Kohler TP-2509 manual

1 K OHLER ® A EGIS ™ 17,20,23 HP S ER VICE M ANUAL L IQUID -C OOLED V ERTICAL C RANKSHAFT[...]

Content s Section 1. Safety and General Information ............................................................................ Section 2. Special T ools .......................................................................................................... Section 3. T roubleshooting ............................................................[...]

1.1 Section 1 Safety and General Information 1 Section 1 Safety and General Information Safety Precautions T o insure safe operations please read the following statement s and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are ex[...]

1.2 Section 1 Safety and General Information Carbon Monoxide can cause severe nausea, fainting or death. Do not operate engine in closed or confined area. W ARNING W ARNING Electrical Shock can cause injury . Do not touch wires while engine is running. CAUTION Hot liquid can cause severe burns. Do not loosen radiator cap while engine is operating o[...]

1.3 Section 1 Safety and General Information 1 L V 675 S A . Model No. Liquid Cooled V ertical Crankshaft Displacement/Size (cc) V ersion Code S = Electric S tart Figure 1-2. Explanation of Engine Identification Numbers. Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specificat[...]

1.4 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly . Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil T ype Use high-quality detergent oil of API (America[...]

1.5 Section 1 Safety and General Information 1 Fuel T ype For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher . In countries using the Research method, it should be 90 octane minimum. Unleaded gasoline is recommended, as it leaves fewer combustion chamber deposits. Leaded gasoline may be used[...]

1.6 Section 1 Safety and General Information Storage If the engine will be out of service for two months or more, use the following storage procedure: 1. Clean the exterior surfaces of the radiator and engine. 2. Change the oil and filter while the engine is still warm from operation. See “Change Oil and Filter” in Section 6. 3. The coolant (an[...]

1.7 Section 1 Safety and General Information 1 Figure 1-4. T ypical Engine Dimensions. 260.6 Cyl. #1 18.2 Oil Fill & Dipstick Mounting Hole ‘‘ A’ ’ 285.5 Oil Fill 451.0 135.7 140.0 479.3 Over All 434.1 Cyl. #2 Fuel Pump Hose C L C L Oil Fill 153.0 Housing Removal 472.4 155.5 Spark Plug 93.5 73.5 Exhaust Port #2 Exhaust Port #1 Mounting [...]

1.8 Section 1 Safety and General Information General Specifications 1 Power (@ 3600 RPM, corrected to SAE J1995) L V560 ............................................................................................. 12.7 kW (17 HP) L V625 ............................................................................................. 14.9 kW (20 HP) L V[...]

1.9 Section 1 Safety and General Information 1 Carburetor and Intake Manifold Intake Manifold Mounting Fasteners T orque ......................................... 6.2 N·m (55 in. lb.) Carburetor Mounting Fasteners T orque ................................................ 6.2 N·m (55 in. lb.) Connecting Rod Cap Fastener T orque (torque in increment[...]

1.10 Section 1 Safety and General Information Crankshaft (Cont'd.) Connecting Rod Journal O.D. - New ..................................................................................... 35.955/35.973 mm (1.4156/1.4163 in.) O.D. - Max. W ear L imit .................................................................. 35.94 mm (1.415 in.) Max. T a[...]

1.11 Section 1 Safety and General Information 1 Ignition S p ark Plug T ype (Champion ® or equivalent) ...................... ................... RC14YC (Kohler Part No. 66 132 01-S) S park Plug Gap .................................................................................... 0.76 mm (0.030 in.) S park Plug T o rque ........................[...]

1.12 Section 1 Safety and General Information ²Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin. Piston, Piston Rings, and Piston Pin (Cont'd.) T op and Middle Compression Ring End Gap L V560 New Bore T op Ring .................................................................................. 0.1[...]

1.13 Section 1 Safety and General Information 1 V alves and V alve Lifters (Cont'd.) Intake V alve Guide I.D. New ................................................................................................ 7.038/7.058 mm (0.2771/0.2779 in.) Max. Wear Limit ............................................................................. 7.134[...]

1.14 Section 1 Safety and General Information English Fastener T orque Recommendations for St andard Applications Grade 2 or 5 Fasteners Into Aluminum Size 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 (1 15) 18.7 (165) 7.9 (70) 1/4-28 9.6 (85) 1[...]

2.1 Section 2 S pecial T ools 2 L V560, L V625, L V675 Section 2 S pecial T ools These quality tools are designed to help you perform specific disassembly , repair , and reassembly procedures. By using tools designed for the job, you can service engines easier , faster , and safer! In addition, you’ll increase your service capabilities and custom[...]

2.2 Section 2 Special T ools Special T ools Y ou Can Make Flywheel Holding T ool Flywheel removal and reinstallation becomes a ‘ ‘snap’’ using a handy holding tool you can make out of a piece of an old ‘‘junk’ ’ flywheel ring gear as shown in Figure 2-2. Using an abrasive cut-off wheel, cut out a six tooth segment of the ring gear a[...]

3.1 Section 3 T roubleshooting 3 Section 3 T roubleshooting T roubleshooting Guide When troubles occur , be sure to check the 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 common causes of engine troubles are listed below . Use these to locate the ca[...]

3.2 Section 3 T roubleshooting Engine Overheat s (cont'd.) 7. Radiator cap faulty or loose. 8. Lean fuel mixture. 9. W ater pump belt failed/off. 10. Water pump malfunction. Engine Knocks 1. Excessive engine load. 2. Low crankcase oil level. 3. Old or improper fuel. 4. Internal wear or damage. 5. Hydraulic lifter malfunction. Engine Loses Powe[...]

