canisters, breather filter can be
carbon canister. On intake stroke of engine fuel vapors removed and cleaned with hot soapy water, dried and
are drawn in through a port in throttle body and burned reinstalled. Do not oil breather screen. This is done
with fuel charge. periodically or if system operation is suspect. Carbon
canister is sealed and requires no maintenance.
In some applications or installations, OEM will have
installed a different canister or fuel vapor recovery
system. See OEM equipment documentation for service
or maintenance information.

32 690 12 Rev. -- KohlerEngines.com 69

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

C B

C
C
E

D G

D
I

A Fixed Guard B Blower Housing C Air Cleaner Cover D Spark Plug Lead
E Oxygen Sensor F Oil Fill/Dipstick G Dipstick Tube H Oil Filter
I Ignition Coil

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 Disassembly/Inspection and Service

Clean all parts thoroughly as engine is disassembled. Pulse Fuel Pump Components
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 A
lubricating properties of engine oil. B
Disconnect Spark Plug Leads
D
NOTE: Pull on boot only, to prevent damage to spark
plug lead.
1. Disconnect leads from spark plugs.
2. Disconnect connectors from ignition coils. C
Ignition coils may remain attached to baffles after
being unplugged or disconnected. E
3. Shut off fuel supply.
A Pulse Fuel Pump B Fuel Filter
Drain Oil From Crankcase and Remove Oil Filter
C Inlet Line D Outlet Line
1. Remove oil fill/dipstick and oil drain plug.
2. Allow ample time for oil to drain from crankcase and E Pulse Line
oil filter. 1. Disconnect outlet line from fuel pump.
3. Remove and appropriately discard oil filter. Inlet line with fuel filter may stay attached to fuel
pump.
Remove Muffler (if equipped)
2. Remove 2 screws securing fuel pump to blower
NOTE: Unless oxygen sensor is damaged or housing.
malfunctioning, disassembly from muffler is
unnecessary. 3. Disconnect pulse (vacuum) line from valve cover,
then remove fuel pump with lines attached.
1. Remove exhaust system and attaching hardware
from engine. Remove Blower Housing
2. Disconnect oxygen sensor connector from wire NOTE: Unless fixed guard is damaged, removal from
harness. blower housing is unnecessary.
Remove Dipstick Tube 1. Remove air cleaner cover.
Remove screw securing dipstick tube to backing plate. 2. Disconnect fuses from fuse holders on blower
Remove dipstick tube. housing and allow them to hang.
3. Remove screws securing blower housing to air
Remove Pulse Fuel Pump cleaner base.
4. Loosen screws securing blower housing to backing
WARNING plate and baffles. Screws may remain in slotted
Explosive Fuel can cause fires and severe holes.
burns. 5. Remove screw securing cable clip on #2 side of
Do not fill fuel tank while engine is hot or blower housing.
running. 6. Remove blower housing.
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.

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Disassembly/Inspection and Service

Remove Fuel Pump Module (FPM) 4. Wrap a shop towel completely around high pressure
fuel line connector.
Press release button and slowly pull connector away
WARNING from FPM, allowing shop towel to absorb any
Explosive Fuel can cause fires and severe residual fuel in high pressure fuel line. Any spilled
burns. fuel must be wiped up immediately.
Do not fill fuel tank while engine is hot or 5. Keep inlet fuel line attached at FPM.
running. Do not cut Oetiker clamp unless fuel line or FPM are
Gasoline is extremely flammable and its vapors can being replaced.
explode if ignited. Store gasoline only in approved 6. Remove screws securing FPM baffle to crankcase
containers, in well ventilated, unoccupied buildings, and remove baffle.
away from sparks or flames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from Remove Throttle Controls
ignition. Never use gasoline as a cleaning agent.
Control Bracket Components
FPM Components

J
A
G
E
E
G B

H D

A
I
F F

C B
I
H
C
B A Linkage Spring B Governor Lever
D C Governor Spring D Control Bracket
E Governor Linkage F Cable Clamp
A Pulse Pump B Inlet Line
G Nut H Cross Shaft
C Outlet to FPM D Pulse Line
Governed Idle
E Electrical Connector F FPM I Spring
High Pressure Fuel 1. Remove screws securing throttle control bracket to
G FPM Baffle H cylinder heads.
Line Connector
I Oetiker Clamp J Vent Hose 2. Unhook governor spring and governed idle spring
from governor lever. Note hole locations for
NOTE: Do not cut Oetiker clamp unless fuel line or FPM reassembly.
are being replaced.
1. Remove screws securing FPM to baffle. Remove External Governor Controls
2. Lift grey locking tab and squeeze to disconnect Loosen nut and remove governor lever from cross shaft.
electrical connector. Leave governor lever attached to throttle and governor
linkage.
3. Using Hose Removal Tool (see Tools and Aids),
disconnect vent line from top of FPM.

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 Disassembly/Inspection and Service

Air Cleaner/Throttle Body Components

B
B

B
C

C
C

H I
G
A

A J

A Air Cleaner Base B Air Cleaner Element C Precleaner D Breather Hose

Throttle Body/
Throttle Linkage/ Throttle Position
E Vent Hose F G Air Cleaner Gasket H
Governor Lever Sensor (TPS)
Assembly
I Throttle Body J Throttle Body Gasket

Remove Air Cleaner and Throttle Body

1. Remove throttle body/air cleaner base mounting nuts.
2. Disconnect breather hose from air cleaner base.
3. Remove air cleaner base with air cleaner element and precleaner (if equipped) and air cleaner gasket from
mounting studs.
4. Remove air cleaner element and precleaner (if equipped) from air cleaner base for servicing.
5. Disconnect throttle position sensor (TPS) connector.
6. Disconnect vent hose from throttle body.
7. Remove throttle body, throttle linkage and governor lever as an assembly.
8. Remove throttle body gasket.
9. If necessary, throttle body, throttle linkage, and governor lever can be separated. Reattach bushings to linkage
following separation to avoid losing them.

32 690 12 Rev. -- KohlerEngines.com 73

Disassembly/Inspection and Service

Starter and Electronic Control Unit (ECU) Components

A
C
B
I
F
E
D H

D
E
G G
A ECU B ECU Bracket C Starter D Inner Baffle
E Outer Baffle F Ignition Coil G Lifting Strap H Oil Sentry™ Switch
Engine Temperature
I Sensor

Remove ECU
NOTE: Unless ECU is damaged or malfunctioning, disassembly from bracket is unnecessary.
1. Remove screws securing ECU to bracket.
2. Disconnect Black and Grey electrical connectors from ECU.
Remove ECU Bracket and Electric Starter Motor
Remove screws, ECU bracket, and starter.
Remove Inner and Outer Baffles
NOTE: Unless Oil Sentry™ switch is damaged or malfunctioning, disassembly from oil pan is unnecessary.
NOTE: Do not remove ignition coils from baffles unless coils are being replaced.
1. Disconnect lead from Oil Sentry™ switch.
2. Remove screw securing engine temperature sensor to crankcase.
3. Remove screws securing lifting straps to cylinder heads; remove lifting straps.
4. Remove screws securing outer baffles to cylinder heads and backing plate. Note location of short screws for
reassembly.
5. Remove screws securing inner baffles to crankcase.

