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Kohler SV470 manual

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Table of contents for the manual

  • Page 1

    1 20 690 01 Rev . F KohlerEngines.com SV470-SV620 Service Manual 2 Safety 3 Maintenance 5 Speci fi cations 13 T ools and Aids 16 T roubleshooting 20 Air Cleaner/Intake 21 Fuel System 31 Governor System 33 Lubrication System 35 Electrical System 44 Starter System 47 Emission Compliant Systems 50 Disassembly/Inspection and Service 63 Reassembly IMPO[...]

  • Page 2

    2 Safety KohlerEngines.com 20 690 01 Rev . F SAFETY PRECAUTIONS W ARNING: 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. W ARNING Exp[...]

  • Page 3

    3 Maintenance 20 690 01 Rev . F KohlerEngines.com MAINTENANCE INSTRUCTIONS W ARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery . Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicin[...]

  • Page 4

    4 Maintenance KohlerEngines.com 20 690 01 Rev . F OIL RECOMMENDA TIONS We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below .[...]

  • Page 5

    5 Speci fi cations 20 690 01 Rev . F KohlerEngines.com Dimensions in millimeters. Inch equivalents shown in [ ]. Engine Dimensions[...]

  • Page 6

    6 Speci fi cations KohlerEngines.com 20 690 01 Rev . F Model . . . . . . . . . . . . . . . . . . . . . SV470 Courage Engine V ertical Shaft Numerical Designation Speci fi cation . . . . . . . . . . . . . . . SV470-0001 Serial . . . . . . . . . . . . . . . . . . . . . 3923500328 Y ear Manufactured Code Factory Code Code Y ear 39 2009 40 2010 41 20[...]

  • Page 7

    7 Speci fi cations 20 690 01 Rev . F KohlerEngines.com TORQUE SPECIFICA TIONS 3,5 SV470-SV480 SV530-SV540 SV590-SV620 Carburetor Fuel Bowl Retaining Screw W albro Nikki 5.1-6.2 N·m (45-55 in. lb.) 10.8-12.8 N·m (96-1 13 in. lb.) Closure Plate Fastener 24.5 N·m (216 in. lb.) Connecting Rod Cap Fastener (torque in 2 increments) 5.5, 1 1.5 N·m (5[...]

  • Page 8

    8 Speci fi cations KohlerEngines.com 20 690 01 Rev . F TORQUE SPECIFICA TIONS 3,5 SV470-SV480 SV530-SV540 SV590-SV620 Speed Control Bracket Assembly Fastener 1 1.0 N·m (95 in. lb.) into new hole 7.5 N·m (65 in. lb.) into used hole Stator Mounting Screw 6.0 N·m (55 in. lb.) into new hole 4.0 N·m (35 in. lb.) into used hole V alve Cover Fastener[...]

  • Page 9

    9 Speci fi cations 20 690 01 Rev . F KohlerEngines.com CLEARANCE SPECIFICA TIONS 3 SV470-SV480 SV530-SV540 SV590-SV620 Crankcase Governor Cross Shaft Bore I.D. New Max. Wear Limit 6.025/6.05 mm (0.2372/0.2382 in.) 6.063 mm (0.2387 in.) Crankshaft End Play (free) 0.225/1.025 mm (0.0089/0.040 in.) Bore in Crankcase I.D. New Max. Wear Limit 41.965/41[...]

  • Page 10

    10 Speci fi cations KohlerEngines.com 20 690 01 Rev . F CLEARANCE SPECIFICA TIONS 3 SV470-SV480 SV530-SV540 SV590-SV620 Cylinder Bore Cylinder Bore I.D. New --- --- 94.010/94.035 mm (3.701/3.702 in.) Spec. 00XX: 84.010/84.035 mm (3.307/3.308 in.) 89.010/89.035 mm (3.504/3.505 in.) --- Spec. 01XX: 89.010/89.035 mm (3.504/3.505 in.) --- --- Spec. 02[...]

  • Page 11

    11 Speci fi cations 20 690 01 Rev . F KohlerEngines.com CLEARANCE SPECIFICA TIONS 3 SV470-SV480 SV530-SV540 SV590-SV620 Piston, Piston Rings, and Piston Pin (Continued) T op and Middle Compression Ring End Gap New Bore T op Ring Middle Ring Used Bore (max.) 0.15/0.40 mm (0.006/0.016 in.) 0.30/0.55 mm (0.012/0.022 in.) 0.77 mm (0.030 in.) Thrust Fa[...]