3.3 Section 3 T roubleshooting 3 NOTE: It is good practice to drain oil at a location away from the workbench. Be sure to allow ample time for complete drainage. Cleaning the Engine After inspecting the external condition of the engine, clean the engine thoroughly before disassembling it. Also clean individual components as the engine is disassembl[...]

3.4 Section 3 T roubleshooting Leakdown T est Instructions 1. Run engine 3-5 minutes to warm it up. 2. Remove spark plugs, dipstick, and air filter from engine. 3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. Y ou will need to hold the engine in this position while testing. The holding[...]

4.1 Section 4 Air Cleaner and Air Int ake System 4 Section 4 Air Cleaner and Air Int ake System L V560, L V625, L V675 Air Int ake System General All intake air , for both cooling and combustion, is drawn in through the screen in the upper blower housing. Service Check the air intake screen daily or before st arting the engine . Check for a buildup[...]

4.2 Section 4 Air Cleaner and Air Int ake System Figure 4-4. Cleaning Separated Screen Assembly . Always reinstall the upper blower assembly after it has been removed for service. Do not operate the engine with the upper blowing housing or screen removed. Air Cleaner General These engines are equipped with a replaceable, high- density paper air cle[...]

4.3 Section 4 Air Cleaner and Air Int ake System 4 2. Remove the precleaner from the paper element. See Figure 4-7. Figure 4-7. Removing Precleaner from Paper Element. 3. W ash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the[...]

4.4 Section 4 Air Cleaner and Air Int ake System 4. Disconnect the breather hose from the air cleaner base. Figure 4-9. Base Plate Removal on St andard T ype. Fuel Pump V acuum Line Breather Hose 5. Slide the clamp and air cleaner base off the stud. 6. Reverse procedure to reassemble components. T orque the hex. flange nuts to 9.9 N·m (88 in. lb. [...]

5.1 Section 5 Fuel System and Governor 5 Section 5 Fuel System and Governor Description W ARNING: Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot o[...]

5.2 Section 5 Fuel System and Governor Fuel System T ests When the engine starts hard, or turns over but will not st art, it is possible that the problem is in the fuel system. T o find out if the fuel system is causing the problem, perform the following tests. T roubleshooting – Fuel System Related Causes T est Conclusion 1. Check the following:[...]

5.3 Section 5 Fuel System and Governor 5 2. Remove the hex. flange screws (securing pump to blower housing) and fuel pump. 3. Remove the vacuum line that connects the pump to the crankcase. 4. Install a new pump using the hex. flange screws. NOTE: Make sure the orientation of the new pump is consistent with the removed pump. Internal damage may occ[...]

5.4 Section 5 Fuel System and Governor Slow Circuit: (Figure 5-2) At low speeds the engine operates only on the slow circuit. As a metered amount of air is drawn through the slow air bleed jet, fuel is drawn through the main jet and further metered through the slow jet. Air and fuel are mixed in the body of the slow jet and exit to the transfer por[...]

5.5 Section 5 Fuel System and Governor 5 Main Circuit: (Figure 5-3) At high speeds the engine operates mostly on the main circuit. As a metered amount of air is drawn through the main air bleed jet, fuel is drawn through the main jet. The air and fuel are mixed in the main nozzle and then enter the main body of air flow , where further mixing of th[...]

5.6 Section 5 Fuel System and Governor T roubleshooting Checklist When the engine starts hard, runs roughly or st alls at low idle speed, check the following areas before adjusting or disassembling the carburetor . • Make sure the fuel tank is filled with clean, fresh gasoline. • Make sure the fuel tank cap vent is not blocked and that it is op[...]

5.7 Section 5 Fuel System and Governor 5 Fuel Shut-off Solenoid Carburetors are equipped with a fuel shut-off solenoid, which also contains the main jet. The solenoid has a spring loaded pin which retracts when the key switch is ‘‘on’ ’, allowing the engine to function normally . When the key switch is turned ‘‘of f’’, the pin exten[...]

5.8 Section 5 Fuel System and Governor Float Replacement If symptoms described in the carburetor troubleshooting guide indicate float level problems, remove the carburetor from the engine to check and/or replace the float. Use a Carburetor Overhaul Kit (see page 5.10) if float replacement is necessary . 1. Remove the upper blower housing and air in[...]

5.9 Section 5 Fuel System and Governor 5 Figure 5-6. Carburetor - Exploded View . Inspection/Rep air T o clean vent ports, internal circuits etc., use a good commercially available carburetor solvent, such as Gumout ™ , and clean, dry compressed air to blow out internal channels and ports. Use a suitable shop rag to prevent debris from hitting so[...]

5.10 Section 5 Fuel System and Governor Overhaul Kit Contains: Reassembly Procedure Reassembly is essentially the reverse of the disassembly procedure. Use new gaskets, springs, and adjusting screws as provided in the repair kit. Also use new carburetor and intake manifold gasket s. Governor General The engine is equipped with a centrifugal flyweig[...]

5.11 Section 5 Fuel System and Governor 5 Figure 5-7. Governor Controls and Linkage (External). Adjustment s General The governed speed setting is determined by the position of the throttle control. It can be variable or constant, depending on the engine application. Initial Adjustment Make this adjustment whenever the governor lever is loosened or[...]

5.12 Section 5 Fuel System and Governor Throttle Control Cable Choke Control Cable Kill Switch Adjusting Screw Dual Control High Idle Lever Stop Screw "Do Not Remove" High Idle Adjusting Screw High Idle Control Lever Choke Control Cable Throttle Control Cable Z Bend Choke Linkage Throttle Control Lever #2 Kill Switch Choke Control Lever #[...]

