SERVICE MANUAL

VERTICAL CRANKSHAFT
COMMAND PRO
CV940-CV1000
Contents
Section 1. Safety and General Information.............................................................................
Section 2. Tools & Aids.............................................................................................................
Section 3. Troubleshooting ......................................................................................................
Section 4. Air Cleaner and Air Intake System.........................................................................
Section 5. Fuel System and Governor.....................................................................................
Section 6. Lubrication System.................................................................................................
Section 7. Electrical System and Components ......................................................................
Section 8. Disassembly.............................................................................................................
Section 9. Inspection and Reconditioning..............................................................................
Section 10. Reassembly............................................................................................................
1
2
3
4
5
6
7
8
9
10
1.1
1
Rotating Parts!
Keep hands, feet , hai r, and cl ot hi ng
away fr om al l movi ng par t s t o pr event
i nj ur y. Never oper at e t he engi ne wi t h
cover s, shr ouds, or guar ds r emoved.
Section 1
Safety and General Information
Safety Precautions
To ensure safe operati on pl ease read the fol l owi ng statements and understand thei r meani ng. Al so
refer to your equi pment manufacturer's manual for other i mportant safety i nformati on. Thi s manual
contai ns safety precauti ons whi ch are expl ai ned bel ow. Pl ease read careful l y.
WARNING
Warni ng i s used to i ndi cate the presence of a hazard that can cause sever e personal i njury, death,
or substanti al property damage i f the warni ng i s i gnored.
CAUTION
Cauti on i s used to i ndi cate the presence of a hazard that wi l l or can cause mi nor personal i njury or
property damage i f the cauti on i s i gnored.
NOTE
Note i s used to noti fy peopl e of i nstal l ati on, operati on, or mai ntenance i nformati on that i s i mportant
but not hazard-rel ated.
For Your Safety!
These pr ecaut i ons shoul d be fol l owed at al l t i mes. Fai l ur e t o fol l ow t hese pr ecaut i ons coul d r esul t i n i nj ur y t o
your sel f and ot her s.
Acci dental Starts can cause
severe i nj ury or death.
Di sconnect and ground spark pl ug
l eads before servi ci ng.
WARNING
Accidental Starts!
Di sabl i ng engi ne. Acci dent al
st art i ng can cause severe i nj ury or
deat h. Befor e wor ki ng on t he engi ne
or equi pment , di sabl e t he engi ne as
fol l ows: 1) Di sconnect t he spar k pl ug
l ead(s). 2) Di sconnect negat i ve (-)
|acrqca||cjrcn|acrq
Rotati ng Parts can cause severe
i nj ury.
Stay away whi l e engi ne i s i n
operati on.
WARNING
Hot Parts can cause severe burns.
Do not touch engi ne whi l e operati ng
or|uslaersloing
WARNING
Hot Parts!
Engi ne component s can get ext r emel y
hot fr om oper at i on. To pr event sever e
bur ns, do not t ouch t hese ar eas whi l e
t he engi ne i s r unni ng - or i mmedi at el y
acriiisiurnc!cNctcrcpcraic
t he engi ne wi t h heat shi el ds or guar ds
r emoved.
1.2
Section 1
Safety and General Information
Exp!nsivcFuc!cancauscrcsand
severe burns.
DonolIIlhefueIlankvhiIelhe
engi ne i s hot or runni ng.
WARNING
Explosive Fuel!
Gasc|inciscxircnc|qanna||can!
i t s vapor s can expl ode i f i gni t ed. St or e
gasol i ne onl y i n appr oved cont ai ner s,
i n wel l vent i l at ed, unoccupi ed
|ui|!ingsauaqjrcnsparkscrancs
Ocnci||incjuc|iankuni|cinc
engi ne i s hot or r unni ng, si nce spi l l ed
fuel coul d i gni t e i f i t comes i n cont act
wi t h hot par t s or spar ks fr om i gni t i on.
Do not st ar t t he engi ne near spi l l ed
fuel . Never use gasol i ne as a cl eani ng
agent .
Cl eani ng Sol vents can cause severe
i nj ury or death.
Use onl y i n wel l venti l ated areas
away from i gni ti on sources.
WARNING
Flammable Solvents!
Car bur et or cl eaner s and sol vent s ar e
cxircnc|qanna||cKccpsparks
ancsan!cincrscurccscjigniiicn
away fr om t he ar ea. Fol l ow t he
cl eaner manufact ur er s war ni ngs and
i nst r uct i ons on i t s pr oper and safe use.
Never use gasol i ne as a cl eani ng agent .
Carbon Monoxi de can cause severe
nausea, f ai nti ng or death.
Avoi d i nhal i ng exhaust fumes, and
never run the engi ne i n a cl osed
buiIdingorconnedarea
WARNING
Lethal Exhaust Gases!
Engi ne exhaust gases cont ai n
poi sonous car bon monoxi de. Car bon
monoxi de i s odor l ess, col or l ess, and can
cause deat h i f i nhal ed. Avoi d i nhal i ng
exhaust fumes, and never r un t he
cngincinac|csc!|ui|!ingcrccnnc!
ar ea.
El ectri cal Shock can cause i nj ury.
Do not touch wi res whi l e engi ne i s
runni ng.
CAUTION
Electrical Shock!
Never t ouch el ect r i cal wi r es or
component s whi l e t he engi ne i s
r unni ng. They can be sour ces of
el ect r i cal shock.
WARNING
Exp!nsivcGascancauscrcsand
severe aci d burns.
ChargebaeryonIyinaveII
venti l ated area. Keep sources of
i gni ti on away.
Explosive Gas!
Bacricsprc!ucccxp|csitcnq!rcgcn
gas whi l e bei ng char ged. To pr event a
rccrcxp|csicncnargc|acricscn|q
i n wel l vent i l at ed ar eas. Keep spar ks,
cpcnancsan!cincrscurccscj
igniiicnauaqjrcninc|acrqaia||
iincsKccp|acricscuicjincrcacn
of chi l dr en. Remove al l j ewel r y when
scrticing|acrics
Befor e di sconnect i ng t he negat i ve (-)
gr ound cabl e, make sur e al l swi t ches
ar e OFF. I f ON, a spar k wi l l occur at
t he gr ound cabl e t er mi nal whi ch coul d
cause an expl osi on i f hydr ogen gas or
gasol i ne vapor s ar e pr esent .
1.3
Section 1
Safety and General Information
1
A. Model No.
C V 980 S
B. Spec. No.
Command Engine
Version Code
S = Electric Start
C. Serial No.
Year Manufactured Code
Code Year
37 2007
38 2008
39 2009
CV940-0001
CV960-0001
CV980-0001
CV1000-0001
Complete Spec Number
(Incorporating Model No. with
Variation No. of Basic Spec.)
Factory Code
3705810334
Identication
Decal
Engine Identication Numbers
When orderi ng parts, or i n any communi cati on
i nvol vi ng an engi ne, al ways gi ve the Model ,
SecicalionandSeriaINumbersincIudingIeer
suxesiflhereareany
TheengineidenlicalionnumbersaearonadecaI
ordecaIsaxedlolheengineshroudingSee
Fi gure 1-1. An expl anati on of these numbers i s shown
i n Fi gure 1-2.
Figure 1-1. Engine Identication DecaI Location.
Numerical Designation
Vertical Crankshaft
Figure 1-2. ExpIanation of Engine Identication Numbers.
1.4
Section 1
Safety and General Information
SAE
10W30
A
P
I
S
E
RV
IC
E
S
J
5W-20, 5W-30
RECOMMENDED SAE VI SCOSI TY GRADES
10W-30
Kohler 10W-30
F -20 0 20 32 40 60 80 100
C -30 -20 -10 0 10 20 30 40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
up to 4C (40F)
* Synthetic oils will provide better starting in extreme cold below
23C (-10F)
**
*
Oil Recommendations
Usi ng the proper type, wei ght, and a consi stent
brand of oi l i n the crankcase i s extremel y i mportant.
So i s checki ng oi l dai l y and changi ng oi l regul arl y.
Fai l ure to use the correct oi l , or usi ng di rty oi l , causes
premature engi ne wear and fai l ure.
Oil Type
Use hi gh-qual i ty detergent oi l of API (Ameri can
Petrol eum I nsti tute) Servi ce Cl ass SJ or hi gher. Sel ect
the vi scosi ty based on the ai r temperature at the ti me
of operati on as shown i n the fol l owi ng tabl e.
NOTE: Usi ng other than servi ce cl ass SJ or hi gher oi l
or extendi ng oi l change i nterval s l onger than
recommended can cause engi ne damage.
NOTI SynlhelicoiIsmeelinglheIisledcIassicalions
may be used wi th oi l changes performed
at the recommended i nterval s. However, to
al l ow pi ston ri ngs to properl y seat, a new or
rebui l t engi ne shoul d be operated for at l east
50 hours usi ng standard petrol eum based oi l
before swi tchi ng to syntheti c oi l .
AIogoorsymboIonoiIconlainersidenlieslheAII
servi ce cl ass and SAE vi scosi ty grade. See Fi gure 1-3.
Figure 1-3. Oil Container Logo.
Refer to Secti on 6 - Lubri cati on System for detai l ed
procedures on checki ng the oi l , changi ng the oi l and
changinglheoiIIler
Fuel Recommendations
WARNING: Explosive Fuel!
Gasc|inciscxircnc|qanna||can!iistapcrscancxp|c!c
i f i gni t ed. Befor e ser vi ci ng t he fuel syst em, make sur e t her e
arcncsparkscpcnancscrcincrscurccscjigniiicn
near by as t hese can i gni t e gasol i ne vapor s. Di sconnect and
gr ound t he spar k pl ug l eads t o pr event t he possi bi l i t y of
spar ks fr om t he i gni t i on syst em.
General Recommendations
Purchase gasol i ne i n smal l quanti ti es that can be used
wi thi n 30 days, and store i n onl y cl ean, approved
conlainersDonolusegasoIineIeoverfromlhe
previ ous season, unl ess treated wi th a fuel stabi l i zer
(see Storage), to mi ni mi ze gum deposi ts and ensure
easy starti ng. Do not use gasol i ne contai ni ng
Methanol , or add oi l to the gasol i ne.
DonoloverIIlhefueIlankLeaveroomforlhefueI
to expand.
Fuel Type
For best resul ts, use onl y cl ean, fresh, unl eaded
gasol i ne wi th a pump sti cker octane rati ng of 87 or
higherIncounlriesusinglheResearchmelhodil
shoul d be 90 octane mi ni mum.
Unl eaded gasol i ne i s recommended as i t l eaves
l ess combusti on chamber deposi ts and reduces
harmful exhaust emi ssi ons. Leaded gasol i ne i s not
recommended and must notbeusedonIIIengines
or on other model s where exhaust emi ssi ons are
regul ated.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl al cohol , 90% unl eaded
gasol i ne by vol ume) i s approved as a fuel for Kohl er
engi nes. Other gasol i ne/al cohol bl ends i ncl udi ng E20
and E85 are not to be used and not approved. Any
fai l ures resul ti ng from use of these fuel s wi l l not be
warranted.
Gasoline/Ether blends
Methyl Terti ary Butyl Ether (MTBE) and unl eaded
gasol i ne bl ends (up to a maxi mum of 15% MTBE by
vol ume) are approved as a fuel for Kohl er engi nes.
Other gasol i ne/ether bl ends are not approved.
1.5
Section 1
Safety and General Information
1
Per for m t hese mai nt enance pr ocedur es mor e fr equent l y under ext r emel y dust y, di r t y condi t i ons.
2
Have a Kohl er Engi ne Ser vi ce Deal er per for m t hi s ser vi ce.
Periodic Maintenance Instructions
WARNING: Accidental Starts!
Di sabl i ng engi ne. Acci dent al st art i ng can cause severe i nj ury or deat h. Befor e wor ki ng on t he engi ne or equi pment ,
!isa||cinccngincasjc||cusOisccnncciincsparkp|ug|ca!sOisccnnccincgaiitc|acrqca||cjrcn|acrq
Maintenance Schedule
These requi red mai ntenance procedures shoul d be performed at the frequency stated i n the tabl e. They shoul d
al so be i ncl uded as part of any seasonal tune-up.
Frequency Maintenance Refer to:
Daily or Before
Starting Engine
Fi l l fuel tank. Section 5
Check oi l l evel . Section 6
Check ai r cl eaner for di rty
1
, l oose, or damaged parts. Section 4
Check ai r i ntake and cool i ng areas, cl ean as necessary. Section 4
Weekly CheckIlerminderoraircIeanereIemenl Section 4
Seasonally or
Every 150 Hours
Check ai r cl eaner el ement. Section 4
ReIacefueIIler Section 5
ChangeoiIOiIIlerisrecommended
(More frequentl y under severe operati ng condi ti ons)
Section 6
Remove cool i ng shrouds and cl ean cool i ng areas
1
. Section 4
CheckoiIcooIernscIeanasnecessary Section 6
Every 200 Hours Check spark pl ug condi ti on and gap. Section 7
Seasonally or
Every 300 Hours
ChangeoiIIler Section 6
Repl ace ai r cl eaner el ement. Section 4
Yearly or
Every 500 Hours
HavesoIenoidshislarlerdisassembIedandcIeaned Section 7
HavecrankshasIinesIubricaled
2
.
Every 600 Hours
Repl ace i nner ai r cl eaner el ement. Section 4
Repl ace spark pl ugs. Section 7
Fi l l the fuel tank wi th cl ean, fresh gasol i ne. Run
the engi ne for 2 to 3 mi nutes to get stabi l i zed
fuel i nto the rest of the system. Cl ose the fuel
shulovaIvevhenlheunilisbeingsloredor
transported.
To empty the system, run the engi ne unti l the
tank and the system are empty.
4. Remove the spark pl ugs and add one tabl espoon
ofengineoiIinloeachsarkIughoIeInslaIIlhe
spark pl ugs, but do not connect the pl ug l eads.
Crank the engi ne two or three revol uti ons.
Disconnecllhebaeryoruseabaeryminderlo
keelhebaerychargedduringslorage
6. Store the engi ne i n a cl ean, dry pl ace.
Storage
IflheengineviIIbeoulofservicefordaysormore
use the fol l owi ng storage procedure.
1. Cl ean the exteri or surfaces of the engi ne. Avoi d
sprayi ng water at the wi ri ng harness or any of the
el ectri cal components.
ChangelheoiIandoiIIlervhiIelheengineis
sti l l warm from operati on. See Change Oi l and
Oi l Fi l ter i n Secti on 6.
3. The fuel system must be compl etel y empti ed,
or the gasol i ne must be treated wi th a stabi l i zer
lorevenldelerioralionIfyouchooselo
use a stabi l i zer, fol l ow the manufacturer s
recommendati ons, and add the correct amount
for the capaci ty of the fuel system.
1.6
Section 1
Safety and General Information
Dimensions in millimeters.
Inch equivalents shown in [ ].
411.64
[16.206]
14.7
[.58]
130.00
[5.118]
152.36
[5.999]
232.22
[9.143]
344.54
[13.565]
89.80
[3.536]
62.70
[2.468]
325.30
[12.807]
577.09
[22.720]
5.9
[.23]
135.00
[5.315]
484.33
[19.068]
365.50
[14.390]
90.22
[3.552]
30.00
[1.181]
45.00
[1.772]
376.56
[14.825]
111.30
[4.382]
17.00
[.669]
115.12
[4.532]
26.80
[1.055]
50.00 [1.969]
470.64
[18.529]
168.95
[6.652]
254.00
[10.00]
M8x1.25-6H
25.0 [0.98] DEEP
7 HOLES
(89.80)
[(3.536)]
60.00
[2.362]
35.00
[1.378]
124.10
[4.886]
427.80
[16.843]
275.08
[10.829]
50.00
[2.362]
84.20
[3.315]
115.12
[4.532]
89.80
[(3.536)]
18.00
[.709]
49.80
[1.961]
70.45 [2.774]
93.45 [3.679]
17.00
[.669]
(Optional Guard)
Figure 1-4. Typical CV PRO Series Engine Dimensions with Heavy Duty Air Cleaner.
1.7
Section 1
Safety and General Information
1
Val ues are i n Metri c uni ts. Val ues i n parentheses are Engl i sh equi val ents. Lubri cate threads wi th engi ne oi l
pri or to assembl y.
GeneraI Specications
Power (@3600 RPM, exceeds Soci ety of Automoti ve Engi neers-Smal l Engi ne Test Code J1940.)
CV940......................................................................................................... 25.3 kW (34 HP)
CV960......................................................................................................... 26.9 kW (36 HP)
CV980......................................................................................................... 28.3 kW (38 HP)
CV1000....................................................................................................... 29.8 kW (40 HP)
Bore .................................................................................................................. 90 mm (3.54 i n.)
Stroke................................................................................................................ 78.5 mm (3.09 i n.)
Di spl acement ................................................................................................... 999 cc (60.96 cu. i n.)
Compressi on Rati o ......................................................................................... 8.8:1
Dry Wei ght ....................................................................................................... 57.6 kg (127 l b.)
OiICaacilyvIleraroximale
delerminedbyoiIIlerused ........................................................................ 2.9 L (3.1 U.S. qt.)
Angl e of Operati on - Maxi mum (At Ful l Oi l Level ) Al l Di recti ons......... 25
Blower Housing and Sheet Metal
M6 Shoul der Screw Torque
Inlo
New, Untapped Hol e (casti ng) .............................................................. 10.7 Nm (95 i n. l b.)
Used , Tapped Hol e (casti ng) ................................................................. 7.3 Nm (65 i n. l b.)
New, Extruded Hol e (sheet metal ) ........................................................ 4.0 Nm (35 i n. l b.)
Used, Extruded Hol e (sheet metal ) ....................................................... 2.0 Nm (17.7 i n. l b.)
MounlingCIivaIIeybae................................................................. 2.5 Nm (22.1 i n. l b.)
M6 Screw Torque
New, Untapped Hol e (casti ng) .............................................................. 10.7 Nm (95 i n. l b)
Used, Tapped Hol e (casti ng) .................................................................. 7.3 Nm (65 i n. l b)
ReclierReguIalorIaslenerTorque............................................................. 2.0 Nm (18 i n. l b.)
Oi l Cool er Fastener Torque............................................................................ 2.2 Nm (20 i n. l b.)
Camshaft
End Pl ay............................................................................................................ 0.3/1.3 mm (0.011/0.051 i n.)
Runni ng Cl earance.......................................................................................... 0.025/0.063 mm (0.0010/0.0025 i n.)
oreID
New............................................................................................................ 20.000/20.025 mm (0.7874/0.7884 i n.)
Max. Wear Li mi t....................................................................................... 20.038 mm (0.7889 i n.)
CamshaearingSurfaceOD
New............................................................................................................ 19.962/19.975 mm (0.7859/0.7864 i n.)
Max. Wear Li mi t....................................................................................... 19.959 mm (0.7858 i n.)
CamLobeIroIeMinimumDimensionMeasuredIromaseCircIeToToOfLobe
Exhaust ............................................................................................................. 35 mm (1.3779 i n.)
Inlake ............................................................................................................... 35 mm (1.3779 i n.)
1.8
Section 1
Safety and General Information
Carburetor, Intake Manifold, and Air Cleaner
InlakeManifoIdMounlingIaslenerTorque
Torque Usi ng Sequence i n Two Stages................................................. rslloNminIb
naIIyloNminIb
Carburetor/Ai r Cl eaner Mounti ng Nut Torque.......................................... 7.9 Nm (70 i n. l b.)
AirCIeanerMounlingScrevTorqueInloInlakeManifoId................... 9.9 Nm (88 i n. l b.)
Control Bracket
MounlingScrevInloInlakeManifoIdfromAirCIeanerTorque ......... 9.9 Nm (88 i n. l b.)
Connecting Rod
Cap Fastener Torque (torque i n i ncrements)............................................... 11.3 Nm (100 i n. l b.)
CrankinIndIDI
New............................................................................................................ 44.030/44.037 mm (1.7334/1.7337 i n.)
Max. Wear Li mi t....................................................................................... 0.070 mm (0.0028 i n.)
Connecti ng Rod-to-Crankpi n Runni ng Cl earance
New............................................................................................................ 0.030/0.055 mm (0.0012/0.0022 i n.)
Max. Wear Li mi t....................................................................................... 0.070 mm (0.0028 i n.)
Connecti ng Rod-to-Crankpi n Si de Cl earance............................................. 0.30/0.59 mm (0.0118/0.0232 i n.)
Connecti ng Rod-to-Pi ston Pi n Runni ng Cl earance.................................... 0.015/0.028 mm (0.0006/0.0011 i n.)
IislonIinIndIDI
New............................................................................................................ 19.015/19.023 mm (0.7486/0.7489 i n.)
Max. Wear Li mi t....................................................................................... 19.036 mm (0.7494 i n.)
Crankcase
GovernorCrossShaoreID
New............................................................................................................ 8.025/8.050 mm (0.3159/0.3169 i n.)
Max. Wear Li mi t....................................................................................... 8.088 mm (0.3184 i n.)
Breather Cover Fastener Torque................................................................... 5.7 Nm (51 i n. l b.)
Oi l Drai n Pl ug Torque.................................................................................... NmIb
Oil Pan
Oi l Pan Fastener Torque................................................................................. 24.4 Nm (216 i n. l b.)
Crankshaft
End Pl ay (Free) ................................................................................................ 0.30/1.50 mm (0.011/0.059 i n.)
CrankshaoreInCrankcase
New, Wi thout Mai n Beari ng................................................................... 50.00/50.025 mm (1.9685/1.969 i n.)
WilhMainearingInslaIIed .................................................................. 45.040/45.145 mm (1.7732/1.7773 i n.)
Max. Wear Li mi t....................................................................................... 45.158 mm (1.7778 i n.)
CrankshaloSIeeveearingCrankcase
Runni ng Cl earance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 i n.)
CrankshaoreInOiIIanNevvilhoulearing............................... 50.025/50.00 mm (1.9694/1.9685 i n.)
1.9
Section 1
Safety and General Information
1
CrankshaloSIeeveearingInOiIIan
Runni ng Cl earance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 i n.)
Flywheel End Main Bearing Journal
O.D. - New ................................................................................................ 44.978/45.00 mm (1.770/1.771 i n.)
O.D. - Max. Wear Li mi t ........................................................................... 44.90 mm (1.767 i n.)
Max. Taper ................................................................................................ 0.022 mm (0.0009 i n.)
Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 i n.)
Closure Plate End Main Bearing Journal
O.D. - New ................................................................................................ 44.978/45.00 mm (1.770/1.771 i n.)
O.D. - Max. Wear Li mi t ........................................................................... 44.90 mm (1.767 i n.)
Max. Taper ................................................................................................ 0.022 mm (0.0009 i n.)
Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 i n.)
Connecting Rod Journal
O.D. - New ................................................................................................ 43.982/44.000 mm (1.731/1.732 i n.)
O.D. - Max. Wear Li mi t ........................................................................... 43.97 mm (1.731 i n.)
Max. Taper ................................................................................................ 0.018 mm (0.0007 i n.)
Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 i n.)
Wi dth ......................................................................................................... 53.00/53.09 mm (2.0866/2.0901 i n.)
Crankshaft T.I.R.
PTO End, Crank i n Engi ne..................................................................... 0.279 mm (0.0110 i n.)
Enti re Crank, i n V-Bl ocks........................................................................ 0.10 mm (0.0039 i n.)
Cylinder Bore
CyIinderoreID
New............................................................................................................ 90.000/90.025 mm (3.543/3.544 i n.)
Max. Wear Li mi t ...................................................................................... 90.075 mm (3.546 i n.)
Max. Out-of-Round ................................................................................. 0.013 mm (0.00051 i n.)
Max. Taper ................................................................................................ 0.013 mm (0.00051 i n.)
Main Bearing I.D. (Crankcase/Oil Pan)
NevInslaIIed......................................................................................... 45.040/45.145 mm (1.773.1.777 i n.)
Max. Wear Li mi t....................................................................................... 45.158 mm
Cylinder Head
Cyl i nder Head Fastener Torque
Head Bol t - Torque i n Two Stages......................................................... rslloNminIb
naIIyloNminIb
Max. Out-of-Fl atness...................................................................................... 0.076 mm (0.003 i n.)
Pi pe Pl ug, 3/4" Torque.................................................................................... 28.25 Nm (250 i n. l b.)
Rocker Arm Stud (AVT) Torque.................................................................... 11.3 Nm (100 i n. l b.)
Setscrew, AVT pi vot l ocki ng.......................................................................... 7.3 Nm (65 i n. l b.)
Fan/Flywheel
Fan Fastener Torque........................................................................................ 9.9 Nm (88 i n. l b.)
Fl ywheel Retai ni ng Screw Torque................................................................ NmIb
1.10
Section 1
Safety and General Information
Grass Screen
Hex Stud Torque............................................................................................ 9.9 Nm (88 i n. l b.)
Mounti ng Screw Torque................................................................................. 9.9 Nm (88 i n. l b.)
Governor
GovernorCrossShaloCrankcaseRunningCIearance.......................... 0.025/0.087 mm (0.0009/0.0034 i n.)
Governor Cross Shaft O.D.
New............................................................................................................ 7.963/8.000 mm (0.3135/.3149 i n.)
Max. Wear Li mi t....................................................................................... 7.936 mm (0.3124 i n.)
GovernorGearShaloGovernorGearRunningCIearance ................... 0.070/0.160 mm (0.0027/0.0063 i n.)
GovernorGearShaOD
New............................................................................................................ 5.990/6.000 mm (0.2358/0.2362 i n.)
Max. Wear Li mi t....................................................................................... 5.977 mm (0.2353 i n.)
Governor Lever Nut Torque.......................................................................... 7.3 Nm (65 i n. l b.)
Ignition
Spark Pl ug Type (Champi on