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 Disassembly/Inspection and Service

Intake Manifold Components

D A
C

E D

A TMAP Sensor B Fuel Rail C Metal Retaining Clip D Fuel Injector

Crankshaft Position
E Intake Manifold F G Rectifier-Regulator
Sensor

Remove Crankshaft Position Sensor NOTE: Make note of fuel injector position before
removing.
NOTE: Do not remove sensor from bracket unless
sensor is being replaced. 1. Disconnect injector plug.
1. Remove screws securing crankshaft position sensor 2. Remove screw and pull injector out of intake
bracket to crankcase posts. manifold for each injector.
2. Disconnect electrical connector from crankshaft 3. When removed, pull metal retaining clip connecting
position sensor. fuel injector to fuel injector cap. There may be some
fuel left in line. Any spilled fuel must be cleaned up
Remove Temperature/Manifold Absolute Pressure immediately.
(TMAP) Sensor
Remove Intake Manifold
NOTE: Unless TMAP sensor is damaged or
malfunctioning, disassembly from intake 1. Disconnect rectifier-regulator B+ wire (purple wire
manifold is unnecessary. covered with black heat shrink tubing) from wiring
harness.
1. Slide locking tab on electrical connector out.
2. Remove screw (from crankcase) securing a ring
2. Squeeze tab and detach connector. terminal which is part of wiring harness.
3. Remove screw and pull TMAP sensor out of intake 3. Remove screws securing intake manifold to cylinder
manifold. heads.
Remove Fuel Injectors 4. Remove intake manifold and intake manifold
gaskets.
NOTE: Unless fuel injectors are damaged or
malfunctioning, disassembly from intake 5. Leave wiring harness attached to manifold.
manifold is unnecessary.

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Disassembly/Inspection and Service

Cylinder Head Components

C K
E A
D F
M
G J
H
I P
L

N Q
O

A Gasket B Valve C Cylinder Head D Spark Plug

E Washer F Valve Stem Seal G Valve Spring H Valve Spring Cap
I Valve Spring Keeper J Push Rod K Guide Plate L Stud
M Rocker Arm N Rocker Arm Pivot O Adjuster P Set Screw
Q Valve Cover

Remove Spark Plugs Remove Cylinder Heads

Remove spark plug from each cylinder head. NOTE: Exhaust side is located on output shaft side of
engine, while intake side is located on fan side
Remove Valve Covers of engine. Cylinder head number is embossed
NOTE: Valve cover is sealed to cylinder head using on outside of each cylinder head.
RTV silicone sealant. When removing valve 1. Loosen inner set screws (T25 Torx), and back off
cover, use care not to damage gasket surfaces adjusters.
of cover and cylinder head. To break RTV seal, 2. Mark location of push rods as either intake or
hold a block of wood against 1 flat face of valve exhaust and cylinder 1 or 2. Push rods should
cover. Strike wood firmly with a mallet. If seal always be installed in same positions.
doesn't break loose after 1 or 2 attempts, repeat
procedure on other side. 3. Remove screws securing each cylinder head.
1. Remove Torx screws securing each valve cover. 4. Remove cylinder head and head gasket.
2. Using a brass wire brush and gasket remover or
similar solvent, clean old RTV from surface of
cylinder head and valve cover.
3. Sealing surface of stamped steel valve covers must
be checked for flatness prior to reinstallation. Hold
valve cover down firmly against a flat, level surface
or precision straight edge, and check around entire
perimeter that a 0.012 in. (0.30 mm) feeler gauge
cannot be inserted anywhere. If gauge goes in
anywhere, cover needs to be replaced.

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 Disassembly/Inspection and Service

Disassemble Cylinder Heads

NOTE: Use a new valve stem seal whenever valve is removed or if valve stem seal is deteriorated or damaged.
Never reuse an old valve stem seal.
1. Remove adjusters, pivots, rocker arms, studs and guide plate from cylinder head.
2. Compress valve springs using a valve spring compressor.
3. Once valve spring is compressed, remove following items.
● Valve spring keepers.
● Valve spring caps.
● Valve springs.
● Intake and exhaust valves (mark position).
● Valve stem seal (intake valve only).
● Washer (intake valve only).
4. Repeat above procedure for other cylinder head. Do not interchange parts from 1 cylinder head to another.

Inspection and Service

Valve Details

Exhaust Insert
A
F B F
E C E
A

G D A G

A H
H

A
Exhaust Valve Intake Valve
B

Intake Insert

Dimension Intake Exhaust

A Seat Angle 44.5° 44.5°
B Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.)
C Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.)
D Guide I.D. 7.040/7.060 mm (0.2772/0.2780 in.) 7.040/7.060 mm (0.2772/0.2780 in.)
E Valve Head Diameter 33.37/33.63 mm (1.3138/1.3240 in.) 29.37/29.63 mm (1.1563/1.1665 in.)
F Valve Face Angle 45° 45°
G Valve Margin (Min.) 1.5 mm (0.0591 in.) 1.5 mm (0.0591 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 corresponding top surface of crankcase, using a surface plate or
precision straight edge and feeler gauge. Maximum allowable out of flatness is 0.076 mm (0.003 in.).

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Disassembly/Inspection and Service

Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion.
Check valves and valve seat area or inserts for evidence of deep pitting, cracks, or distortion.
Check clearance of valve stems in guides. See valve details and specifications.
Hard starting, or loss of power accompanied by high fuel consumption may be symptoms of faulty valves. Although
these symptoms could also be attributed to worn rings, remove and check valves first. After removal, clean valve
heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as warped
head, excessive corrosion, or worn stem end. Replace valves found to be in bad condition.
Valve Guides
If a valve guide is worn beyond specifications, it will not guide valve in a straight line. This may result in burnt valve
faces or seats, loss of compression, and excessive oil consumption.
To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure
inside diameter of guide. Then, using an outside micrometer, measure diameter of valve stem at several points on
stem where it moves in valve guide. Use largest stem diameter to calculate clearance by subtracting stem diameter
from guide diameter. If intake clearance exceeds 0.040/0.078 mm (0.0016/0.0031 in.) or exhaust clearance exceeds
0.052/0.090 mm (0.0020/0.0035 in.), determine whether valve stem or guide is responsible for excessive clearance.
Maximum (I.D.) wear on intake valve guide is 7.140 mm (0.2811 in.) while 7.160 mm (0.2819 in.) is maximum allowed
on exhaust 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.
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 a 44.5° 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
NOTE: Exhaust valves that are black in color cannot be ground and do not require lapping.
Reground or new valves must be lapped in, to provide fit. Use a hand valve grinder with suction cup for final lapping.
Lightly coat valve face with fine grade of grinding compound, then rotate valve on seat with grinder. Continue grinding
until 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.
Intake Valve Stem Seal
Always use a new seal when valves are removed from cylinder head. Seals should also be replaced if deteriorated or
damaged in any way. Never reuse an old seal.

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 Disassembly/Inspection and Service

Flywheel/Ignition/Breather Components Remove Debris Screen, Fan, and Flywheel

NOTE: Always use a flywheel strap wrench or flywheel
holding tool (see Tools and Aids) to hold flywheel
A when loosening or tightening flywheel and fan
retaining fasteners. Do not use any type of bar
or wedge between fins of cooling fan, as fins
B could become cracked or damaged.
C NOTE: Always use a puller to remove flywheel from
crankshaft. Do not strike crankshaft or flywheel,
D as these parts could become cracked or
E damaged. Striking puller or crankshaft can
cause crank gear to move, affecting crankshaft
endplay.
F
1. Unsnap debris screen from cooling fan.
2. Remove retaining screw, washer, and fan mounting
plate, securing fan and flywheel to crankshaft.
3. Lift fan to disengage 2 retainers and remove fan
G from flywheel. Two plastic retainers may remain in
fan.
4. Remove flywheel from crankshaft by pulling from
under ring gear with large gear puller.
H 5. Remove flywheel key from crankshaft.
Flywheel Inspection
Inspect flywheel for cracks, and flywheel keyway for
damage. Replace flywheel if it is cracked. Replace
flywheel, crankshaft, and key if flywheel key is sheared
I or keyway is damaged.
J Inspect ring gear for cracks or damage. Kohler does
K not provide ring gears as a serviceable part. Replace
L flywheel if ring gear is damaged.
M Remove Backing Plate and Stator
1. Remove screws and backing plate from crankcase.
2. Remove screws and stator. Note routing of stator
leads.
Remove Breather Reed Assembly
1. RTV sealant is used between breather reed cover
and crankcase. Remove nut and sealing (flat)
A Debris Screen B Flywheel Screw washer securing breather reed cover to crankcase.
Carefully pry under small tab of cover flange to
C Washer D Fan Mounting Plate separate and remove. Do not bend or distort cover.
Flywheel Fan 2. Unscrew and remove mounting stud, retainer and
E F Fan
Retainer breather reed.
G Flywheel H Stator
Breather Reed
I Backing Plate J Cover
K Stud L Retainer
M Breather Reed