6.1 Section 6 Lubrication System 6 Section 6 Lubrication System General This engine uses a full pressure lubrication system. This system delivers oil under pressure to the crankshaft, camshaft and connecting rod bearing surfaces. In addition to lubricating the bearing surfaces, the lubrication system supplies oil to the hydraulic valve lifters. A h[...]

6.2 Section 6 Lubrication System Figure 6-3. Oil Level Marks on Dip stick. NOTE: T o prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the ‘‘ ADD’’ mark or above the ‘ ‘FULL ’’ mark on the dipstick. 3. Unthread and remove the oil fill cap[...]

6.3 Section 6 Lubrication System 6 3. Before removing the oil filter , clean the surrounding area to keep dirt and debris out of the engine. Remove the old filter and wipe/clean the surface where the filter mounts. 4. Reinstall the drain plug. Make sure it is tightened to 13.6 N·m (10 f t. lb.) . 5. Place a new oil filter in a shallow pan with the[...]

6.4 Section 6 Lubrication System T o install the switch, follow these steps: 1. Apply Loctite ® No. 592 Pipe Sealant with T eflon ® (or equivalent) to the threads of the switch. 2. Install the switch into the t apped hole in the breather cover . See Figure 6-5. 3. T orque the switch to 4.5 N·m (40 in. lb.) . T esting Compressed air , a pressure [...]

7.1 Section 7 Cooling System 7 Section 7 Cooling System W ARNING: Explosive release of fluids from pressurized cooling system can cause serious burns! When it is necessary to open cooling system at radiator cap, shut off engine and remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure [...]

7.2 Section 7 Cooling System Coolant Recommendations Use equal parts of ethylene glycol (anti-freeze) and water only . Distilled or deionized water is recommended, especially in areas where the water contains a high mineral content. Propylene glycol based anti-freeze is not recommended. This mixture will provide protection from -37º C (-34º F) to[...]

7.3 Section 7 Cooling System 7 Figure 7-4. Coolant Levels on Reservoir . NOTE: Do not operate the engine without coolant in the system. Do not remove the radiator cap when hot. Engine coolant is hot and under pressure and can cause severe burns. T o prevent engine overheating and damage, do not exceed more than 70% anti-freeze in the cooling system[...]

7.4 Section 7 Cooling System Figure 7-8. Removing Overflow Reservoir . 7. Reinstall the reservoir , inserting the two lower molded protrusions into the mounting holes in the lower support bracket. Engage the top bracket around the upper protrusion of the reservoir . Hold it in this position and torque the two screws to 7.3 N·m (65 in. lb. ). 8. Re[...]

7.5 Section 7 Cooling System 7 Hoses and T ubes Hoses and tubes are used to connect the components within the cooling system. T o guard against coolant loss and hose failure, the hoses, tubes and their connections should be checked regularly for leaks or damage. Loss of coolant can result in serious engine damage. Over time, engine vibration can af[...]

7.6 Section 7 Cooling System High T emperature Sensor A high temperature sensor may be mounted in the intake manifold and is used to activate a warning light, audible alarm, or kill the engine (depending on the application), if the safe operating temperature is exceeded. The sensor is a ‘ ‘normally open’ ’ switch which completes a circuit, [...]

7.7 Section 7 Cooling System 7 Figure 7-12. Adapter Inst alled onto the T ester . 2. Pressurize the tester to 15 psi. 3. Observe the indicated pressure. It should hold steady and not decrease or leak down. If leakage is detected, the cap should be replaced. If the tester pressure is increased to 16 psi, or above, the cap should then ‘ ‘bleed of[...]

7.8 Section 7 Cooling System[...]

8.1 Section 8 Electrical System and Component s 8 Section 8 Electrical System and Component s This section covers the operation, service and repair of the electrical system components. Systems and components covered in this section are: • S park Plugs • Battery and Charging System • Electronic CD Ignition System • Electric S tarter Sp ark P[...]

8.2 Section 8 Electrical System and Component s Normal: A plug t aken from an engine operating under normal conditions will have light tan or gray colored deposits. If the center electrode is not worn, a plug in this condition could be set to the proper gap and reused. Inspection Inspect each spark plug as it is removed from the cylinder head. The [...]

8.3 Section 8 Electrical System and Component s 8 Overheated: Chalky , white deposits indicate very high combustion temperatures. This condition is usually accompanied by excessive gap erosion. Lean carburetor settings, an intake air leak, or incorrect spark timing are normal causes for high combustion temperatures. Battery General A 12 volt batter[...]

8.4 Section 8 Electrical System and Component s Electronic CD Ignition Systems Operation of CD Ignition Systems Capacitive Discharge with Fixed T iming This system consists of the following components. See Figure 8-3. • A magnet assembly which is permanently affixed to the flywheel. • T wo electronic capacitive discharge ignition modules which [...]

8.5 Section 8 Electrical System and Component s 8 Figure 8-5. Cap acitive Discharge Ignition Module. Operation: As the flywheel rotates, the magnet grouping passes the input coil (L1). The corresponding magnetic field induces energy into the input coil (L1). The resultant pulse is rectified by D1 and charges capacitor C1. As the magnet assembly com[...]

8.6 Section 8 Electrical System and Component s T est 1. If one side is not firing, check all wiring, connections, and terminations on that side. If wiring is okay , replace ignition module and retest for spark. If the tester shows spark, but the engine misses or won't run on that cylinder , try a new spark plug. If neither side is firing, rec[...]

8.7 Section 8 Electrical System and Component s 8 Battery Battery (R) _ + Starter (L/R) Run (R) Ignition Kill (W) Accessory (Y) Key Switch Ground (B) Ground St arter Battery Accessory Key Switch Ignition Kill Run Connector L R St arter Solenoid Stud St arter Solenoid T ang St arter Assembly Accessory T erminal (+) (Y) Regulator Rectifier AC B+ AC R[...]