  • Page 12

    12 Speci fi cations KohlerEngines.com 20 690 01 Rev . F GENERAL T ORQUE V ALUES Metric Fastener T orque Recommendations for Standard Applications Property Class Noncritical Fasteners Into Aluminum Size 4.8 5.8 8.8 10.9 12.9 Tightening T orque: N·m (in. lb.) ± 10% M4 1.2 (1 1) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) M5 2.5 (22) 3.2 (28) 5.8 [...]

  • Page 13

    T ools and Aids 13 20 690 01 Rev . F KohlerEngines.com Certain quality tools are designed to help you perform speci fi c 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 decreasi[...]

  • Page 14

    T ools and Aids 14 20 690 01 Rev . F KohlerEngines.com TOOLS Description Source/Part No. Hydraulic V alve Lifter T ool For removing and installing hydraulic lifters. Kohler 25 761 38-S Ignition System T ester For testing output on all systems, including CD. Kohler 25 455 01-S Inductive T achometer (Digital) For checking operating speed (RPM) of an [...]

  • Page 15

    T ools and Aids 15 20 690 01 Rev . F KohlerEngines.com FL YWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A fl ywheel holding tool can be made out of an old junk fl ywheel ring gear and used in place of a strap wrench. 1. Using an abrasive cut-off wheel, cut out a six tooth segment of ring gear as shown. 2. Grind off any burrs or sharp edges. 3. I[...]

  • Page 16

    T roubleshooting 16 20 690 01 Rev . F KohlerEngines.com Engine Cranks But Will Not Start ● Battery connected backwards. ● Blown fuse. ● Carburetor solenoid malfunction. ● Choke not closing. ● Clogged fuel line or fuel fi lter . ● Diode in wiring harness failed in open circuit mode. ● DSAI or DSAM malfunction. ● Empty fuel tank. ●[...]

  • Page 17

    17 20 690 01 Rev . F KohlerEngines.com T roubleshooting Engine Loses Power ● Dirty air cleaner element. ● Engine overheated. ● Excessive engine load. ● Restricted exhaust. ● Faulty spark plug(s). ● High crankcase oil level. ● Incorrect governor setting. ● Low battery . ● Low compression. ● Low crankcase oil level. ● Quality of[...]

  • Page 18

    T roubleshooting 18 20 690 01 Rev . F KohlerEngines.com 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 fl atness, reassemble, and[...]

  • Page 19

    19 20 690 01 Rev . F KohlerEngines.com T roubleshooting COMPRESSION TEST For Command T wins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary mor[...]

  • Page 20

    20 Air Cleaner/Intake KohlerEngines.com 20 690 01 Rev . F BREA THER TUBE Ensure both ends of breather tube are properly connected. AIR COOLING W ARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed. Proper cooling is essential. T o prevent over [...]

  • Page 21

    21 Fuel System 20 690 01 Rev . F KohlerEngines.com T ypical carbureted fuel system and related components include: ● Fuel tank. ● Fuel lines. ● In-line fuel fi lter . ● Fuel pump. ● Carburetor . Fuel from tank is moved through in-line fi lter and fuel lines by fuel pump. Fuel then enters carburetor fl oat bowl and is drawn into carbure[...]

  • Page 22

    22 Fuel System KohlerEngines.com 20 690 01 Rev . F FUEL SYSTEM TESTS When engine starts hard or turns over but will not start, fuel system might be causing problems. T est fuel system by performing following test. 1. Check for fuel in combustion chamber . a. Disconnect and ground spark plug lead. b. Close choke on carburetor . c. Crank engine sever[...]

  • Page 23

    23 Fuel System 20 690 01 Rev . F KohlerEngines.com CARBURETOR W ARNING Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. N[...]

  • Page 24

    24 Fuel System KohlerEngines.com 20 690 01 Rev . F These engines are equipped with either a W albro or Nikki fi xed main jet carburetor . Carburetors will have a low idle speed adjustment screw , and either fi xed idle, or a limiter cap on idle fuel adjustment needle. T roubleshooting Checklist When engine starts hard, runs rough, or stalls at lo[...]