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Disassembly/Inspection and Service

Crankshaft/Governor Gear/Oil Pump Components M Drain Plug N Oil Seal

O Oil Pump P Oil Sentry™
C Q Ball R Spring
Ground Strap
S Oil Pick-up Screen T
D Location
B U Outer Gerotor Gear
A
Remove Oil Pan Assembly
1. Remove screws securing oil pan to crankcase.
2. Locate splitting tab cast into perimeter of oil pan.
Insert drive end of a 1/2” breaker bar between
splitting tab and crankcase and turn it to break RTV
seal. Do not pry on sealing surfaces as this can
cause leaks.
Inspection
Inspect oil seal in oil pan and remove it if it is worn
E or damaged. New oil seal is installed after oil pan is
assembled to crankcase. See Reassembly, Oil Seal in
Oil Pan.
Inspect main bearing surface for wear or damage (refer
to Specifications). Replace oil pan assembly if required.
Governor Assembly
F Governor gear assembly is located inside oil pan. If
service is required, continue following steps.
O Inspection
G Inspect governor gear teeth. Replace gear if it is worn,
chipped, or if any teeth are missing. Inspect governor
S weights. They should move freely in governor gear.
P H
Disassembly
U I
Governor Shaft Component and Details
R J C
Q K

T
L B
A

Governor Cross
A B Lower Washer
Shaft
C Nylon Washer D E-Clip
34.0 mm (1.3386 in.)
E Crankshaft F Valve Tappets A B 19.40 mm (0.7638 in.)
33.5 mm (1.3189 in.)
G Camshaft H Regulating Pin C Gear Shaft
I Shaft J Governor Gear
Locking Tab Thrust
K L Oil Pan
Washer

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 Disassembly/Inspection and Service

NOTE: Governor gear is held onto shaft by small Remove Camshaft and Valve Tappets
molded tabs in gear. When gear is removed from
shaft, these tabs are destroyed and gear must 1. Position crankcase so flywheel side is down.
be replaced. Therefore, remove gear only if Remove camshaft and shim.
absolutely necessary. 2. Remove valve tappets from crankcase and mark
Governor gear must be replaced once it is removed from them by their location, as either intake or exhaust
oil pan. and cylinder 1 or 2. Tappets should always be
reinstalled in same position.
1. Use 2 small screwdrivers and carefully pry upward to
remove regulating pin and governor gear assembly. Camshaft Inspection and Service
Check lobes of camshaft for wear or damage. See
2. Remove locking tab thrust washer located under Specifications for minimum lift specifications. Inspect
governor assembly. cam gear for badly worn, chipped or missing teeth.
3. Carefully inspect governor gear shaft and replace it Replacement of camshaft will be necessary if any of
only if it is damaged. After removing damaged shaft, these conditions exist.
press or lightly tap replacement shaft into oil pan to Valve Tappets Inspection
depth shown. Check base surface of valve tappet(s) for wear or
Reassembly damage. Replace tappet(s) if condition is questionable
1. Install locking tab thrust washer on governor gear in any way. Corresponding camshaft lobe(s) should also
shaft with tab down. be checked for wear or damage. Whenever tappets are
2. Position regulating pin within governor gear/ replaced, apply a liberal coating of Kohler lubricant to
flyweights assembly and slide both onto governor base of each new tappet before it is installed.
shaft until assembly locks into place.
Remove Governor Cross Shaft
Oil Pump Assembly Governor Cross Shaft Oil Seal Details
Oil pump is mounted inside oil pan. If service is required,
continue with Disassembly, Inspection, and Reassembly. C
A D
Disassembly B
1. Remove screws.
2. Lift oil pump assembly from oil pan. Remove outer
gerotor gear from oil pan.
3. Ensure ball and spring remain installed in pressure
relief hole of oil pan. If ball and spring fall out of
pressure relief hole, see reassembly for correct
installation.
Inspection
Inspect oil pump housing, gear, and rotors for nicks,
burrs, wear, or any visible damage. If any parts
are worn or damaged, replace oil pump assembly.
Check oil pickup screen for damage or restriction,
replace if necessary. Disassembly of oil pump is not
recommended.
Reassembly Governor Cross
A 2.0 mm (0.0787 in.) B
1. Lubricate outer gerotor gear with oil. Install outer Shaft Seal
gerotor gear through shaft of oil pump, around inner C E-Clip D Nylon Washer
gerotor gear. Matching molding dots on inner and
outer gerotor gears is not necessary and will not
affect oil pump efficiency. 1. Remove E-clip and nylon washer from governor
cross shaft.
2. Reinstall ball, then spring into pressure relief hole of
oil pan. 2. Remove cross shaft with lower washer through
inside of crankcase.
3. Install oil pump inserting center shaft into
corresponding recess in oil pan. Secure oil pump by 3. Remove governor shaft seal from crankcase.
torquing screws (in no specific sequence) to 9.9 N·m If governor cross shaft seal is damaged and/or leaks,
(88 in. lb.). replace it using following procedure.
4. After torquing, rotate gear and check for freedom of Remove oil seal from crankcase and replace it with a
movement. Make sure there is no binding. If binding new one. Install new seal to depth shown.
occurs, loosen screws, reposition pump, retorque
screws and recheck movement.

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Disassembly/Inspection and Service

Connecting Rods/Piston/Breather Components Inspection and Service

Check bearing area (big end) for excessive wear, score
B marks, running and side clearances (See Specifications).
Replace rod and cap if scored or excessively worn.
D C I Service replacement connecting rods are available in
STD size and 0.25 mm (0.010 in.) undersize. Undersized
rods, 0.25 mm (0.010 in.), have an identification marking
B on lower end of rod shank. Always refer to appropriate
parts information to ensure correct replacements are
used.
A F Piston and Rings
E Inspection
Piston and Rings Components and Details
G A
H
A Piston Ring Set B Piston Pin Retainer
B
C Piston D Piston Pin
Connecting Rod C
E Connecting Rod F End Cap
Breather
G Breather Filter H Cover
I Oil Seal
Remove Breather Assembly
Breather system is designed to control amount of oil
in head area and still maintain necessary vacuum in D
crankcase.
When pistons move downward, crankcase gases are E
pushed past reed through breather filter into intake
system. Upward travel of pistons closes reed and
creates a low vacuum in lower crankcase. Any oil F
separated out through filter drains back into crankcase.
1. Remove screws securing breather cover to
crankcase.
G
2. Carefully remove cover and breather filter. Make
sure drain back hole is not plugged or restricted.
Remove Connecting Rods with Pistons and Rings H
NOTE: If a carbon ridge is present at top of either A Piston Ring B End Gap
cylinder bore, use a ridge reamer tool to remove
it before attempting to remove piston. C Identification Mark D Piston
NOTE: Cylinders are numbered on crankcase. Use Top Compression Middle Compression
E F
numbers to mark each end cap, connecting rod Ring Ring
and piston for reassembly. Do not mix end caps G Rails H Expander
and connecting rods.
Scuffing and scoring of pistons and cylinder walls occurs
1. Remove screws securing closest connecting rod end when internal engine temperatures approach welding
cap. Remove end cap. point of piston. Temperatures high enough to do this are
2. Carefully remove connecting rod and piston created by friction, which is usually attributed to improper
assembly from cylinder bore. lubrication and/or overheating of engine.
3. Repeat above procedure for other connecting rod Normally, very little wear takes place in piston boss-
and piston assembly. piston pin area. If original piston and connecting rod can
be reused after new rings are installed, original pin can
Connecting Rods also be reused but new piston pin retainers are required.
Offset, stepped-cap connecting rods are used in all A piston pin is included as part of piston assembly – if
these engines. pin boss in piston or pin are worn or damaged, a new
piston assembly is required.