8.8 Section 8 Electrical System and Component s Lighting Lead (Y ellow) Charging Lead (Black) Diode Lighting St ator 3 Amp Charging St ator Figure 8-9. 3 amp/70 W att S t ator . Figure 8-8. 15/20/25 amp St ator and Rectifier-Regulator . Rectifier-Regulator Connector AC AC B+ AC Leads 15 Amp St ator[...]

8.9 Section 8 Electrical System and Component s 8 St ator The stator is mounted on the crankcase behind the flywheel. Should the stator have to be replaced, follow the procedures in Section 9 - “Disassembly .” Rectifier-Regulator The rectifier-regulator is mounted inside the lower blower housing. See Figure 8-10. T o replace it; remove the uppe[...]

8.10 Section 8 Electrical System and Component s T roubleshooting Guide 15/20/25 amp Battery Charging Systems If it is difficult to keep the battery charged, or the battery overcharges, the problem is usually with the charging system or the battery . NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. V oltage tests[...]

8.11 Section 8 Electrical System and Component s 8 T roubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting S tator NOTE: Zero ohmmeters on each scale to ensure accurate readings. V oltage tests should be made with engine running at 3000 RPM - no load. Battery must be fully charged. Problem No Charge to Battery No Light s T est 1.[...]

8.12 Section 8 Electrical System and Component s Solenoid Shift Electric S tarters The following subsection covers the solenoid shift style electric starters. Some of the information in the preceding subsection relates also to this style of starter , so it is not repeated here. A Nippendenso or Delco-Remy solenoid shift starter may be used. The Nip[...]

8.13 Section 8 Electrical System and Component s 8 Delco-Remy St arters Figure 8-13. Removing Solenoid Screws. Figure 8-14. Solenoid Removed from St arter . 3. Lift and unhook the plunger assembly from the drive lever . Remove the gasket from the recess in the housing. See Figure 8-15. Figure 8-15. Removing Plunger . 4. Remove the two thru (larger)[...]

8.14 Section 8 Electrical System and Component s Figure 8-21. Retaining Ring Det ail. 5. Remove the commutator end plate assembly , containing the brush holder , brushes, springs, and locking caps. Remove the thrust washer from inside the commutator end. See Figure 8-17. Figure 8-17. Removing Commutator End Plate Assembly . 6. Remove the frame from[...]

8.15 Section 8 Electrical System and Component s 8 Lever Solenoid CE Frame Bolt Ring Stop Drive Armature W asher 1 1. Remove the retainer from the armature shaft. Save the stop collar . NOTE: Do not reuse the old retainer . Figure 8-22. Removing Retaining Ring. 12. Remove the drive pinion assembly from the armature. 13. Clean the parts as required.[...]

8.16 Section 8 Electrical System and Component s Inspection Drive Pinion Check and inspect the following areas: a. The pinion teeth for abnormal wear or damage. b. The O.D. surface between the pinion and the clutch mechanism for nicks, or irregularities which could cause seal damage. c. Check the drive clutch by holding the clutch housing and rotat[...]

8.17 Section 8 Electrical System and Component s 8 2. Remove the two screws securing the brush holder assembly to the end cap (plate). Note the orientation for reassembly later . See Figure 8-27. Discard the old brush holder assembly . Figure 8-27. Removing Brush Holder . 3. Clean the component parts as required. 4. The new brushes and springs come[...]

8.18 Section 8 Electrical System and Component s 4. Apply a small amount of oil to the bearing in the drive end cap, and install the armature with the drive pinion. 5. Lubricate the fork end and center pivot of the drive lever with drive lubricant (Kohler Part No. 52 357 02-S). Position the fork end into the space between the captured washer and th[...]

8.19 Section 8 Electrical System and Component s 8 10. S t arter reassembly when replacing the Brushes/ Brush Holder Assembly: a. Hold the starter assembly vertically on the end housing, and carefully position the assembled brush holder assembly with the supplied protective tube, against the end of the commutator/armature. The mounting screw holes [...]

8.20 Section 8 Electrical System and Component s 1 1. Install the end cap onto armature and frame, aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive (+) brush lead. 12. Install the two thru bolts, and the two brush holder mounting screws. T orque the thru bolts to 5.6-9.0 N•m (49-79 in. lb.) . [...]

8.21 Section 8 Electrical System and Component s 8 St arter Assembly Figure 8-44. Nippendenso Solenoid Shif t St arter . Operation – Solenoid Shif t St arter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear . When the pinion reaches the end of the [...]

8.22 Section 8 Electrical System and Component s 8. The outward travel of the drive pinion is controlled by a snap ring, installed in a groove in the armature shaft, and a two-piece stop collar . The snap ring fits into a recess in the pinion (lower) stop collar , which locks it in the groove (see Figure 8-45). The thrust receiving (upper) stop col[...]

9.1 Section 9 Disassembly 9 Section 9 Disassembly W ARNING: Accidental St arts! 19. Remove water pump and transfer tube. 20. Remove by-pass hose and wiring harness. 21. Remove intake manifold, temperature sensor , and thermostat. 22. Remove lower blower housing and oil fill/dipstick tube. 23. Remove Oil Sentry ™ (if so equipped). 24. Remove breat[...]

9.2 Section 9 Disassembly Shut Off Fuel Supply Drain Oil From Crankcase and Remove Oil Filter 1. Remove the dipstick and one of the oil drain plugs. See Figures 9-2 and 9-3. Figure 9-2. Removing Oil Fill Cap/Dip stick. Figure 9-3. Oil Drain Plugs and Oil Filter . 2. Allow ample time for the oil to drain from the crankcase and oil filter . Oil Filte[...]