or Equi val ent) ............................................. XC10YC

Spark Pl ug Gap................................................................................................ 0.76 mm (0.030 i n.)
Spark Pl ug Torque........................................................................................... NmIb
IgnilionModuIeAirGa ............................................................................... 0.28/0.33 mm (0.011/0.013 i n.)
IgnilionModuIeIaslenerTorque ................................................................. 6.2 Nm (55 i n. l b.) i nto new hol es, or
4.0 Nm (35 i n. l b.) i nto used hol es
Lifter Feed Chamber
CoveraeScrevTorque ............................................................................ 6.2 Nm (55 i n. l b.)
Mufer
MuerRelainingNulTorque....................................................................... 24.4 Nm (216 i n. l b.)
ScrevinlermienlbrackelinloveIdnul................................................. 13.5 Nm (120 i n. l b.)
Oil Cooler
Mounti ng Screws Torque............................................................................... 3.9 Nm (35 i n. l b.)
Oil Filter
Oi l Fi l ter Torque.............................................................................................. lurnaergaskelconlacl
Oil Filter Adapter/Housing
Mounti ng Screw Torque................................................................................. 24.4 Nm (216 i n. l b.)
Piston, Piston Rings, and Piston Pin
Pi ston-to-Pi ston Pi n Runni ng Cl earance..................................................... 0.006/0.018 mm (0.0002/0.0007 i n.)
IislonIinoreID
New............................................................................................................ 19.006/17.013 mm (0.7482/0.7485 i n.)
Max. Wear Li mi t....................................................................................... 19.025 mm (0.7490 i n.)
Pi ston Pi n O.D.
New............................................................................................................ 18.995/19.000 mm (0.7478/0.7480 i n.)
Max. Wear Li mi t....................................................................................... 18.994 mm (0.7478 i n.)
1.11
Section 1
Safety and General Information
1
MeasuremminabovelheboomoflheislonskirlalrighlangIeslolheislonin
Top Compressi on Ri ng-to-Groove Si de Cl earance.................................... 0.04/0.08 mm (0.0015/0.0031 i n.)
Mi ddl e Compressi on Ri ng-to-Groove Si de Cl earance.............................. 0.04/0.08 mm (0.0015/0.0031 i n.)
Oi l Control Ri ng-to-Groove Si de Cl earance................................................ 0.03/0.19 mm (0.0011/0.0074 i n.)
Top and Center Compressi on Ri ng End Gap
New Bore .................................................................................................. 0.30/0.55 mm (0.011/0.021 i n.)
Used Bore (Max.)...................................................................................... 0.94 mm (0.037 i n.)
Pi ston Thrust Face O.D.
New ........................................................................................................... 89.953/89.967 mm (3.5414/3.5420 i n.)
Max. Wear Li mi t ..................................................................................... 89.925 mm (3.540 i n.)
Pi ston Thrust Face-to-Cyl i nder Bore Runni ng Cl earance
New............................................................................................................ 0.033/0.72 mm (0.0013/0.0028 i n.)
Starter Assembly
Thru Bol t Torque
DeIcoRemySoIenoidShi .................................................................. 5.6-9.0 Nm (49-79 i n. l b.)
Mounti ng Screw Torque................................................................................. 15.3 Nm (135 i n. l b.)
Brush Hol der Mounti ng Screw Torque
Del co-Remy Starter .................................................................................. 2.5-3.3 Nm (22-29 i n. l b.)
Solenoid (Starter)
Mounti ng Hardware Torque
Del co-Remy Starter .................................................................................. 4.0-6.0 Nm (35-53 i n. l b.)
Nut, Posi ti ve (+) Brush Lead Torque
Del co-Remy Starter .................................................................................. 8.0-11.0 Nm (71-97 i n. l b.)
Stator
Mounti ng Screw Torque................................................................................. 6.2 Nm (55 i n. l b.)
Throttle/Choke Control Bracket
Fastener Torque............................................................................................... 9.9 Nm (88 i n. l b.)
Valve Cover
Val ve Cover Fastener Torque......................................................................... 7.9 Nm (70 i n. l b.)
Valves and Valve Lifters
HydrauIicVaIveLierloCrankcaseRunningCIearance......................... 0.012/0.050 mm (0.0004/0.0019 i n.)
InlakeVaIveSlemloVaIveGuideRunningCIearance............................. 0.038/0.076 mm (0.0015/0.0030 i n.)
Exhaust Val ve Stem-to-Val ve Gui de Runni ng Cl earance.......................... 0.050/0.088 mm (0.0020/0.0035 i n.)
InlakeVaIveGuideID
New............................................................................................................ 7.038/7.058 mm (0.2771/0.2779 i n.)
Max. Wear Li mi t....................................................................................... 7.135 mm (0.2809 i n.)
IxhauslVaIveGuideID
New............................................................................................................ 7.038/7.058 mm (0.2771/0.2779 i n.)
Max. Wear Li mi t....................................................................................... 7.159 mm (0.2819 i n.)
1.12
Section 1
Safety and General Information
Tightening Torque: Nm (in. lb.) + or - 10%
Property Class Noncritical
Fasteners
Into Aluminum
Si ze
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: Nm (ft. lb.) + or - 10%
Property Class
Noncritical
Fasteners
Into Aluminum
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 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
5.8 8.8 10.9 12.9
4.8
5.8
10.9
12.9
4.8
8.8
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications
Val ve Gui de Reamer Si ze
Standard .................................................................................................... 7.048 mm (0.2775 i n.)
0.25 mm O.S. ............................................................................................. 7.298 mm (0.2873 i n.)
Nomi nal Val ve Face Angl e............................................................................ 45
1.13
Section 1
Safety and General Information
1
English Fastener Torque Recommendations for Standard Applications
Grade 2 or 5
Fasteners Into
Aluminum
Si ze
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) --------- --------- ---------
Si ze
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) 142.4 (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) ---------
5/8-11 149.2 (110) 244.1 (180) 352.6 (260) ---------
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) ---------
3/4-10 199.3 (150) 332.2 (245) 474.6 (350) ---------
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) ---------
Tightening Torque: Nm (ft. lb.) + or - 20%
Tightening Torque: Nm (in. lb.) + or - 20%
Grade 2 Grade 5 Grade 8
Bolts, Screws, Nuts and Fasteners
Assembled Into Cast Iron or Steel
Nm = i n. l b. x 0.113
NmIbx
i n. l b. = Nm x 8.85
IbNmx
Torque
Conversions
1.14
2.1
Section 2
Tools & Aids
2
Section 2
Tools & Aids
Tools
Description Source/Part No.
CamshaEndp!ayP!atc
IorcheckingcamshaendIay
SITooIsKLR
Camsha5ca!PrntcctnrAcgis
ToroleclseaIduringcamshainslaIIalion
SITooIsKLR
Cy!indcrLcakdnwnTcstcr
IorcheckingcombuslionrelenlionandifcyIinderislonringsorvaIvesarevorn
KohIerS
E!cctrnnicFuc!In|cctinnEFIDiagnnstic5nwarc
UsevilhLaloorDeskloIC
KohIerS
EFI5crviccKit
IorlroubIeshoolingandseinguanIIIengine
KohIerS
IndividuaIComonenlsAvaiIabIe
IressureTesler
NoidLighl
Adaler
OelikerCIamIIiers
CodeIIugRedWire
CodeIIugIueWire
DesignTechnoIogyInc
DTI
DTI
DTI
DTI
DTI
DTI
F!ywhcc!Hn!dingTnn!C55crics SITooIsKLR
F!ywhcc!Pu!!cr
ToremoveyvheeIfromengine
SITooIsKLR
F!ywhcc!5trapWrcnch
TohoIdyvheeIduringremovaI
SITooIsKLR
CerlainquaIilylooIsaredesignedloheIyouerformsecicdisassembIyreairandreassembIyrocedures
yusinglooIsdesignedforlhe|obyoucanroerIyserviceengineseasierfaslerandsaferInaddilionyouII
increaseyourservicecaabiIiliesandcuslomersalisfaclionbydecreasingenginedovnlime
HereislheIisloflooIsandlheirsource
Separate Tool Suppliers:
KohIerTooIs
Conlaclyoursource
ofsuIy
SITooIs
HovardSl
LaeerMI
Ihone
ToIIIree
Iax
DesignTechnoIogyInc
urrOakDrive
WeslmonlIL
Ihone
2.2
Section 2
Tools & Aids
Tools (Continued)
Description Source/Part No.
Hydrau!icVa!vcLicrTnn!
ToremoveandinslaIIhydrauIicIiers
KohIerS
Ignitinn5ystcmTcstcr
IorleslingoululonaIIsyslemsexcelCD
IorleslingoululoncaacilivedischargeCDignilionsyslem
KohIerS
KohIerS
OsctWrcnchKM5crics
ToremoveandreinslaIIcyIinderbarreIrelainingnuls
SITooIsKLR
Oi!PrcssurcTcstKit
ToleslandverifyoiIressure
KohIerS
RccticrRcgu!atnrTcstcrvn!tcurrcnt
RccticrRcgu!atnrTcstcrvn!tcurrcnt
UsedloleslreclierreguIalors
KohIerS
KohIerS
IndividuaIComonenlsAvaiIabIe
CSIROReguIalorTeslHarness
SeciaIReguIalorTeslHarnessvilhDiode
DesignTechnoIogyInc
DTI
DTI
5parkAdvanccMndu!c5AMTcstcr
TolesllheSAMASAMandDSAMonenginesvilhSMARTSIARK
KohIerS
5tartcrRctainingRingTnn!IncrtiaDrivc
ToremoveandreinslaIIdriverelainingringsexcIudingIASCOslarlers
KohIerS
5tartcr5crvicingKitA!!5tartcrs
To remove and reinstall drive retaining rings and brushes.
SE Tools KLR-82411
Individual Component Available
Starter Brush Holding Tool (Solenoid Shift)
SE Tools KLR-82416
Tachometer (Digital Inductive)
For checking operating speed (RPM) of an engine.
Design Technology Inc.
DTI-110
Vacuum/Pressure Tester
Alternative to a water manometer.
Kohler 25 761 22-S
2.3
Section 2
Tools & Aids
2
Aids
Description Source/Part No.
CamshaLubricantVaIsarZZ KohIerS
Dic!cctricGrcascGINovaguardG KohIerS
Dic!cctricGrcascIeIIro LubriSeI
E!cctric5tartcrDrivcLubricantInerliaDrive KohIerS
E!cctric5tartcrDrivcLubricantSoIenoidShi KohIerS
RTV5i!icnnc5ca!ant
Loclile

HeavyodyinozaerosoIdisenser
OnIyoximebasedoiIresislanlRTVseaIanlssuchaslhoseIisledarearovedfor
useLoclileNosorarerecommendedforbeslseaIingcharaclerislics
Loclile