  • Page 25

    25 Fuel System 20 690 01 Rev . F KohlerEngines.com FUEL SYSTEM Fuel Shut-off Solenoid Most carburetors are equipped with a fuel shut-off solenoid. Solenoid is attached to fuel bowl. Solenoid has a spring-loaded pin that retracts when 12 volts is applied to lead, allowing fuel fl ow to main jet. When current is removed, pin extends blocking fuel ?[...]

  • Page 26

    26 Fuel System KohlerEngines.com 20 690 01 Rev . F 1. Place throttle control into idle or slow position. Adjust low idle speed to 1200 RPM. Follow Low Idle Speed (RPM) Adjustment. 2. Low idle fuel needle(s) setting: place throttle into idle or slow position. a. T urn 1 low idle fuel adjusting needle out (counterclockwise) from preliminary setting u[...]

  • Page 27

    27 Fuel System 20 690 01 Rev . F KohlerEngines.com Choke Adjusting Screw Details A A Choke Adjusting Screw NOTE: Choke is placed ON by moving throttle control slightly past fast position. If throttle control does not have a designated choke ON position, be sure to leave suf fi cient throttle control travel past fast position. This will enable chok[...]

  • Page 28

    28 Fuel System KohlerEngines.com 20 690 01 Rev . F Starting an Engine Equipped with Unitized Throttle and Choke Control Starting Throttle Control Details A A Cold Engine or W arm Engine NOTE: Do not crank engine continuously for more than 10 seconds at a time. If engine does not start, allow a 60 second cool down period between starting attempts. F[...]

  • Page 29

    29 Fuel System 20 690 01 Rev . F KohlerEngines.com 4. Loosen speed control bracket mounting screws. Slide bracket forward or backward, until desired high speed (RPM) is reached. Check speed with a tachometer . T o increase high speed (RPM), move bracket toward carburetor . T o decrease high speed (RPM), move bracket away from carburetor . 5. T ight[...]

  • Page 30

    30 Fuel System KohlerEngines.com 20 690 01 Rev . F Throttle Control Installation 1. Loosen two cable clamp screws on speed control bracket assembly . 2. Move application throttle control lever to maximum full (fast) throttle position, and then move it back 3/16" or 4.75 mm. Insert cable boden wire into throttle control lever on control plate. [...]

  • Page 31

    31 Governor System 20 690 01 Rev . F KohlerEngines.com 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 fl yweight mechanical [...]

  • Page 32

    32 Governor System KohlerEngines.com 20 690 01 Rev . F Governor Sensitivity Adjustment Governor sensitivity is adjusted by repositioning governor spring in holes in governor lever . If speed surging occurs with a change in load, governor is set too sensitive. If a big drop in speed occurs when a normal load is applied, governor should be set for gr[...]

  • Page 33

    33 Lubrication System 20 690 01 Rev . F KohlerEngines.com OIL RECOMMENDA TIONS Refer to Maintenance. CHECK OIL LEVEL NOTE: T o prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicator on dipstick. Ensure engine is cool. Clean oil fi ll/dipstick areas of any debris. 1. Remove dipstick; wipe o[...]

  • Page 34

    34 Lubrication System KohlerEngines.com 20 690 01 Rev . F OIL SENTR Y ™ (if equipped) This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry ™ may not shut down a running engine before damage occurs. In some applications this switch may activate a warning signal. Read your equipment manuals for more[...]

  • Page 35

    35 Electrical System 20 690 01 Rev . F KohlerEngines.com SP ARK PLUGS CAUTION Electrical Shock can cause injury . Do not touch wires while engine is running. Spark Plug Component and Details B A C D A Wire Gauge B Spark Plug C Ground Electrode D Gap NOTE: Do not clean spark plug in a machine using abrasive grit. Some grit could remain in spark plug[...]

  • Page 36

    36 Electrical System KohlerEngines.com 20 690 01 Rev . F Carbon Fouled Soft, sooty , black deposits indicate incomplete combustion caused by a restricted air cleaner , over rich carburetion, weak ignition, or poor compression. Overheated Chalky , white deposits indicate very high combustion temperatures. This condition is usually accompanied by exc[...]

  • Page 37

    37 Electrical System 20 690 01 Rev . F KohlerEngines.com Electronic Ignition System T ests NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate fi ndings. Battery on unit must be fully charged and properly connected before performing tests (a battery that is hooked up or charged bac[...]