82 KohlerEngines.com 32 690 12 Rev. --

 Disassembly/Inspection and Service

Ring failure is usually indicated by excessive oil Install New Piston Rings
consumption and blue exhaust smoke. When rings fail, NOTE: Rings must be installed correctly. Ring
oil is allowed to enter combustion chamber where it is installation instructions are usually included with
burned along with fuel. High oil consumption can also new ring sets. Follow instructions carefully. Use
occur when piston ring end gap is incorrect because a piston ring expander to install rings. Install
ring cannot properly conform to cylinder wall under this bottom (oil control) ring first and top
condition. Oil control is also lost when ring gaps are not compression ring last.
staggered during installation.
To install new piston rings, proceed as follows:
When cylinder temperatures get too high, lacquer and
varnish collect on pistons causing rings to stick, which 1. Oil control ring (bottom groove): Install expander and
results in rapid wear. A worn ring usually takes on a then rails. Make sure ends of expander are not
shiny or bright appearance. overlapped.
Scratches on rings and pistons are caused by abrasive 2. Middle compression ring (center groove): Install
material such as carbon, dirt, or pieces of hard metal. center ring using a piston ring expander tool. Make
sure identification mark is up or colored dye stripe (if
Detonation damage occurs when a portion of fuel charge contained) is to left of end gap.
ignites spontaneously from heat and pressure shortly
after ignition. This creates 2 flame fronts, which meet 3. Top compression ring (top groove): Install top ring
and explode to create extreme hammering pressures on using a piston ring expander tool. Make sure
a specific area of piston. Detonation generally occurs identification mark is up or colored dye stripe (if
from using low octane fuels. contained) is left of end gap.
Preignition or ignition of fuel charge before timed spark Remove Crankshaft
can cause damage similar to detonation. Preignition
damage is often more severe than detonation damage. Carefully pull crankshaft from crankcase.
Preignition is caused by a hot spot in combustion Inspection and Service
chamber such as glowing carbon deposits, blocked Inspect gear teeth of crankshaft. If teeth are badly worn,
cooling fins, an improperly seated valve, or wrong spark chipped, or some are missing, replacement of crankshaft
plug(s). will be necessary.
Replacement pistons are available in STD bore size, Inspect crankshaft bearing surfaces for scoring,
and 0.25 mm (0.010 in.) oversize. Replacement pistons grooving, etc. Measure running clearance between
include new piston ring sets and new piston pins. crankshaft journals and their respective bearing bores.
Replacement ring sets are also available separately for Use an inside micrometer or telescoping gauge to
STD, and 0.25 mm (0.010 in.) oversize pistons. Always measure inside diameter of both bearing bores in vertical
use new piston rings when installing pistons. Never use and horizontal planes. Use an outside micrometer to
old rings. measure outside diameter of crankshaft main bearing
journals. Subtract journal diameters from their respective
Some important points to remember when servicing bore diameters to get running clearances. Check results
piston rings: against values in Specifications. If running clearances
1. Cylinder bore must be de-glazed before service ring are within specification, and there is no evidence of
sets are used. scoring, grooving, etc., no further reconditioning is
necessary. If bearing surfaces are worn or damaged,
2. If cylinder bore does not need re-boring and if old crankcase and/or oil pan will need to be replaced.
piston is within wear limits and free of score or scuff
marks, old piston may be reused. Inspect crankshaft keyways. If worn or chipped,
replacement of crankshaft will be necessary.
3. Remove old rings and clean up grooves. Never
reuse old rings. Inspect crankpin for score marks or metallic pickup.
Slight score marks can be cleaned with crocus cloth
4. Before installing new rings on piston, place top 2 soaked in oil. If wear limits are exceeded, as stated in
rings, each in turn, in its running area in cylinder Specifications, it will be necessary to replace crankshaft.
bore and check end gap. Top compression ring end
gap clearance is 0.189/0.277 mm (0.0074/0.0109 in.) Remove Flywheel and PTO End Oil Seals
for a new bore, or 0.531 mm (0.0209 in.) for a used
bore. Middle compression ring end cap is Remove oil seals from crankcase and oil pan.
1.519/1.797 mm (0.0598/0.0708 in.) for a new bore,
or 2.051 mm (0.0808 in.) for a used bore.
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-
groove side clearance 0.030/0.070 mm
(0.0010/0.026 in.). If side clearance is greater than
specified, a new piston must be used.

32 690 12 Rev. -- KohlerEngines.com 83

Disassembly/Inspection and Service

Crankcase 2. With lower edge of each stone positioned even with

lowest edge of bore, start drill and honing process.
Inspection and Service Move hone up and down while resizing to prevent
Check all gasket surfaces to make sure they are free of formation of cutting ridges. Check size frequently.
gasket fragments. Gasket surfaces must also be free of
deep scratches or nicks. 3. When bore is within 0.064 mm (0.0025 in.) of
desired size, remove coarse stones and replace
Check cylinder bore for scoring. In severe cases, them with burnishing stones. Continue with
unburned fuel can cause scuffing and scoring of cylinder burnishing stones until bore is within 0.013 mm
wall. It washes necessary lubricating oils off piston and (0.0005 in.) of desired size and then use finish
cylinder wall. As raw fuel seeps down cylinder wall, stones (220-280 grit) and polish bore to its final size.
piston rings make metal to metal contact with wall. A crosshatch should be observed if honing is done
Scoring of cylinder wall can also be caused by localized correctly. Crosshatch should intersect at
hot spots resulting from blocked cooling fins or from approximately 23°-33° off horizontal. Too flat an
inadequate or contaminated lubrication. angle could cause rings to skip and wear
If cylinder bore is badly scored, excessively worn, excessively, and too steep an angle will result in high
tapered, or out-of-round, resizing is necessary. Use an oil consumption.
inside micrometer to determine amount of wear (refer 4. After resizing, check bore for roundness, taper, and
to Specifications). A 0.25 mm (0.010 in.) oversize piston size. Use an inside micrometer, telescoping gauge,
is available if resizing is selected. Initially, resize using or bore gauge to take measurements. These
a boring bar, then use these following procedures for measurements should be taken at 3 locations in
honing cylinder. cylinder – at top, middle, and bottom. Two
Honing measurements should be taken (perpendicular to
each other) at 3 locations.
Details
Clean Cylinder Bore After Honing
Proper cleaning of cylinder walls following boring and/
A or honing is very critical to a successful overhaul.
Machining grit left in cylinder bore can destroy an engine
in less than 1 hour of operation after a rebuild.
Final cleaning operation should always be a thorough
scrubbing with a brush and hot, soapy water. Use a
strong detergent capable of breaking down machining
oil while maintaining a good level of suds. If suds break
down during cleaning, discard dirty water and start again
with more hot water and detergent. Following scrubbing,
rinse cylinder with very hot, clear water, dry it completely,
and apply a light coating of engine oil to prevent rusting.

A 23°-33° Crosshatch
NOTE: Kohler pistons are custom-machined to exacting
tolerances. When over-sizing a cylinder, it
should be machined exactly 0.25 mm (0.010 in.)
over new diameter (refer to Specifications).
Oversize Kohler replacement piston will then fit
correctly.
While most commercially available cylinder hones can
be used with either portable drills or drill presses, use
of a low speed drill press is preferred as it facilitates
more accurate alignment of bore in relation to crankshaft
crossbore. Honing is best accomplished at a drill speed
of about 250 RPM and 60 strokes per minute. After
installing coarse stones in hone, proceed as follows:
1. Lower hone into bore and after centering, adjust so
stones are in contact with cylinder wall. Use of a
commercial cutting-cooling agent is recommended.