Loclile

UIlraIack
Loclile

UIlraIue
Loclile

UIlraCoer
KohIerS
5p!incDrivcLubricant KohIerS
2.4
Section 2
Tools & Aids
Special Tools You Can Make
Flywheel Holding Tool
AyvheeIhoIdinglooIcanbemadeoulofanoId
|unkyvheeIringgearasshovninIigureand
usedinIaceofaslravrench
UsinganabrasiveculovheeIculoulasix
loolhsegmenloflheringgearasshovn
Grindoanyburrsorsharedges
InverllhesegmenlandIaceilbelveenlhe
ignilionbossesonlhecrankcasesolhallhelooI
bossesviIIIocklhelooIandyvheeIinosilion
forIooseninglighleningorremovingvilha
uIIer
Figure 2-1. Flywheel Holding Tool.
Rocker Arm/Crankshaft Tool
AsannervrenchloIilherockerarmsorlurnlhe
crankshamaybemadeoulofanoId|unkconnecling
rod
IindausedconneclingrodfromaHIor
IargerengineRemoveanddiscardlherodca
RemovelhesludsofaIosiLockrodorgrindo
lheaIigningslesofaCommandrodsolhe|oinl
surfaceisal
IindainIongcascrevvilhlhecorrecllhread
sizelomalchlhelhreadsinlheconneclingrod
UseaalvashervilhlhecorreclIDlosIion
lhecascrevandaroximaleIyODKohIer
IarlNo5AssembIelhecascrev
andvasherlolhe|oinlsurfaceoflherodas
shovninIigure
Figure 2-2. Rocker Arm/Crankshaft Tool.
3.1
3
Section 3
Troubleshooting
Troubleshooting Guide
When troubl es occur, be sure to check the si mpl e
causesvhichalrslmayseemlooobviouslobe
consi dered. For exampl e, a starti ng probl em coul d be
causedbyanemlyfueIlank
SomegeneraIcommoncausesofenginelroubIesare
IisledbeIovUselheseloIocalelhecausingfaclors
Referlolhesecicseclionsvilhinlhisservice
manuaIformoredelaiIedinformalion
Engine Cranks But Will Not Start
ImlyfueIlank
IueIshulovaIvecIosed
IoorfueIdirlorvalerinlhefueIsyslem
CIoggedfueIIine
SarkIugIeadsdisconnecled
KiIIsvilchinoosilion
IauIlysarkIugs
IauIlyignilionmoduIes
CarburelorsoIenoidmaIfunclion
VacuumfueIummaIfunclionoroiIinvacuum
hose.
VacuumhoselofueIumIeakingcracked
aeryconnecledbackvards
SafelyinlerIocksyslemengaged
Engine Starts But Does Not Keep Running
ReslricledfueIlankcavenl
IoorfueIdirlorvalerinlhefueIsyslem
IauIlyormisad|usledchokeorlhroIeconlroIs
4. Loose wi res or connecti ons that short the ki l l
lerminaIofignilionmoduIeloground
IauIlycyIinderheadgaskel
IauIlycarburelor
VacuumfueIummaIfunclionoroiIinvacuum
hose.
LeakingcrackedvacuumhoselofueIum
InlakesyslemIeak
Engine Starts Hard
ITOdriveisengaged
DirlorvalerinlhefueIsyslem
CIoggedfueIIine
LooseorfauIlyviresorconneclions
IauIlyormisad|usledchokeorlhroIeconlroIs
IauIlysarkIugs
7. Low compressi on.
8. Weak spark.
IueIummaIfunclioncausingIackoffueI
IngineoverhealedcooIingaircircuIalion
restri cted.
QuaIilyoffueI
IIyvheeIkeysheared
InlakesyslemIeak
Engine Will Not Crank
ITOdriveisengaged
aeryisdischarged
SafelyinlerIocksvilchisengaged
LooseorfauIlyviresorconneclions
IauIlykeysvilchorignilionsvilch
IauIlyeIeclricslarlerorsoIenoid
7. Sei zed i nternal engi ne components.
Engine Runs But Misses
DirlorvalerinlhefueIsyslem
2. Spark pl ug l ead di sconnected.
IoorquaIilyoffueI
IauIlysarkIugs
LooseviresorconneclionslhalinlermienlIy
ground the i gni ti on ki l l ci rcui t.
Ingineoverhealed
IauIlyignilionmoduIeorincorreclairga
Carburelorad|usledincorreclIy
Engine Will Not Idle
DirlorvalerinlhefueIsyslem
SlaIefueIandorgumincarburelor
IauIlysarkIugs
IueIsuIyinadequale
IdIefueIad|uslingneedIesimroerIysel
IdIeseedad|uslingscrevimroerIysel
7. Low compressi on.
ReslricledfueIlankcavenl
IngineoverhealedcooIingsyslemaircircuIalion
probl em.
3.2
Section 3
Troubleshooting
Engine Overheats
AirinlakegrassscreencooIingnsorcooIing
shrouds cl ogged.
IxcessiveengineIoad
LovcrankcaseoiIIeveI
HighcrankcaseoiIIeveI
IauIlycarburelor
LeanfueImixlure
Engine Knocks
IxcessiveengineIoad
LovcrankcaseoiIIeveI
OIdorimroerfueI
4. Internal wear or damage.
HydrauIicIiermaIfunclion
QuaIilyoffueI
IncorreclgradeofoiI
Engine Loses Power
LovcrankcaseoiIIeveI
HighcrankcaseoiIIeveI
DirlyaircIeanereIemenl
DirlorvalerinlhefueIsyslem
IxcessiveengineIoad
Ingineoverhealed
IauIlysarkIugs
8. Low compressi on.
9. Exhaust restri cti on.
Lovbaery
Incorreclgovernorseing
Engine Uses Excessive Amount of Oil
IncorrecloiIviscosilylye
CIoggedbrokenorinoeralivecrankcase
breather.
3. Worn or broken pi ston ri ngs.
WorncyIinderbore
WornvaIveslemsvaIveguides
CrankcaseoverIIed
Iovnheadgaskeloverhealed
Oil Leaks from Oil Seals, Gaskets
CIoggedbrokenorinoeralivecrankcase
breather.
LooseorimroerIylorquedfasleners
IislonbIovbyorIeakyvaIves
4. Restri cted exhaust.
External Engine Inspection
eforecIeaningordisassembIinglheenginemakea
lhoroughinseclionofilsexlernaIaearanceand
condilionThisinseclioncangivecIueslovhal
mighlbefoundinsidelheengineandlhecause
when i t i s di sassembl ed.
CheckforbuiIduofdirlanddebrisonlhe
crankcasecooIingnsgrassscreenandolher
exlernaIsurfacesDirlordebrisonlheseareas
arecausesofhigheroeralinglemeraluresand
overhealing
CheckforobviousfueIandoiIIeaksand
damagedcomonenlsIxcessiveoiIIeakage
canindicaleacIoggedorimroerIyassembIed
brealhervorndamagedseaIsandgaskelsor
IooseorimroerIylorquedfasleners
ChecklheaircIeanercoverandbasefordamage
orindicalionsofimroerlandseaI
ChecklheaircIeanereIemenlLookforhoIes
learscrackedordamagedseaIingsurfacesor
olherdamagelhalcouIdaIIovunIleredairinlo
lheengineAIsonoleiflheeIemenlisdirlyor
cl ogged. These coul d i ndi cate that the engi ne has
beenunderserviced
ChecklhecarburelorlhroalfordirlDirlinlhe
lhroalisfurlherindicalionlhallheaircIeaneris
nolfunclioningroerIy
ChecklheoiIIeveINoleiflheoiIIeveIisvilhin
lheoeralingrangeonlhedislickorifilisIov
oroverIIed
ChecklhecondilionoflheoiIDrainlheoiIinlo
aconlainerlheoiIshouIdovfreeIyCheckfor
melaIchisandolherforeignarlicIes
SIudgeisanaluraIbyroduclofcombusliona
smaIIaccumuIalionisnormaIIxcessivesIudge
formalioncouIdindicaleoverrichcarburelion
veakignilionoverexlendedoiIchangeinlervaIs
orvrongveighlorlyeofoiIvasusedloname
afev
NOTI IlisgoodraclicelodrainoiIala
Iocalionavayfromlhevorkbenche
sureloaIIovamIelimeforcomIele
drai nage.
Cleaning the Engine
AerinseclinglheexlernaIcondilionoflheengine
cIeanlheenginelhoroughIybeforedisassembIing
ilAIsocIeanindividuaIcomonenlsaslheengine
isdisassembIedOnIycIeanarlscanbeaccuraleIy
insecledandgaugedforvearordamageThere
aremanycommerciaIIyavaiIabIecIeanerslhal
viIIquickIyremovegreaseoiIandgrimefrom
engi ne parts. When such a cl eaner i s used, fol l ow
t he manufact ur er s i nst r uct i ons and safet y pr ecaut i ons
car eful l y.
3.3
Section 3
Troubleshooting
3
MakesureaIIlracesoflhecIeanerareremovedbefore
the engi ne i s reassembl ed and pl aced i nto operati on.
IvensmaIIamounlsoflhesecIeanerscanquickIy
breakdovnlheIubricalingroerliesofengineoiI
Basic Engine Tests
Crankcase Vacuum Test
AarliaIvacuumshouIdberesenlinlhe
crankcase when the engi ne i s operati ng. Pressure
inlhecrankcasenormaIIycausedbyacIoggedor
imroerIyassembIedbrealhercancauseoiIlobe
forcedoulaloiIseaIsgaskelsorolheravaiIabIesols
Crankcasevacuumisbeslmeasuredvilheilhera
valermanomeleroravacuumgaugeseeSeclion
ComIeleinslruclionsarerovidedinlhekils
Tolesllhecrankcasevacuumvilhlhemanomeler
InserllhesloerhoseinlolheoiIIIhoIeLeave
lheolherlubeofmanomeleroenloalmoshere
MakesurelheshulocIamiscIosed
2. Start the engi ne and run at no-l oad hi gh speed
loRIM
OenlhecIamandnolelhevalerIeveIinlhe
tube.
TheIeveIinlheenginesideshouIdbeaminimum
of10.2 cm (4 i n.) abovelheIeveIinlheoenside
IflheIeveIinlheenginesideisIesslhansecied
IovnovacuumorlheIeveIinlheengineside
isIoverlhanlheIeveIinlheoensideressure
checkforlhecondilionsinlhelabIebeIov
CIoselheshulocIambef ore stoppi ng the
engi ne.
TolesllhecrankcasevacuumvilhlheVacuum
IressureGaugeKilseeSeclion
RemovelhedislickoroiIIIIugca
InslaIIlheadalerinlolheoiIIIdislicklube
openi ng.
IushlhebarbedingonlhegaugesoIidIyinlo
the hol e i n the adapter.
4. Start the engi ne and bri ng i t up to operati ng
seedRIM
ChecklhereadingonlhegaugeIflhereading
i s to the ofonlhegaugevacuumor
negaliveressureisindicaledIflhereadingislo
the ri ghtofonlhegaugeosiliveressureis
present.
CrankcasevacuumshouIdbeamimimumof
inchesofvalerIflhereadingisbeIovlhe
secicalionorifressureisresenlchecklhe
labIebeIovforossibIecausesandremedies
No Crankcase Vacuum/Pressure in Crankcase
Possible Cause Solution
CrankcasebrealhercIoggedorinoeralive DisassembIebrealhercIeanarlslhoroughIyreassembIe
and recheck pressure
SeaIsandorgaskelsIeakingLooseor
imroerIylorquedfasleners
Repl ace al l worn or damaged seal s and gaskets. Make sure
aIIfaslenersarelighlenedsecureIyUsearorialelorque
vaIuesandsequencesvhennecessary
IislonbIovbyorIeakyvaIvesconrmby
inseclingcomonenls
RecondilionislonringscyIinderborevaIvesandvaIve
gui des.
Restri cted exhaust. ReairreIacereslricledmuerexhauslsyslem
3.4
Section 3
Troubleshooting
Leakdown Test Results
Airescaingfromcrankcasebrealher .......................................................RingsorcyIindervorn
Airescaingfromexhauslsyslem.............................................................DefecliveexhauslvaIveimroersealing
Airescaingfromcarburelor......................................................................DefecliveinlakevaIveimroersealing
GaugereadinginIovgreenzone........................................................IislonringsandcyIinderingood
condi ti on.
GaugereadinginmoderaleyeIIovzone............................................Engi ne i s sti l l usabl e, but there i s some
wear present. Customer shoul d start
IanningforoverhauIorreIacemenl
Gaugereadinginhighredzone...........................................................RingsandorcyIinderhaveconsiderabIe
wear. Engi ne shoul d be recondi ti oned or
repl aced.
IflheyvheeIendismoreaccessibIeusea
breakerbarandsockelonlheyvheeInulscrev
lohoIdilinosilionAnassislanlmaybeneeded
lohoIdlhebreakerbarduringleslingIflhe
engineismounledinaieceofequimenlilmay
beossibIelohoIdilbycIamingorvedginga
drivencomonenl}uslbecerlainlhallheengine
cannolrolaleoofTDCineilherdireclion
4. Instal l the adapter i nto the spark pl ug hol e, but
donolaachillolheleslerallhislime
ConneclanairsourceofalIeaslsilolhe
tester.
6. Turn the regul ator knob i n the i ncrease di recti on
cIockviseunliIlhegaugeneedIeisinlheyeIIov
selareaallheIovendoflhescaIe
7. Connect the tester qui ck-di sconnect to the adapter
hosevhiIermIyhoIdinglheenginealTDC
NolelhegaugereadingandIislenforescaing
ai r at the carburetor i ntake, exhaust outl et, and
crankcase breather.
ChecklheleslresuIlsagainsllhefoIIovinglabIe
Compression Test
Acomressionleslisbeslerformedonavarm
engineCIeananydirlordebrisavayfromlhebase
oflhesarkIugsbeforeremovinglhemesure
lhechokeisoandlhelhroIeisvideoenduring
the test. Compressi on shoul d be at l east 160 psi and
shouIdnolvarymorelhanbelveencyIinders
Cylinder Leakdown Test
AcyIinderIeakdovnleslcanbeavaIuabIeaIlernalive
loacomressionleslyressurizinglhecombuslion
chamberfromanexlernaIairsourceyoucan
delermineiflhevaIvesorringsareIeakingandhov
badIy
TheCyIinderLeakdovnTeslerisareIaliveIysimIe
inexensiveIeakdovnleslerforsmaIIenginesThe
leslerincIudesaquickdisconneclforaachinglhe
adapter hose, and a hol di ng tool .
Leakdown Test Instructions
Runlheengineforminuleslovarmilu
RemovelhesarkIugsandlheairIlerfrom
engi ne.
RolalelhecrankshaunliIlheislonof
cyIinderbeinglesledisallodeadcenlerof
the compressi on stroke. Hol d the engi ne i n thi s
posi ti on whi l e testi ng. The hol di ng tool suppl i ed
vilhlheleslercanbeusediflheITOendof
lhecrankshaisaccessibIeLocklhehoIding
looIonlolhecrankshaInslaIIabreaker
barinlolhehoIesIoloflhehoIdinglooIsoil
i s perpendi cul ar to both the hol di ng tool and
crankshaITO
4.1
4
Section 4
Air Cleaner and Air Intake System
Paper Element
Inner
Element
Inlet Screen
Air Cleaners
General
These engi nes uti l i ze a Heavy-Duty styl e ai r cl eaner
as shown i n Fi gure 4-1, consi sti ng of a cyl i ndri cal
housingaachedlolhecarburelorandinlake
mani fol d. The ai r cl eaner housi ng contai ns a paper
el ement and i nner el ement, desi gned for l onger
serviceinlervaIsThesyslemisCARIIAcerlied
andlhecomonenlsshouIdnolbeaIleredormodied
i n any way.
Heavy-Duty Style Air Cleaner
Figure 4-1. Heavy-Duty Style Air Cleaner.
Service
Weekl y and every 150 hours: CheckIlerminderif
equiedunhooklhelvorelainingcIisoneachend
and remove the end caps. Perform i nspecti on of the
paper el ement and i nl et screen area.
Seasonal l y or every 300 hours ofoeralionmore
oenunderexlremeIyduslyordirlycondilions
reIacelheaereIemenlandchecklheinner
el ement. Fol l ow these steps.
UnhooklhelvorelainingcIisoneachend
and remove the end caps from the ai r cl eaner
housi ng.
CheckandcIeanlhescreenareaonlheinIelside
Pul l the ai r cl eaner el ement out of the housi ng on
opposi te si de. See Fi gures 4-2 and 4-3.
Figure 4-2. Accessing Inlet Screen.
Figure 4-3. Removing Elements.
AerlheaereIemenlisremovedchecklhe
condilionoflheinnereIemenlIlshouIdbe
repl aced whenever i t appears di rty, typi cal l y
every other ti me the paper el ement i s repl aced or
every 600 hoursCIeanlheareaaroundlhebase
oflheinnereIemenlbeforeremovingilsodirl
does not get i nto the engi ne.
4.2
Section 4
Air Cleaner and Air Intake System
Ejector
Area
Cylinder
Shroud
4. Do not wash the paper el ement and i nner
el ement or use compressed ai r, thi s wi l l damage
lheeIemenlsReIacedirlybenlordamaged
el ements wi th new genui ne Kohl er el ements as
requi red. Handl e the new el ements careful l y;
donoluseiflheseaIingsurfacesarebenlor
damaged.
CheckaIIarlsforvearcracksordamageand
that ejector area i s cl ean. See Fi gure 4-4. Repl ace
any damaged components.
Figure 4-4. Ejector Area.
InslaIIlhenevinnereIemenlfoIIovedbylhe
paper el ement. Sl i de each ful l y i nto pl ace i n the
ai r cl eaner housi ng.
7. Rei nstal l the end caps and secure wi th the
retai ni ng cl i ps. See Fi gure 4-1.
Air Cleaner Components
Whenever the ai r cl eaner cover i s removed, or the
aereIemenlorinnereIemenlareservicedchecklhe
fol l owi ng:
Ai r Cl eaner Housi ng Makesurelhehousingisnol
damagedorbrokenandroerIysecured.
Ai r Cl eaner I nl et - MakesurelheaircIeanerinIelis
securedlighlIylolhecarburelorandnolcrackedor
damaged.
Breather Tube - Makesurelhelubeisaachedlolhe
aircIeanerbaseandlhebrealhercover
NOTE: Damaged, worn or l oose ai r cl eaner
comonenlscanaIIovunIleredairinlolhe
engi ne causi ng premature wear and fai l ure.
Ti ghten or repl ace al l l oose or damaged
components.
Air Intake/Cooling System
ToensureroercooIingmakesurelhegrassscreen
cooIingfannsandexlernaIsurfacesoflheengine
arekelcIeanalaIIlimes
Seasonal l y or every 150 hoursofoeralionmore
oenunderexlremeIyduslyordirlycondilions
removelhecyIindershroudsandbIoverhousing
CIeanlhecooIingnsandexlernaIsurfacesas
necessaryMakesureaIIshroudsarereinslaIIed
Figure 4-5. Removing Shrouds for Cleaning.
5.1
5
Section 5
Fuel System and Governor
Description
Thi s secti on covers the carbureted fuel system used on
these engi nes. The governor system i s covered at the
end of thi s secti on.
WARNING: Explosive Fuel!
Gasc|inciscxircnc|qanna||can!iistapcrscancxp|c!c
ijigniic!Sicrcgasc|inccn|qinapprctc!ccniaincrsin
uc||tcnii|aic!uncccupic!|ui|!ingsauaqjrcnsparkscr
ancsOcnci||incjuc|iankuni|cinccngincisncicr
runningsinccspi||c!juc|ccu|!igniicijiiccncsinccniaci
uiinncipariscrsparksjrcnigniiicnOcncisiariinc
cngincncarspi||c!juc|Nctcruscgasc|incasac|caning
agcni
Fuel System Components
The typi cal carbureted fuel system and rel ated
components i ncl ude the fol l owi ng:
Fuel Tank and Val ve
Fuel Li nes
In-l i ne Fuel Fi l ter
Fuel Pump
Carburetor
Operation
The fuel from the tank i s moved through the i n-l i ne
IlerandfueIIinesbylhefueIumOnenginesnol
equi pped wi th a fuel pump, the fuel tank outl et i s
l ocated above the carburetor i nl et al l owi ng gravi ty to
feed fuel to the carburetor.
IueIlhenenlerslhecarbureloroalbovIandis
drawn i nto the carburetor body. There, the fuel i s
mi xed wi th ai r. Thi s fuel -ai r mi xture i s then burned i n
the engi ne combusti on chamber.
Fuel Recommendations
General Recommendations
Purchase gasol i ne i n smal l quanti ti es that can be used
wi thi n 30 days and store onl y i n cl ean, approved
conlainersDonolusegasoIineIeoverfromlhe
previ ous season, unl ess treated wi th a fuel stabi l i zer
(see Storage i n Secti on 1), to mi ni mi ze gum deposi ts
and ensure easy starti ng. Do not use gasol i ne
contai ni ng Methanol , or add oi l to the gasol i ne.
DonoloverIIlhefueIlankLeaveroomforlhefueI
to expand.
Fuel Type
For best resul ts, use onl y cl ean, fresh, unl eaded
gasol i ne wi th a pump sti cker octane rati ng of 87 or
hi gher. In countri es usi ng the Research fuel rati ng
method, i t shoul d be 90 octane mi ni mum.
Unl eaded gasol i ne i s recommended as i t l eaves
l ess combusti on chamber deposi ts and reduces
harmful exhaust emi ssi ons. Leaded gasol i ne i s not
recommended.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl al cohol , 90% unl eaded
gasol i ne by vol ume) i s approved as a fuel for Kohl er
enginesOlhergasoIineaIcohoIbIendsincIudingI
andIarenollobeusedandnolarovedAny
fai l ures resul ti ng from use of these fuel s wi l l not be
warranted.
Gasoline/Ether blends
MelhyITerliaryulyIIlherMTIandunIeaded
gasoIinebIendsuloamaximumofMTIby
vol ume) are approved as a fuel for Kohl er engi nes.
OlhergasoIineelherbIendsarenolaroved
Fuel Filter
Most engi nes are equi pped wi th an i n-l i ne fuel
IlerIeriodicaIIyinsecllheIlerandreIacevilh
agenuineKohIerIlerseasonal l y or every 150
operati ng hours.
Fuel Line
TheseenginesuseLovIermealionSAIRraled
fueIIinecerliedlomeelemissionrequiremenls
SlandardfueIIinemaynolbeusedOrder
repl acement hose by part number through a Kohl er
IngineServiceDeaIer
5.2
Section 5
Fuel System and Governor
Fuel System Tests
When the engi ne starts hard, or turns over but wi l l not start, i t i s possi bl e that the probl em i s i n the fuel system.
TondouliflhefueIsyslemiscausinglherobIemerformlhefoIIovinglesl
Troubleshooting Fuel System Related Causes
Test Conclusion
1. Check the fol l owi ng:
a. Make sure the fuel tank contai ns cl ean, fresh,
proper fuel .
b. Make sure the vent i n fuel tank cap i s open.
c. Make sure the fuel val ve i s open.
d. Make sure the fuel l i nes to fuel pump are
secured and i n good condi ti on.
CheckforfueIinlhecombuslionchamber
a. Di sconnect and ground spark pl ug l eads.
b. Cl ose the choke on the carburetor.
c. Crank the engi ne several ti mes.
d. Remove the spark pl ug and check for fuel at
the ti p.
Iflherei s fuel at the ti p of the spark pl ug, fuel i s
reachi ng the combusti on chamber.
If there i s no fuel at the ti p of the spark pl ug,
checkforfueIovfromlhefueIlankTesl
CheckforfueIovfromlhelanklolhefueIum
a RemovelhefueIIinefromlheinIelingof
the fuel pump.
b HoIdlheIinebeIovlheboomoflhelank
OenlheshulovaIveifsoequiedand
observeov
3. If fuel doesovfromlheIinecheckforfauIly
fuel pump (Test 4).
If fuel does notovfromlheIinechecklhefueI
lankcavenlfueIickuscreeninIineIler
shulovaIveandfueIIineCorreclanyobserved
probl em and reconnect the l i ne.
4. Check the operati on of the fuel pump.
a RemovelhefueIIinefromlheinIelingof
the carburetor.
b. Crank the engi ne several ti mes and observe
ov
4. If fuel doesovfromlheIinecheckforfauIly
carburetor. (Refer to the "Carburetor" porti ons of
thi s secti on.)
If fuel does notovfromlheIinecheckfora
cl ogged fuel l i ne. If the fuel l i ne i s unobstructed,
checkforoverIIedcrankcaseandoroiIinuIse
l i ne. If none of the checks reveal the cause of the
probl em, repl ace the pump.
5.3
Section 5
Fuel System and Governor
5
Self-Relieving
Choke
Fuel Shut-Off
Solenoid
Bowl Drain Screw
Slow Jets
Bowl Vent
Low Idle Fuel
Adjustments
(With Limiters)
Fuel Pump
General
These engi nes use ei ther a pul se styl e fuel pump,
or opti onal remote-mounted el ectri c fuel pump
assembIySeeIiguresandTheumingaclion
of pul se styl e pumps i s created by the osci l l ati on of
posi ti ve and negati ve pressures wi thi n the crankcase.
ThisressureislransmiedlolheuIseum
through the rubber hose connected between the
pump and crankcase. The pumpi ng acti on causes the
di aphragm on the i nsi de of the pump to pul l fuel i n on
i ts downward stroke and to push i t i nto the carburetor
on i ts upward stroke. Two check val ves prevent fuel
from goi ng backward through the pump.
Figure 5-1. Pulse Style Fuel Pump.
Figure 5-2. Optional Electric Fuel Pump.
Fuel Pump - Replacement
Replacing the Pulse Style Fuel Pump
Repl acement pumps are avai l abl e through your
source of suppl y. To repl ace the pul se pump fol l ow
these steps. Note ori entati on of pump before
removingSeeIigure
Figure 5-3. Keihin 2-Barrel Carburetor.
WARNING: Explosive Fuel
Gasc|inciscxircnc|qanna||can!iistapcrscancxp|c!c
ijigniic!Sicrcgasc|inccn|qinapprctc!ccniaincrsin
uc||tcnii|aic!uncccupic!|ui|!ingsauaqjrcnsparkscr
ancsOcnci||incjuc|iankuni|cinccngincisncicr
runningsinccspi||c!juc|ccu|!igniicijiiccncsinccniaci
uiinncipariscrsparksjrcnigniiicnOcncisiariinc
cngincncarspi||c!juc|Nctcruscgasc|incasac|caning
agcni
1. Di sconnect the fuel l i nes from the i nl et, outl et
anduIseingsonfueIum
Removelhelvomounlingscrevsandlakeo
the pump.
3. Connect the pul se l i ne to the new fuel pump and
make sure opposi te end i s properl y connected to
oiIIlerhousinging
NOTI Makesurelheorienlalionoflhenev
pump i s consi stent wi th the removed
pump. Internal damage may occur i f
i nstal l ed i ncorrectl y.
AachlhenevfueIumusinglhehexange
screws.Torque the screws to 2.3 Nm (20 i n. l b.).
5. Reconnect the fuel l i nes to the i nl et and outl et
ingsandsecurevilhlhecIams
Carburetor
General
InginesinlhisseriesareequiedvilhaKeihin
KlvobarreIsidedracarburelorvilhxedmain
jets on a matchi ng i ntake mani fol d. The carburetor
features a sel f-rel i evi ng choke, servi ceabl e sl ow
jets, mai n jets and a fuel shutdown sol enoi d. See
Iigure
Pulse
Fuel Pump
5.4
Section 5
Fuel System and Governor
Troubleshooting Checklist
When the engi ne starts hard, runs roughl y or stal l s
at l ow i dl e speed, check the fol l owi ng areas before
adjusti ng or di sassembl i ng the carburetor.
MakesurelhefueIlankisIIedvilhcIeanfresh
gasol i ne.
Make sure the fuel tank cap vent i s not bl ocked
and that i t i s operati ng properl y.
Make sure fuel i s reachi ng the carburetor. Thi s
incIudescheckinglhefueIshulovaIvefueI
lankIlerscreeninIinefueIIlerfueIIinesand
fuel pump for restri cti ons or faul ty components
as necessary.
Make sure the ai r cl eaner base and carburetor are
securel y fastened to the engi ne usi ng gaskets i n
good condi ti on.
Make sure the ai r cl eaner el ement (i ncl udi ng
precl eaner i f equi pped) i s cl ean and al l ai r cl eaner
components are fastened securel y.
Make sure the i gni ti on system, governor system,
exhauslsyslemandlhroIeandchokeconlroIs
are operati ng properl y. If the engi ne i s hard-
starti ng, runs roughl y, or stal l s at l ow i dl e speed,
i t may be necessary to adjust or servi ce the
carburetor.
Troubleshooting Carburetor Related Causes
Condition Possible Cause/Probable Remedy
IngineslarlshardrunsroughIy
or stal l s at i dl e speed.
LovidIefueImixluresomemodeIsseedimroerIy
ad|usledAd|usllheIovidIeseedlablhenad|usllheIovidIe
fuel needl e.
Inginerunsrichindicaledby
bl ack, sooty exhaust smoke,
misringIossofseedandover
governor hunti ng, or excessi ve
lhroIeoening
a CIoggedaircIeanerCIeanorreIace
b ChokearliaIIycIosedduringoeralionChecklhechokeIever
l i nkage to ensure choke i s operati ng properl y.
c LovidIefueImixlureisimroerIyad|usledAd|uslIovidIe
fuel needl e (some model s).
d. Fl oat l evel i s set too hi gh. Separate carburetor ai r horn from
carburelorbodyad|usloalaccordingloIIoalReIacemenl
procedure.
e. Di rt under the fuel i nl et needl e. Remove needl e; cl ean needl e
and seat and bl ow wi th compressed ai r.
f. Bowl vent or ai r bl eeds pl ugged. Remove l ow i dl e fuel adjusti ng
needl e. Cl ean vent, ports, and ai r bl eeds. Bl ow out al l passages
wi th compressed ai r.
g LeakycrackedordamagedoalSubmergeoallocheckfor
l eaks.
InginerunsIeanindicaledby
misringIossofseedandover
governor hunti ng or excessi ve
lhroIeoening
a LovidIefueImixlureisimroerIyad|usledAd|uslIovidIe
fuel needl e (some model s).
b. Fl oat l evel i s set too l ow. Separate carburetor ai r horn from
carburelorbodyad|usloalaccordingloIIoalReIacemenl
procedure.
c. Idl e hol es pl ugged; di rt i n fuel del i very channel s. Remove l ow
i dl e fuel adjusti ng needl e. Cl ean mai n fuel jet and al l passages;
bl ow out wi th compressed ai r.
4. Fuel l eaks from carburetor. a IIoalIeveIselloohighSeeRemedyd
b DirlunderfueIinIelneedIeSeeRemedye
c. Bowl vents pl ugged. Bl ow out wi th compressed ai r.
d. Carburetor bowl gasket l eaks. Repl ace gasket.
5.5
Section 5
Fuel System and Governor
5
Fuel Shut-Off
Solenoid
High Altitude Operation
WhenoeralinglheenginealaIliludesofm
andabovelhefueImixlurelendslogel
over-ri ch. Thi s can cause condi ti ons such as bl ack,
soolyexhauslsmokemisringIossofseedand
power, poor fuel economy, and poor or sl ow governor
response.
TocomensaleforlheeeclsofhighaIliludeseciaI
hi gh al ti tude jet ki ts are avai l abl e. The ki ts i ncl ude
new mai n jets, sl ow jets (where appl i cabl e), necessary
gaskelsandORingsReferlolhearlsmanuaIforlhe
correct ki t number.
Fuel Shut-off Solenoid
MoslcarburelorsareequiedvilhafueIshulo
soIenoidThesoIenoidisaachedlolhefueIbovISee
IigureThesoIenoidhasasringIoadedinlhal
relraclsvhenvoIlsisaIiedlolheIeadaIIoving
fueIovlolhemain|elsWhencurrenlisremoved
lheinexlendsbIockinglhefueIov
Figure 5-4. Fuel Shut-off Solenoid.
eIovisasimIeleslmadevilhlheengineolhal
can determi ne i f the sol enoi d i s functi oni ng properl y:
ShulofueIandremovelhesoIenoidfromlhe
carburetor. When the sol enoi d i s l oosened and
removed, gas wi l l l eak out of the carburetor.
Have a contai ner ready to catch the fuel .
WielhelioflhesoIenoidvilhasholoveIor
bIovilovilhcomressedairloremoveany
remai ni ng fuel . Take the sol enoi d to a l ocati on
wi th good venti l ati on and no fuel vapors present.
YouviIIaIsoneedavoIloversourcelhalcan
besvilchedonando
esurelheoversourceissvilchedo
Connect the posi ti ve power source l ead to the red
l ead of the sol enoi d. Connect the negati ve power
source l ead to the sol enoi d body.
Turnlheoversourceonandobservelhe
pi n i n the center of the sol enoi d. The pi n shoul d
relraclvilhlheoveronandrelurnloils
originaIosilionvilhlheoveroTeslseveraI
ti mes to veri fy operati on.
Carburetor Details
TheKeihinKlvobarreIcarburelorisasidedra
desi gn. The ci rcui ts wi thi n the carburetor functi on as
descri bed fol l owi ng:
Float Circuit:
ThefueIIeveIinlhebovIismainlainedbylheoal
andfueIinIelneedIeThebuoyanlforceoflheoal
slosfueIovvhenlheengineisalreslWhen
fueIisbeingconsumedlheoalviIIdroandfueI
pressure wi l l push the i nl et needl e away from the
seat, al l owi ng more fuel to enter the bowl . When
demandceaseslhebuoyanlforceoflheoalviII
agai n overcome the fuel pressure, ri si ng to the
redelerminedseingandslolheov
Slow & Mid-Range Circuit:
AlIovseedslheengineoeralesonIyonlhesIov
circuilAsameleredamounlofairisdravnlhrough
the sl ow ai r bl eed jets, fuel i s drawn through the two
mai n jets and further metered through the sl ow jets.
AirandfueIaremixedinlhebodyoflhesIov|eland
exi t to the transfer port. From the transfer port the
ai r fuel mi xture i s del i vered to the i dl e progressi on
chamber. From the i dl e progressi on chamber the
ai r fuel mi xture i s metered through the i dl e port
assagesAlIovidIevhenlhevacuumsignaIis
veaklheairfueImixlureisconlroIIedbylheseing
of the i dl e fuel adjusti ng screws. Thi s mi xture i s then
mi xed wi th the mai n body of ai r and del i vered to
lheengineAslhelhroIeIaleoeningincreases
grealeramounlsofairfueImixlurearedravnin
lhroughlhexedandmeleredidIerogressionhoIes
AslhelhroIeIaleoensfurlherlhevacuumsignaI
becomes great enough so the mai n ci rcui t begi ns to
work.
Main (High-Speed) Circuit:
AlhighseedsIoadslheengineoeralesonlhemain
circuilAsameleredamounlofairisdravnlhrough
the four ai r jets, fuel i s drawn through the mai n jets.
The ai r and fuel are mi xed i n the mai n nozzl es and
lhenenlerlhemainbodyofairovvherefurlher
mi xi ng of the fuel and ai r occurs. Thi s mi xture i s then
del i vered to the combusti on chamber. The carburetor
hasaxedmaincircuilnoad|uslmenlisossibIe
5.6
Section 5
Fuel System and Governor
Lean
Rich
Adjust to
Midpoint
Lean
Rich
Adjust to
Midpoint
Left Side Right Side
Carburetor Adjustments
Adjustment
NOTI Carburelorad|uslmenlsshouIdbemadeonIy
aerlheenginehasvarmedu
The carburetor i s desi gned to del i ver the correct
fuel -to-ai r mi xture to the engi ne under al l operati ng
condi ti ons. The mai n fuel jet i s cal i brated at the
factory and i s not adjustabl e*. The i dl e fuel adjusti ng
needl e i s al so set at the factory and normal l y does not
need adjustment.
NOTI InginesoeralingalaIliludesabove
aroximaleIymmay
requi re a speci al hi gh al ti tude mai n
|elReferloHighAIliludeOeralion
l ater i n thi s secti on.
If, however, the engi ne i s hard-starti ng or does not
operate properl y, i t may be necessary to adjust or
servi ce the carburetor.
Low Idle Speed (RPM) Adjustment
1. LnwId!c5pccdRPM5cingIIacelhelhroIe
control i n the i dl eorsl owosilionSellhe
l ow i dl e speed approxi matel y 300 RPM l ess than
lheinlendedorseciedGovernedIdIeSeed
by turni ng the l ow i dl e speed adjusti ng screw
i n or out. Check the speed usi ng a tachometer.
I MPORTANT: The Governed I dl e Speed
Ad|ustmcntmustIn!!nwanyrcscingnIthc
Low I dl e Speed.
NOTI TheacluaIIovidIeseeddeendson
the appl i cati on. Refer to the equi pment
manufacturer s recommendati ons.
The l ow i dl e speed for basi c engi nes i s
1200 RPM. To ensure best resul ts when
seinglheIovidIefueIneedIelheIov
i dl e speed shoul d be 1200 RPM ( 75
RPM).
Figure 5-5. Carburetor Adjustment Locations.
Low Idle Fuel Adjustment
NOTI InginesviIIhavexedIovidIeorIimiler
caps on the two i dl e fuel adjusti ng needl es.
Step 3 can onl y be performed wi thi n the
IimilsaIIovedbylhecaDonolaemllo
remove the l i mi ter caps.
SlarllheengineandrunalhaIflhroIeforlo
mi nutes to warm up. The engi ne must be warm
beforedoingslesand
IIacelhelhroIeconlroIinlolheidIeorsIov
osilionAd|usllheIovidIeseedlo
RIMIoIIovlheAd|uslinglheLovIdIeSeed
RIMrocedure
3. LnwId!cFuc!Nccd!cs5cing Pl ace the
lhroIeinlolheidIeorsIovosilion
a. Turn one of the l ow i dl e fuel adjusti ng
needl es out (countercl ockwi se) from the
reIiminaryseingunliIlheengineseed
decreases (ri ch). Note the posi ti on of the
needl e. Now turn the adjusti ng needl e i n
(cl ockwi se). The engi ne speed may i ncrease,
then i t wi l l decrease as the needl e i s turned
i n (l ean). Note the posi ti on of the needl e. Set
the adjusti ng needl e mi dway between the
richandIeanseingsSeeIigure
b. Repeat the procedure on the other
l ow i dl e adjustment needl e.
Recheckad|usllheLovIdIeSeedRIMlolhe
seciedseing
Figure 5-6. Optimum Low Idle Fuel Settings.
Low Idle
Speed
(RPM)
Adjustment
Screw
Low Idle Fuel
Adjustments
(With Limiters)
Bowl
Vent
5.7
Section 5
Fuel System and Governor
5
Governed Idle System
AgovernedidIeconlroIsyslemisusedlomainlaina
desi red i dl e speed regardl ess of ambi ent condi ti ons
(temperature, parasi ti c l oad, etc.) that may change.
Anoulersecondarysringconnecledbelveenlhe
governor l ever and the governed i dl e adjuster on the
mai n bracket establ i shes the governed i dl e speed. See
Iigure
Figure 5-7. Governor Springs Installed.
Governed Idle Speed Adjustment
1. Make sure the governed i dl e spri ng i s i n the outer
hol e i n the governor l ever and the hol e i n the
governedidIeoulerad|uslerSeeIigure
MakesurelhegovernorsringisinlheinnersIol
of the governor l ever and the hol e i n the hi gh
seedinnerad|uslerSeeIigureIuIIlhe
governor l ever away from carburetor to the l i mi t
of i ts travel and check that the governor spri ng i s
IooseandnolunderanylensionSeeIigure
Turn the hi gh speed (RPM) adjustment screw
counter-cl ockwi se (i f requi red) unti l spri ng i s
IooseSeeIigure
Figure 5-8. Holding Governor Lever and Checking
Spring Looseness.
3. Hol d the governor l ever away from the
carburelorsolhelhroIeIeverisagainsllheidIe
speed (RPM) adjustment screw of the carburetor.
Start the engi ne and al l ow i t to warm up, then
adjust the screw to set approxi matel y 1200 RPM.
Check usi ng a tachometer. Turn the adjustment
screw (i nner) cl ockwi se (i n) to i ncrease or
countercl ockwi se (out) to decrease speed.
4. Rel ease the governor l ever and check that the
lhroIeIeverisinlheidIecenleredosilion
SeeIigureTurnlhegovernedidIeouler
adjuster screw to obtai n the equi pment
manufacturer s recommended i dl e speed (1500-
1800 RPM). The governed i dl e speed (RPM) i s
typi cal l y 300 RPM (approxi mate) hi gher than the
IovidIeseedSeeIigure
Figure 5-9. Throttle Lever in Idle Position (Air
Cleaner Removed for Clarity).
Figure 5-10. Setting Governed Idle Speed (RPM).
MovelhelhroIeIeverlolhevideoenfuII
lhroIeosilionandhoIdinlhisosilionCheck
the RPM usi ng a tachometer. Turn the hi gh speed
screw to obtai n the i ntended hi gh speed no-l oad
RPM. The governed i dl e speed must be set
bef ore maki ng thi s adj ustment.SeeIigure
Governed Idle
Speed
Adjustment Screw
Governed
Idle Spring
Governor
Spring
Governor
Spring
Must Be
Loose
In Slot
Pivot/Hold
Lever Away
From Carburetor
5.8
Section 5
Fuel System and Governor
Figure 5-11. Setting High Speed RPM (Air Cleaner
Removed for Clarity).
Carburetor Servicing
The fol l owi ng secti on covers the di sassembl y,
vari ous servi ci ng procedures and reassembl y of the
carburetor. For each procedure careful l y i nspect
al l components and repl ace those that are worn or
damaged. The fol l owi ng shoul d al so be noted as
aIialedservicingiserformed
Inspect the carburetor body for cracks, hol es, and
other wear or damage.
InsecllheoalforcrackshoIesandmissing
ordamagedoallabsChecklheoalhingeand
shaforvearordamage
Inspect the fuel i nl et needl e and seat for wear or
damage.
The choke pl ate i s spri ng l oaded. Check to make
sureilmovesfreeIyonlhesha
NOTI ThemainandsIov|elsarexedandside
secicandcanberemovedifrequired
Fi xed jets for hi gh al ti tudes are avai l abl e.
Float Replacement
If symptoms descri bed i n the carburetor
lroubIeshoolingguideindicaleoalIeveIrobIems
removelhecarburelorfromlheenginelocheckand
orreIacelheoalUseaoalkilloreIacelheoal
inoalvaIvecIiandscrev
1. Perform the removal procedures for the
appropri ate ai r cl eaner and the carburetor
oulIinedinSeclionDisassembIy
CIeanlheexleriorsurfacesofdirlorforeign
materi al before di sassembl i ng the carburetor.
Remove the four mounti ng screws and careful l y
separate the fuel bowl from the carburetor. Do
noldamagelheinnerorbovIORingTransfer
any remai ni ng fuel i nto an approved contai ner.
Save al l parts. Fuel can al so be drai ned pri or to
bovIremovaIbyIooseningremovaIoflhebovI
drainscrevSeeIigure
Figure 5-12. Fuel Bowl Removed From Carburetor.
RemovelheoalinscrevandIioullhe
oIdoalinandinIelneedIeSeeIigure
Di scard al l of the parts. The seat for the i nl et
needl e i s not servi ceabl e, and shoul d not be
removed.
Figure 5-13. Removing Float and Inlet Needle.
4. Cl ean the carburetor bowl and i nl et seat areas as
requi red, before i nstal l i ng the new parts.
AachlheinIelneedIelolheIasliclangof
lheoalvilhlhevirecIiTheformedIi
shoul d poi nt up, wi th the needl e val ve hangi ng
dovnSeeIigure
Move and Hold
Lever in "Full
Throttle" Position
High Speed (RPM)
Adjustment Screw
Fuel Bowl
Bowl Drain Screw
Float
Inlet
Needle
5.9
Section 5
Fuel System and Governor
5
Figure 5-14. Float and Inlet Needle Details.
InslaIIlheoalandinIelneedIedovninlolhe
seat and carburetor body. Instal l the new pi vot
inlhroughlheoalhingeandsecurevilhlhe
nevrelainingscrevSeeIigure
Figure 5-15. Installing Float Assembly.
HoIdlhecarburelorbodysolheoalassembIy
hangs verti cal l y and rests l i ghtl y agai nst the
fuel i nl et needl e. The i nl et needl e shoul d be
ful l y seated but the center pi n of the needl e (on
retai ner cl i p end) shoul d not be depressed. Check
lheoalheighlad|uslmenl
NOTI TheinIelneedIecenlerinissring
IoadedMakesurelheoalreslsagainsl
the fuel i nl et needl e wi thout depressi ng
the center pi n.
Thecorrecloalheighlseingis17 mm (0.669
i n.) 1.5 mm (0.059 i n.)measuredfromlheoal
boomlolhebodyoflhecarburelorSeeIigure
ReIacelheoaliflheheighlisdierenl
lhanseciedDO NOTaemlload|uslby
bendingoallab
NOTI esurelomeasurefromlhecasling
surface, not the rubber gasket, i f sti l l
aached
Figure 5-16. Checking Float Height.
Whenlheroeroalheighlisoblained
careful l y rei nstal l the fuel bowl , usi ng new
ORingsonlolhecarburelorSecurevilhlhefour
ori gi nal screws. Torque the screws to
2.5 0.3 Nm (23 2.6 i n. l b.)SeeIigure
Figure 5-17. Installing Fuel Bowl.
10. Instal l the carburetor and reassembl e the engi ne
asoulIinedinSeclionReassembIy
Disassembly/Overhaul
1. Cl ean the exteri or surfaces of di rt or forei gn
materi al before di sassembl i ng the carburetor.
Remove the four mounti ng screws and separate
the fuel bowl from the carburetor. Transfer any
remai ni ng fuel i nto an approved contai ner.
RemoveanddiscardlheoIdORingsIueI
can al so be drai ned pri or to bowl removal by
IooseningremovaIoflhebovIdrainscrevSee
Iigure
Float
Inlet
Needle
Clip
Retaining
Screw
Pivot
Pin
5.10
Section 5
Fuel System and Governor
Figure 5-18. Fuel Bowl Removed From Carburetor.
NOTI IurlherdisassembIyoflhefueIbovI
i s not necessary unl ess the Fuel
Sol enoi d Ki t, or Fuel Bowl Ki t (obtai ned
separatel y), wi l l al so be i nstal l ed.
RemovelheoalinscrevandIioullheoId
oalinandinIelneedIeSeeIigure
Di scard al l the ol d parts. The seat for the i nl et
needl e i s not servi ceabl e, and shoul d not be
removed.
Figure 5-19. Removing Float and Inlet Needle.
Useanarorialesizealscrevdriverand
careful l y remove the two mai n jets from the
carburetor. Note and mark the jets by l ocati on for
roerinslaIIalionThemain|elsmaybesizeside
secicAerlhemain|elsareremovedlhemain
nozzIescanberemovedoullhroughlheboom
oflhemainloversNolelheorienlaliondireclion
of the nozzl es. The end wi th the two rai sed
shouIdersshouIdbeouldovnad|acenllolhe
mai n jets. Save the parts for cl eani ng and reuse.
SeeIigure