  • Page 38

    38 Electrical System KohlerEngines.com 20 690 01 Rev . F BA TTER Y CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Disconnect recti fi er-regulator plug and/or wiring harness plug before doing any electric we[...]

  • Page 39

    39 Electrical System 20 690 01 Rev . F KohlerEngines.com 3 Amp/70 W att Lighting Stator NOTE: Zero ohmmeter on each scale to ensure accurate readings. V oltage tests should be made with engine running at full throttle with no load. Battery must be fully charged. T o test charging system for no charge to battery: 1. With engine running in fast setti[...]

  • Page 40

    40 Electrical System KohlerEngines.com 20 690 01 Rev . F 3 Amp/70 W att Braking Stator NOTE: Zero ohmmeter on each scale to ensure accurate readings. V oltage tests should be made with engine running at full throttle with no load. Battery must be fully charged. T o test charging system for no charge to battery: 1. With engine running in fast settin[...]

  • Page 41

    41 Electrical System 20 690 01 Rev . F KohlerEngines.com Wiring Diagram-9 or 15 Amp Regulated Battery Charging System H G D R S J N P L Q E C T O U A M F I K J T P Q B B V AC AC B+ A Red B Green C Violet D White E Spark Plug F Optional Fuel Solenoid G Optional Oil Sentry ™ Switch (Shutdown) H Bendix Starter I Engine Connector J Starter Solenoid K[...]

  • Page 42

    42 Electrical System KohlerEngines.com 20 690 01 Rev . F 9/15 Amp Regulated Battery Charging System NOTE: Zero ohmmeter on each scale before testing to ensure accurate readings. V oltage tests should be made with engine running at full throttle with no load. Battery must be fully charged. T o test charging system for no charge to battery: 1. Insert[...]

  • Page 43

    43 Electrical System 20 690 01 Rev . F KohlerEngines.com As Kohler blade stop stator brake circuit often is operated in conjunction with other application circuits, relay in Kohler circuit is specially con fi gured with a 680 ohm resistor in parallel with relay coil. This is done to negate transient voltage signals that would be normally created b[...]

  • Page 44

    44 Starter System KohlerEngines.com 20 690 01 Rev . F 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 suf fi cient speed to disengage starter but does not keep running (a false star[...]

  • Page 45

    45 Starter System 20 690 01 Rev . F KohlerEngines.com When power is applied to starter , armature rotates. As armature rotates, drive pinion moves out on splined drive shaft and into mesh with fl ywheel ring gear . When pinion reaches end of drive shaft, it rotates fl ywheel and cranks engine. When engine starts, fl ywheel rotates faster than st[...]

  • Page 46

    46 Starter System KohlerEngines.com 20 690 01 Rev . F Starter Disassembly 1. Remove drive components following instructions for servicing drive. 2. Remove nut and insulating washer from positive (+) brush lead stud. 3. Remove thru bolts and recessed nuts. 4. Remove commutator end cap and lift out brush carrier assembly with brushes and springs. 5. [...]

  • Page 47

    47 Emission Compliant Systems 20 690 01 Rev . F KohlerEngines.com EV APORA TIVE EMISSION COMPLIANT SYSTEM Carbon Canister System A Fuel T ank Cap B Fuel T ank C Roll Over V alve (ROV) D Carbon Canister E Canister Breather Filter F T o Carburetor A B C D E F Operation Fuel vapors travel from fuel tank through tubing to carbon canister . On intake st[...]

  • Page 48

    48 Emission Compliant Systems KohlerEngines.com 20 690 01 Rev . F SECONDAR Y EMISSION COMPLIANT SYSTEM T win Secondary Air Induction System A Hose T o Exhaust Manifold B Inlet Screen C Secondary Air V alve Assembly D Hose T o Carburetor E Hose T o Exhaust Manifold Single Secondary Air Induction System F Secondary Air V alve Assembly G Hose T o Exha[...]

  • Page 49

    49 Emission Compliant Systems 20 690 01 Rev . F KohlerEngines.com Remove Inlet Screen Inlet Components A B C A Secondary Air V alve Assembly B Barb C Inlet Screen 1. Remove inlet screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away from valve assembly . 2. Use a soft brush to remove debris from screen. 3[...]

  • Page 50

    50 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F W ARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery . Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing[...]