9.3 Section 9 Disassembly 9 Figure 9-6. Separating Screen from Housing. Remove Muffler 1. Remove the muffler or exhaust system and attaching hardware from the engine. See Figure 9-7. Figure 9-7. Removing Muffler . Drain Cooling System 1. Make sure the engine is cool. Slowly remove the radiator cap. See Figure 9-8. Figure 9-8. Removing Radiator Cap.[...]

9.4 Section 9 Disassembly 2. Disconnect the fuel lines at the inlet of the carburetor , and the in-line fuel filter . See Figure 9-1 1. Figure 9-1 1. Removing Fuel Line at Carburetor . 3. Remove the two hex. flange screws securing the fuel pump to the blower housing and remove the pump and lines as an assembly . Slide the fuel line out of the clip [...]

9.5 Section 9 Disassembly 9 Figure 9-17. Loosening Governor Lever Clamp Nut. 3. Remove the four hex. flange screws securing the throttle control bracket to the cylinder heads. See Figure 9-18. Remove Control Bracket Assembly and External Governor Lever 1. Disconnect any remote throttle and/or choke control cables connected to the throttle control b[...]

9.6 Section 9 Disassembly 4. Remove the throttle control bracket, governor lever , and governor spring as an assembly . See Figure 9-19. Figure 9-19. Removing Main Bracket and Governor Lever . Remove Electric St arter 1. Disconnect the leads from the starter . 2. Remove the two starter motor mounting screws. See Figure 9-20. Figure 9-20. Removing t[...]

9.7 Section 9 Disassembly 9 Figure 9-23. Location of Four Screws Securing Blocking Plates. Remove Overflow Reservoir 1. Remove the reservoir cap from the reservoir . 2. Loosen the two screws holding the overflow reservoir retainer bracket to the radiators. See Figure 9-24. 3. Carefully lift the bracket up slightly to unhook the locking tab, and rem[...]

9.8 Section 9 Disassembly Figure 9-27. Removing Ignition Module. 4. Repeat the procedure for the other ignition module. Remove Flywheel 1. Use a flywheel holding tool (a suitable handle may be attached for convenience, refer to Section 2) to hold the flywheel and loosen the hex. flange screw securing the flywheel to the crankshaft. See Figure 9-28.[...]

9.9 Section 9 Disassembly 9 Figure 9-31. Removing Center Mounting Nut. 2. Cut the metal tie strap from around the lower hose/tube assembly , secured to the blower housing. See Figure 9-32. Remove Radiators and Cooling System 1. Remove the hex. nut from the center mounting stud, located between the two radiators and through the main support bracket.[...]

9.10 Section 9 Disassembly Figure 9-36. Lower Hose Removed. 6. Lift the entire cooling system, with the radiators, hoses, and supporting brackets att ached, of f the engine. See Figure 9-37. Further disassembly may be performed as required. When disassembly of hose connections is necessary , the use of a rubber lubricant on the inside of hoses will[...]

9.11 Section 9 Disassembly 9 Figure 9-40. Removing B+ Charging Lead from Connector . 4. Remove the stator and rectifier-regulator . Remove Cam Pulley and Coolant Pump Belt 1. Remove the hex. flange screw and flat washer , securing the cogged drive pulley to the camshaft. See Figure 9-41. Figure 9-41. Removing Cam Pulley Mounting Hardware. 2. Lift t[...]

9.12 Section 9 Disassembly Figure 9-44. Removing Hex. Cap Section. 3. Remove the six screws securing the water pump to the crankcase. See Figure 9-45. Figure 9-45. Removing the Six W ater Pump Screws. 2. Loosen and unscrew the hex. cap section, securing the transfer tube to the 90° fitting in the crankcase. See Figure 9-44. Support the fitting wit[...]

9.13 Section 9 Disassembly 9 Figure 9-48. Removing No. 1 Side Intake Manifold Screws with the Ground Leads. 3. Disconnect the wire leads from the Oil Sentry ™ and safety interlock switch, temperature sensor , and/or warning alarm, as equipped. See Figures 9-49 and 9-50. 2. Remove the two No. 1 side intake manifold mounting screws securing the gro[...]

9.14 Section 9 Disassembly Figure 9-52. Removing Remaining Int ake Manifold Screws. 2. Separate the intake manifold from the cylinder heads and remove it, by shifting it toward the crankshaft, until the carburetor studs clear the lower blower housing. Remove the intake manifold gaskets. See Figure 9-53. Figure 9-53. Removing Intake Manifold and Gas[...]

9.15 Section 9 Disassembly 9 Figure 9-56. Removing Dip stick T ube Assembly . Remove Oil Sentry ™ (If So Equipped) 1. Remove the Oil Sentry ™ switch, from the breather cover . See Figure 9-57. Figure 9-57. Removing Oil Sentry ™ Switch. Remove Breather Cover 1. Remove the four hex. flange screws securing the breather cover to the crankcase. Se[...]

9.16 Section 9 Disassembly Figure 9-63. Removing the V alve Cover . Remove Cylinder Heads and Hydraulic Lif ters 1. Rotate the crankshaf t until the valves of one of the cylinders are closed. Loosen the rocker arm screws until the rocker arms can be pivoted to free the push rods. 2. Remove and mark the location of the push rods (intake or exhaust) [...]

9.17 Section 9 Disassembly 9 Figure 9-65. Removing Hex. Flange Nuts and W ashers from Studs. 5. Carefully remove the cylinder heads, and head gaskets. See Figure 9-66. NOTE: It is not necessary to remove the cylinder studs from the crankcase unless replacement is intended. If studs are removed for any reason, discard the old stud(s), do not reuse/r[...]