Figure 5-20. Main Jets and Nozzles Removed.
Removelhescrevsecuringlhealvasherand
ground l ead (i f equi pped), from the top of the
carburelorlhencarefuIIyuIIIioullhelvo
sIov|elsThesIov|elsmaybesizedsidesecic
mark or tag for proper reassembl y. Note the smal l
ORingonlheboomofeach|elSeeIigure
andSavearlsforcIeaningandreuseunIess
a Jet Ki t i s al so bei ng i nstal l ed. Cl ean the sl ow
jets usi ng compressed ai r. Do not use wi re or
carburetor cl eaner.
Figure 5-21. Removing Screw and Washer.
Figure 5-22. Slow Jets and O-Ring Detail.
Float
Inlet
Needle
Fuel Bowl
Bowl Drain Screw Main Jets
Main Nozzles
Slow (Idle Fuel) Jets
O-Ring
5.11
Section 5
Fuel System and Governor
5
RemovelheidIeseedRIMad|uslmenlscrev
and spri ng from the carburetor. Di scard the parts.
NOTI ThecarburelorisnovdisassembIedfor
appropri ate cl eani ng and i nstal l ati on
of the parts i n the overhaul ki t. Further
di sassembl y i s not necessary. The
lhroIeshaassembIyfueIinIelseal
i dl e fuel adjustment screws wi th l i mi ter,
and carburetor body, are non-servi ceabl e
i tems and shoul d not be removed. The
chokeshaassembIyisserviceabIe
however i t shoul d not be removed
unl ess a Choke Repai r Ki t wi l l be
i nstal l ed.
CIeanlhecarburelorbodymain|elsvenlorls
seats, etc. usi ng a good commerci al l y avai l abl e
carburetor sol vent. Keep away from pl asti c or
rubber parts i f non-compati bl e. Use cl ean, dry
compressed ai r to bl ow out the i nternal channel s
and ports. Do not use metal tool s or wi re to
cIeanoricesand|elsInseclandlhoroughIy
check the carburetor for cracks, wear, or damage.
Inspect the fuel i nl et seat for wear or damage.
Check the spri ng l oaded choke pl ate to make sure
ilmovesfreeIyonlhesha
7. Cl ean the carburetor fuel bowl as requi red.
8. Instal l the two mai n nozzl es i nto the towers
of the carburetor body. The end of the mai n
nozzl es wi th the two rai sed shoul ders shoul d
beouldovnad|acenllolhemain|elsMake
surelhenozzIesarecomIeleIyboomed
Careful l y i nstal l the mai n jets i nto the towers
of the carburetor body on the appropri ate si de,
asidenliedvhenremovaIvaserformedSee
Iigure
Figure 5-23. Installing Main Nozzles and Main Jets.
MakesurelheORingnearlheboomofeach
sIov|elisnevoringoodcondilionAIign
and i nsert the two sl ow jets i nto the top of the
carburelorSeeIigure
InslaIIlheIargealrelainingvasherandsecure
vilhlhemounlingscrevaachinglheground
l ead i f ori gi nal l y secured by the screw.
11. Instal l the new i dl e speed (RPM) adjustment
screw and spri ng onto the carburetor. Thread
i n unti l 3 or 4 threads are exposed, as an i ni ti al
ad|uslmenlSeeIigure
Figure 5-24. Installing Idle Speed Adjusting Screw
and Spring.
AachlheinIelneedIelolheIasliclangof
lheoalvilhlhevirecIiTheformedIi
shoul d poi nt up, wi th the needl e val ve hangi ng
dovnSeeIigure
Figure 5-25. Float and Inlet Needle Details.
InslaIIlheoalandinIelneedIedovninlolhe
seat and carburetor body. Instal l the new pi vot
inlhroughlheoalhingeandsecurevilhlhe
nevrelainingscrevSeeIigure
Idle Speed
Screw and
Spring
Nozzle End with
Two Shoulders
(Out/Down)
Main
Jets
5.12
Section 5
Fuel System and Governor
Figure 5-26. Installing Float Assembly.
HoIdlhecarburelorbodysolheoalassembIy
hangs verti cal l y and rests l i ghtl y agai nst the
fuel i nl et needl e. The i nl et needl e shoul d be
ful l y seated but the center pi n of the needl e (on
retai ner cl i p end) shoul d not be depressed. Check
lheoalheighlad|uslmenl
NOTI TheinIelneedIecenlerinissring
IoadedMakesurelheoalreslsagainsl
the fuel i nl et needl e wi thout depressi ng
the center pi n.
Thecorrecloalheighlseingis17 mm (0.669
i n.) 1.5 mm (0.059 i n.)measuredfromlheoal
boomlolhebodyoflhecarburelorSeeIigure
ReIacelheoaliflheheighlisdierenl
lhanseciedDonolaemlload|uslby
bendinglheoallab
NOTI esurelomeasurefromlhecasling
surface, not the rubber gasket, i f sti l l
aached
Figure 5-27. Checking Float Height.
Whenlheroeroalheighlisoblained
careful l y rei nstal l the fuel bowl , usi ng new
ORingsonlolhecarburelorSecurevilhlhefour
ori gi nal screws. Torque the screws to
2.5 0.3 Nm (23 2.6 i n. l b.)SeeIigure
Figure 5-28. Installing Fuel Bowl.
Choke Repair
1. Remove the carburetor from the engi ne. Di scard
the ol d mounti ng gaskets for the ai r cl eaner and
carburetor.
CIeanlheareasaroundlhechokeshaandlhe
sel f-rel i evi ng choke mechani sm thoroughl y.
3. Remove and di scard the pl asti c cap from the end
oflhechokeIevershaassembIy
4. Note the posi ti on of the spri ng l egs and the choke
pl ate for correct reassembl y l ater. See Fi gure
Removelhelvoscrevsaachinglhechoke
IalelolhechokeshaIuIIlheshaouloflhe
carburetor body, note the prel oad of spri ng and
di scard the removed parts.
Figure 5-29. Choke Details.
Retaining
Screw
Pivot
Pin
5.13
Section 5
Fuel System and Governor
5
Useascrevexlracloreasyoulandremovelhe
originaIchokeshabushingvilhlheoIdchoke
l ever from the carburetor housi ng. Save the
bushi ng to use as a dri ver for i nstal l i ng the new
bushi ng. Di scard the ol d l ever.
CIeanlheIDofbolhchokeshaboresas
requi red.
7. Insert the new bushi ng through the new choke
l ever from the outsi de, and start the bushi ng i n
lheoulershaboreIosilionlhechokeIeverso
the protrudi ng boss on the carburetor housi ng i s
between the two stops formed i n the choke l ever.
SeeIigure
Figure 5-30. Assembling Choke Lever.
8. Turn the ol d bushi ng upsi de down and use i t
as a dri ver to careful l y press or tap the new
bushinginlolhecarburelorbodyunliIilbooms
Check that the choke l ever pi vots freel y wi thout
reslriclionorbindingSeeIigure
Figure 5-31. Installing Bushing.
9. Instal l the new return spri ng onto the new choke
shasolheoulboardIegoflhesringisbehind
lheformedsloonlheendoflhechokesha
SeeIigure
NOTI MakesureilslaysinlhisIocalionduring
the fol l owi ng step.
Figure 5-32. Choke Shaft and Spring Details.
SIidelhechokeshaandsringinlolhe
carburelorIivolreIoadlheshalurn
countercl ockwi se wi th the i nner l eg of the spri ng,
agai nst the formed stop wi thi n the choke l ever as
originaIIyassembIedSeeIiguresand
The outer l eg of the spri ng must sti l l be behi nd
lheformedslooflhechokesha
Figure 5-33. Installing Choke Assembly
Components.
11. Pl ace a drop of Locti te

on the threads of each

new screw. Posi ti on and i nstal l the new choke
IalelolhealsideoflhechokeshaSlarllhe
two screws. Cl ose the choke and check the pl ate
al i gnment wi thi n the carburetor throat, then
ti ghten the screws securel y. Do not overti ghten.
SeeIigure
Stops
Boss
Choke Shaft
Spring Ends
5.14
Section 5
Fuel System and Governor
ORingIueIovILover
13. Drai n Screw
14. Bowl Screw (4)
IueISoIenoid
SeaIingWasher
17. Fl oat
18. Pi n
19. Screw
IIoalCIi
IIoalVaIveInIelNeedIe
MainNozzIeRighlSide
1. Carburetor Body Subassembl y
IdIeSeedScrev
3. Idl e Speed Spri ng
4. Screw
GroundLead
RelainingWasher
7. Sl ow Jet - RH Si de
8. Sl ow Jet - LH Si de
ORingSIov}el
10. Fuel Bowl
ORingIueIovIUer
MainNozzIeLeSide
Main}elRighlSide
Main}elLeSide
ChokeDuslCa
ChokeSha
Sring
ushing
30. Choke Lever
31. Choke Pl ate
ChokeIIaleScrev
Figure 5-34. Installing Choke Plate.
Checkforroeroeralionandfreemovemenlof
the parts. Instal l the new cap.
AIvaysusenevgaskelsvhenservicingor
rei nstal l i ng carburetors. Repai r ki ts are avai l abl e
whi ch i ncl ude new gaskets and other components.
ServicereairkilsavaiIabIeforKeihinKlvobarreI
carburelorsandaIialedcomonenlsare
CarburelorOverhauIKil
Fl oat Ki t
Fuel Sol enoi d Ki t
Bowl Ki t
HighAIliludeKilm
HighAIliludeKilOverm
Figure 5-35. Keihin BK Two-Barrel Carburetor - Exploded View.
5.15
Section 5
Fuel System and Governor
5
Governor
Lever
Governor
Cross Shaft
Governed
Idle Spring
Linkage
Governor
Spring
Governor
General
The governor i s desi gned to hol d the engi ne speed
constant under changi ng l oad condi ti ons. Most
enginesareequiedvilhacenlrifugaIyveighl
mechanicaIgovernorThegovernorgearyveighl
mechani sm of the mechani cal governor i s mounted
insidelhecrankcaseandisdrivenolhegearonlhe
camshaThisgovernordesignvorksasfoIIovs
Centri fugal force acti ng on the rotati ng governor
gearassembIycauseslheyveighlslomove
outward as speed i ncreases. Governor spri ng
tensi on moves them i nward as speed decreases.
Figure 5-36. Governor Linkage (Air Cleaner
Removed for Clarity).
Aslheyveighlsmoveoulvardlheycauselhe
regul ati ng pi n to move outward.
The regul ati ng pi n contacts the tab on the cross
shacausinglheshalorolale
Oneendoflhecrosssharolrudeslhroughlhe
crankcaseTherolalingaclionoflhecrossshais
lransmiedlolhelhroIeIeveroflhecarburelor
lhroughlheexlernaIlhroIeIinkageSeeIigure

WhenlheengineisalreslandlhelhroIeisin
the f astosilionlhelensionoflhegovernor
sringhoIdslhelhroIeIaleoenWhenlhe
engi ne i s operati ng, the governor gear assembl y
i s rotati ng. The force appl i ed by the regul ati ng
inagainsllhecrossshalendslocIoselhe
lhroIeIaleThegovernorsringlensionand
the force appl i ed by the regul ati ng pi n bal ance
each other duri ng operati on, to mai ntai n engi ne
speed.
When l oad i s appl i ed and the engi ne speed and
governor gear speed decreases, the governor
spri ng tensi on moves the governor arm to open
lhelhroIeIaleviderThisaIIovsmorefueI
i nto the engi ne, i ncreasi ng the engi ne speed.
Aslheseedreacheslhegovernedseinglhe
governor spri ng tensi on and the force appl i ed by
lhereguIalinginviIIagainoseleacholherlo
hol d a steady engi ne speed.
Adjustments
NOTI Donollamervilhlhegovernorseing
OverseedishazardousandcouIdcause
personal i njury.
General
Thegovernedseedseingisdelerminedbylhe
osilionoflhelhroIeconlroIIlcanbevariabIeor
constant, dependi ng on the engi ne appl i cati on.
Initial Adjustment Procedure
Make thi s adjustment whenever the governor arm i s
IoosenedorremovedfromlhecrossshaSeeIigure
andad|uslasfoIIovs
MakesurelhelhroIeIinkageisconnecledlo
lhegovernorarmandlhelhroIeIeveronlhe
carburetor.
LoosenlhehexnulhoIdinglhegovernorIeverlo
lhecrosssha
3. Move the governor l ever toward the carburetor
asfarasilviIIgovideoenlhroIeandhoId
i n thi s posi ti on.
4. Insert a l ong thi n rod or tool i nto the hol e on the
crossshaandrolalelheshacIockvisevieved
from the end) as far as i t wi l l turn, then torque
the hex nut to 7.3 Nm (65 i n. l b.).
High Speed (RPM) Adjustment (Refer to Figure
5-37.)
WilhlheenginerunningmovelhelhroIe
control to f ast. Use a tachometer to check the
RPM speed.
Turnlheinneruerscrevoulvardlodecrease
or i nward to i ncrease the RPM speed. Check RPM
wi th a tachometer.
5.16
Section 5
Fuel System and Governor
Hold Lever in
"Full Throttle"
Position
High Speed (RPM)
Adjustment Screw
3. Stop when the desi red RPM speed i s obtai ned.
Figure 5-37. Adjusting High Speed RPM (Air
Cleaner Removed for Clarity).
6.1
6
Section 6
Lubrication System
SAE
10W30
A
P
I
S
E
RV
IC
E
S
J
5W-20, 5W-30
RECOMMENDED SAE VI SCOSI TY GRADES
10W-30
Kohler 10W-30
F -20 0 20 32 40 60 80 100
C -30 -20 -10 0 10 20 30 40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
up to 4C (40F)
* Synthetic oils will provide better starting in extreme cold below
23C (-10F)
**
*
General
Thi s engi ne uses a ful l pressure l ubri cati on system.
Thi s system del i vers oi l under pressure to the
crankshacamshaandconneclingrodbearing
surfaces. In addi ti on to l ubri cati ng the beari ng
surfaceslheIubricalionsyslemsuIiesoiIlolhe
hydrauIicvaIveIiers
AhigheciencygerolorumisIocaledinlheoiI
anTheoiIummainlainshighoiIovandoiI
ressureevenalIovseedsandhighoeraling
temperatures. A pressure rel i ef val ve l i mi ts the
maxi mum pressure of the system.
Service
TheoiIanmuslberemovedloservicelheoiIicku
lheressurereIiefvaIveandlheoiIumReferlo
lhearorialeroceduresinSeclionsand
Oil Recommendations
Usinglheroerlyeveighlandaconsislenl
brand of oi l i n the crankcase i s extremel y i mportant.
So i s checki ng oi l dai l y and changi ng oi l regul arl y.
IaiIurelouselhecorrecloiIorusingdirlyoiIcauses
remalureenginevearandfaiIure
Use hi gh-qual i ty detergent oi l of API (Ameri can
Petrol eum I nsti tute) servi ce cl ass SJ, or hi gher. Sel ect
the vi scosi ty based on the ai r temperature at the ti me
ofoeralionasshovninlhefoIIovinglabIe
NOTI UsingolherlhanservicecIassS}orhigher
oiIorexlendingoiIchangeinlervaIsIonger
than recommended can cause engi ne
damage.
NOTE: Syntheti c oi l s meeti ng the l i sted
cIassicalionsmaybeusedvilhoiIchanges
performed at the recommended i nterval s.
HoveverloaIIovislonringsloroerIy
sealanevorrebuiIlengineshouIdbe
oeraledforalIeaslhoursusingslandard
elroIeumbasedoiIbeforesvilchinglo
syntheti c oi l .
AIogoorsymboIonoiIconlainersidenlieslheAII
servicecIassandSAIviscosilygradeSeeIigure
Figure 6-1. Oil Container Logo.
TheloorlionoflhesymboIshovsservicecIass
such as API SERVI CE CLASS SJ. The symbol may
shovaddilionaIcalegoriessuchasSH, SG/CC, or
CDThecenlerorlionshovslheviscosilygradesuch
asSAIWIflheboomorlionshovsInergy
ConservingilmeanslhaloiIisinlendedloimrove
fuel economy i n passenger car engi nes.
6.2
Section 6
Lubrication System
Oil Drain Plug
Drain Plug
Operating
Range
Checking Oil Level
The i mportance of checki ng and mai ntai ni ng
the proper oi l l evel i n the crankcase cannot be
overemphasi zed. Check oi l BEFORE EACH USE as
foIIovs
MakesurelheengineissloedIeveIandiscooI
so the oi l has had ti me to drai n i nto the sump.
CIeanlheareaaroundlheoiIIIcadislick
beforeremovingilThisviIIheIlokeedirl
grasscIiingselcouloflheengine
RemovelheoiIIIcadislickvieoiIo
Reinserllhedislickinlolhelubeandresllhe
oiIIIcaonlhelubeDonollhreadlhecaonlo
the tube. See Fi gure 6-2.
Figure 6-2. Oil Fill Cap/Dipstick.
RemovedislickandcheckoiIIeveITheIeveI
shouIdbebelveenlheIandLmarksIfIov
removelhecafromlheoiIIIlubeandaddoiI
oflheroerlyeulolheImarkReinslaII
oiIIIcaanddislickReferloOiITye
onageAIvayschecklheIeveIvilhlhe
di psti ck before addi ng more oi l .
Figure 6-3. Oil Level Marks on Dipstick.
NOTI Torevenlexlensiveenginevearordamage
aIvaysmainlainlheroeroiIIeveIinlhe
crankcaseNeveroeralelheenginevilhlhe
oiIIeveIbeIovlheLmarkorabovelheI
mark on the di psti ck.
Changing Oil and Oil Filter
Changing Oil
Change oi l seasonal l y or every 150 hours of
oeralionmorefrequenlIyunderseverecondilions
ReIIvilhservicecIassS}orhigheroiIasseciedin
lheViscosilyGradeslabIeonage
ChangelheoiIvhiIelheengineissliIIvarmTheoiI
viIIovmorefreeIyandcarryavaymoreimurilies
MakesurelheengineisIeveIvhenIIingorchecking
oi l .
ChangelheoiIasfoIIovs
CIeanlheareasaroundoneoflhedrainIugsoiI
IIcadislick
RemoveoneoflheoiIdrainIugsoiIII
cadislickesureloaIIovamIelimefor
compl ete drai nage.
Figure 6-4. Drain Plug (Starter Side).
Figure 6-5. Drain Plug (No. 2. Side).
Oil Fill Cap/Dipstick
F
L
6.3
Section 6
Lubrication System
6
ReinslaIIlhedrainIugandlorquelo21.4 Nm
!b.
IiIIlhecrankcasevilhnevoiIoflheroer
lyelolheImarkonlhedislickReferlo
OiITyeonageAIvayschecklheIeveI
vilhlhedislickbeforeaddingmoreoiI
ReinslaIIlheoiIIIcadislickandlighlen
securel y.
Figure 6-6. Reinstalling Oil Fill Cap/Dipstick.
Changing Oil Filter
TheoiIIleronmoslenginesisIocaledonlooflhe
crankcasebelveenlhecyIindersSomemodeIsuse
aremolemounledoiIIlerSeeIiguresand
ReIacelheoiIIlerseasonal l y (150 hours)oralIeasl
everyolheroiIchangeevery 300 hours ofoeralion
AIvaysuseagenuineKohIeroiIIler
Figure 6-7. Engine Mounted Oil Filter.
Figure 6-8. Optional Remote Mounted Oil Filter.
ReIacelheoiIIlerasfoIIovs
eforeremovinglheoiIIlercIeanlhearea
aroundlheoiIIlerandhousinglokeedirland
debrisouloflheengineRemovelheoIdIlerOn
crankcasemounledoiIIlerhousingsasring
IoadedinnercuaIIovsaulomalicoiIdrainback
inlolhecrankcaseaslheoiIIlerisremoved
WieolhesurfacevherelheoiIIlermounls
DrainlheoiIfromlheenginecrankcase
AIIovamIelimeforlheoiIlodrainfromlhe
crankcase.
ReinslaIIlhedrainIugandlorquelo21.4 Nm
!b.
AIyalhinImofcIeanoiIlolherubbergaskel
onlhenevIlerIarliaIreIIingoflheoiIIler
i s recommended.
InslaIIlhereIacemenloiIIlerlolheIler
adaleroroiIcooIerTurnlheoiIIlercIockvise
unliIlherubbergaskelconlaclslheoiIIler
housingnolinnerculhenlighlenlheIleran
addi ti onal 3/4-1 turn.
IiIIlhecrankcasevilhnevoiIoflheroerlye
lolheImarkonlhedislick
8. Start the engi ne and check for oi l l eaks. Correct
any l eaks before pl aci ng the engi ne i nto servi ce.
Check oi l l evel to be sure i t i s up to but not over
lheImark
Oil Filter
Oil Filter
Housing
6.4
Section 6
Lubrication System
Pressure
Switch
Service Oil Cooler
TheseenginesareequiedvilhanoiIcooIer
mounledunderlheNosidecyIindershroud
searalefromlheoiIIlerSeeIigure
Figure 6-9. Oil Cooler.
Inspect and cl ean the oi l cool er every 150 hours of
operati onmorefrequenlIyunderseverecondilions
InorderlobeeeclivelheoiIcooIermuslbekelfree
of debri s.
ToservicelheoiIcooIercIeanlheoulsideofns
vilhabrushvacuumorcomressedairIfrequired
removelhelvoscrevshoIdinglhecooIerunillolhe
backingshroudassembIyCarefuIIyIilhecooIer
andcIeanlheundersideoflhecooIerAercIeaning
reinslaIIlheoiIcooIerlolhebackingshroudvilhlhe
lvomounlingscrevs
Figure 6-10. Cleaning Top of Oil Cooler.
Figure 6-11. Cleaning Underside of Oil Cooler.
Oil Sentry
General
SomeenginesareequiedvilhanolionaIOiI
SenlryoiIressuremonilorsvilchSeeIigure
IflheoiIressuredrosbeIovanaccelabIeIeveIlhe
OiISenlryviIIeilhershulolheengineoraclivale
avarningsignaIdeendingonlheaIicalion
Theressuresvilchisdesignedlobreakconlaclas
lheoiIressureincreasesabovesiandmake
conlaclaslheoiIressuredecreasesbeIovsi
OnslalionaryorunaendedaIicalionsums
generalorselclheressuresvilchcanbeusedlo
ground the i gni ti on modul e to stop the engi ne. On
vehicuIaraIicalionsIavnlraclorsmoverselc
lheressuresvilchcanonIybeusedloaclivalea
IovoiIvarningIighlorsignaI
NOTI MakesurelheoiIIeveIischeckedbcInrc
each useandismainlainedulolheI
mark on the di psti ck. Thi s i ncl udes engi nes
equiedvilhOiISenlry
Figure 6-12. Oil Sentry Pressure Switch.
Oil Cooler
Oil Cooler
6.5
Section 6
Lubrication System
6
Installation
TheOiISenlryressuresvilchisinslaIIedinlhe
oiIanressureorlSeeIigureOnenginesnol
equiedvilhOiISenlrylheinslaIIalionhoIeis
seaIedvilha1/8-27 N.P.T.F. pi pe pl ug.
ToinslaIIlhesvilchfoIIovlhesesles
AIypipcsca!antwithTcnn

Loclile

No.
orequivaIenllolhelhreadsoflhesvilch
InslaIIlhesvilchinlolhelaedhoIeinoiIan
SeeIigure
TorquelhesvilchloNmin!b.
Testing
ComressedairaressurereguIalorressuregauge
andaconlinuilyleslerarerequiredlolesllhesvilch
ConnecllheconlinuilylesleracrosslhebIade
lerminaIandlhemelaIcaseoflhesvilchWilh
0 psi ressureaIiedlolhesvilchlhelesler
shoul d i ndi cate conti nui ty (swi tch cl osed).
GraduaIIyincreaselheressurelolhesvilchAs
the pressure i ncreases through the range of
7-11 psi the tester shoul d i ndi cate a change to
no conti nui ty (swi tch open)ThesvilchshouId
remai n open as the pressure i s i ncreased to 90 psi
maxi mum.
GraduaIIydecreaselheressurelhroughlhe
range of 7-11 psi . The tester shoul d i ndi cate a
change to conti nui ty (swi tch cl osed) down to
0 psi .
ReIacelhesvilchifildoesnoloeraleas
secied
6.6
7.1
7
Section 7
Electrical System and Components
Thi s secti on covers the operati on, servi ce, and repai r
of the el ectri cal system components. Systems and
components covered i n thi s secti on are:
Spark Pl ugs
aeryandChargingSyslem
El ectri c Starter
IIeclronicIgnilionSyslemsCDandDSAI
Spark Plugs
InginemisreorslarlingrobIemsareoencaused
byasarkIuglhalhasimroergaorisinoor
condi ti on.
The engi ne i s equi pped wi th the fol l owi ng spark
pl ugs:
Type: TheslandardsarkIugisaChamion