84 KohlerEngines.com 32 690 12 Rev. --

 Disassembly/Inspection and Service

Measuring Piston-to-Bore Clearance

Piston Detail

A 6 mm (0.2362 in.)
NOTE: Do not use a feeler gauge to measure piston-to-
bore clearance, it will yield inaccurate
measurements. Always use a micrometer.
Before installing piston into cylinder bore, it is necessary
that clearance be accurately checked. This step is
often overlooked, and if clearances are not within
specifications, engine failure will usually result.
Use following procedure to accurately measure piston-
to-bore clearance:
1. Use a micrometer and measure diameter of piston
6 mm (0.2362 in.) above bottom of piston skirt and
perpendicular to piston pin.
2. Use an inside micrometer, telescoping gauge, or
bore gauge and measure cylinder bore.
Measurement approximately 63.5 mm (2.5 in.) below
top of bore and perpendicular to piston pin.
3. Piston-to-bore clearance is difference between bore
diameter and piston diameter (step 2 minus step 1).

32 690 12 Rev. -- KohlerEngines.com 85

Reassembly

NOTE: Make sure engine is assembled using all Install Flywheel End Oil Seal
specified torque values, tightening sequences,
and clearances. Failure to observe specifications 1. Make sure seal bore of crankcase is clean and free
could cause severe engine wear or damage. of any nicks or burrs.
Always use new gaskets. 2. Apply a light coat of engine oil to outside diameter of
Make sure all traces of any cleaner are removed before oil seal.
engine is assembled and placed into operation. Even 3. Install oil seal into crankcase using a seal driver.
small amounts of these cleaners can quickly break down Make sure oil seal is installed straight and true in
lubricating properties of engine oil. bore and tool bottoms against crankcase.
Check oil pan, crankcase, cylinder heads, and valve
covers to be certain all old sealing material has been Install Breather Filter and Breather Cover
removed. Use gasket remover, lacquer thinner, or paint
remover to remove any remaining traces. Clean surfaces Fastener Torque Sequence and Sealant
with isopropyl alcohol, acetone, lacquer thinner, or
electrical contact cleaner.
A
Connecting Rods/Piston/Breather Components
B 1&5
3
D C I

B
4 2
A F A Sealant Bead
E
J NOTE: Always use fresh sealant. Using outdated
sealant can result in leakage. Refer to Tools and
G Aids for a listing of approved sealants.
H
NOTE: To ensure proper adhesion of sealant to both
A Piston Ring Set B Piston Pin Retainer sealing surfaces, perform step 4 immediately (5
minutes maximum) after application of RTV.
C Piston D Piston Pin
Connecting Rod NOTE: RTV sealant should be allowed to cure a
E Connecting Rod F minimum of 1 hour before engine is started.
End Cap
Breather 1. Install breather filter between 2 ribs inside breather
G Breather Filter H chamber.
Cover
I Oil Seal J Breather Hose 2. Make sure sealing surfaces are clean and free of
nicks or damage.
3. Apply a 1.5 mm (1/16 in.) bead of RTV sealant to
sealing surface of breather cover. See sealant
pattern.
4. Immediately install cover onto crankcase. Do not
allow RTV sealant to come into contact with any
other components.
5. Secure breather cover with M5 screws. Torque
screws in sequence shown to 6.2 N·m (55 in. lb.)
into a new, cored hole, or 4.0 N·m (35 in. lb.) into a
used hole.
6. Attach breather hose if disconnected earlier.

86 KohlerEngines.com 32 690 12 Rev. --

 Reassembly

Crankshaft/Governor Gear/Oil Pump Components M Drain Plug N Oil Seal

O Oil Pump P Oil Sentry™
C Q Ball R Spring
Ground Strap
S Oil Pick-up Screen T
D Location
B U Outer Gerotor Gear
A
Install Governor Cross Shaft
NOTE: If governor cross shaft seal was removed, see
Disassembly/Inspection and Service procedure
to install seal.
1. Lubricate governor cross shaft bearing surfaces in
crankcase with engine oil.
2. Slide lower washer onto governor cross shaft and
install cross shaft from inside of crankcase.
E 3. Install nylon washer onto governor cross shaft.
Install E-clip into groove on cross shaft. Use a 0.25
mm (0.010 in.) feeler gauge to make sure gap
between washer and clip is at least 0.25 mm
(0.010 in.).
Install Crankshaft
F 1. Lubricate flywheel side main bearing surface and
lips of oil seal in crankcase with clean engine oil.
O 2. Carefully slide flywheel end of crankshaft through
G main bearing in crankcase.

S Install Connecting Rods with Pistons and Rings

P H
Piston and Connecting Rod Details
U I

R J
Q K

T
L
B

A
M
A Side 1 B Side 2
N
NOTE: Cylinders are numbered on crankcase. Make
Governor Cross sure to install piston, connecting rod, and end
A B Lower Washer cap into its appropriate cylinder bore as
Shaft
previously marked during disassembly. Do not
C Nylon Washer D E-Clip mix end caps and connecting rods.
E Crankshaft F Valve Tappets
NOTE: Proper orientation of piston/connecting rod
G Camshaft H Regulating Pin assemblies inside engine is extremely important.
I Shaft J Governor Gear Improper orientation can cause extensive wear
or damage. Be certain pistons and connecting
Locking Tab Thrust rods are assembled exactly as shown.
K L Oil Pan
Washer

32 690 12 Rev. -- KohlerEngines.com 87

Reassembly

NOTE: Align chamfer of connecting rod with chamfer of 3. Position timing mark of crankshaft gear at 12 o’clock
its mating end cap. When installed, flat faces of position.
connecting rods should face each other. Faces 4. Turn governor cross shaft clockwise until lower end
with raised rib should be toward outside. (blade) is laying against bottom of cylinder. Make
1. If piston rings were removed, see Disassembly/ sure cross shaft remains in this position while
Inspection and Service procedure to install rings. installing camshaft.
2. Lubricate cylinder bore, piston, and piston rings with 5. Slide camshaft into bearing surface of crankcase,
engine oil. Compress rings using a piston ring positioning timing mark of camshaft gear at 6 o’clock
compressor. position. Make sure camshaft gear and crankshaft
3. Lubricate crankshaft journals and connecting rod gear mesh with both timing marks aligned.
bearing surfaces with engine oil.
Oil Pump Assembly
4. Make sure FLY stamping on piston is facing toward
flywheel side of engine. Use a hammer with a rubber Oil pump is mounted inside oil pan. If service
or wood grip and gently tap piston into cylinder. Be was required and oil pump was removed, refer to
careful oil ring rails do not spring free between Disassembly/Inspection and Service procedure.
bottom of ring compressor and top of cylinder.
Governor Assembly
5. Install inner rod cap to connecting rod using screws.
Torque in increments to 13.6 N·m (120 in. lb.). Governor assembly is located inside oil pan. If service
was required and governor was removed, refer to
6. Repeat above procedure for other connecting rod Disassembly/Inspection and Service procedure.
and piston assembly.
Install Oil Seal in Oil Pan
Install Valve Tappets and Camshaft
Oil Seal Component and Detail
Timing Mark Detail

A
B
A 6.5 mm (0.255 in.) B Oil Seal
1. Check to make sure there are no nicks or burrs in
crankshaft bore of oil pan.
2. Apply a light coat of engine oil to outside diameter of
Camshaft Gear Crankshaft Gear oil seal.
A B
Timing Mark Timing Mark
3. Drive oil seal into oil pan using a seal driver. Make
NOTE: Exhaust valve tappets are located on output sure oil seal is installed straight and true in bore, to
shaft side of engine, while intake valve tappets depth shown.
are located on fan side of engine. Cylinder
number is embossed on outside of each cylinder
on crankcase. Valve tappets should always be
installed in same position as before disassembly.
1. Apply camshaft lubricant to contact surface of valve
tappets. Note mark or tag identifying tappets and
install them in their appropriate crankcase locations.
A small amount of grease applied to stems will hold
valve tappets up until camshaft is installed.
2. Liberally apply camshaft lubricant to lobes of
camshaft. Lubricate camshaft bearing surfaces of
crankcase and camshaft with engine oil.