9.18 Section 9 Disassembly Figure 9-72. Removing Oil Pan Fasteners. 2. Locate the splitting tab cast into the perimeter of the oil pan. Insert the drive end of a breaker bar between the splitting tab and the crankcase, and turn it to break the RTV seal. See Figure 9-73. Do not pry on the sealing surfaces as this can cause leaks. 3. Remove the oil p[...]

9.19 Section 9 Disassembly 9 Oil Pump Assembly The oil pump is mounted in the oil pan. If service is required, refer to the service procedures under ‘‘Oil Pump Assembly’’ in Section 10. Remove Camshaf t 1. Remove the camshaft and shim. See Figure 9-74. Figure 9-74. Removing Camshaf t and Shim. Remove Governor Cross Shaf t 1. Remove the reta[...]

9.20 Section 9 Disassembly 2. Carefully remove the connecting rod and piston assembly from the cylinder bore. See Figure 9-78. NOTE: The cylinders are numbered on the crankcase. Use the numbers to mark each end cap, connecting rod, and piston for reassembly . Do not mix end caps and connecting rods. Figure 9-78. Removing Connecting Rod and Piston A[...]

10.1 Section 10 Inspection and Reconditioning 10 Section 10 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine component s. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner , Section 4 Carburetor & Externa[...]

10.2 Section 10 Inspection and Reconditioning Inspect the crankpin for score marks or metallic pick up. Slight score marks can be cleaned with crocus cloth soaked in oil. If wear limits, as stated in “S pecifications and T olerances,” are exceeded, it will be necessary to either replace the crankshaft or regrind the crankpin to 0.25 mm (0.010 i[...]

10.3 Section 10 Inspection and Reconditioning 10 Crankcase These engines contain a cast-iron cylinder liner that may be reconditioned as follows: Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments. Gasket surfaces must also be free of deep scratches or nicks. Check the cylinder bore for scoring. In sever[...]

10.4 Section 10 Inspection and Reconditioning 2. Use an inside micrometer , telescoping gauge, or bore gauge and measure the cylinder bore. T ake the measurement approximately 63.5 mm (2.5 in.) below the top of the bore and perpendicular to the piston pin. 3. Piston-to-bore clearance is the difference between the bore diameter and the piston diamet[...]

10.5 Section 10 Inspection and Reconditioning 10 A B C D E F G H Seat Angle Insert O.D. Guide Depth Guide I.D. V alve Head Diameter V alve Face Angle V alve Margin (Min.) V alve S tem Diameter Dimension 89° 36.987/37.013 mm 4 mm 7.038/7.058 mm 33.37/33.63 mm 45° 1.5 mm 6.982/7.000 mm Intake Exhaust 89° 32.987/33.013 mm 6.5 mm 7.038/7.058 mm 29.3[...]

10.6 Section 10 Inspection and Reconditioning Leakage: A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only . Coking: Coking is normal on intake valves and is not harmful. If the seat is good, the valve could be reused after cleaning. Excessive Combustion T emperatures: The white deposits seen here i[...]

10.7 Section 10 Inspection and Reconditioning 10 V alve Guides If a valve guide is worn beyond specifications, it will not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. T o check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a[...]

10.8 Section 10 Inspection and Reconditioning Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the welding point of the piston. T emperatures high enough to do this are created by friction, which is usually attributed to improper lubrication, and/or overheating of the engine.[...]

10.9 Section 10 Inspection and Reconditioning 10 Replacement pistons are available in STD bore size, 0.08 mm (0.03 in.) , 0.25 mm (0.010 in.), and 0.50 mm (0.20 in.) oversizes. Replacement pistons include new piston ring sets and new piston pins. Service replacement piston ring sets are also available separately for STD, 0.08 mm (0.03 in.) , 0.25 m[...]

10.10 Section 10 Inspection and Reconditioning Install Piston Rings T o install piston rings, proceed as follows: NOTE: Rings must be installed correctly . Ring installation instructions are usually included with new ring sets. Follow instructions carefully . Use a piston ring expander to inst all rings (see Figure 10-10). Install the bottom (oil c[...]

10.11 Section 10 Inspection and Reconditioning 10 NOTE: The governor gear is held onto the shaft by small molded tabs in the gear . When the gear is removed from the shaft, these tabs are destroyed and the gear must be replaced. Therefore, remove the gear only if absolutely necessary . 1. Remove the regulating pin and governor gear assembly . See F[...]

10.12 Section 10 Inspection and Reconditioning Figure 10-15. Installing Cross Shaf t Oil Seal. Figure 10-16. Governor Shaf t Seal Inst allation. 2.0 mm (0.0787 in.) Governor Cross Shaft Seal Figure 10-17. Governor Shaf t Seal Position. W ater Pump The water/coolant pump consists of a sealed impeller assembly , which includes the outer cover and a c[...]

11.1 Section 1 1 Reassembly 11 Section 1 1 Reassembly L V560, L V625, L V675 General NOTE: Make sure the engine is assembled using all specified torque values, tightening sequences, and clearances. Failure to observe specifications could cause severe engine wear or damage. Always use new gaskets, seals, and O-Rings. Make sure all traces of any clea[...]

11.2 Section 1 1 Reassembly Figure 1 1-1. Installing Flywheel End Oil Seal in Crankcase. The camshaft seal should be installed to a depth of 1-1.5 mm (.039-.059 in.) below the top of the seal bore. See Figure 1 1-2. Do not bottom the seal in the bore or the oil passage may be obstructed. Figure 1 1-3. Inst alling Crankshaf t. Inst all Connecting Ro[...]