XCYCKohIerIarlNoS
IquivaIenlaIlernalebrandIugscanaIsobe
used.
Gap: mmin
Thread Si ze: mm
Reach: mmin
Hex Si ze: mmin
Spark Plug Service
Every 200 hours of operati on, remove each spark
IugCheckilscondilionandeilherresellhegaor
repl ace wi th a new pl ug as necessary. Repl ace spark
pl ugs every 600 hours. To servi ce the pl ugs, perform
the fol l owi ng steps:
eforeremovingeachsarkIugcIeanlhearea
aroundlhebaseoflheIuglokeedirland
debrisouloflheengine
RemovelheIugandcheckilscondilionSee
Inspecti on fol l owi ng thi s procedure. Repl ace
the pl ug i f necessary.
NOTI DonolcIeansarkIuginamachine
usingabrasivegrilSomegrilcouId
remai n i n the spark pl ug and enter the
engi ne causi ng extensi ve wear and
damage.
ChecklhegausingavirefeeIergaugeAd|usl
the gap to 0.76 mm (0.030 i n.)bycarefuIIy
bendinglhegroundeIeclrodeSeeIigure
Figure 7-1. Servicing Spark Plug.
ReinslaIIlhesarkIuginlolhecyIinderhead
and torque to Nm!b.
Inspection
Inspect each spark pl ug as i t i s removed from
the cyl i nder head. The deposi ts on the ti p are an
i ndi cati on of the general condi ti on of the pi ston ri ngs,
vaIvesandcarburelor
NormaIandfouIedIugsareshovninlhefoIIoving
photos:
Wire Gauge
Spark Plug
Ground
Electrode
0.76 mm
(0.030 in.) Gap
7.2
Section 7
Electrical System and Components
Nnrma!AIuglakenfromanengineoeralingunder
normal condi ti ons wi l l have l i ght tan or gray col ored
deposi ts. If the center el ectrode i s not worn, a pl ug
inlhiscondilioncouIdbesellolheroergaand
reused.
CarbnnFnu!cdSosoolybIackdeosilsindicale
incomIelecombuslioncausedbyareslricledair
cIeaneroverrichcarburelionveakignilionoroor
compressi on.
Worn:OnavornIuglhecenlereIeclrodeviIIbe
roundedandlhegaviIIbegrealerlhanlhesecied
gap. Repl ace a worn spark pl ug i mmedi atel y.
WctFnu!cdAvelIugiscausedbyexcessfueIor
oiIinlhecombuslionchamberIxcessfueIcouId
becausedbyareslricledaircIeaneracarburelor
robIemoroeralinglheenginevilhloomuch
chokeOiIinlhecombuslionchamberisusuaIIy
causedbyareslricledaircIeanerabrealherrobIem
worn pi ston ri ngs or val ve gui des.
Overheated:ChaIkyvhiledeosilsindicalevery
highcombuslionlemeraluresThiscondilionis
usuaIIyaccomaniedbyexcessivegaerosionLean
carburelorseingsaninlakeairIeakorincorrecl
sarklimingarenormaIcausesforhighcombuslion
temperatures.
7.3
Section 7
Electrical System and Components
7
DC Voltmeter
Battery
Battery
General
AvoIlbaeryvilhcoIdcrankingamsccais
general l y recommended for starti ng i n al l condi ti ons.
AsmaIIercaacilybaeryisoensucienlifan
appl i cati on i s started onl y i n warmer temperatures.
ReferlolhefoIIovinglabIeforminimumcaacilies
basedonanlicialedambienllemeraluresThe
actual col d cranki ng requi rement depends on engi ne
si ze, appl i cati on, and starti ng temperatures. The
cranki ng requi rements i ncrease as temperatures
decreaseandbaerycaacilyshrinksReferaIsololhe
operati ng i nstructi ons of the equi pment thi s engi ne
oversforsecicbaeryrequiremenls
Battery Size Recommendations
Iflhebaerychargeisinsucienllolurnoverlhe
enginerechargelhebaery
Battery Maintenance
ReguIarmainlenanceisnecessaryloroIongbaery
l i fe.
WARNING: Explosive Gas!
Bacricsprc!ucccxp|csitcnq!rcgcngasuni|c|cing
cnargc!Tcprctcniarccrcxp|csicncnargc|acricscn|q
inuc||tcnii|aic!arcasKccpscurccscjigniiicnauaqjrcn
inc|acrqaia||iincsKccp|acricscuicjincrcacncj
cni|!rcn|cnctca||jcuc|rquncnscrticing|acrics
Bcjcrc!isccnncciingincncgaiitcgrcun!ca||cnakc
surca||suiicncsarcO|||jONasparkui||cccuraiinc
grcun!ca||cicrnina|unicnccu|!causcancxp|csicnij
nq!rcgcngascrgasc|inctapcrsarcprcscni
ReguIarIychecklheIeveIofeIeclroIyleAdd
di sti l l ed water as necessary to mai ntai n the
recommended l evel .
NOTI DonoloverIIlhebaeryIoor
performance or earl y fai l ure due to l oss
of el ectrol yte wi l l resul t.
KeelhecabIeslerminaIsandexlernaIsurfaces
oflhebaerycIeanAbuiIduofcorrosiveacid
or gri me on the external surfaces can cause the
baeryloseIfdischargeSeIfdischargeoccurs
rapi dl y when moi sture i s present.
WashlhecabIeslerminaIsandexlernaIsurfaces
vilhamiIdbakingsodaandvalersoIulion
Ri nse thoroughl y wi th cl ear water.
NOTI DonolaIIovlhebakingsodasoIulion
to enter the cel l s as thi s wi l l destroy the
el ectrol yte.
Battery Test
TolesllhebaeryyouviIIneedaDCvoIlmeler
IerformlhefoIIovingslesSeeIigure
ConnecllhevoIlmeleracrosslhebaery
termi nal s.
CranklheengineIflhebaerydrosbeIov
voIlsvhiIecrankinglhebaeryisloosmaII
di scharged, or faul ty.
Figure 7-2. Battery Voltage Test.
Temperature Battery Required
Above 32F (0C) 300 cca minimum
0F to 32F (-18C to 0C) 300 cca minimum
-5F to 0F (-21C to -18C) 300 cca minimum
-10F (-23C) or below 400 cca minimum
7.4
Section 7
Electrical System and Components
Molex Plug
(Some Models)
TherearelvodierenllyesofignilionsyslemsusedonlheseenginesAIIsyslemsuseanignilionmoduIe
vhichenergizeslhesarkIugThedierenceinlhesyslemisinlhevaylheignilionlimingislriggered
The FixcdIgnitinn5ystcmuliIizesaCaaciliveDischargeCDcoiISeeIigureThisisabasicignilion
syslemlhalusesaxedignilionmoduIevherelheignilionlimingandsarkremainsconslanlregardIessoflhe
engi ne speed.
The Digita!5parkAdvanccIgnitinnDSAISyslemSeeIigureThissyslemusesadigilaImicrorocessor
whi ch i s l ocated i n the i gni ti on modul es. The i gni ti on ti mi ng vari es dependi ng upon the engi ne speed wi th thi s
system.
Operati on:AslheyvheeIrolaleslhemagnel
grouingasseslheinulcoiILThecorresonding
magneliceIdinducesenergyinlolheinulcoiIL
TheresuIlanluIseisrecliedbyDandcharges
caacilorCAslhemagnelassembIycomIelesils
assilaclivaleslhelriggeringdeviceLvhich
causeslhesemiconduclorsvilchSCSlolurnon
WilhlhedevicesvilchONlhechargingcaacilor
CisdireclIyconnecledacrosslherimaryIoflhe
oulullransformerTAslhecaacilordischarges
lhecurrenlinilialesafaslrisinguxeIdinlhe
lransformercoreAhighvoIlageuIseisgeneraled
from thi s acti on i nto the secondary wi ndi ng of the
transformer. Thi s pul se i s del i vered to the spark pl ug
gap. Ioni zati on of the gap occurs, resul ti ng i n an arc
allheIugeIeclrodesThissarkignileslhefueIair
mixlureinlhecombuslionchamber
Electronic Ignition Systems
Figure 7-3. Electronic CD Fixed Ignition Timing System.
Operation of CD Ignition Systems
Fixed Timing System
ThissyslemIigureconsislsoflhefoIIoving
components:
AmagnelassembIyvhichisermanenlIyaxed
lolheyvheeI
TvoeIeclroniccaacilivedischargeignilion
modul es whi ch mount on the engi ne crankcase
Iigure
AkiIIsvilchorkeysvilchvhichgroundslhe
modul es to stop the engi ne.
Two spark pl ugs.
7.5
Section 7
Electrical System and Components
7
Kill Switch or
Off Position of
Key Switch
Ignition
Modules
Spark Plug
Magnet
Flywheel
(0.28/0.33 mm)
0.011/0.013 in. Air Gap
L1
D1
C1
T1
P S
Spark Plug
L2
SCS
Figure 7-5. Capacitive Discharge (CD) Ignition Module Schematic.
Figure 7-4. Capacitive Discharge Fixed Timing Ignition System.
ThelimingoflhesarkisconlroIIedbylheIocalionoflheyvheeImagnelgrouasreferencedloenginelo
dead center.
Troubleshooting CD Ignition Systems
TheCDignilionsyslemsaredesignedlobelroubIe
freeforlheIifeoflheengineOlherlhaneriodicaIIy
checkingreIacinglhesarkIugsnomainlenance
orlimingad|uslmenlsarenecessaryorossibIe
MechanicaIsyslemsdooccasionaIIyfaiIorbreak
dovnhoveversolhefoIIovinglroubIeshooling
i nformati on i s provi ded to hel p you get to the root of
areorledrobIem
CAUTION: High-Energy Electric Spark!
TncCOigniiicnsqsicnsprc!uccanigncncrgqc|cciric
spark|uiincsparknusi|c!iscnargc!cr!anagcicinc
sqsicncanrcsu|iOcncicrankcrrunancngincuiina
sparkp|ug|ca!!isccnnccic!A|uaqsprcti!capainjcrinc
sparkic!iscnargcicgrcun!
ReorledignilionrobIemsaremosloenduelo
oorconneclionseforebeginninglheleslrocedure
checkaIIexlernaIviringecerlainaIIignilionreIaled
wi res are connected, i ncl udi ng the spark pl ug l eads.
ecerlainaIIlerminaIconneclionslsnugIyMake
sure the i gni ti on swi tch i s i n the run posi ti on.
NOTI TheCDignilionsyslemsaresensilivelo
excessi ve l oad on the ki l l l ead. If a customer
compl ai ns of hard starti ng, l ow power,
ormisreunderIoadilmaybeduelo
excessi ve draw on the ki l l ci rcui t. Perform the
appropri ate test procedure.
Test Procedure for Standard (Fixed Timing) CD
Ignition System
IsoIaleandverifylhelroubIeisvilhinlheengine
i gni ti on system.
LocalelheIugconneclorsvherelheviring
harnesses from the engi ne and equi pment are
|oinedSearalelheconneclorsandremovelhe
vhilekiIIIeadfromlheengineconneclorRe|oin
the connectors and posi ti on or i nsul ate the ki l l
l ead termi nal so i t cannot touch ground. Try to
start the engi ne to veri fy whether the reported
robIemissliIIresenl
NOTI Iflheengineslarlsorrunsduringanyoflhe
testi ng, you may need to ground the ki l l l ead
to shut i t down. Because you have i nterrupted
the ki l l ci rcui t, i t may not stop usi ng the
swi tch.
7.6
Section 7
Electrical System and Components
a IflherobIemisgonelheeIeclricaIsyslem
onlheunilissuseclChecklhekeysvilch
wi res, connecti ons, safety i nterl ocks, etc.
b IflherobIemersislslhecondilionis
associ ated wi th the i gni ti on or el ectri cal
syslemoflheengineLeavelhekiIIIead
i sol ated unti l al l testi ng i s compl eted.
TeslforsarkonbolhcyIindersvilhKohIer
ignilionleslerKohIerIarlNoS
DisconneclonesarkIugIeadandconneclillo
lheosllerminaIoflheleslerConnecllhecIilo
a good ground, not to the spark pl ug.
Molex Plug
(Some Models)
Figure 7-6. Digital Spark Advance Ignition (DSAI) System.
Cranklheengineandobservelheleslersark
gap. Repeat the procedure on the other cyl i nder.
RememberloreconnecllherslsarkIugIead
a IfonesideisnolringcheckaIIviring
connecti ons, and termi nal s on that si de. If
wi ri ng i s okay, repl ace i gni ti on modul e and
retest for spark.
b Iflheleslershovssarkbullheengine
mi sses or wont run on that cyl i nder, try a
new spark pl ug.
c Ifneilhersideisringrecheckosilionof
i gni ti on swi tch and check for shorted ki l l
l ead.
Operation of DSAI Ignition Systems
DSAI Ignition System Explanation
AdigilaIsarkadvanceignilionsyslemDSAIis
usedonsomemodeIsTheDSAIignilionsyslemisan
advancedvoIlversionoflhexedlimingignilion
syslemusedonolhermodeIsTvoinducliveslyIe
ignilionmoduIesconlroIlheignilionlimingbasedon
engineRIMAlyicaIDSAIaIicalionIigure
consi sts of the fol l owi ng components:
AmagnelassembIyvhichisermanenlIyaxed
lolheyvheeI
TvoinduclivevoIlignilionmoduIesvhich
mounlonlheenginecrankcaseIigure
AvoIlbaeryvhichsuIiescurrenllolhe
i gni ti on modul es.
AkiIIsvilchorkeysvilchvhichgroundslhe
spark advance modul e to stop the engi ne.
Two spark pl ugs.
Operation
The system provi des more consi stent energy to the
sarkIugsalaIIengineseedsbyusinglhevoIl
baeryasilssourceofoverIngineseedandlo
deadcenlerTDCIocalionreferenceinformalion
isrovidedbylheyvheeImagnelgrouasil
passes the i gni ti on modul e. System tri ggeri ng and
enginelimingiserformedbyadigilaIIyconlroIIed
mi croprocessor. Thi s di gi tal control provi des
reealabIeandconsislenlenginecyIindersark
limingIachDSAImoduIeerformsilsfunclion
i ndependentl y for each engi ne cyl i nder.
7.7
Section 7
Electrical System and Components
7
Troubleshooting DSAI Ignition Systems
TheDSAIignilionsyslemisdesignedlobelroubIe
freeforlheIifeoflheengineOlherlhaneriodicaIIy
checkingreIacinglhesarkIugsnomainlenance
limingormoduIead|uslmenlsarenecessaryor
ossibIeMechanicaIsyslemsdooccasionaIIy
faiIorbreakdovnhoveversolhefoIIoving
lroubIeshoolinginformalionisrovidedloheIyou
gellolheroolofarobIem
ReorledignilionrobIemsaremosloenduelo
oorconneclionseforebeginninglheleslrocedure
checkaIIexlernaIviringecerlainaIIignilionreIaled
wi res are connected, i ncl udi ng the spark pl ug l eads.
ecerlainaIIlerminaIconneclionslsnugIyMake
sure the i gni ti on swi tch i s i n the RUN posi ti on.
Test Procedure for DSAI Ignition Systems
The fol l owi ng procedures are provi ded for
lroubIeshoolingignilionrobIemsonDSAIequied
engi nes. They wi l l al l ow you to i sol ate and pi npoi nt
lhefaiIedcomonenls
Special Tools Required:
Hand Tachometer
IgnilionTeslerKohIerIarlNoS
AulomoliveTimingLighl
MuIlimelerDigilaI
Specications Required:
SarkIuggammin
NOTI IgnilionleslerKohIerIarlNo
Smuslbeusedloleslignilion
on these engi nes. Use of any other tester can
resuIlininaccuralendingsThebaeryon
lheunilmuslbefuIIychargedandroerIy
connecledbeforemakinganyoflheselesls
abaerylhalishookeduorcharged
backvardviIIcranklheenginebulilvonl
havesarkecerlainlhedriveisinneulraI
and al l external l oads are di sconnected.
Test 1. Isolate and Verify the Trouble is Within the
Engine Ignition System
Localelheconneclorsvherelheviringharnesses
fromlheengineandequimenlare|oined
Separate the connectors and remove the whi te
kiIIIeadfromlheengineconneclorRe|oinlhe
connectors and posi ti on or i nsul ate the ki l l l ead
termi nal so i t cannot touch ground. Try to start
lheengineloverifyvhelherlhereorledrobIem
i s sti l l present.
NOTI Iflheengineslarlsorrunsduringanyoflhe
testi ng, you may need to ground the ki l l l ead
to shut i t down. Because you have i nterrupted
the ki l l ci rcui t, i t may not stop usi ng the
swi tch.
a IflherobIemgoesavaylheeIeclricaIsyslemon
lheequimenlissuseclChecklhekeysvilch
wi res, connecti ons, safety i nterl ocks, etc.
b IflherobIemersislslhecondilionisassocialed
wi th the i gni ti on or el ectri cal system of the
engineLeavelhekiIIIeadisoIaledunliIaIIlesling
i s compl eted.
c. Identi fy the whi te ki l l l ead of the engi ne wi ri ng
harnessconneclorIslabIishaconneclionloa
known good ground l ocati on. The engi ne shoul d
ki l l compl etel y. If not, or onl y one cyl i nder i s
aecledgoloTeslbulaIsochecklhevhilekiII
IeadconneclionforlheaecledDSAImoduIe
Test 2. Test for Spark
Wilhlheenginesloeddisconneclonesark
IugIeadConnecllhesarkIugIeadloosl
lerminaIofsarkleslerKohIerIarlNo
SandaachleslercIiloagood
engi ne ground.
NOTI IflvoleslersareavaiIabIeleslingcanbe
erformedsimuIlaneousIyforbolhcyIinders
HoveverifonIyoneleslerisavaiIabIelvo
individuaIleslsmuslbeerformedTheside
nolbeinglesledmuslhavelhesarkIug
IeadconnecledorgroundedDonolcrank
the engi ne or perform tests wi th one spark
pl ug l ead di sconnected and not grounded, or
permanent system damage may occur.
7.8
Section 7
Electrical System and Components
CranklheengineovereslabIishingaminimum
ofRIMandobserveleslersforsark
ReeallhesarkleslonlheoosilecyIinderif
cyIindersarebeinglesledindividuaIIy
a IfbolhcyIindershavegoodsarkbullhe
engi ne runs poorl y, or exi sti ng pl ug condi ti on
oraearanceisqueslionabIeinslaIInev
spark pl ugs gapped at 0.76 mm (0.030 i n.),
andreleslengineerformanceIfrobIem
ersislsgoloTesl
b IfonecyIinderhadgoodsarkbullheolher
cyIinderhadnosarkorinlermienlsark
goloTesl
c IflherevassarkonbolhcyIindersbul
overissuseclgoloTesl
Test 3. Check for Timing Advance
MakeaIinenearlheedgeoflheyvheeIscreen
wi th a marki ng pen, chal k, or narrow tape. See
Iigure
ConneclanaulomolivelimingIighllocyIinder
that had good spark.
Figure 7-7. Mark For Timing Advance.
RunlheenginealidIeanduselhelimingIighl
beamloIocalelheIineonlhescreenDravaIine
onlhebIoverhousingnexllolheIineonlhe
screenAcceIeralelofuIIlhroIeandvalchfor
movement of the l i ne on the screen rel ati ve to the
IineonlhebIoverhousingIfbolhcyIindershad
good spark, repeat the test on the other cyl i nder.
SeeIigure
Flywheel Screen Mark
Figure 7-8. Check For Timing Advance.
a. If the l i ne on the screen moved away from
lheIineonlhebIoverhousingduring
acceIeralionlheDSAIignilionmoduIe
forlhecyIinderbeinglesledisvorking
roerIyIfildidnlmoveavaygoloTesl
b IfyouvereabIelochecklimingonbolh
cyIinderslheIinesyoumadeonlhebIover
housingshouIdbeaarlIfnolgoloTesl

Test 4. Test the Ignition Modules and Connections

RemovelhebIoverhousingfromlheengine
Insecllheviringforanydamageculsbad
crimsIooselerminaIsorbrokenviresCheck
that connecti ons are ori ented properl y on
termi nal s of modul es.
DisconnecllheIeadsfromlheignilionmoduIes
andcIeanaIIoflhelerminaIsmaIeandfemaIe
wi th aerosol el ectri cal contact cl eaner to remove
any ol d di el ectri c compound, dark resi due, di rt,
orconlaminalionDisconnecllhesarkIug
l eads from the spark pl ugs.
UsingamuIlimelerchecklhalaroerground
iseslabIishedbelveenlhegroundbIackIead
oflheDSAImoduIecIosesllosarkIugIead
and a known good ground l ocati on on the
engi ne.
TurnlhekeysvilchlolheONosilionand
checkforvoIlsallhecenleroverredIead
lerminaIoflheDSAImoduIeUselhesame
groundIocalionforlhemuIlimelerasinSle
a IfaIIleslsareOKandmoduIehasnosark
orfaiIsloadvancereIacelheaecled
modul e.
b Ifanyoflheleslsarebaddelerminecause
andxasrequiredlhenrelesl
7.9
Section 7
Electrical System and Components
7
Battery Charging System
General
Most engi nes are equi pped wi th a 15, 20, or 25 amp
reguIaledchargingsyslemSeeIigureslhrough
NOTI ObservelhefoIIovingguideIineslo
avoi d damage to the el ectri cal system and
components:
MakesurelhebaeryoIarilyiscorreclAnegalive
groundsyslemisused
DisconnecllhereclierreguIalorIugandor
lheviringharnessIugbeforedoinganyeIeclric
veIdingonlheequimenloveredbylheengine
AIsodisconneclaIIolhereIeclricaIaccessoriesin
common ground wi th the engi ne.
IrevenllheslalorACIeadsfromlouchingor
shorti ng whi l e the engi ne i s runni ng. Thi s coul d
damage the stator.
Figure 7-9. 25 Amp Stator and Rectier-ReguIator. Figure 7-10. 15 Amp Stator and Rectier-ReguIator.
NOTI amchargingsyslemsuseaamslalorvilhaamreclierreguIalor
15/20/25 Amp Stator and Rectier-ReguIator
7.10
Section 7
Electrical System and Components
15/20/25 Amp Regulated Charging System
Figure 7-11. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with CD Ignition and
Four Pin Connector.
7.11
Section 7
Electrical System and Components
7
Figure 7-12. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and
Four Pin Connector.
7.12
Section 7
Electrical System and Components
Figure 7-13. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and
Five Pin Connector.
7.13
Section 7
Electrical System and Components
7
Stator
Theslalorismounledonlhecrankcasebehind
lheyvheeIIoIIovlheroceduresinSeclion
DisassembIyandSeclionReassembIyifslalor
repl acement i s necessary.
Rectier-ReguIator
ThereclierreguIalorismounledonlhebacking
shroudassembIySeeIigureToreIaceil
remove the two mounti ng screws, then di sconnect the
pl ug and ground l ead.
NOTI WheninslaIIinglhereclierreguIalorlake
note of the termi nal posi ti ons and i nstal l the
pl ug correctl y.
Figure 7-14. Rectier-ReguIator.
TeslingoflhereclierreguIalormaybeerformed
asfoIIovsusinglhearorialeReclierReguIalor
TeslerseeSeclion
To Test
NOTI DisconneclaIIeIeclricaIconneclionsaached
lolhereclierreguIalorTeslingmaybe
erformedvilhlhereclierreguIalor
mounledorIooseTheguresshovlhearl
removed from the engi ne for cl ari ty. Repeat
lheaIicabIeleslrocedure two or three
ti mes to determi ne the condi ti on of the part.
20/25 Amp Rectier-ReguIators
ConnecllhesingIeIeadadalerinbelveenlhe
cenlerlerminaIofreclierreguIalorbeing
tested and the squared si ngl e end of the tandem
adalerIeadSeeIigure
Figure 7-15. Connected Adapter.
ConnecllheleslergroundIeadvilhsring
cIamlolhebodyoflhereclierreguIalor
ConnecllheredIeadandoneoflhebIackIeads
to the pai r of termi nal s on the open end of
the tandem adapter l ead (connecti ons are not
Iocalionsecic
ConnecllheremainingbIackIeadfromlhelesler
looneoflheoulerAClerminaIsonlhereclier
reguIalorSeeIigure
Figure 7-16. Connected Tester.
Ground
Lead
Connector Plug
Rectier-
Regulator
7.14
Section 7
Electrical System and Components
IIuglheleslerinlolheroerACoulIelover
forleslerbeingusedTurnonlheoversvilch
TheIOWIRIighlshouIdbeiIIuminaledand
oneoflhefourslalusIighlsmaybeonasveII
SeeIigureThisdoes not represent the
condi ti on of the part.
Figure 7-17. Powered Tester.
IresslheTISTbuonunliIacIickisheard
andlhenreIeaseSeeIigureMomenlariIy
one of the four l i ghts wi l l i l l umi nate i ndi cati ng
the partia!cnnditinn of the part.
Figure 7-18. Pressing Test Button.
a IflheOKgreenIighlcomeson
disconnecllheleslerbIackIeadaachedlo
oneAClerminaIandreconneclillolheolher
AClerminaIReeallheleslIflheOK
greenIighlcomesonagainlhearlisgood
andmaybeused
b IfanyolherIighlisdisIayedineilherof
lheleslslhereclierreguIalorisfauIlyand
shouIdnolbeused
NOTI AashingLOWIighlcanaIsooccur
as a resul t of an i nadequate ground l ead
connecti on. Make certai n the connecti on
l ocati on i s cl ean and the cl amp i s secure.
15 Amp Rectier-ReguIators
ConnecllheleslergroundIeadvilhsring
cIamlolhebodyoflhereclierreguIalorbeing
tested.
ConnecllheleslerredIeadlolhelerminaIof
lhereclierreguIalorandlhelvobIacklesler
IeadslolhelvoAClerminaIsSeeIigure
Figure 7-19. Tester Connected to 15 Amp Rectier-
Regulator.
IIuglhelesleronloavoIloulIelandlurnon
lheoversvilchSeeIigureTheIOWIR
IighlshouIdbeiIIuminaledandoneoflhefour
slalusIighlsmaybeonasveIIThisdoes not
represent the condi ti on of the part.
IresslheTISTbuonunliIacIickisheard
andlhenreIeaseSeeIigureMomenlariIyon
of the four status l i ghts wi l l i l l umi nate, i ndi cati ng
the condi ti on of the part.
a IflheOKgreenIighlcomesonandslays
sleadylhearlisgoodandmaybeused
b IfanyolherIighlisdisIayedlhereclier
reguIalorisfauIlyandshouIdnolbeused
NOTI AashingLOWIighlcanaIsooccur
as a resul t of an i nadequate ground l ead
connecti on. Make certai n connecti on
l ocati on i s cl ean and cl amp i s secure.
7.15
Section 7
Electrical System and Components
7
Troubleshooting Guide
15/20/25 Amp Battery Charging Systems
WhenrobIemsoccurinkeeinglhebaerychargedorlhebaerychargesalloohigharalelherobIemcan
usuaIIybefoundsomevhereinlhechargingsyslemorvilhlhebaery
NOTE: A!wayszcrnnhmmctcrnncachsca!cbcInrctcstingto ensure accurate readi ngs. Vol tage tests shoul d
bemadevilhlheenginerunningalRIMnoIoadThcbacrymustbcgnndandIu!!ychargcd
Problem Test Conclusion
No Charge
to Battery
TraceIeadfromreclierreguIalor
lokeysvilchorolheraccessibIe
conneclionDisconneclilfrom
svilchorconneclionConnecl
an ammeter from l oose end of B+
IeadloosilivelerminaIofbaery
ConneclDCvoIlmelerfromIoose
end of B+ l ead to negati ve termi nal
ofbaeryWilhenginerunning
alRIMreadvoIlageon
vol tmeter.
IfvoIlageisvoIlsormoreIace
aminimumIoadofamson
baeryloreducevoIlageObserve
ammeter.
IfvoIlageis13.8-14.7 and charge rate
i ncreases when l oad i s appl i ed, the chargi ng
syslemisOKandbaeryvasfuIIycharged
IfvoIlageisIesslhanorchargeraledoes
not i ncrease when l oad i s appl i ed, test stator
Teslsand
Removeconneclorfromreclier
reguIalorWilhenginerunningal
RIMmeasureACvoIlage
acrossslalorIeadsusinganAC
vol tmeter.
IfvoIlageisvoIlsormoreslalorisOK
ReclierreguIalorisfauIlyReIacelhe
reclierreguIalor
If vol tage i s l ess than vn!ts, stator i s
robabIyfauIlyandshouIdbereIacedTesl
slalorfurlherusinganohmmelerTesl
a Wilhenginesloedmeasurelhe
resi stance across stator l eads usi ng
an ohmmeter.
a Ifresislanceis0.064/0.2 ohms, the stator i s
OK
Iflheresislanceisinnilyohmsslaloris
open. Repl ace stator.
b Wilhlheenginesloedmeasure
the resi stance from each stator l ead
to ground usi ng an ohmmeter.
b Iflheresislanceisinnilyohmsno
conlinuilylheslalorisOKnolshorledlo
ground
Ifresislanceorconlinuilyismeasuredlhe
stator l eads are shorted to ground. Repl ace
stator.
Battery
Continuously
Charges at
High Rate
Ierformsameleslassleabove IflhevoIlageisvn!ts or l ess the chargi ng
syslemisOKThebaeryisunabIelo
hoIdachargeServicebaeryorreIaceas
necessary.
If vol tage i s more than vn!tslhereclier
reguIalorisfauIlyReIacereclierreguIalor
7.16
Section 7
Electrical System and Components
DC Voltmeter
Rectier-ReguIator
Flywheel
Stator
Ammeter
Battery
(-)
(+)
Figure 7-20. Connections for Testing Charging System.
Electric Starting Motors
TheseenginesusesoIenoidshislarlersforeIeclric
slarlingADeIcoRemysoIenoidshislarleris
typi cal l y used.
Starting Motor Precautions
NOTI DonolcranklheengineconlinuousIyfor
morelhansecondsalalimeIflheengine
doesnolslarlaIIovasecondcooIdovn
eriodbelveenslarlingaemlsIaiIure
lofoIIovlheseguideIinescanburnoullhe
starter motor.
NOTI IflheenginedeveIossucienlseedlo
disengagelheslarlerbuldoesnolkee
runningafaIseslarllheenginerolalion
muslbeaIIovedlocomeloacomIeleslo
beforeaemlingloreslarllheengineIf
lheslarlerisengagedvhiIelheyvheeIis
rolalinglheslarlerinionandyvheeIring
gear may cl ash, resul ti ng i n damage to the
starter.
NOTI Iflheslarlerdoesnolcranklheengineshul
olheslarlerimmedialeIyDonolmake
furlheraemlsloslarllheengineunliIlhe
condi ti on i s corrected.
NOTI Donoldrolheslarlerorslrikelheslarler
frameDoingsocandamagelheslarler
Operation Solenoid Shift Starter
WhenoverisaIiedlolheslarlerlheeIeclric
sol enoi d moves the dri ve pi ni on out onto the dri ve
shaandinlomeshvilhlheyvheeIringgearWhen
lheinionreacheslheendoflhedriveshailrolales
lheyvheeIandcrankslheengine
WhenlheengineslarlsandlheslarlsvilchisreIeased
the starter sol enoi d i s deacti vated, the dri ve l ever
movesbackandlhedriveinionmovesoulofmesh
wi th the ri ng gear i nto the retracted posi ti on.
Starter Removal and Installation
ReferlolheDisassembIyandReassembIy
Secti ons for starter removal and i nstal l ati on
procedures.
7.17
Section 7
Electrical System and Components
7
Torx Head Screws
TroubIeshooting Guide - Starting DifcuIties
Delco-Remy Starters
Figure 7-21. Delco-Remy Starter.
Starter Disassembly
Removelhehexnulanddisconnecllheosilive
brushIeadbrackelfromlhesoIenoidlerminaI
RemovelhelhreeTorxheadscrevssecuringlhe
soIenoidlolheslarlerSeeIigure
Figure 7-22. Removing Solenoid Screws.
UnhooklheIungerinfromlhedriveIever
Remove the gasket from the recess i n the
housingSeeIiguresand
NOTI Teslrocedureforcheckingslarler
soIenoidisonagesand
Problem Possible Fault Correction
Starter
Does Not
Energize
Battery
ChecklhesecicgravilyoflhebaeryIfIovrechargeor
reIacebaeryasnecessary
Wiring
CIeancorrodedconneclionsandlighlenIooseconneclions
ReIaceviresinoorcondilionandvilhfrayedorbroken
i nsul ati on.
Starter Switch
or Solenoid
yasslhesvilchorsoIenoidvilha|umervireIfslarler
cranks normal l y, repl ace the faul ty components. Remove
and perform i ndi vi dual sol enoi d test procedure. See pages
and.
Starter
Energizes
but Turns
Slowly
Battery
ChecklhesecicgravilyoflhebaeryIfIovrechargeor
reIacebaeryasnecessary
Brushes
CheckforexcessiveIydirlyorvornbrushesand
commulalorCIeanusingacoarsecIolhnolemerycIolh
ReIacebrushesifexcessiveIyorunevenIyvorn
Transmission
or
Engine
MakesurelhecIulchorlransmissionisdisengagedor
pl aced i n neutral . Thi s i s especi al l y i mportant on equi pment
vilhhydroslalicdriveThelransmissionmuslbeexaclIyin
neutral to prevent resi stance whi ch coul d keep the engi ne
from starti ng.
Checkforseizedenginecomonenlssuchaslhebearings
connecti ng rod, and pi ston.
7.18
Section 7
Electrical System and Components
Figure 7-23. Solenoid Removed from Starter.
Figure 7-24. Removing Plunger.
RemovelhelvolhruIargerboIlsSeeIigure

Figure 7-25. Removing Thru Bolts.