88 KohlerEngines.com 32 690 12 Rev. --

 Reassembly

Install Oil Pan Assembly Flywheel/Ignition/Breather Components

Sealant Pattern
A

B
C
D
E

Fastener Torque Sequence

G
1
3
10
5 H
8

7
I
6
J
9 K
2 4 L
M
RTV sealant is used as a gasket between oil pan
and crankcase. Refer to Tools and Aids for a listing of
approved sealants. Always use fresh sealant. Using
outdated sealant can result in leakage.
1. Be sure sealing surfaces have been cleaned and
prepared as described at beginning of Reassembly.
2. Check to make sure there are no nicks or burrs on
sealing surfaces of oil pan or crankcase.
A Debris Screen B Flywheel Screw
3. Apply a 1.5 mm (1/16 in.) bead of black RTV sealant
to sealing surface of oil pan. See sealant pattern. Oil C Washer D Fan Mounting Plate
pan must be installed within 5 minutes of sealant Flywheel Fan
being applied for proper sealing to occur. E F Fan
Retainer
4. Make sure end of governor cross shaft is lying G Flywheel H Stator
against bottom of cylinder inside crankcase.
5. Install oil pan to crankcase. Carefully seat camshaft Breather Reed
I Backing Plate J
with shim and crankshaft into their mating bearings. Cover
Rotate crankshaft to help engage oil pump and K Stud L Retainer
governor gear meshes.
M Breather Reed
6. Install 10 screws securing oil pan to crankcase.
Torque fasteners in sequence shown to 25.7 N·m
(227 in. lb.).

32 690 12 Rev. -- KohlerEngines.com 89

Reassembly

Install Breather Reed and Breather Reed Cover Install Flywheel, Fan, and Debris Screen
Breather Reed Cover Sealant CAUTION
A Damaging Crankshaft and Flywheel can
cause personal injury.

Using improper procedures can lead to broken

fragments. Broken fragments could be thrown from
engine. Always observe and use precautions and
procedures when installing flywheel.

NOTE: Before installing flywheel, make sure crankshaft

taper and flywheel hub are clean, dry, and
completely free of lubricants. Presence of
lubricants can cause flywheel to be overstressed
A Sealant Bead and damaged when screw is torqued to
specifications.
NOTE: RTV sealant should be allowed to cure a
minimum of 1 hour before engine is started. NOTE: Make sure flywheel key is installed properly in
1. Install breather reed, followed by retainer over keyway. Flywheel can become cracked or
passage hole and mounting hole in crankcase. Hold damaged if key is not installed properly.
in position and secure with mounting stud. Torque 1. Set flywheel onto crankshaft.
stud to 6.2 N·m (55 in. lb.) into a new, cored hole, or 2. Install flywheel key into keyway of crankshaft and
4.0 N·m (35 in. lb.) into a used hole. flywheel.
2. Invert breather reed cover and apply a 1.5 mm 3. Install fan onto flywheel, so locating posts fit into
(1/16 in.) bead of RTV sealant to perimeter flange of corresponding holes. Drive 2 retainers down
cover as shown. Use Loctite® 5900TM or 5910TM. completely to secure.
3. Immediately install breather reed cover over 4. Install fan mounting plate onto fan, aligning 4
mounting stud and onto crankcase. Do not allow cutouts, followed by heavy flat washer and screw.
RTV sealant to come in contact with breather reed,
or reed sealing surface. 5. Use a flywheel strap wrench or holding tool to hold
flywheel. Torque screw securing flywheel to
4. Secure with a new sealing washer and M5 nut. crankshaft to 74.5 N·m (55 ft. lb.).
Torque nut to 1.3 N·m (12 in. lb.). Check that a
complete seal has occurred by RTV sealant being 6. Snap debris screen in place on fan.
squeezed out around entire flange perimeter.
Install Stator and Backing Plate
Backing Plate Torque Sequence
4
3
1 2

1. Apply pipe sealant with Teflon® (Loctite® PST® 592TM

or equivalent) to stator mounting holes.
2. Position stator aligning mounting holes so leads are
at bottom, toward crankcase.
3. Install and torque screws to 8.8 N·m (78 in. lb.).
4. Install backing plate. Secure with screws. Torque
screws to 7.3 N·m (65 in. lb.) in sequence shown.

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Cylinder Head Components

C K
E A
D F
M
G J
H
4 2 2 4
I P
L

1 3 3 1 R

N Q
O
#1 #2

A Gasket B Valve C Cylinder Head D Spark Plug

E Washer F Valve Stem Seal G Valve Spring H Valve Spring Cap
I Valve Spring Keeper J Push Rod K Guide Plate L Stud
M Rocker Arm N Rocker Arm Pivot O Adjuster P Set Screw
Q Valve Cover R Torque Sequence

Assemble and Install Cylinder Heads Install Cylinder Heads

Valve Stem Seals NOTE: Match numbers embossed on cylinder heads
Use a new seal whenever valve is removed, or if seal is and crankcase.
deteriorated or damaged. Never reuse an old seal. NOTE: When installing cylinder heads, new screws
Assemble Cylinder Heads should always be used. New screws are
Prior to installation, lubricate all components with engine supplied in gasket sets.
oil, paying particular attention to lip of valve stem seal,
valve stems, and valve guides. Install following items in NOTE: Push rods should always be installed in same
order listed below using a valve spring compressor. position as before disassembly.
● Intake and exhaust valves. 1. Check to make sure there are no nicks or burrs on
● Valve stem seal (intake valve only). sealing surfaces of cylinder head or crankcase.
● Washer (intake valve only). Make sure dowel locating pins are in lower 2 cylinder
● Valve springs. bolt holes on each side.
● Valve spring caps. 2. Install a new cylinder head gasket (with printing up)
● Valve spring keepers. on each side.
3. Install each cylinder head and start screws.
4. Torque screws in 2 stages; first to 22.6 N·m
(200 in. lb.), then finally to 41.8 N·m (370 in. lb.),
following sequence.

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Install Rocker Arms Check Assembly

1. Note mark or tag identifying push rod as either Rotate crankshaft a minimum of 2 revolutions to check
intake or exhaust and cylinder 1 or 2. Check each longblock assembly and overall proper operation.
push rod is straight and not bent. Dip ends of push
rods in engine oil and install in their original Install Valve Covers
positions, making sure each push rod ball seats in its
tappet socket. Valve Cover RTV Sealant
2. Install guide plate and studs. Torque studs to
11.3 N·m (100 in. lb.).
3. Apply grease to contact surfaces of adjusters, rocker
arms and rocker arm pivots. Install rocker arms and
rocker arm pivots onto appropriate cylinder head,
and install adjuster finger tight. Make sure set screw
is backed out until flush with adjuster.
Adjust Valve Clearance
Adjusters Retaining Push Rods
A