11.3 Section 1 1 Reassembly 11 Figure 1 1-5. Proper Piston Connecting Rod Orient ation. 1. S tagger the piston rings in the grooves. The end gaps of the top two rings should be 180° ap art and perpendicular to the rail end gaps, which should also be 180° apart. 2. Lubricate cylinder bore, piston, and piston rings with engine oil. Compress the rin[...]

11.4 Section 1 1 Reassembly Figure 1 1-8. Assembly of Nylon W asher , Ret ainer , and Setting the End play . Inst all Camshaf t 1. Inspect the edges of the keyway in the end of camshaft and make sure they are not nicked or burred. Wrap this end using cellophane t ape, so the keyway is covered, to protect the seal from being cut when the camshaft is[...]

11.5 Section 1 1 Reassembly 11 Determining Camshaft End Play 1. Install the shim removed during disassembly onto the camshaft. 2. Position the camshaft end play checking tool on the camshaft. See Figure 1 1-12. Figure 1 1-12. Checking Camshaft End Play . 3. Apply pressure on the end play tool, pushing the camshaft toward the crankshaft. Use a feele[...]

11.6 Section 1 1 Reassembly 3. Install the O-Ring in groove as shown. See Figure 1 1-14. Apply a 1.5 mm (1/16 in.) bead of sealant to the sealing surface of the oil pan. See Figure 1 1-15 for the sealant pattern. 6. Install the ten hex. flange screws securing the oil pan to the crankcase. T orque fasteners in the proper sequence to 24.4 N·m (216 i[...]

11.7 Section 1 1 Reassembly 11 Figure 1 1-17. Applying Loctite to New Stud. 2. T ighten two nuts together on the shorter threaded section. 3. Thread the end of the stud with the Loctite ® into the crankcase, until an exposed stud height of 75 mm (2.952 in.) is obtained. The end with the dash mark must be out. See Figure 1 1-18. When threading in t[...]

11.8 Section 1 1 Reassembly Assemble Cylinder Heads Prior to installation, lubricate all components with engine oil, paying p articular attention to the lip of the valve stem seal, valve stems, and valve guides. Install the following items in the order listed below using a valve spring compressor . See Figures 1 1-21, 1 1-22, and 1 1-23. • V alve[...]

11.9 Section 1 1 Reassembly 11 Figure 1 1-24. Cylinder Head T orque Sequence. Figure 1 1-25. T orquing Cylinder Heads. 6. Note the mark or tag identifying each push rod. Lightly apply assembly lubricant or grease to the ends of the push rods and install. Make sure that each push rod ball seats in its respective hydraulic lifter socket. NOTE: Push r[...]

11.10 Section 1 1 Reassembly 9. Mount a dial indicator to touch the top of the valve retainer , of the valve to be set. See Figure 1 1-27. NOTE: At this time, the valve will not be completely seated. Do not rot ate the crankshaf t . Figure 1 1-29. Back Off Screw Until Needle Stops. 12. Using the reading from step 1 1, refer to the Shim Selection Ch[...]

11.11 Section 1 1 Reassembly 11 Figure 1 1-30. Installing Shim(s). 14. Reassemble the rocker arm and pivot assembly to the head and seat the push rod. See Figure 1 1-30. T orque the fastener; 1 1.3 N·m (100 in. lb.) for a hex. flange screw , or 17.3 N·m (153 in. lb.) for a lock nut. See Figure 1 1-31. 15. Hold down the push rod end of the rocker [...]

11.12 Section 1 1 Reassembly Figure 1 1-33. Depressing T o Bottom Limit of Lif ter Plunger T ravel. 10. With the lif ter still compressed , slowly tighten the rocker arm fastener (clockwise) until the free end of the rocker arm just makes contact with the end of the valve. See Figure 1 1-34. Figure 1 1-35. Determining Clearance with Feeler Gauge. 1[...]

11.13 Section 1 1 Reassembly 11 Figure 1 1-36. Installing Shim(s). Figure 1 1-37. T orquing Rocker Arm. 15. Hold down the push rod end of the rocker arm (step 9). Using a feeler gauge, check that there is 0.03-0.3 mm (0.001 to 0.010 in.) clearance between the rocker arm and the end of the valve. See Figure 1 1-38. Figure 1 1-38. Checking for 0.001 [...]

11.14 Section 1 1 Reassembly Figure 1 1-42. Installing Pipe Plug. Inst all Oil Fill/Dip stick T ube Assembly and Lower Blower Housing 1. Lubricate the O-Ring with engine oil, and install it on the lower end of the dipstick tube. Push the lower end of the tube assembly down into the crankcase until it seats into place. Orient the mounting tab so it [...]

11.15 Section 1 1 Reassembly 11 Figure 1 1-44. Tie S trap in Lower Blower Housing. 3. Set the lower blower housing down into position on the crankcase, and align the eight mounting screw locations. Insert the mounting tab of the oil fill/dipstick tube into the corresponding blower housing slot from the bottom. 4. Position the #2 side lifting bracke[...]

11.16 Section 1 1 Reassembly Figure 1 1-48. T orquing Thermost at Housing Screws. 4. Check that the gasket surfaces of the intake manifold and cylinder heads are clean and free of any nicks or damage. 5. Install new intake manifold gaskets onto the port surfaces of the cylinder heads. The use of gasket adhesive to prevent movement, will aid install[...]

11.17 Section 1 1 Reassembly 11 from the crankshaft. Orient the parts as shown in Figure 1 1-54 while tightening. T orque the six intake manifold mounting screws in two stages; initially to 7.4 N·m (66 in. lb.) then to 9.9 N·m (88 in. lb.) in the sequence shown in Figure 1 1-55. Figure 1 1-54. Ground Lead(s) Installation/Position. Figure 1 1 -55.[...]