RemovelhecommulalorendIaleassembIy
conlaininglhebrushhoIderbrushessrings
and l ocki ng caps. Remove the thrust washer from
insidelhecommulalorendSeeIigure
Figure 7-26. Removing Commutator End Plate
Assembly.
Removelheframefromlhearmalureanddrive
endcaSeeIigure
Figure 7-27. Starter Frame Removed.
RemovelhedriveIeverivolbushingand
backingIalefromlheendcaSeeIigure
Figure 7-28. Removing Backing Plate and Pivot
Bushing.
7.19
Section 7
Electrical System and Components
7
Drive
End Cap
Screw
Plunger
Spring
Lever
Plate
Plug
Solenoid
Frame & Field
Brush Holder
Nut
Commutator
End Plate
Screw
Bolt
Collar
Retaining Ring
Stop
Drive
Armature
Washer
Tube
TakeoullhedriveIeveranduIIlhearmalure
ouloflhedriveendcaSeeIigure
Removelhelhruslvasherfromlhearmalure
shaSeeIigure
Figure 7-29. Armature and Lever Removed.
IushlheslocoIIardovnloexoselherelaining
ringSeeIigure
Figure 7-30. Retaining Ring Detail.
Removelherelainerfromlhearmaluresha
Save the stop col l ar.
NOTI DonolreuselheoIdrelainer
Figure 7-31. Removing Retaining Ring.
RemovelhedriveinionassembIyfromlhe
armature.
CIeanlhearlsasrequired
NOTI Do not soak the armature or use sol vent
vhencIeaningWiecIeanusingaso
cl oth, or use compressed ai r.
Figure 7-32. Delco-Remy Starter.
7.20
Section 7
Electrical System and Components
Wear Limit Length
7.6 mm (0.300 in.)
Mica Insulation
Commutator O.D.
Inspection
Drive Pinion
CheckandinsecllhefoIIovingareas
a TheinionleelhforabnormaIvearor
damage.
b ThesurfacebelveenlheinionandlhecIulch
mechani sm for ni cks, or i rregul ari ti es whi ch
coul d cause seal damage.
c ChecklhedrivecIulchbyhoIdinglhecIulch
housi ng and rotati ng the pi ni on. The pi ni on
shoul d rotate i n one di recti on onl y.
Brushes and Springs
Inseclbolhlhesringsandbrushesforvearfaligue
ordamageMeasurelheIenglhofeachbrushThe
minimumIenglhforeachbrushis 7.6 mm
(0.300 i n.)SeeIigureReIacelhebrushesiflhey
arevornundersizeorlheircondilionisqueslionabIe
Figure 7-33. Checking Brushes.
Armature
CIeanandinsecllhecommulalorouler
surfaceThemicainsuIalionmuslbeIoverlhan
lhecommulalorbarsunderculloensureroer
oeralionoflhecommulalorSeeIigure
Figure 7-34. Commutator Mica Inspection.
UseanohmmelersellolheRxscaIeTouchlhe
robesbelveenlvodierenlsegmenlsoflhe
commulalorandcheckforconlinuilySeeIigure
TeslaIIlhesegmenlsConlinuilymuslexisl
belveenaIIorlhearmalureisbad
Figure 7-35. Checking Armature.
CheckforconlinuilybelveenlhearmalurecoiI
segments and the commutator segments. See
IigureThereshouIdbenoconlinuilyIf
conlinuilyexislsbelveenanylvolhearmalure
isbad
ChecklhearmalurevindingsinsuIalionfor
shorti ng.
Shift Fork
ChecklhallheshiforkiscomIeleandlheivol
and contact areas are not excessi vel y worn, cracked, or
broken
Continuity Check
Armature
Coil
Insulation
Check
7.21
Section 7
Electrical System and Components
7
Brush Replacement
ThebrushesandsringsareservicedasaselUse
anevKohIerrushandSringKilifreIacemenlis
necessary.
IerformslesinSlarlerDisassembIy
Removelhelvoscrevssecuringlhebrush
hoIderassembIylolheendcaIaleNolelhe
orienlalionforreassembIyIalerSeeIigure
DiscardlheoIdbrushhoIderassembIy
Figure 7-36. Removing Brush Holder.
CIeanlhecomonenlarlsasrequired
ThenevbrushesandsringscomereassembIed
inabrushhoIdervilharoleclivesIeevelhal
viIIaIsoserveasaninslaIIalionlooISeeIigure

Figure 7-37. Service Brush Kit.

IerformSlesinlheSlarlerReassembIy
sequenceInslaIIalionmuslbedoneaerlhe
armature, dri ve l ever, and frame are i nstal l ed, i f
lheslarlerhasbeendisassembIed
Starter Service
CIeanlhedriveIeverandarmalureshaAIy
KohIereIeclricslarlerdriveIubricanlseeSeclion
VersiIubeGLorMobiITemSHClolheIever
andshaCIeanandchecklheolherslarlerarlsfor
wear or damage as requi red.
Starter Reassembly
AIydriveIubricanlseeSeclionlolhe
armalureshasIinesInslaIIlhedriveinion
onlolhearmaluresha
InslaIIandassembIelheslocoIIarrelainer
assembIy
a. Instal l the stop col l ar down onto the armature
shavilhlhecounlerborerecessu
b InslaIIanevrelainerinlheIargerrear
grooveoflhearmalureshaSqueezevilha
pl i ers to compress i t i n the groove.
c. Sl i de the stop col l ar up and l ock i t i nto
pl ace, so the recess surrounds the retai ner
i n the groove. If necessary, rotate the pi ni on
outward on the armature spl i nes agai nst the
retai ner to hel p seat the col l ar around the
retai ner.
Figure 7-38. Installing Stop Collar and Retainer.
NOTI AIvaysuseanevrelainerDonolreuse
oIdrelainersvhichhavebeenremoved
7.22
Section 7
Electrical System and Components
InslaIIlheosellhruslslovashersolhe
smaIIeroseloflhevasherfaceslherelainer
coIIarSeeIigure
Figure 7-39. Installing Thrust Washer.
AIyasmaIIamounlofoiIlolhebearinginlhe
dri ve end cap, and i nstal l the armature wi th the
dri ve pi ni on.
Lubricalelheforkendandcenlerivoloflhe
driveIevervilhdriveIubricanlseeSeclion
Iosilionlheforkendinlolhesacebelveenlhe
captured washer and the rear of the pi ni on.
SIidelhearmalureinlolhedriveendcaand
at the same ti me seat the dri ve l ever i nto the
housi ng.
NOTI CorreclIyinslaIIedlhecenlerivol
seclionoflhedriveIeverviIIbeush
orbeIovlhemachinedsurfaceoflhe
housingvhichreceiveslhebacku
vasherSeeIigure
Figure 7-40. Installing Armature and Pivot Lever.
InslaIIlhebackuvasherfoIIovedbylherubber
grommet, i nto the matchi ng recess of the dri ve
end cap. The mol ded recesses i n the grommet
shouIdbeoulmalchingandaIignedvilh
lhoseinlheendcaSeeIigure
Figure 7-41. Installing Backup Washer and
Grommet.
InslaIIlheframevilhlhesmaIInolchforvard
onlolhearmalureanddriveendcaAIignlhe
notch wi th the correspondi ng secti on i n the
rubbergrommelInslaIIlhedrainlubeinlherear
culoulifilvasremovedreviousIySeeIigure

Figure 7-42. Installing Frame and Drain Tube.

InslaIIlheallhruslvasheronlolhecommulalor
endoflhearmalureshaSeeIigure
Thrust Washer
7.23
Section 7
Electrical System and Components
7
Figure 7-43. Installing Thrust Washer.
SlarlerreassembIyvhenrcp!acinglherushes
rushHoIderAssembIy
a HoIdlheslarlerassembIyverlicaIIyonlhe
end housi ng, and careful l y posi ti on the
assembIedbrushhoIderassembIyvilhlhe
suIiedroleclivelubeagainsllheendof
lhecommulalorarmalureThemounling
screvhoIesinlhemelaIcIismuslbe
uoulSIidelhebrushhoIderassembIy
down i nto pl ace around the commutator, and
inslaIIlheosilivebrushIeadgrommelin
lheculouloflheframeSeeIigureThe
roleclivelubemaybesavedandusedfor
future servi ci ng.
Figure 7-44. Installing Brush Holder Assembly with
Supplied Tube.
SlarlerreassembIyvhennntrcp!acinglherushes
rushHoIderAssembIy
a CarefuIIyunhooklherelainingcasfrom
overeachoflhebrushassembIiesDonol
IoselhesringsSeeIigure
Figure 7-45. Removing Retaining Clips.
b Iosilioneachoflhebrushesbackinlheir
sIolssolheyareushvilhlheIDoflhe
brushhoIderassembIyInserllherush
InslaIIalionTooIvilhexlensionoruselhe
lubedescribedabovefromariorbrush
inslaIIalionlhroughlhebrushhoIder
assembIysolhehoIesinlhemelaImounling
cIisareuoul
c InslaIIlhebrushsringsandsnaonlhefour
relainercasSeeIigure
Figure 7-46. Brush Installation Tool with Extension.
Thrust
Washer
7.24
Section 7
Electrical System and Components
Extension.
d HoIdlheslarlerassembIyverlicaIIyonlhe
end housi ng, and careful l y pl ace the tool
vilhexlensionandassembIedoriginaI
brushhoIderassembIyonlolheendof
lhearmalureshaSIidelhebrushhoIder
assembIydovninloIacearoundlhe
commulalorinslaIIlheosilivebrush
l ead grommet i n the cutout of the frame. See
Iigure
Figure 7-47. Installing Brush Holder Assembly
using Tool with Extension.
InslaIIlheendcaonlolhearmalureandframe
aIigninglhelhinraisedribinlheendcavilh
the correspondi ng sl ot i n the grommet of the
osilivebrushIead
InslaIIlhelvolhruboIlsandlhelvobrush
hoIdermounlingscrevsTorquelhelhruboIlslo
Nmin!bTorquelhebrush
hol der mounti ng screws to 2.5-3.3 Nm
in!bSeeIiguresand
Figure 7-48. Torquing Thru Bolts.
Figure 7-49. Torquing Brush Holder Screws.
HooklheIungerbehindlheuerendof
the dri ve l ever, and i nstal l the spri ng i nto the
sol enoi d. Insert the three mounti ng screws
through the hol es i n the dri ve end cap. Use these
to hol d the sol enoi d gasket i n posi ti on, then
mount the sol enoi d. Torque the screws to
Nmin!b.
ConnecllheosilivebrushIeadbrackel
to the sol enoi d and secure wi th the hex nut.
Torque the nut to Nmin!bDonol
overlighlenSeeIigure
Figure 7-50. Positive (+) Brush Lead Connection.
Positive
Brush
Lead
7.25
Section 7
Electrical System and Components
7
VOM Leads
12 volt Test Leads
Momentary
Connection Only
Solenoid Test Procedure
Solenoid Shift Style Starters
DisconneclaIIIeadsfromlhesoIenoidincIuding
lheosilivebrushIeadaachedlolheIoverslud
termi nal . Remove the mounti ng hardware and
separate the sol enoi d from the starter for testi ng.
Test 1. Solenoid Pull-In Coil/Plunger Actuation
Test.
UseavoIloversuIyandlvoleslIeads
ConnecloneIeadlolhealsadeSslarllerminaI
on the sol enoi d. Momentari l y* connect the other l ead
lolheIoverIargeosllerminaISeeIigure
WhenlheconneclionismadelhesoIenoidshouId
energizeaudibIecIickandlheIungerrelracl
Repeat the test several ti mes. If the sol enoi d fai l s to
aclivaleilshouIdbereIaced
NOTI: DONOTIeavelhevoIlleslIeads
connected to the sol enoi d for any ti me
over what i s necessary for performi ng
each of the i ndi vi dual tests. Internal
damage to the sol enoi d may otherwi se
occur.
Figure 7-51. Testing Pull-In Coil/Plunger Actuation.
Test 2. Solenoid Pull-In Coil/Contact Continuity
Test.
UseanohmmelersellolheaudibIeorRxKscaIeand
connect the two ohmmeter l eads to the two l arge post
lerminaIsIerformlherecedingleslandcheck
forconlinuilySeeIigureTheohmmelershouId
i ndi cate conti nui ty, i f no conti nui ty i s i ndi cated the
soIenoidshouIdbereIacedReealleslseveraIlimes
loconrmcondilion
Figure 7-52. Testing Pull-In Coil/Solenoid Contact
Continuity.
Test 3. Solenoid Hold-In Coil Function Test.
ConneclonevoIlleslIeadlolhealsadeS
start termi nal on the sol enoi d, and the other l ead to
lhebodyormounlingsurfaceoflhesoIenoidThen
manual l y push the pl unger In and check i f the
HoIdIncoiIhoIdslheIungerrelracledSeeIigure
DonolaIIovlheleslIeadsloremainconnecled
to the sol enoi d for a prol onged peri od of ti me. If the
IungerfaiIsloslayrelracledlhesoIenoidshouIdbe
repl aced.
12 volt Test Leads
Momentary
Connection Only
Figure 7-53. Testing Hold-In Coil/Function Test.
Manually Push
Plunger "In"
12 volt Test Leads
Connect Only Long
Enough to Test
7.26
Section 7
Electrical System and Components
Test 4. Solenoid Hold-In Coil/Contact Continuity
Test.
UseanohmmelersellolheaudibIeorRxKscaIeand
connect the two ohmmeter l eads to the two l arge post
lerminaIsIerformlherecedingleslandcheck
forconlinuilySeeIigureThemelershouId
i ndi cate conti nui ty, i f no conti nui ty i s i ndi cated the
soIenoidshouIdbereIacedReealleslseveraIlimes
loconrmcondilion
Figure 7-54. Testing Hold-In Coil/Solenoid Contact
Continuity.
Plunger
Pushed "In"
VOM Meter
Leads
12 volt Test Leads
8.1
8
Section 8
Disassembly
WARNING: Accidental Starts!
Di sabl i ng engi ne. Acci dent al st art i ng can cause severe i nj ury or deat h. Befor e wor ki ng on t he engi ne or equi pment ,
!isa||cinccngincasjc||cusOisccnncciincsparkp|ug|ca!sOisccnnccincgaiitc|acrqca||cjrcn|acrq
Cl ean al l parts thoroughl y as the engi ne i s
di sassembl ed. Onl y cl ean parts can be accuratel y
i nspected and gauged for wear or damage. There
are many commerci al l y avai l abl e cl eaners that wi l l
qui ckl y remove grease, oi l and gri me from engi ne
parts. When such a cl eaner i s used, fol l ow the
manufacturer s i nstructi ons and safety precauti ons
careful l y.
Make sure al l traces of the cl eaner are removed before
the engi ne i s reassembl ed and pl aced i nto operati on.
Even smal l amounts of these cl eaners can qui ckl y
break down the l ubri cati ng properti es of engi ne oi l .
Typical Disassembly Sequence
The fol l owi ng sequence i s suggested for compl ete
engi ne di sassembl y. The sequence can be vari ed to
accommodate opti ons or speci al equi pment.
1. Di sconnect spark pl ug l eads.
ShulofueIsuIy
DrainoiIfromcrankcaseandremoveoiIIler
Removemuer
5. Remove cyl i nder shrouds and bl ower housi ng.
6. Remove el ectri c starter motor.
7. Remove ai r cl eaner assembl y.
8. Remove fuel pump.
9. Remove control bracket, governor spri ngs and
l ever.
10. Remove carburetor.
11. Remove i ntake mani fol d.
12. Remove Oi l Sentry (i f equi pped).
RemovebaesandinlakemanifoId
14. Remove oi l cool er.
RemoveoiIIlerhousing
16. Remove i gni ti on modul es.
17. Remove grass screen and cool i ng fan.
RemoveyvheeI
RemoveslalorreclierreguIalorandviring
harness.
20. Remove backi ng shroud assembl y.
21. Remove spark pl ugs.
22. Remove val ve covers.
RemovecyIinderheadsandhydrauIicIiers
24. Remove breather assembl y.
25. Remove oi l pan assembl y.
Removecamsha
27. Remove connecti ng rods wi th pi stons and ri ngs.
Removecranksha
29. Removal of governor gear.
RemovegovernorgearyokecrossshaandseaI
RemoveIierfeedchambercoverandgaskels
RemoveyvheeIandITOendoiIseaIs
33. Removal of mai n beari ngs.
Disconnect Spark Plug Leads
1. Di sconnect the l eads from the spark pl ugs. See
Iigure
NOTI IuIIonboolonIylorevenldamagelosark
pl ug l ead.
Figure 8-1. Disconnect Spark Plug Leads.
8.2
Section 8
Disassembly
Cylinder Shroud
Shut Off Fuel Supply
Drain Oil from Crankcase and Remove Oil
Filter
CIeanlheoiIIlerandhousingareaRemoveand
discardlheoiIIlerSeeIigure
Figure 8-2. Removing Oil Filter.
2. Remove the di psti ck and one of the oi l drai n
pl ugs.
Figure 8-3. Removing Dipstick from Tube.
Figure 8-4. Oil Drain Plug Location.
3. Al l ow ampl e ti me for the oi l to drai n from the
crankcase.
Remove Mufer
Removelheexhauslsyslemandaaching
hardware from the engi ne.
Remove Cylinder Shrouds and Blower
Housing
1. Remove the top mounti ng screw and l oosen the
lvoshouIderscrevsoneachsideLiolhelvo
cyIindershroudsSeeIigure
Figure 8-5. Removing Cylinder Shrouds.
2. Remove the four mounti ng screws and separate
the bl ower housi ng from the backi ng shroud
assembIyOnescrevaIsosecureslheoiIII
dislicklubeSeeIigureThexedguard
(equi pped model s) may be removed wi th the
bl ower housi ng.
Figure 8-6. Removing Blower Housing.
Drain Plug
(Starter Side Shown)
Mounting
Screws
8.3
Section 8
Disassembly
8
3. Remove the l ower mounti ng screw and pul l the
oiIIIlubeouloflhecrankcase
Figure 8-7. Removing Oil Fill Tube.
Remove Electric Starter Motor
1. Di sconnect the l eads from the starter.
Removelhelvohexangescrevsandslarler
SeeIigure
Figure 8-8. Removing Electric Starter.
Remove Air Cleaner Assembly
1. Di sconnect the breather hose from the ai r cl eaner,
and the formed vent hose from the vent port on
the carburetor.
RemovelhefourhexangenulsandgroundIead
fromlhemounlingsludsSeeIigure
Figure 8-9. Air Cleaner Mounting Details.
3. Remove the two screws securi ng the ai r cl eaner
and mai n control bracket to the i ntake mani fol d
bossesSeeIigure
Figure 8-10. Mounting Screws.
4. Remove the ai r cl eaner from the engi ne as an
assembIySeeIigure
Figure 8-11. Removing Air Cleaner Assembly.
Oil Fill Tube
Lower Mounting
Screw Location
Mounting
Screws
Breather
Hose
Mounting Nuts
Vent Hose
Ground Lead
Mounting Screws
8.4
Section 8
Disassembly
Remove Fuel Pump
WARNING: Explosive Fuel!
Gasc|inciscxircnc|qanna||can!iistapcrscancxp|c!c
ijigniic!Sicrcgasc|inccn|qinapprctc!ccniaincrsin
uc||tcnii|aic!uncccupic!|ui|!ingsauaqjrcnsparkscr
ancsOcnci||incjuc|iankuni|cinccngincisncicr
r unni ng, si nce spi l l ed fuel coul d i gni t e i f i t comes i n cont act
wi t h hot par t s or spar ks fr om i gni t i on. Do not st ar t t he
engi ne near spi l l ed fuel . Never use gasol i ne as a cl eani ng
agent .
NOTE: Based on the styl e of fuel pump used, refer to
the fol l owi ng.
Pulse Style Fuel Pump
The pul se styl e fuel pump i s mounted to the si de of
the control bracket. It may be removed separatel y or
wi th the bracket.
To remove separatel y:
Removelhelvohexangemounlingscrevs
securi ng the fuel pump to the control bracket.
2. Di sconnect the i nl et, outl et, and pul se (vacuum)
hosesandremovelhefueIumSeeIigure
IroerIyconlainanyremainingfueI
Figure 8-12. Removing Pulse Pump.
Electric Fuel Pump
1. Removal wi l l be determi ned based on mounted
l ocati on and appl i cati on. Di sconnect the l ead
connecti ons, fuel l i ne connecti ons and mounti ng
hardvareasrequiredIroerIyconlainany
remai ni ng fuel .
Remove Control Bracket, Governor
Springs and Lever
1. Unhook the governed i dl e and governor spri ngs
from the control s on the mai n bracket and the
governor l ever. Note the col or, l ocati on, and
osilionofeachSeeIigure
DisconnecllhelhroIeIinkageanddamening
spri ng from the governor l ever at the smal l
bushingSeeIigure
Figure 8-13. Disconnect Linkages and Governor
Springs.
CarefuIIyryolheaInulremovelhelvo
washers (note assembl y order), and di sconnect
the choke l i nkage from the pi vot l ever. Do not
l ose any parts. Secure the remai ni ng pi vot parts
wi th tape, to avoi d l osi ng them. Al ways use a
new pal nut duri ng reassembl y.
4. If the fuel pump i s bei ng removed wi th the
bracket di sconnect the pul se (vacuum) hose and
oulIelfueIhosefromlheuIseumIroerIy
conlainanyremainingfueISeeIigure
Figure 8-14. Disconnecting Pulse Hose.
5. Remove the l ower mounti ng screw goi ng i nto
the i ntake mani fol d and remove the mai n control
brackelSeeIigure
Governor
Springs
Throttle
Linkage
Pal Nut
Choke
Linkage
Pulse Hose
Mounting Screws
Outlet Hose
Fitting
Pulse
Hose
8.5
Section 8
Disassembly
8
Figure 8-15. Removing Control Bracket.
Loosenlhehexangenulandremovelhe
governorIeverfromcrossshaSeeIigure
Figure 8-16. Removing Governor Lever.
Remove Carburetor
WARNING: Explosive Fuel!
Gasc|inciscxircnc|qanna||can!iistapcrscancxp|c!c
ijigniic!Sicrcgasc|inccn|qinapprctc!ccniaincrsin
uc||tcnii|aic!uncccupic!|ui|!ingsauaqjrcnsparkscr
ancsOcnci||incjuc|iankuni|cinccngincisncicr
r unni ng, si nce spi l l ed fuel coul d i gni t e i f i t comes i n cont act
wi t h hot par t s or spar ks fr om i gni t i on. Do not st ar t t he
engi ne near spi l l ed fuel . Never use gasol i ne as a cl eani ng
agent .
DisconnecllhefueIshulosoIenoidIead
2. Remove the fuel i nl et hose from the carburetor.
IroerIyconlainanyremainingfueI
3. Remove the carburetor, and l i nkages as an
assembIySeeIigure
Figure 8-17. Removing Carburetor.
4. Remove the carburetor gasket.
5. The carburetor and l i nkages can be separated as
necessary.
Remove Oil Sentry

(If Equipped)
1. Di sconnect the l ead from the Oi l Sentry

swi tch.
2. Remove the Oi l Sentry

swi tch from the oi l pan.