A
A RTV Sealant

Valve Cover Torque Sequence

A Adjuster B Rocker Arm 1&5 3

1. Rotate crankshaft to establish TDC on compression
stroke for cylinder 1.
Check for:
a. Compression will be felt through spark plug hole.
b. Keyway of crankshaft will be aligned with cylinder
1.
c. No rocker arm/push rod movement if crankshaft
is rotated slightly back and forth. If they are
moving, rotate crankshaft 1 full revolution.
2. Insert a 0.127 mm (0.005 in.) feeler gauge between 4 2
end of 1 valve and rocker arm. Turn adjuster until a
slight drag is felt. Hold in this position and tighten set
screw securely. Torque set screw to 7.9 N·m NOTE: Always use fresh sealant. Using outdated
(70 in. lb.). After tightening recheck adjustment. sealant can result in leakage. Refer to Tools and
Proper valve clearance is 0.101/0.152 mm Aids for information on sealant dispenser.
(0.004/0.006 in.).
NOTE: To ensure proper adhesion of sealant to both
3. Repeat procedure for other valve on side 1. sealing surfaces, perform step 3 immediately (5
4. Viewed from PTO end, rotate crankshaft 270° (3/4 minutes maximum) after application of RTV.
turn) counterclockwise and align crankshaft keyway RTV silicone sealant is used as a gasket between valve
with cylinder 2, which now puts cylinder at TDC on cover and cylinder head. Refer to Tools and Aids for a
compression stroke. listing of approved sealants.
5. Repeat steps 3-4 for setting valve clearance on side 1. Prepare sealing surfaces of cylinder heads and
2. valve covers. Flatness of sealing surface must be
6. Rotate crankshaft to check for free operation of checked prior to reinstallation. See Disassembly.
valve train. Check for clearance between valve 2. Apply a 1.5 mm (1/16 in.) bead of sealant to valve
spring coils at full lift, or bending of push rod(s) can cover as shown.
occur. Minimum allowable clearance is 0.25 mm
(0.010 in.).

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3. Position covers on cylinder heads. Valve cover with pulse fitting hole must be installed on side 2. Install screws in
each cover and finger tighten.
4. Torque valve cover fasteners to 13.6 N·m (120 in. lb.), using sequence shown.
Install Spark Plugs
1. Check gap using wire feeler gauge. Adjust gap to 0.76 mm (0.030 in.).
2. Install plug into cylinder head.
3. Torque plug to 27 N·m (20 ft. lb.).

Intake Manifold Components

D A
C

E D

A TMAP Sensor B Fuel Rail C Metal Retaining Clip D Fuel Injector

Crankshaft Position Backing Plate
E Intake Manifold F G Rectifier-Regulator H
Sensor Support Clip

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Reassembly

Install Intake Manifold Install Temperature/Manifold Absolute Pressure

(TMAP) Sensor
Torque Sequence
NOTE: Ensure all parts are clean, undamaged and free
of debris and make sure electrical connector has
4 3 seal in place.
1. Lightly oil TMAP sensor O-ring and push sensor into
2 1 bore in intake manifold.
2. Torque screw to 7.3 N·m (65 in. lb.).
Install intake manifold using new gaskets, with wiring 3. Push electrical connector on TMAP sensor making
harness attached, onto cylinder heads. Reinstall any sure a good connection is made. Slide lock tab to
wiring harness clips and/or wire ties, if removed, before secure.
installing manifold. Install ground wire to boss and torque
screw to 7.3 N·m (65 in. lb.). Using sequence shown, Install Crankshaft Position Sensor
torque screws to 10.5 N·m (93 in. lb.).
NOTE: Ensure all parts are clean, undamaged and free
Install Rectifier-Regulator of debris and make sure electrical connectors
1. Connect rectifier-regulator B+ wire (purple wire have seal in place.
covered with black heat shrink tubing) to wiring 1. If removed, install crankshaft position sensor to
harness. bracket and torque screws to 11.3 N·m (100 in. lb.).
2. Attach rectifier-regulator to opening in backing plate 2. Install crankshaft position sensor and bracket
from underside, and secure with screws. Torque assembly to crankcase posts. Torque bracket screws
screws to 3.4 N·m (30 in. lb.). to 8.3 N·m (73 in. lb.).
3. Route wire into support clip in backing plate. 3. Push electrical connector on crankshaft position
sensor making sure a good connection is made.
Install Fuel Injectors
NOTE: Ensure all parts are clean, undamaged and free
of debris and make sure electrical connectors
have seal in place.
NOTE: O-rings and retaining clips should be replaced
any time fuel injector is separated from its
normal mounting position.
1. Lightly lubricate fuel injector O-rings with clean
engine oil.
2. Push retaining clip onto fuel injector, aligning clip as
shown.
3. Press fuel injector into fuel injector cap until retaining
clip snaps into place.
4. Press fuel injector into bore in intake manifold and
rotate to original position.
5. Install fuel injector cap screw into intake manifold
and torque to 7.3 N·m (65 in. lb.).
6. Push electrical connector on fuel injector making
sure a good connection is made.
7. Repeat steps 1 through 6 for other fuel injector.

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 Reassembly

Starter and Electronic Control Unit (ECU) Components

A
C
B
I
F
E
D H

D
E
G G
A ECU B ECU Bracket C Starter D Inner Baffle
E Outer Baffle F Ignition Coil G Lifting Strap H Oil Sentry™ Switch
Engine Temperature
I Sensor

Install Inner and Outer Baffles and Lifting Straps

1. Attach lifting strap and inner baffles aligning baffle top to cylinder head flanges and baffle bottom tab to crankcase
mounting bosses.
2. Install both outer baffles and secure lifting straps. Ensure baffle top tab is under backing plate and baffle bottom
tab aligned to cylinder block. Ensure stator wires and rectifier-regulator wires are not pinched when installing #2
outer baffle.
3. Secure with screws and torque M5 screws to 8.5 N·m (75 in. lb.) into a new cored hole, or 4.0 N·m (35 in. lb.) into
a used hole. Torque M6 screws to 10.7 N·m (95 in. lb.) into a new cored hole, or 7.3 N·m (65 in. lb.) into a used
hole.
4. If removed, install ignition coils onto baffles. Torque screws to 10.2 N·m (90 in. lb.).
5. Plug connectors into ignition coils.
6. Secure engine temperature sensor to crankcase with screw. Torque screw to 11.9 N·m (105 in. lb.).
7. Connect wire lead (green) to Oil Sentry™ terminal.
Install Electric Starter Motor and ECU Bracket
1. Insert starter bolts into ECU bracket and starter. Mount starter.
2. Torque screws to 23.8 N·m (211 in. lb.).
Install ECU
NOTE: ECU pins should be coated with a thin layer of electrical grease to prevent fretting and corrosion and may
need to be reapplied if ECU is being reused.
1. Install ECU to ECU bracket using screws. Torque M5 screws to 6.2 N·m (55 in. lb.) into new holes or 4.0 N·m
(35 in. lb.) into used holes.
2. Connect Black and Grey electrical connectors. Connectors and ECU are keyed in such a way so they cannot be
installed incorrectly.

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Reassembly

Air Cleaner/Throttle Body Components

B
B

B
C

C
C

H I
G
A

A J

A Air Cleaner Base B Air Cleaner Element C Precleaner D Breather Hose

Throttle Body/
Throttle Linkage/ Throttle Position
E Vent Hose F G Air Cleaner Gasket H
Governor Lever Sensor (TPS)
Assembly
I Throttle Body J Throttle Body Gasket

Install Throttle Body and Air Cleaner Base

NOTE: Ensure all parts are clean, undamaged and free of debris and make sure electrical connector has seal in
place.
1. Install a new throttle body gasket.
2. Install throttle body, throttle linkage, and governor lever, as an assembly.
3. Connect vent hose to throttle body.
4. Push electrical connector onto throttle position sensor (TPS) making sure a good connection is made.
5. Install air cleaner base with new air cleaner base gasket onto mounting studs. Torque nuts to 6.8 N·m (60 in. lb.).
6. Connect breather hose to air cleaner base.