11.18 Section 1 1 Reassembly Figure 1 1-59. Inst alling O-Ring in Crankcase for Water Pump. NOTE: A mark or dot of paint applied to top of pulley indicating the keyway location will make installation easier . 2. If the fitting for the by-pass hose in the water pump was removed previously , apply pipe sealant with T eflon ® (not T eflon ® tape) on[...]

11.19 Section 1 1 Reassembly 11 Figure 1 1-62. Installing Ferrule and Hex. Cap onto Fitting. 2 ) Insert the plain end of the transfer tube through the hex. cap and compression ring. See Figure 1 1-63. Figure 1 1-63. Inserting T ube into Ferrule and Hex. Cap. b. For reinstallation of an existing tube or if ferrule is locked onto tube: 1 ) Insert the[...]

11.20 Section 1 1 Reassembly NOTE: When installation is complete, the tangs of the two hose clamps must be down toward the crankcase, away from the flywheel and below the adjacent flange of the lower blower housing. See Figure 1 1-66. 10 . Install the drive belt onto the cogged pulley of the water pump, then around the cam pulley . Slide the cam pu[...]

11.21 Section 1 1 Reassembly 11 Figure 1 1-70. By-p ass Hose Inst allation. Inst all St ator and Rectifier-Regulator 1. Position the stator onto the mounting bosses so the leads are at the bottom, and directed out toward the rectifier-regulator mount on the #1 side. Apply pipe sealant with T eflon ® (not T eflon ® tape) to the threads of the two [...]

11.22 Section 1 1 Reassembly 3. Place the small sleeve spacer onto the stud, in the center of the intake manifold. If the stud was removed from the manifold, apply Loctite ® No. 290 to the lower set of threads and install until stud bottoms, or an exposed height of 32 mm (1.26 in.) is obtained. 4. Apply rubber lubricant to the inner surfaces of th[...]

11.23 Section 1 1 Reassembly 11 8. Lift the by-pass hose and secure it within the metal clip under the main support bracket. See Figure 1 1-78. Figure 1 1-78. Seating By-pass Hose. Inst all Electric St arter 1. Position the starter mounting plate onto the crankcase so that the cutout is at the bottom, and the offset is toward the dipstick tube. Ins[...]

11.24 Section 1 1 Reassembly Inst all Ignition Modules and Flywheel 1. Route the spark plug leads of the ignition modules, out through the corresponding cutouts in the lower blower housing assembly . 2. Route the white kill leads from the wiring harness and connect them to the ‘‘kill’ ’ tabs of the ignition modules. See Figures 1 1-82 and 1[...]

11.25 Section 1 1 Reassembly 11 3. Lower the flywheel down into position on crankshaft and make sure the ring gear section is below the legs of the ignition modules. See Figure 1 1-85. If clearance is OK, continue with installation of the ignition modules. If clearance is insufficient or contact is noted; remove the flywheel and recheck the tension[...]

11.26 Section 1 1 Reassembly 7. Rotate the flywheel back and forth checking for clearance between the magnet and ignition modules. Make sure the magnet does not strike the modules. Recheck the gap with a feeler gauge and readjust if necessary . Final Air Gap: 0.28/0.33 mm (0.01 1/0.013 in.) . Inst all Sp ark Plugs 1. Install the sp ark plugs into t[...]

11.27 Section 1 1 Reassembly 11 Figure 1 1-93. Att aching Linkages onto Carburetor . Checking V alve T rain 1. Rotate engine to check for free operation of the valve train. Check the clearance between valve spring coils at full lift. Minimum allowable clearance is 0.25 mm (0.01 in.). If engine seems tight or spring coils do not have proper clearanc[...]

11.28 Section 1 1 Reassembly 3. Install the carburetor as an assembly , onto the carburetor studs. See Figure 1 1-94. Carefully lift up on the lower blower housing, directly above the carburetor , and slide the carburetor into place against the gasket and manifold. 3. Pivot the governor lever toward the carburetor as far as it will move (wide-open [...]

11.29 Section 1 1 Reassembly 11 Install Throttle Controls 1. Connect the choke linkage from the carburetor into the choke actuator lever on the speed control bracket assembly . See Figure 1 1-97. W asher , flat (3) Lever Throttle Control (middle) Lever , Throttle Actuator (bottom) Bracket, Speed Control Spring, Choke Return Nut, M5x0.8 Lock Figure [...]

11.30 Section 1 1 Reassembly Inst all Air Cleaner Base 1. Install a new air cleaner base gasket onto the carburetor studs. 2. Install the air cleaner base onto the carburetor studs. Attach the clip around the fuel line onto the right side stud and install the two hex. flange nut s onto the studs to secure. T orque the nuts to 9.9 N·m (88 in. lb.) [...]

11.31 Section 1 1 Reassembly 11 Figure 1 1-102. Rechecking Governor Linkage Adjustment. 4. After adjustment is correct, reinstall the black bushing and linkage into the governor lever . Inst all Muffler 1. Inst all the muffler or exhaust system to the exhaust port studs. T orque hex. flange nuts to 24.4 N·m (216 in. lb.) . See Figure 1 1-103. Figu[...]

11.32 Section 1 1 Reassembly 1. Use equal parts of ethylene glycol (anti-freeze) and water only . Distilled or deionized water is recommended, especially in areas where the water contains a high mineral content. Propylene glycol based anti-freeze is not recommended. 2. Fill the cooling system, through neck for radiator cap, with the coolant mix. Al[...]

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FOR SALES AND SER VICE INFORMA TION IN U.S. AND CANADA, CALL 1-800-544-2444 LITHO IN U.S.A. FORM NO.: TP-2509 ISSUED: 9/01 REVISED: 5/04 MAILED: 6/04[...]