SeeIigure
Figure 8-18. Oil Sentry

Switch Location in Oil

Pan.
Remove Bafes and Intake ManifoId
RemovelhescrevssecuringlhevaIIeybaeslo
the cyl i nder heads and backi ng shroud assembl y.
Governor
Lever
Pressure
Switch
Control
Bracket
Lower
Mount
8.6
Section 8
Disassembly
NOTE: New cl amps are recommended any ti me
di sassembl y i s performed, or i f cl amps
have been l oosened (expanded) several
ti mes.
Figure 8-19. Removing VaIIey Bafes.
2. Remove the four screws securi ng each of the
oulercyIinderbaesinIaceSeeIigure
Figure 8-20. Removing Outer CyIinder Bafes.
Removelhefourhexangescrevssecuringlhe
i ntake mani fol d to the cyl i nder heads. Cut any
wi re ti es securi ng wi ri ng.
4. Remove the i ntake mani fol d and gaskets. See
Iigure
Figure 8-21. Removing Intake Manifold.
Remove Oil Cooler
1. Remove the two oi l cool er mounti ng screws. Do
nolIoseanyvashersifusedSeeIigure
Figure 8-22. Removing Oil Cooler Mounting
Screws.
2. Loosen the cl amps and di sconnect each of the
hosesfromlheoiIcooIerSeeIigure
Figure 8-23. Disconnecting Hoses From Oil Cooler.
Remove Oil Filter Housing
RemovelhescrevsecuringlheoiIIlerhousing
andindividuaIORingslolhecrankcaselhen
carefuIIysearalelhearlsSeeIigure
NOTI IurlherdisassembIyoflheoiIIler
housi ng assembl y i s not necessary
unl ess bei ng servi ced i ndi vi dual l y.
Fol l ow Substeps a, b, and c.
Mounting
Screw Locations
Valley
Bafe
Mounting
Locations
Mounting
Locations
8.7
Section 8
Disassembly
8
Figure 8-24. Removing Oil Filter Housing.
IerformlhefoIIovingonIyiflheoiIIlerhousing
assembl y requi res i ndi vi dual servi ci ng.
a RemovelheniIefromlhecuandoiIIler
housingusingaAIIenvrenchbilSee
Iigure
Figure 8-25. Removing Nipple.
b RemovelheoiIIlercuandsringfrom
housingSeeIigure
Figure 8-26. Disassembled Cup and Spring.
c. Remove the rubber val ve and spri ng from the
cuSeeIigure
Figure 8-27. Rubber Valve and Spring Removed
from Cup.
Remove Ignition Modules
RolalelheyvheeIsolhemagnelisavayfrom
the modul es.
2. Remove the mounti ng screws and di sconnect
the ki l l l ead from the i gni ti on modul es. Note
the posi ti on of the i gni ti on modul es and wi ri ng
harnesscIiSeeIigure
Figure 8-28. Removing and Disconnecting Ignition
Modules.
Oil Filter
Housing
Mounting
Screw
Nipple
Mounting
Screws
Kill Lead
Ignition
Module
Spring
Cup
Nipple
Housing
Cup
Rubber
Valve
Spring
8.8
Section 8
Disassembly
Remove Grass Screen and Cooling Fan
Removelhescrevsaachinghardvareandhex
sludssecuringlhegrassscreenslienersand
cooIingfanlolheyvheeISeeIiguresand

Figure 8-29. Removing Grass Screen Fasteners.

Figure 8-30. Removing Cooling Fan and Hex
Studs.
Remove Flywheel
UseayvheeIslravrenchorhoIdinglooIsee
SeclionlohoIdlheyvheeIandIoosenlhe
hexangescrevsecuringlheyvheeIlolhe
crankshaSeeIigure
NOTI AIvaysuseayvheeIslravrenchor
hoIdinglooIlohoIdlheyvheeIvhen
IooseningorlighleninglheyvheeI
screw. Do not use any type of bar or
vedgelohoIdlheyvheeIUseofsuch
looIscouIdcauselheyvheeIlobecome
cracked or damaged.
Figure 8-31. Removing Flywheel Fastener Using
Holding Tool.
Removelhehexangescrevandvasher
UseauIIerloremovelheyvheeIfromlhe
crankshaSeeIigure
NOTI AIvaysuseayvheeIuIIerloremove
lheyvheeIfromlhecrankshaDo
notslrikelhecrankshaoryvheeI
as these parts coul d become cracked or
damaged.
Figure 8-32. Removing Flywheel with a Puller.
Removelhevoodrukeyfromlhecranksha
Remove Stator, Rectier-ReguIator and
Wiring Harness
DisconnecllheIugfromlhereclierreguIalor
If the B+ (center ) l ead must be removed from the
pl ug, use the ti p of the di psti ck or a si mi l ar smal l
allooIlobendlheIockinglangThenremove
the l ead.
Screws (3)
Fan
Hex Studs (4)
Fasteners
8.9
Section 8
Disassembly
8
Wiring
Harness
Molded
Clips
2. Remove the mounti ng screws securi ng the
reclierreguIalorlolhebackingshroud
assembl y. Note the l ocati on of the ground l ead.
IflhereclierreguIalorisnolbeingreIaced
i t may remai n mounted to the backi ng shroud
assembIySeeIigure
Figure 8-33. Rectier-ReguIator DetaiIs.
3. Remove the two screws securi ng the stator to the
crankcase and careful l y separate the stator wi res
fromlhemoIdedcIisSeeIigure
Figure 8-34. Removing Stator.
4. Unhook the wi ri ng harness from the mol ded
cIisifbeingservicedsearaleIySeeIigure
Figure 8-35. Removng Wiring Harness.
Remove Backing Shroud Assembly
1. Remove the four screws securi ng the backi ng
shroud assembl y to the crankcase. See Fi gure

Figure 8-36. Removing Backing Shroud Mounting

Screws.
Remove Spark Plugs
1. Remove the spark pl ug from each cyl i nder head.
Figure 8-37. Removing Spark Plugs.
Mounting
Screws
Molded
Clips
Ground
Lead
Plug
Rectier-
Regulator
Backing Shroud
Assembly
Screws
8.10
Section 8
Disassembly
Remove Valve Covers
1. Remove the screw and grommet securi ng each
val ve cover.
2. Remove the val ve cover and gasket from each
cyl i nder head. Note the l ocati ons of i ndi vi dual
vaIvecoversiflheyaredierenlSeeIigure
Figure 8-38. Removing Valve Covers.
Remove Cylinder Heads and Hydraulic
Lifters
Loosenlheinnerselscrevsandbackolhe
rocker arm adjusti ng nuts.
2. Remove the pi pe pl ug from the cyl i nder head to
access the screw i n the center l ocati on. See Fi gure

Figure 8-39. Removing Pipe Plug.

Removelhevehexangescrevssecuringeach
cyl i nder head. Note the l ocati ons of washers and
lhesacerSeeIigure
Figure 8-40. Removing Cylinder Head Fasteners.
3. Mark the posi ti on of the push rods as ei ther
inlakeorexhauslandcyIinderorIush
rods shoul d al ways be rei nstal l ed i n the same
posi ti ons.
4. Careful l y remove the push rods, cyl i nder head,
andheadgaskelsSeeIigure
5. Repeat the procedure for the other cyl i nder head.
Figure 8-41. Removing Cylinder Head Assembly.
RemovelheIiersfromlheIierboresUsea
HydrauIicLierTooIDonoluseamagnello
removeIiersMarklheIiersbyIocalionas
ei ther i ntake or exhaust and cyl i nder 1 or 2.
HydrauIicIiersshouIdaIvaysbereinslaIIedin
lhesameosilionSeeIiguresand
NOTI TheexhauslIiersareIocaledonlhe
oululshasideoflheenginevhiIelhe
inlakeIiersareIocaledonlhefanside
of the engi ne. The cyl i nder head number
i s embossed on the outsi de of each
cyIinderheadSeeIigure
Pipe Plug
Spacer
Washers
8.11
Section 8
Disassembly
8
Figure 8-42. Removing Hydraulic Lifters.
Figure 8-43. Match Numbers on Cylinder Barrel
and Heads.
Disassemble Cylinder Heads
1. Remove the two adjusters, rocker arm pi vots,
and rocker arms from the cyl i nder head. Remove
the pi vot studs and gui de pl ate as requi red. See
Iigure
Figure 8-44. Removing Rocker Arms.
2. Compress the val ve spri ngs usi ng a val ve spri ng
comressorSeeIigure
Figure 8-45. Removing Valves with Valve Spring
Compressor.
3. Once the val ve spri ng i s compressed, remove the
foIIovingilemsSeeIiguresand
Val ve spri ng keepers
Val ve spri ng retai ners
Val ve spri ngs
Val ve spri ng caps
Intake and exhaust val ves (mark posi ti on)
Val ve stem seal s
Figure 8-46. Valve Train Components.
Match
Numbers
8.12
Section 8
Disassembly
Figure 8-47. Valve Stem Seals.
NOTE: These engi nes use val ve stem seal s on
the i ntake and exhaust val ves. Use a
new seal whenever val ves are removed,
or i f the seal i s deteri orated i n any way.
Never reuse an ol d seal .
4. Repeat the above procedure for the other cyl i nder
head. Do not i nterchange parts from one cyl i nder
head to the other.
Remove Breather Assembly
Removelhefourhexangescrevssecuringlhe
breather assembl y, and gasket to the crankcase.
2. Careful l y break the gasket seal and remove the
brealherandIlerDonolryonlheseaIing
surfaces as i t coul d cause damage resul ti ng i n
l eaks. Note the assembl y and ori entati on of parts.
SeeIiguresand
Figure 8-48. Removing Breather Assembly.
Figure 8-49. Removing Breather Filter.
Remove Oil Pan Assembly
Removelhefourleenhexangescrevssecuring
lheoiIanlolhecrankcaseSeeIigure
Figure 8-50. Removing Oil Pan Screws.
2. Locate the two protrudi ng tabs on the oi l pan.
Careful l y tap to break the gasket seal . Do not pry
on the seal i ng surfaces as thi s coul d cause l eaks.
Separate the oi l pan from the crankcase. See
IiguresandRemovelheoIdgaskel
Figure 8-51. Location of Protruding Tabs.
Valve Stem Seals
Breather
Gasket Tabs
Filter
8.13
Section 8
Disassembly
8
Figure 8-52. Removing Oil Pan.
Oil Pump Assembly
The oi l pump i s mounted to the i nsi de of the oi l pan.
If servi ce i s requi red, refer to the servi ce procedures
underOiIIumAssembIyinSeclion
Remove Camshaft
RemovelhecamshaandshimifusedSee
Iigure
Figure 8-53. Removing Camshaft.
Remove Connecting Rods with Pistons
and Rings
Removelhelvohexangescrevssecuringlhe
cl osest connecti ng rod end cap. Remove the end
caSeeIiguresand
Figure 8-54. Removing Connecting Rod Screws.
NOTE: If a carbon ri dge i s present at the top
of ei ther cyl i nder bore, use a ri dge
reamer tool to remove the ri dge before
aemlingloremovelheislon
Figure 8-55 Remove Connecting Rod Caps.
NOTE: The cyl i nders are numbered on the
crankcase. Use the numbers to mark
each end cap, connecti ng rod and pi ston
for reassembl y. Do not mi x end caps and
connecti ng rods.
8.14
Section 8
Disassembly
2. Careful l y remove the connecti ng rod and pi ston
assembIyfromlhecyIinderboreSeeIigure
Figure 8-56. Removing Piston/Connecting Rod
Assemblies.
3. Repeat the above procedures for the other
connecti ng rod and pi ston assembl y.
Remove Crankshaft
CarefuIIyuIIlhecrankshafromlhecrankcase
SeeIigureNolelhruslvashersandshimsif
used.
Figure 8-57. Removing Crankshaft.
Removal of Governor Gear Assembly
ThegovernorgearisheIdonlolheshabysmaII
mol ded tabs i n the gear. When the gear i s removed
fromlheshalheselabsaredeslroyedandlhegear
must be repl aced. Therefore, remove the gear onl y
ifabsoIuleIynecessaryIflhegovernorcrosssha
yoke, or gear condi ti on does not requi re removal ,
lhegovernorgearmaybeIeinIaceIfremovaIis
necessary, perform as fol l ows:
1. Remove the l ocki ng tab thrust washer and note
ori entati on.
2. Usi ng a screwdri ver, careful l y pry up to unseat
governor gear assembl y from the governor gear
shaRemovelhereguIalinginandgovernor
gearassembIySeeIigure
Figure 8-58. Removing Governor Gear.
Insecllhegovernorgearshaforvearor
damageRemovelheshaonIyifreIacemenlis
needed.
Remove Governor Yoke, Cross Shaft, and
Oil Seal
1. Remove the two mounti ng screws securi ng the
yokelolhegovernorcrossshaSeeIigure
Figure 8-59. Removing Cross Shaft/Yoke Screws.
IuIIlhegovernorcrossshaoulofcrankcaseand
remove seal .
Governor Gear
8.15
Section 8
Disassembly
8
Remove Lifter Feed Chamber Cover and
Gaskets
RemovelhelhreescrevssecuringlheIierfeed
chamber cover, and gaskets. Careful l y separate
lhearlsfromlhecrankcaseSeeIigure
Figure 8-60. Removing Lifter Feed Chamber Cover
Components.
Remove Flywheel and PTO End Oil Seals
1. Remove the oi l seal s from the crankcase and oi l
anusingaseaIuIIerSeeIigure
Figure 8-61. Removing Oil Seals.
Removal of Main Bearings
NOTI IIyvheeIandITOsidemainbearings
shoul d onl y be removed i f repl acement
i s requi red due to wear. If removal i s
performed, use a press and support the
adjacent cast surface around the beari ng
angevhenerformingDo not press
againslorsuorlbylhegaskelouler
erimelersurfaceSeeIigure
Figure 8-62. Support Surface Details.
Cover
Gasket
Screws
Support
This Surface
8.16
9
9.1
Section 9
Inspection and Reconditioning
Thi s secti on covers the operati on, i nspecti on, and
repai r/recondi ti oni ng of major i nternal engi ne
components. The fol l owi ng components are not
covered i n thi s secti on. They are covered i n secti ons of
thei r own:
Ai r Cl eaner, Secti on 4
Carburetor & External Governor, Secti on 5
Igni ti on, Chargi ng & El ectri c Starter, Secti on 7
Cl ean al l parts thoroughl y. Onl y cl ean parts can be
accuratel y i nspected and gauged for wear or damage.
There are many commerci al l y avai l abl e cl eaners
that wi l l qui ckl y remove grease, oi l , and gri me from
engi ne parts. When such a cl eaner i s used, fol l ow the
manufacturer s i nstructi ons and safety precauti ons
careful l y. Make sure al l traces of the cl eaner are
removed before the engi ne i s reassembl ed and pl aced
i nto operati on. Even smal l amounts of these cl eaners
can qui ckl y break down the l ubri cati ng properti es of
engi ne oi l .
Use an aerosol gasket remover, pai nt stri pper, or
l acquer thi nner to remove any ol d gasket materi al .
Appl y the sol vent, al l ow ti me for i t to work, and
then brush the surface wi th a brassvirebrushAer
al l ol d materi al i s removed, cl ean the surface wi th
i sopropyl al cohol , l acquer thi nner, or aerosol el ectri cal
contact cl eaner. Do not scrape the surfaces, as any
scratches, ni cks, or burrs can resul t i n l eaks. See
Servi ce Bul l eti n 252 for further i nformati on.
Refer to A Gui de to Engi ne Rebui l di ng (TP-2150-A)
for addi ti onal i nformati on. Measurement Gui de
(TP-2159-B) and Engi ne Inspecti on Data Record
(TP-2435) are al so avai l abl e; use these to record
i nspecti on resul ts.
Camshaft
Inspection and Service
ChecklheIobesoflhecamshaforvearordamage
SeeSeclionforminimumIiandordimensionaI
secicalionsInsecllhecamgearforbadIyvorn
chi pped, or mi ssi ng teeth. Repl acement of the
camshaviIIbenecessaryifanyoflhesecondilions
exi st.
Crankshaft
Inspection and Service
InsecllhegearleelhoflhecrankshaIflheleelh
are badl y worn, chi pped, or some are mi ssi ng,
reIacemenloflhecrankshaviIIbenecessary
Insecllhecrankshabearingsurfacesforscoring
groovi ng, etc. Repl aceabl e beari ngs are used i n the
crankshaboreoflheoiIanandorcrankcaseDo
not repl ace the beari ngs unl ess they show si gns of
damageorareoulofrunningcIearancesecicalions
IflhecrankshalurnseasiIyvilhoulnoiseandlhere
i s no evi dence of scori ng, groovi ng, etc., on the races
or beari ng surfaces, the beari ngs can be reused.
InsecllhecrankshakeyvaysIflheyarevorn
orchiedreIacemenloflhecrankshaviIIbe
necessary.
Inspect the crankpi n for score marks or metal l i c
pi ckup. Sl i ght score marks can be cl eaned wi th
crocus cl oth soaked i n oi l . If the wear l i mi ts, as stated
inSecicalionsandToIerancesareexceededil
viIIbenecessaryloeilherreIacelhecrankshaor
regri nd the crankpi n to 0.25 mm (0.010 i n.) undersi ze.
If reground, a 0.25 mm (0.010 i n.) undersi ze
connecti ng rod (bi g end) must then be used to achi eve
proper runni ng cl earance. Measure the crankpi n for
si ze, taper, and out-of-round.
Section 9
Inspection and Reconditioning
9.2
45
High Point from
Fillet Intersections
This Fillet Area
Must Be
Completely Smooth
Minimum
The Fillet Must
Blend Smoothly
with the Bearing
Journal Surface
NOTE: If the crankpi n i s reground, vi sual l y check to
ensurelhallheIIelbIendssmoolhIyvilh
the crankpi n surface. See Fi gure 9-1.
Figure 9-1. Crankpin Fillets.
The connecti ng rod journal can be ground one si ze
underWhengrindingacrankshagrindingslone
deposi ts can get caught i n the oi l passages, whi ch
coul d cause severe engi ne damage. Removi ng the
crankinIugvhenlhecrankshaisgroundrovides
easy access for removi ng any gri ndi ng deposi ts that
may col l ect i n the oi l passages.
Use the fol l owi ng procedure to remove and repl ace
the pl ug.
Procedure to Remove Crankshaft Plug:
1. Dri l l a 3/16" hol e through the pl ug i n the
cranksha
2. Thread a 3/4" or 1" l ong sel f-tappi ng screw wi th a
alvasherinlolhedriIIedhoIeThealvasher
must be l arge enough to seat agai nst the shoul der
of the pl ug bore. See Fi gure 9-2.
3. Ti ghten the sel f-tappi ng screw unti l i t draws the
Iugouloflhecranksha
Procedure to Install New Plug:
UseasingIecyIindercamshainKohIerIarl
No. 47 380 09-S as a dri ver and tap the pl ug i nto
lheIugboreunliIilsealsallheboomoflhe
bore. Make sure the pl ug i s tapped i n evenl y to
prevent l eakage.
Figure 9-2. Removing Crankpin Plug.
Crankcase
Inspection and Service
Check al l gasket surfaces to make sure they are free of
gasket fragments. Gasket surfaces must al so be free of
deep scratches or ni cks.
Inspect the mai n beari ng (i f so equi pped) for wear or
damagereferloSeclionSecicalionsToIerances
andSeciaITorqueVaIuesReIacelhebearing
or crankcase usi ng a mi ni bl ock or short bl ock as
requi red.
Check the cyl i nder bore for scori ng. In severe cases,
unburnedfueIcancausescungandscoringoflhe
cyl i nder wal l . It washes the necessary l ubri cati ng
oiIsolheislonandcyIindervaIIAsravfueI
seeps down the cyl i nder wal l , the pi ston ri ngs make
metal to metal contact wi th the wal l . Scori ng of the
cyl i nder wal l can al so be caused by l ocal i zed hot
solsresuIlingfrombIockedcooIingnsorfrom
i nadequate or contami nated l ubri cati on.
If the cyl i nder bore i s badl y scored, excessi vel y worn,
tapered, or out-of-round, resi zi ng i s necessary. Use an
i nsi de mi crometer to determi ne the amount of wear
referlolheSecicalionsToIerancesandSeciaI
TorqueVaIuesinSeclionlhenseIecllhenearesl
sui tabl e oversi ze of ei ther 0.25 mm (0.010 i n.) or 0.50
mm (0.020 i n.). Resi zi ng to one of these oversi zes wi l l
al l ow usage of the avai l abl e oversi ze pi ston and ri ng
assembl i es. Ini ti al l y, resi ze usi ng a bori ng bar, then
use the fol l owi ng procedures for honi ng the cyl i nder.
Honing
Whi l e most commerci al l y avai l abl e cyl i nder hones
can be used wi th ei ther portabl e dri l l s or dri l l presses,
the use of a l ow speed dri l l press i s preferred as i t
faci l i tates more accurate al i gnment of the bore i n
reIalionlolhecrankshacrossboreHoningisbesl
Flat Washer
Self-Tapping Screw
Plug
Crankshaft
Section 9
Inspection and Reconditioning
9
9.3
11 mm (0.433 in.)
Measure 11 mm above the
Bottom of Piston Skirt at
Right Angles to Piston Pin
accompl i shed at a dri l l speed of about 250 RPM and
slrokeserminuleAerinslaIIingcoarseslonesin
hone, proceed as fol l ows:
Loverhoneinloboreandaercenleringad|usl
so the stones are i n contact wi th the cyl i nder
vaIIUseofacommerciaIcuingcooIingagenlis
recommended.
2. Wi th the l ower edge of each stone posi ti oned
even wi th the l owest edge of the bore, start dri l l
and honi ng process. Move the hone up and down
vhiIeresizinglorevenllheformalionofcuing
ri dges. Check the si ze frequentl y.
NOTI KohIerislonsarecuslommachinedlo
exacti ng tol erances. When oversi zi ng a
cyl i nder, i t shoul d be machi ned exactl y
0.25 mm (0.010 i n.) or 0.50 mm (0.020 i n.)
over the new di ameter (Secti on 1). The
corresondingoversizeKohIerreIacemenl
islonviIIlhenlcorreclIy
3. When the bore i s wi thi n 0.064 mm (0.0025 i n.) of
the desi red si ze, remove the coarse stones and
repl ace them wi th burni shi ng stones. Conti nue
wi th the burni shi ng stones unti l the bore i s
wi thi n 0.013 mm (0.0005 i n.) of the desi red si ze
andlhenusenishslonesgriland
oIishlheboreloilsnaIsizeAcrosshalch
shoul d be observed i f honi ng i s done correctl y.
The crosshatch shoul d i ntersect at approxi matel y
olhehorizonlaITooalanangIecouId
cause the ri ngs to ski p and wear excessi vel y,
and too steep an angl e wi l l resul t i n hi gh oi l
consumpti on. See Fi gure 9-3.
Figure 9-3. Cylinder Bore Crosshatch after Honing.
Aerresizingchecklheboreforroundness
taper, and si ze. Use an i nsi de mi crometer,
tel escopi ng gauge, or bore gauge to take
measurements. The measurements shoul d be
taken at three l ocati ons i n the cyl i nder at the
lomiddIeandboomTvomeasuremenls
shoul d be taken (perpendi cul ar to each other) at
each of the three l ocati ons.
Clean Cylinder Bore After Honing
Proper cl eani ng of the cyl i nder wal l s fol l owi ng bori ng
and/or honi ng i s very cri ti cal to a successful overhaul .
MachininggrilIeinlhecyIinderborecandeslroy
anengineinIesslhanonehourofoeralionaera
rebui l d.
ThenaIcIeaningoeralionshouIdaIvaysbea
thorough scrubbi ng wi th a brush and hot, soapy
water. Use a strong detergent that i s capabl e of
breaki ng down the machi ni ng oi l whi l e mai ntai ni ng
a good l evel of suds. If the suds break down duri ng
cl eani ng, di scard the di rty water and start agai n
wi th more hot water and detergent. Fol l owi ng the
scrubbi ng, ri nse the cyl i nder wi th very hot, cl ear
water, dry i t compl etel y, and appl y a l i ght coati ng of
engi ne oi l to prevent rusti ng.
Measuring Piston-to-Bore Clearance
Before i nstal l i ng the pi ston i nto the cyl i nder bore, i t
i s necessary that the cl earance be accuratel y checked.
ThissleisoenoverIookedandiflhecIearancesare
nolvilhinsecicalionsenginefaiIureviIIusuaIIy
resul t.
NOTE: Do not use a feel er gauge to measure pi ston-
to-bore cl earance i t wi l l yi el d i naccurate
measurements. Al ways use a mi crometer.
Use the fol l owi ng procedure to accuratel y measure
the pi ston-to-bore cl earance:
1. Use a mi crometer and measure the di ameter of
the pi ston 11 mm (0.433 i n.)abovelheboomof
the pi ston ski rt and perpendi cul ar to the pi ston
pi n. See Fi gure 9-4.
Figure 9-4. Measuring Piston Diameter.
Section 9
Inspection and Reconditioning
9.4
Feeler Gauge
2. Use an i nsi de mi crometer, tel escopi ng gauge, or
bore gauge and measure the cyl i nder bore. Take
the measurement approxi matel y 63.5 mm
(2.5 i n.) bel ow the top of the bore and
perpendi cul ar to the pi ston pi n.
IislonloborecIearanceislhedierencebelveen
the bore di ameter and the pi ston di ameter (step 2
mi nus step 1).
Flywheel
Inspection
InsecllheyvheeIforcracksandlheyvheeI
keyvayfordamageReIacelheyvheeIifilis
crackedReIacelheyvheeIlhecrankshaand
lhekeyifyvheeIkeyisshearedorlhekeyvayis
damaged.
InsecllheringgearforcracksordamageKohIer
does not provi de the ri ng gear as a servi ceabl e part.
ReIacelheyvheeIiflheringgearisdamaged
Cylinder Head and Valves
Inspection and Service
AercIeaningchecklhealnessoflhecyIinderhead
and the correspondi ng top surface of the crankcase,
usi ng a surface pl ate or pi ece of gl ass and feel er gauge
as shown i n Fi gure 9-5. The maxi mum al l owabl e out
ofalnessis 0.076 mm (0.003 i n.).
Figure 9-5. Checking Cylinder Head Flatness.
Careful l y i nspect the val ve mechani sm parts. Inspect
the val ve spri ngs and rel ated hardware for excessi ve
wear or di storti on. Check the val ves and val ve seat
areaorinserlsforevidenceofdeeiingcracks
or di storti on. Check cl earance of the val ve stems
i n the gui des. See Fi gure 9-6 for val ve detai l s and
secicalions
Section 9
Inspection and Reconditioning
9
9.5
EXHAUST VALVE INTAKE VALVE
A B
C
D
D
F
E
G
H
F
E
G
H
INT
EXH
Figure 9-6. Valve Details.
HardslarlingorIossofoveraccomaniedbyhigh
fuel consumpti on may be symptoms of faul ty val ves.
AIlhoughlhesesymlomscouIdaIsobearibuledlo
vornringsremoveandchecklhevaIvesrslAer
removal , cl ean the val ve heads, faces, and stems wi th
a power wi re brush.
Then, careful l y i nspect each val ve for defects such as a
warped head, excessi ve corrosi on, or a worn stem end.
Repl ace val ves found to be i n bad condi ti on. A normal
val ve and val ves i n bad condi ti on are shown i n the
accompanyi ng i l l ustrati ons.
Dimension Intake Exhaust
A Seat Angl e
B Seat Taper 30 30
C Gui de Depth mmin mmin
D Gui de I.D. mmin mmin
E VaIveHeadDiameler mmin mmin
F Val ve Face Angl e 45 45
G Val ve Margi n (Mi n.) 1.0 mm (0.0393 i n.) 1.0 mm (0.0393 i n.)
H Val ve Stem Di ameter mmin mmin
Section 9
Inspection and Reconditioning
9.6
Normal :IvenaerIonghoursofoeralionavaIve
can be recondi ti oned and reused i f the face and
margi n are i n good shape. If a val ve i s worn to where
the margi n i s l ess than 1/32" do not reuse i t. The val ve
shown was i n operati on for al most 1000 hours under
control l ed test condi ti ons.
Bad Condi ti on: The val ve depi cted here shoul d be
repl aced. Note the warped head; margi n damaged
andloonarrovThesecondilionscouIdbearibuled
to excessi ve hours or a combi nati on of poor operati ng
condi ti ons.
Leakage: A poor gri nd on face or seat of val ve wi l l
al l ow l eakage resul ti ng i n a burned val ve on one si de
onl y.
Coki ng: Coki ng i s normal on i ntake val ves and i s not
harmful . If the seat i s good, the val ve coul d be reused
aercIeaning
Section 9
Inspection and Reconditioning
9
9.7
Excessi ve Combusti on Temperatures: The whi te
deposi ts seen here i ndi cate very hi gh combusti on
temperatures, usual l y due to a l ean fuel mi xture.
Gum: Gum deposi ts usual l y resul t from usi ng stal e
gasol i ne. Gum i s a preval ent cause of val ve sti cki ng.
The cure i s to ream the val ve gui des and cl ean or
repl ace the val ves, dependi ng on thei r condi ti on.
Stem Corrosi on: Moi sture i n fuel or from
condensati on are the most common causes of val ve
stem corrosi on. Condensati on occurs from i mproper
preservati on duri ng storage and when engi ne i s
repeatedl y stopped before i t has a chance to reach
normal operati ng temperatures. Repl ace corroded
val ves.
Overheati ng: An exhaust val ve subject to overheati ng
wi l l have a dark di scol orati on i n the area above the
val ve gui de. Worn gui des and faul ty val ve spri ngs
may cause thi s condi ti on. Al so check for cl ogged ai r
inlakeandbIockednsvhenlhiscondilionisnoled
Section 9
Inspection and Reconditioning
9.8
Valve Seat Cutter
Pilot
Valve Guides
IfavaIveguideisvornbeyondsecicalionsilviII
not gui de the val ve i n a strai ght l i ne. Thi s may resul t
i n burnt val ve faces or seats, l oss of compressi on, and
excessi ve oi l consumpti on.
To check val ve gui de-to-val ve stem cl earance,
thoroughl y cl ean the val ve gui de and, usi ng a spl i t-
bal l gauge, measure the i nsi de di ameter of the
gui de. Then, usi ng an outsi de mi crometer, measure
the di ameter of the val ve stem at several poi nts on
the stem where i t moves i n the val ve gui de. Use
the l argest stem di ameter to cal cul ate the cl earance
by subtracti ng the stem di ameter from the gui de
di ameter. If the i ntake cl earance exceeds
0.038/0.076 mm (0.0015/0.0030 i n.), or the exhaust
cl earance exceeds 0.050/0.088 mm
(0.0020/0.0035 i n.), determi ne whether the val ve stem
or gui de i s responsi bl e for the excessi ve cl earance.
The maxi mum (I.D.) wear on the i ntake val ve gui de
i s 7.134 mm (0.2809 i n.) whi l e 7.159 mm (0.2819 i n.)
i s the maxi mum al l owed on the exhaust gui de. The
gui des are not removabl e but can be reamed 0.25
mm 0.010 i n.) oversi ze. Val ves wi th 0.25 mm oversi ze
stems must then be used.
If the gui des are wi thi n l i mi ts but the val ve stems are
worn beyond l i mi ts, i nstal l new val ves.
Valve Seat Inserts
HardenedsleeIaIIoyinlakeandexhauslvaIveseal
inserlsareressedinlolhecyIinderheadThe
i nserts are not repl aceabl e but can be recondi ti oned i f
nolloobadIyiedordislorledIfcrackedorbadIy
warped, the cyl i nder head shoul d be repl aced.
Recondi ti on the val ve seat i nserts fol l owi ng the
inslruclionsrovidedvilhlhevaIvesealcuerbeing
usedAlyicaIcuerisshovninIigureThenaI
culshouIdbemadevilhancuerassecied
forlhevaIvesealangIeinIigureCuinglhe
roervaIvefaceangIeasseciedinIigure
9-6, and the proper val ve seat angl e (44.5, hal f of the
fuIIangIeviIIachievelhedesiredfuII
cut) i nterference angl e where the maxi mum pressure
occurs on the outsi de di ameters of the val ve face and
seat.
Figure 9-7. Typical Valve Seat Cutter.
Lapping Valves
Reground or new val ves must be l apped i n, to provi de
roerlUseahandvaIvegrindervilhasuclion
cufornaIIaingLighlIycoallhevaIvefacevilh
anegradeofgrindingcomoundlhenrolalelhe
val ve on i ts seat wi th the gri nder. Conti nue gri ndi ng
unti l a smooth surface i s obtai ned on the seat and on
the val ve face. Thoroughl y cl ean the cyl i nder head i n
soap and hot water to remove al l traces of gri ndi ng
comoundAerdryinglhecyIinderheadaIya
l i ght coati ng of SAE 10 oi l to prevent rusti ng.
Valve Stem Seals
These engi nes use val ve stem seal s on the i ntake and
exhaust val ves. Al ways use new seal s when the val ves
are removed from the cyl i nder head. The seal s shoul d
al so be repl aced i f deteri orated or damaged i n any
way. Never reuse an ol d seal .
Pistons and Rings
Inspection
ScungandscoringofislonsandcyIindervaIIs
occurs when i nternal engi ne temperatures approach
the wel di ng poi nt of the pi ston. Temperatures hi gh
enough to do thi s are created by fri cti on, whi ch i s
usuaIIyaribuledloimroerIubricalionandor
overheati ng of the engi ne.
NormaIIyveryIiIevearlakesIaceinlheislon
boss-pi ston pi n area. If the ori gi nal pi ston and
conneclingrodcanbereusedaernevringsare
i nstal l ed, the ori gi nal pi n can al so be reused but new
pi ston pi n retai ners are requi red. The pi ston pi n i s
i ncl uded as part of the pi ston assembl y i f the pi n
boss i n the pi ston or the pi n are worn or damaged, a
new pi ston assembl y i s requi red.
Section 9
Inspection and Reconditioning
9
9.9
Overheated or Deteriorated Oil Scored Piston and Rings
Abrasive Scratched Rings Stuck, Broken Rings
Ri ng fai l ure i s usual l y i ndi cated by excessi ve oi l
consumpti on and bl ue exhaust smoke. When ri ngs
fai l , oi l i s al l owed to enter the combusti on chamber
vhereilisburnedaIongvilhlhefueIHighoiI
consumpti on can al so occur when the pi ston ri ng
end gap i s i ncorrect because the ri ng cannot properl y
conform to the cyl i nder wal l under thi s condi ti on. Oi l
control i s al so l ost when ri ng gaps are not staggered
duri ng i nstal l ati on.
When cyl i nder temperatures get too hi gh, l acquer and
varni sh col l ect on pi stons causi ng ri ngs to sti ck, whi ch
resul ts i n rapi d wear. A worn ri ng usual l y takes on a
shi ny or bri ght appearance.
Scratches on ri ngs and pi stons are caused by abrasi ve
materi al such as carbon, di rt, or pi eces of hard metal .
Detonati on damage occurs when a porti on of the fuel
charge i gni tes spontaneousl y from heat and pressure
shorlIyaerignilionThiscrealeslvoamefronls
whi ch meet and expl ode to create extreme hammeri ng
ressuresonasecicareaoflheislonDelonalion
general l y occurs from usi ng l ow octane fuel s.
Prei gni ti on or i gni ti on of the fuel charge before the
ti med spark can cause damage si mi l ar to detonati on.
Ireigniliondamageisoenmoreseverelhan
detonati on damage. Prei gni ti on i s caused by a hot
spot i n the combusti on chamber from sources such
asgIovingcarbondeosilsbIockedcooIingnsan
i mproperl y seated val ve, or wrong spark pl ug(s).
SeeIigureforsomecommonlyesofislonand
ri ng damage.
Figure 9-8. Common Types of Piston Damage.
Section 9
Inspection and Reconditioning
9.10
Repl acement pi stons are avai l abl e i n STD bore si ze,
and i n 0.25 mm (0.010 i n.), and 0.50 mm (0.020 i n.)
oversi ze. Repl acement pi stons i ncl ude new pi ston ri ng
sets and new pi ston pi ns.
Repl acement ri ng sets are al so avai l abl e separatel y
for STD, 0.25 mm (0.010 i n.), and 0.50 mm (0.020 i n.)
oversi ze pi stons. Al ways use new pi ston ri ngs when
i nstal l i ng pi stons. Never use ol d ri ngs.
Some i mportant poi nts to remember when servi ci ng
pi ston ri ngs:
1. The cyl i nder bore must be degl azed before
servi ce ri ng sets are used.
2. If the cyl i nder bore does not need rebori ng and
i f the ol d pi ston i s wi thi n wear l i mi ts and free
ofscoreorscumarkslheoIdislonmaybe
reused.
3. Remove the ol d ri ngs and cl ean up the grooves.
Never reuse ol d ri ngs.
4. Before i nstal l i ng the new ri ngs on the pi ston,
pl ace the top two ri ngs, each i n turn, i n i ts
runni ng area i n the cyl i nder bore and check the
end gap. (See Fi gure 9-9.) Compare the ri ng gap
lolhesecicalionsIisledinSeclion
Figure 9-9. Measuring Piston Ring End Gap.
AerinslaIIinglhenevcomressionloand
mi ddl e) ri ngs on the pi ston, check the pi ston-
to-ri ng si de cl earance. Compare the cl earance
losecicalionsIisledinSeclionIflheside
cIearanceisgrealerlhanseciedanevislon
must be used. Refer to Fi gure 9-10.
Figure 9-10. Measuring Piston Ring Side
Clearance.
Install New Piston Rings
To i nstal l new pi ston ri ngs, proceed as fol l ows:
NOTE: Ri ngs must be i nstal l ed correctl y. Ri ng
i nstal l ati on i nstructi ons are usual l y i ncl uded
wi th new ri ng sets. Fol l ow i nstructi ons
careful l y. Use a pi ston ri ng expander to
i nstal l ri ngs (see Fi gure 9-11). Instal l the
boomoiIconlroIringrslandlhelo
compressi on ri ng l ast. Refer to Fi gure 9-12.
Figure 9-11. Installing Piston Rings.
Piston Ring
Piston Ring
Expander
Section 9
Inspection and Reconditioning
9
9.11
Figure 9-12. Piston Ring Installation.
OiIConlroIRingoomGrooveInslaIIlhe
expander and then the rai l s. Make sure the ends
of the expander are not overl apped.
2. Mi ddl e Compressi on Ri ng (Center Groove):
Instal l the center ri ng usi ng a pi ston ri ng
inslaIIalionlooIMakesurelheidenlicalion
mark i s up or the dykem stri pe (i f contai ned) i s to
lheIeoflheendga
3. Top Compressi on Ri ng (Top Groove): Instal l the
top ri ng usi ng a pi ston ri ng expander. Make sure
lheidenlicalionmarkisuorlhedykem
slrieifconlainedislolheIeoflheendga
Connecting Rods
Oselsleedcaconneclingrodsareusedinlhese
engi nes.
Inspection and Service
Check the beari ng area (bi g end) for excessi ve wear,
score marks, runni ng and si de cl earances (refer to
SeclionSecicalionsToIerancesandSeciaI
TorqueVaIuesReIacelherodandcaifscoredor
excessi vel y worn.
Servi ce repl acement connecti ng rods are avai l abl e i n
STD crankpi n si ze and 0.25 mm (0.010 i n.) undersi ze.
Al ways refer to the appropri ate parts i nformati on to
ensure that correct repl acements are used.
Hydraulic Lifters
Inspection
ChecklhebasesurfaceoflhehydrauIicIiersforvear
ordamageIflheIiersneedlobereIacedaIya
IiberaIcoalingofKohIerIubricanl25 357 14-S to the
baseofeachnevIierbeforeilisinslaIIed
Bleeding the Lifters
To prevent a possi bl e bent push rod or broken rocker
armilisimorlanllobIeedanyexcessoiIouloflhe
IiersbeforelheyareinslaIIed
1. Cut a 50-75 mm (2-3 i n.) pi ece from the end of an
ol d push rod and chuck i t i n a dri l l press.
2. Lay a rag or shop towel on the tabl e of the dri l l
ressandIacelheIieroenenduonlhe
towel .
3. Lower the chucked push rod unti l i t contacts the
IungerinlheIierSIovIyumlheIunger
two or three ti mes to force the oi l out of the feed
hoIeinlhesideoflheIier
Governor Gear Assembly
Inspection
The governor gear i s l ocated wi thi n the crankcase.
Inspect the governor gear teeth. Repl ace the gear i f i t
i s worn, chi pped, or i f any teeth are mi ssi ng. Inspect
the governor wei ghts. They shoul d move freel y i n the
governor gear.
Disassembly
The governor gear must be repl aced once i t i s
removed from the crankcase.
NOTI ThegovernorgearisheIdonlolheshaby
smal l mol ded tabs i n the gear. When the
gearisremovedfromlheshalheselabsare
destroyed and the gear must be repl aced.
Therefore, remove the gear onl y i f absol utel y
necessary.
Piston Ring
End Gap
Identication
Mark
Piston
Top
Compression
Ring
Center
Compression
Ring
Rails
Expander
Oil Control Ring
(Three-piece)
Dykem
Stripe
Section 9
Inspection and Reconditioning
9.12
Oil Pan Assembly
Inspecti on
Inspect the oi l seal i n the oi l pan and remove i t i f i t i s
worn or damaged. Refer to Instal l Oi l Pan Oi l Seal
i n Secti on 10 for new oi l seal i nstal l ati on.
Inspect the mai n beari ng surface for wear or damage
referloSeclionSecicalionsToIerancesand
SeciaITorqueVaIuesReIacelhebearingoroiI
pan assembl y i f requi red.
Oil Pump Assembly
Disassembly
Removelhelhreehexangescrevssecuring
the oi l pump housi ng i ncl udi ng the rel i ef val ve
baeandlhesingIescrevforlheickuSee
Fi gure 9-13.
2. Remove the oi l pump housi ng and pi ckup from
the oi l pan.
3. Remove the oi l pump gerotor gears from the oi l
pan recess.
4. Remove the oi l pi ckup by pul l i ng i t free from the
oi l pump body.
5. The rel i ef val ve i s a one-pi ece styl e, staked to
the oi l pump housi ng; removal shoul d not be
aemlednorisinlernaIservicingossibIeIfa
probl em wi th the rel i ef val ve i s encountered, the
oi l pump shoul d be repl aced. See Fi gure 9-15.
Figure 9-13. Oil Pump and Pickup.
Inspection
Inspect the oi l pump housi ng, Gerotor gears, and
oi l pan recess for ni cks, burrs, wear, or any vi si bl e
damage. Inspect the i nl et seal for the pi ckup i n the
housi ng. If any parts are worn or damaged, repl ace
the i nl et seal , oi l pump or oi l pan as requi red.
Reassembly
1. Make sure the recess i n the cl osure pl ate for the
oi l pump gerotor gears i s cl ean.
2. Lubri cate the oi l pump Gerotor gears wi th grease
(Lubri pl ate