  • Page 51

    51 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Clean all parts thoroughly 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, fol[...]

  • Page 52

    52 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Flywheel/Ignition Components G F H I B C D E A A Flywheel Screw B W asher C Fan Mounting Plate D Fan E Magnet F Flywheel G Ignition Module H Stator I Flywheel Key Remove Ignition Module 1. Disconnect kill lead from ignition module. 2. Rotate fl ywheel magnet away from module[...]

  • Page 53

    53 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Disassemble Cylinder Head NOTE: Before disassembly , mark all valve train components that will be reused, to assure they are reassembled on same side. 1. Remove spark plug. 2. Remove adjustment nuts, pivots and rocker arms from pivot studs. 3. Remove rocker arm pivot studs an[...]

  • Page 54

    54 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Model SV470/480/530/540/590/600/610 V alve Details A A E D F G G E D F B B C C Dimension Intake Exhaust A Seat Angle 89° 89° B Guide Depth 10.20 mm 6.2 mm C Guide I.D. 6.038/6.058 mm 6.038/6.058 mm D V alve Head Diameter 37.625/37.375 mm 32.125/32.375 mm E V alve Face Angle[...]

  • Page 55

    55 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Inspection and Service Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion. Check valves and valve seats for evidence of deep pitting, cracks, or distortion. Check running clearance between valve stems and guide[...]

  • Page 56

    56 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F 4. If wiring harness needs to be separated from closure plate, pry open clamps and pull out through slot. Disassemble Closure Plate NOTE: Governor gear is held onto shaft by small molded tabs in gear . When gear is removed these tabs are destroyed and gear must be replaced. G[...]

  • Page 57

    57 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com 1. Remove thrust washer(s) and cam gears from cam shafts. Later models will have a thrust washer on exhaust side only . 2. Remove screws securing cam levers to crankcase. Mark cam levers for proper reassembly . 3. Pull exhaust side cam shaft and slotted thrust washer , out of[...]

  • Page 58

    58 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Balance Weight/Piston Assembly Components A B C E F G P O H K L N M J I D A Crankshaft Gear B Crankshaft C Crank Gear Key D Third Generation Balance Weight E Governor Cross Shaft F W asher G Hitch Pin H Oil Seal I End Cap J Connecting Rod K Wrist Pin Retainer L Wrist Pin M Pi[...]

  • Page 59

    59 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Piston and Rings Inspection Piston and Rings Components and Details A Piston Ring B End Gap C Identi fi cation Mark D Piston E T op Compression Ring F Center Compression Ring G Rails H Expander I Oil Control Ring (3 Piece) A B C D E F G I H Scuf fi ng and scoring of pistons[...]

  • Page 60

    60 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F T o install piston rings, proceed as follows: 1. Oil control ring (bottom groove): Install expander and then rails. Make sure ends of expander are not overlapped. 2. Compression ring (center groove): Install center ring using a piston ring installation tool. Make sure identi [...]

  • Page 61

    61 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Measuring Balance Weight to Crankshaft Eccentric Ring(s) Clearance 1. Use an inside micrometer , telescoping gauge, or bore gauge and measure inside diameter of balance weight bearing surface. T ake two measurements 90° to each other on each weight. 2. Then use an outside mi[...]

  • Page 62

    62 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Clean Cylinder Bore after Honing Proper cleaning of cylinder walls following honing is critical. Grit left in cylinder bore can destroy an engine in less than one hour of operation after a rebuild. Final cleaning operation should always be a thorough scrubbing with a brush an[...]

  • Page 63

    63 Reassembly 20 690 01 Rev . F KohlerEngines.com NOTE: Make sure engine is assembled using all speci fi ed torque values, torque sequences, and clearances. Failure to observe speci fi cations could cause severe engine wear or damage. Always use new gaskets. Apply a small amount of oil to threads of critical fasteners before assembly , unless a s[...]

  • Page 64

    64 Reassembly KohlerEngines.com 20 690 01 Rev . F Install PTO Side Oil Seal PTO Seal Depth Details A B A Oil Seal B Seal Depth 5.5 mm (0.216 in.) Use a seal driver and install to a depth of 5.5 mm (0.216 in.) into crankcase. Install Governor Cross Shaft 1. Place thin thrust washer onto governor cross shaft as far as it will go. 2. Lightly lubricate[...]