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 Reassembly

Install Throttle Controls Governor Lever Hole Position

A E
C D
B C
B
D
A
E

F A Governor Lever B Hole 1

C Hole 2 D Hole 3
G E Hole 4
J H 1. Connect governor spring and governed idle spring
I from throttle control bracket to appropriate holes in
governor lever.
A
2. Install main control bracket to cylinder heads using
screws. Two lower screws should also secure inner
baffles. Torque screws to 10.7 N·m (95 in. lb.) into
K new holes, or 7.3 N·m (65 in. lb.) into used holes.
Install Air Cleaner Element
L
Install air cleaner element (with precleaner if equipped),
onto air cleaner base.
M C

Throttle Actuator
A Control Bracket B Lever
C Throttle Lever D Hex Head Screw
E Hex Lock Nut F Linkage Spring
G Governor Linkage H Governor Lever
I Cross Shaft J Nut
Governed Idle
K Cable Clamp L Spring
M Governor Spring
1. Install governor lever onto governor cross shaft if
disconnected previously.
2. Make sure throttle linkage, linkage spring, and black
linkage bushing are connected to governor lever and
to throttle lever on throttle body.
3. Move governor lever and spring toward throttle body
as far as it will go (wide-open throttle), and hold in
this position.
4. Use 7 mm hex socket on end of cross shaft and
rotate shaft counterclockwise (viewed from end) as
far as it will turn, then torque nut to 6.8 N·m (60 in. lb.).

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Reassembly

Install Fuel Pump Module (FPM) NOTE: Ensure all parts are clean, undamaged and free
of debris and make sure electrical connector has
seal in place.
WARNING
Explosive Fuel can cause fires and severe NOTE: FPM pins should be coated with a thin layer of
burns. electrical grease to prevent fretting and
corrosion and may be reapplied if FPM is being
Do not fill fuel tank while engine is hot or reused.
running.
1. Install screws to secure fuel pump module baffle to
Gasoline is extremely flammable and its vapors can crankcase. Torque screws to 11.9 N·m (105 in. lb.)
explode if ignited. Store gasoline only in approved into new holes, or 7.8 N·m (69 in. lb.) into used
containers, in well ventilated, unoccupied buildings, holes.
away from sparks or flames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from 2. Push high pressure fuel line connector onto FPM
ignition. Never use gasoline as a cleaning agent. fitting.
3. If Oetiker clamp was cut to remove inlet fuel line,
FPM Components slide a new Oetiker clamp onto fuel line and connect
fuel line. Only use an Oetiker clamp pliers to crimp
Oetiker clamps. Oetiker clamp crimp must point up,
away from top of FPM and abrasion sleeve must be
J positioned over Oetiker clamp.
K 4. Connect electrical connector to top of FPM. Ensure
G grey locking tab is pulled out before connecting.
E Push connector onto terminal until a click is heard,
then push in grey locking tab to lock connector.
5. Install FPM to baffle using screws. Torque screws to
9.2 N·m (81 in. lb.).
6. Connect vent line to FPM.
7. Insert vent line and inlet line into hose retainer to
A secure.
I
F

C H

B
D

A Pulse Pump B Inlet Line

C Outlet to FPM D Pulse Line
E Electrical Connector F FPM
High Pressure Fuel
G FPM Baffle H Line Connector
I Oetiker Clamp J Vent Hose
K Hose Retainer

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External Engine Components

C B

C
C
E

D G

D
I

A Fixed Guard B Blower Housing C Air Cleaner Cover D Spark Plug Lead
E Oxygen Sensor F Oil Fill/Dipstick G Dipstick Tube H Oil Filter
I Ignition Coil

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Reassembly

Install Blower Housing and Air Cleaner Cover Install Pulse Fuel Pump
NOTE: Do not completely tighten screws until all are
installed to allow shifting for hole alignment. WARNING
1. Install blower housing onto engine. Attach cable clip Explosive Fuel can cause fires and severe
(if equipped) on #2 side of blower housing (clip burns.
between blower housing and barrel baffle) and start Do not fill fuel tank while engine is hot or
all screws. Make sure wire harness and fuel lines running.
exit out through appropriate openings in shrouding. Gasoline is extremely flammable and its vapors can
2. Torque screws as follows: explode if ignited. Store gasoline only in approved
M5 Thread Forming Fasteners: 8.5 N·m (75 in. lb.) containers, in well ventilated, unoccupied buildings,
into new holes, or 4.0 N·m (35 in. lb.) into used away from sparks or flames. Spilled fuel could ignite
holes. if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
M4 HI-LO Screws: 2.8 N·m (25 in. lb.).
M3 HI-LO Screws: 2.3 N·m (20 in. lb.). Pulse Fuel Pump Components
3. Install air cleaner cover. Position air cleaner cover
with levers outward over air cleaner; turn levers D
inward to lock or reinstall cover; place latches onto C
cover; pull down bails to secure cover.
F
4. Snap fuse holders into fuse covers on side of blower
housing. E

Install Fixed Guard (if equipped)

Install fixed guard. Torque screw to 0.85 N·m (7.5 in. lb.).
Install Dipstick Tube
1. Lubricate dipstick tube O-ring and install into
crankcase.
2. Secure to backing plate using M5 screw and torque A
B
to 3.4 N·m (30 in. lb.).

A Outlet Fuel Line B Pulse Hose

C Inlet Fuel Line D Hose Retainer
E Fuel Filter F Pulse Fuel Pump
NOTE: If a new fuel pump is being installed, make sure
orientation of new pump is consistent with
removed pump. Internal damage may occur if
installed incorrectly.
1. Install pulse line into valve cover.
2. Install pulse fuel pump to housing using screws.
Torque screws to 2.8 N·m (25 in. lb.).
3. Connect inlet and outlet fuel lines to pump. Route
inlet fuel line through hose retainer and outlet fuel
line through clip (if used).
4. If removed, connect in-line 10 micron EFI fuel filter
and hose to inlet barb of fuel pump and secure with
spring clamp.

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Install Muffler (if equipped) Prepare Engine for Operation

1. Install exhaust gaskets and muffler. Install nuts to NOTE: If ECU, throttle body, TPS or fuel pump module
exhaust studs. Torque nuts to 24.4 N·m (216 in. lb.). were replaced, an ECU Reset and TPS Learn is
Install oxygen sensor and connect to wire harness. required. Refer to Electrical System Reset and
Torque smaller 14 mm (9/16 in.) wrench size sensor TPS Learn procedure.
to 18 N·m (159 in. lb.). Engine is now completely reassembled. Before starting
Torque larger 22 mm (7/8 in.) wrench size sensor to or operating engine, be sure to follow steps below.
50.1 N·m (37 ft. lb.). 1. Make sure all hardware is tightened securely.
2. Install remaining muffler support hardware and 2. Make sure oil drain plugs, Oil Sentry™ pressure
torque to 9.9 N·m (88 in. lb.).
switch, and a new oil filter are installed.
Connect Spark Plug Leads 3. Verify crankcase has been filled with correct amount,
Connect leads to spark plugs. weight, and type of oil. Refer to oil recommendations
and procedures in Maintenance, Specifications, and
Install Oil Filter and Fill Crankcase with Oil Lubrication System.
4. Turn on fuel supply.
NOTE: Make sure oil drain plug is installed and torqued
to specification to prevent oil leakage. Testing Engine
1. Install oil drain plug. Torque plug to 13.6 N·m It is recommended engine be operated on a stand or
(10 ft. lb.). bench prior to installation in piece of equipment.
2. Place new filter in shallow pan with open end up. Fill 1. Run engine at idle for 2-3 minutes, then 5-6 minutes
with new oil until oil reaches bottom of threads. Allow more between idle and midrange.
2 minutes for oil to be absorbed by filter material.
2. Adjust idle speed screw and high speed as
3. Apply a thin film of clean oil to rubber gasket on new necessary. Make sure maximum engine speed does
filter. not exceed 3750 RPM (no load).
4. Refer to instructions on oil filter for proper
installation.
5. Fill crankcase with new oil. Level should be at top of
indicator on dipstick.
6. Reinstall oil fill/dipstick and tighten securely.

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