  • Page 65

    65 Reassembly 20 690 01 Rev . F KohlerEngines.com 5. Install intake cam shaft down into crankcase boss. Seat rubber oil pump outlet seal into machined pocket. If an open style outlet seal is used, check to make sure small feed hole is open and aligned with lower main bearing oil feed hole. Use a 3/32” allen wrench, or a light with a mirror . Push[...]

  • Page 66

    66 Reassembly KohlerEngines.com 20 690 01 Rev . F Cam/Closure Plate Components G F H L G O N K J I M P B C D E A A Oil Seal B Closure Plate C Oil Passage Cover D Gasket E Cam Gears F Thrust W asher G Cam Levers H Cam Shaft (Exhaust) I Closure Plate Gasket J Gerotor Gears K Oil Pump L Cam Shaft Pin M Cam Shaft (Intake) N Regulating Pin O Governor Ge[...]

  • Page 67

    67 Reassembly 20 690 01 Rev . F KohlerEngines.com Install Flywheel Side Oil Seal Lubricate outside diameter and lip of fl ywheel end oil seal. Support closure plate and install oil seal. Using a seal driver , drive seal to a depth of 5 mm (0.196 in.) in seal bore. Install Closure Plate Gasket, Closure Plate, and Wiring Harness Closure Plate Fasten[...]

  • Page 68

    68 Reassembly KohlerEngines.com 20 690 01 Rev . F Assemble Cylinder Head Prior to assembly , lubricate all components with engine oil, including tips of valve stems and valve guides. Using a valve spring compressor , install following items in order listed. ● Intake and exhaust valves. ● V alve spring caps. ● V alve springs. ● V alve spring[...]

  • Page 69

    69 Reassembly 20 690 01 Rev . F KohlerEngines.com 1. Check to make sure there are no nicks or burrs on sealing surfaces of cylinder head or crankcase. 2. If engine uses a drain back check ball, install it into keyhole slot in top of crankcase. 3. Install a new cylinder head gasket. 4. Install cylinder head and start six screws. Install thick washer[...]

  • Page 70

    70 Reassembly KohlerEngines.com 20 690 01 Rev . F Flywheel/Ignition Components G F H I J B C D E A A Flywheel Screw B W asher C Fan Mounting Plate D Fan E Magnet F Flywheel G Ignition Module H Stator I Flywheel Key J Pulse Line Fitting Install Stator and Wiring Harness Install Stator 1. Position stator onto mounting bosses so leads lay in channel a[...]

  • Page 71

    71 Reassembly 20 690 01 Rev . F KohlerEngines.com Install Electric Starter Install electric starter to closure plate and secure with nuts. Make sure wires are clear of any moving parts and torque nuts to 3.6 N·m (32 in. lb.). Install Ignition Module 1. Rotate fl ywheel so magnet is away from ignition module bosses. Using screws, install ignition [...]

  • Page 72

    72 Reassembly KohlerEngines.com 20 690 01 Rev . F Install Spark Plug 1. Check gap using wire feeler gauge. Adjust gap to 0.76 mm (0.03 in.). 2. Install plug into cylinder head. 3. T orque plug to 27 N·m (20 ft. lb.). Install Heat De fl ector , Carburetor , Linkage and Air Cleaner Base 1. If carburetor mounting stud was removed, reinstall it in ou[...]

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    73 Reassembly 20 690 01 Rev . F KohlerEngines.com Early Style Governor Spring Location A B High Speed RPM Governed Idle RPM Governor Lever Hole Throttle Lever Hole White Spring Green Spring Black Spring 3201-3400 B A X 3201-3400 B A X 3201-3400 1601-1800 B A X Later Style Governor Spring Location A B B C D High Speed RPM Governed Idle RPM Governor [...]

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    74 Reassembly KohlerEngines.com 20 690 01 Rev . F Install Fuel Pump (if equipped) NOTE: If fuel pump is attached to air cleaner base, fuel lines and pulse line should still be connected to fuel pump. Connect pulse line to pulse fi tting and secure with clamp. 1. Attach fuel pump mounting bracket to speed control bracket with two M5 screws. T orque[...]

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    75 20 690 01 Rev . F KohlerEngines.com[...]

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    76 KohlerEngines.com 20 690 01 Rev . F © 201 1 by Kohler Co. All rights reserved.[...]