IreKoleorequivaIenland
i nstal l i nto the recess. See Fi gure 9-14.
Figure 9-14. Installing and Lubricating Oil Pump
Gerotor Gears.
3. Li ghtl y l ubri cate wi th oi l and i nstal l the i nl et seal
i nto the oi l pump housi ng unti l i t i s ful l y seated.
See Fi gure 9-15.
Figure 9-15. Installing Inlet Seal in Oil Pump
Housing.
Inlet Seal
Relief
Valve
Mounting
Screws
Pickup
Oil
Pump
Bafe
(Covering
Relief
Valve)
Pickup
Mounting
Screw
Section 9
Inspection and Reconditioning
9
9.13
O-Ring
3
2
1
4
4. Instal l the O-Ri ng i n the groove of the oi l pump
housi ng. Use a smal l quanti ty of grease to hol d i t
i n pl ace. See Fi gure 9-16.
Figure 9-16. O-Ring Installed in Oil Pump Housing.
5. Li ghtl y l ubri cate the I.D. of the i nl et seal wi th
oi l and careful l y i nsert the end of the pi ckup
through the seal , i nto the oi l pump housi ng.
6. Instal l the oi l pump housi ng wi th the pi ckup
tube, over the oi l pump boss and gears. Posi ti on
lhereIiefvaIvebaeonscrevsandAIignlhe
three screw hol e l ocati ons.
Figure 9-17. Installing Oil Pump and Pickup.
7. Check the al i gnment of parts and torque the
oiIumhousingscrevsasseciedusinglhe
sequenceshovninIigure
TorquelhehexangescrevsasfoIIovs
a. Instal l fastener i nto l ocati on No. 1 and
l i ghtl y ti ghten to posi ti on the pump.
b. Instal l fastener i nto l ocati on No. 2 and ful l y
torque to the recommended val ue.
c. Instal l fastener i nto l ocati on No. 3 and ful l y
torque to the recommended val ue.
d. Fi ni sh torqui ng fastener i n l ocati on No. 1
to the recommended val ue.
Fi rst Ti me Instal l ati on: 10.7 Nm (95 i n. l b.)
Al l Rei nstal l ati ons: 6.7 Nm (60 i n. l b.)
Figure 9-18. Oil Pump Screws Torque Sequence.
InslaIIandlorquelheickumounlingscrevlo
10.7 Nm (95 i n. l b.) i nto a new hol e, or 7.3 Nm
(65 i n. l b.) i nto a used hol e. See Fi gure 9-17.
Mounting
Screws
Pickup
Oil
Pump
Bafe
(Covering
Relief
Valve)
Pickup
Mounting
Screw
9.14
10.1
10
Section 10
Reassembly
General
NOTE: Make sure the engi ne i s assembl ed usi ng
aIIseciedlorquevaIueslighlening
sequencesandcIearancesIaiIureloobserve
secicalionscouIdcausesevereenginevear
ordamageAIvaysusenevgaskelsAIya
smaIIamounlofoiIlolhelhreadsofcrilicaI
faslenersbeforeassembIyunIessaSeaIanlor
Loclile

isseciedorreaIied
MakesureaIIlracesofanycIeanerareremovedbefore
lheengineisassembIedandIacedinlooeralion
IvensmaIIamounlsoflhesecIeanerscanquickIy
breakdovnlheIubricalingroerliesofengineoiI
ChecklheoiIancrankcasecyIinderheadsand
vaIvecoverslobecerlainlhalaIIoflheoIdgaskel
maleriaIhasbeenremovedUsegaskelremover
Iacquerlhinnerorainlremoverloremoveany
remaininglracesCIeanlhesurfacesvilhisoroyI
aIcohoIaceloneIacquerlhinneroreIeclricaIconlacl
cIeaner
Typical Reassembly Sequence
ThefoIIovingsequenceissuggesledforcomIele
enginereassembIyThisrocedureassumeslhalaII
comonenlsarenevorhavebeenrecondilionedand
aIIcomonenlsubassembIyvorkhasbeencomIeled
Thesequencemayvaryloaccommodaleolionsor
seciaIequimenlDelaiIedroceduresfoIIov
InslaIIyvheeIendoiIseaI
InslaIIIierfeedchambergaskelsandcover
InslaIIyvheeIendmainbearing
InslaIIgovernorshasseaIandgovernorgear
InslaIIcranksha
InslaIIconneclingrodsvilhislonsandrings
InslaIIcamsha
InslaIIoiIanseaIandmainbearing
InslaIIoiIanassembIy
CheckcrankshaendIay
InslaIIbrealherassembIy
InslaIIhydrauIicIiers
AssembIeandinslaIIcyIinderheads
InslaIIushrodsandrockerarms
InslaIIvaIvecovers
InslaIIsarkIugs
InslaIIoiIIlerhousing
InslaIIinlakemanifoId
InslaIIbackingshroudassembIy
InslaIIslalorviringharnessandreclier
reguIalor
InslaIIyvheeI
InslaIIignilionmoduIe
InslaIIoulercyIinderbaes
InslaIIoiIcooIer
InslaIIcooIingfanandgrassscreen
InslaIIeIeclricslarler
InslaIIvaIIeybaes
InslaIIcarburelor
InslaIIgovernorIever
InslaIIconlroIbrackelandaircIeanerassembIy
InslaIIlhroIeandchokeIinkages
InslaIIfueIum
InslaIIOiISenlry

svilchifequied
InslaIIbIoverhousingandcyIindershroud
InslaIImuer
InslaIIoiIIlerandaddoiIlocrankcase
ConneclsarkIugIeads
Install Flywheel End Oil Seal
MakesurelhallheseaIboreoflhecrankcaseis
cIeanandfreeofanynicksorburrsSeeIigure

Figure 10-1. Seal Bore of Crankcase.

10.2
Section 10
Reassembly
AIyaIighlcoalofcIeanengineoiIlolhe
oulsidediameleroflheoiIseaI
InslaIIlheoiIseaIinlolhecrankcaseusingaseaI
driverMakesurelheoiIseaIisinslaIIedslraighl
andlrueinlheboreandlhallhelooIbooms
againsllhecrankcaseSeeIiguresand
Figure 10-2. Installing Oil Seal.
Figure 10-3. Installed Flywheel Side Oil Seal.
Install Lifter Feed Chamber Gaskets and
Cover
InslaIIlheIierfeedchambergaskelfoIIovedby
lheIierfeedcoveroverlheIierfeedchamber
InslaIIlhelhreescrevsMakesureaIIlhearls
areroerIyaIignedTorquelhescrevslo
6.2 Nm (55 i n. l b.)inlonevhoIesor4.0 Nm
(35 i n. l b.)inlousedhoIesSeeIigure
Figure 10-4. Lifter Feed Chamber Assembly
Details.
Install Flywheel End Main Bearing
IflheyvheeIendmainbearingvasremovedin
servicinginslaIIanevbearingusinganarborress
anddriver
Makesurelhecrankcaseboreforlhemain
bearingiscIeandryandfreeofnicksorburrs
IresslheyvheeIendmainbearinginIacevilh
lhenolchorienledinlheocIockosilionusing
anarborressanddriverSeeIigureMake
surelhebearingisfuIIysealedagainsllheange
andlheoiIfeedhoIeisoeninlhecrankcaseSee
Iigure
AIyaIighlcoalofcIeanengineoiIlolheinner
surfaceoflhemainbearing
Figure 10-5. Installing Main Bearing.
Mounting
Screws
Cover
Gasket
Lifter
Feed
Chamber
10.3
Section 10
Reassembly
10
Oil Seal
Seal depth
1.5 - 2.0 mm (0.059 - 0.078 in)
Crankcase
Surface
12.66 mm
(0.498 in.)
Crankcase Surface
Governor
Gear Shaft
Figure 10-6. Installed Main Bearing.
Install Governor Shafts, Seal, and
Governor Gear
IflhegovernorshasseaIandorgovernorgearvere
removedindisassembIyreassembIeasfoIIovs
LighlIyIubricalelheIiandoulsidediamelerof
lhenevgovernorcrossshaseaIvilhoiIInslaII
lheseaIinlolhecrankcaselolhedelhshovnin
Iigure
Figure 10-7. Installing Governor Cross Shaft Seal.
Figure 10-8. Governor Shaft Seal Depth.
Iflhegovernorgearshavasremovedressor
IighlIylalhereIacemenlshainlolheoiIan
lodelhshovninIigure
Figure 10-9. Installed Governor Gear Shaft.
Figure 10-10. Governor Gear Shaft Press Depth.
Lubricalelhegovernorcrossshabearing
surfacesinlhecrankcasevilhengineoiIInserl
lheendvilhlhealforlhegovernorgearyoke
inlolhecrankcaserslandosilionsolhealis
uSeeIigure
Figure 10-11. Installing Governor Cross Shaft.
Seal
Notch
Main
Bearing
Governor
Gear Shaft
Governor
Cross Shaft
10.4
Section 10
Reassembly
Aachlhegovernoryokelolhecrossshasolhe
curvedseclionisuasmarkedSecurevilh
lhelvoscrevsIfalhreadIockingcomoundis
nolreaIiedaIyasmaIIamounlofLoclile

NoorequivaIenllolhescrevlhreadsbefore
inslaIIingTorquelhescrevslo2.2 Nm
(20 i n. l b.)SeeIigure
Figure 10-12. Installed Governor Shaft Yoke.
InslaIIlherslreguIalinginvilhlhehead
dovnsoilviIIconlacllheyokeInslaIIlhe
governorgearvilhlhesecondreguIalingin
andlheyveighlassembIyindovnonlolhe
governorshaunliIilIocksinloosilionAIy
asmaIIamounlofgreaselolheIockinglablhrusl
vasherandinslaIIonlooflhegovernorgearso
lhelangisfacinguinlheocIockosilion
SeeIiguresand
Figure 10-13. Regulating Pin Details.
Figure 10-14. Installing Governor Gear Assembly.
Figure 10-15. Installed Locking Tab Washer.
Install Crankshaft
CarefuIIysIidelheyvheeIendoflhecranksha
lhroughlhemainbearinginlhecrankcaseSee
Iigure
Figure 10-16. Installing Crankshaft.
Governor
Gear Assembly
Tab
Position
Second
Regulating
Pin
First
Regulating
Pin
Governor
Gear
10.5
Section 10
Reassembly
10
No. 1 Side No. 2 Side
Install Connecting Rods with Pistons and
Rings
NOTI ThecyIindersarenumberedonlhecrankcase
MakesureloinslaIIlheislonconnecling
rodandendcainloilsarorialecyIinder
boreasreviousIymarkedaldisassembIy
Do notmixlheendcasandconnecling
rods
NOTI Iroerorienlalionoflheislonconnecling
rodassembIiesinsidelheengineisexlremeIy
imorlanlImroerorienlalioncancause
exlensivevearordamageecerlainlhe
islonsandconneclingrodsareassembIed
exaclIyasshovninIigure
SlaggerlheislonringsinlhegroovesunliIlhe
endgasareaarlTheoiIringraiIsshouId
aIsobeslaggered
Figure 10-17. Proper Piston and Connecting Rod
Orientation.
LubricalelhecyIinderboreislonandislon
ringsvilhengineoiIComresslheringsoflhe
islonusingaislonringcomressor
Lubricalelhecranksha|ournaIsandconnecling
rodbearingsurfacesvilhengineoiI
MakesurelheIIyslamingonlheislonis
facinglovardlheyvheeIsideoflheengine
SeeIigureUseahammervilharubber
griandgenlIylalheisloninlolhecyIinderas
shovninIigureecarefuIlhallheoiIring
raiIsdonolsringfreebelveenlheboomoflhe
ringcomressorandlooflhecyIinder
Figure 10-18. Fly Mark on Piston.
Figure 10-19. Installing Piston Assembly Using
Ring Compressor Tool.
InslaIIlheinnerrodcalolheconneclingrod
usinglhelvohexangescrevsTorquelhe
screvsinincremenlslo11.3 Nm (100 i n. l b.)
IIIuslraledinslruclionsarerovidedinlhe
servicerodackageSeeIigure
NOTI AIignlhechamferoflheconneclingrodvilh
lhechamferofilsmalingendcaWhen
inslaIIedlhealfacesoflheconneclingrods
shouIdfaceeacholherThefacesvilhlhe
raisedribshouIdbelovardlheoulside
10.6
Section 10
Reassembly
Figure 10-20. Torquing Connecting Rod End Cap
Screws.
Reeallheaboverocedureforlheolher
conneclingrodandislonassembIy
Install Camshaft
LiberaIIyaIycamshaIubricanlKohIer
IarlNo25 357 14-SloeachoflhecamIobes
Lubricalelhecamshabearingsurfacesoflhe
crankcaseandlhecamshavilhengineoiISee
Iigure
Figure 10-21. Camshaft Lubricant Applied to Cam
Lobes.
Iosilionlhelimingmarkoflhecrankshagearal
lheocIockosilion
SIidelhecamshainlolhebearingsurfaceoflhe
crankcaseosilioninglhelimingmarkoflhe
camshagearallheOcIockosilionMake
surelhallhecamshagearandcrankshagear
meshvilhbolhlimingmarksaIignedSeeIigure

Figure 10-22. Aligning Crankshaft and Camshaft

Timing Marks.
Determining Camshaft End Play
IIaceanevoiIangaskelinloosiliononlhe
crankcase
IosilionlhecamshaendIaycheckinglooIover
camshaUseafeeIergaugelochecklheendIay
belveenlhecamshaandendIaycheckinglooI
CamshaendIayshouIdbebelveen0.3/1.3 mm
(0.011/0.051 i n.)SeeIigure
Figure 10-23. Checking Camshaft End Play.
NoshimislyicaIIyusedfromlhefaclory
HoveveriflhecamshaendIayisnolvilhin
lheseciedrangeremovelhecheckinglooIand
shimasnecessary
SeveraIcoIorcodedshimsareavaiIabIe
Whi te: mmin
Bl ue: mmin
Red: mmin
Yel l ow: mmin
Green: mmin
Gray: mmin
Bl ack: mmin
Lubricant
Applied
Feeler
Gauge
Timing Marks
10.7
Section 10
Reassembly
10
Oil
Seal
3 mm (0.118 in.)
ReinslaIIlheendIaycheckinglooIandrecheck
lheendIay
Install Oil Pan Seal and Main Bearing
Main Bearing
IflheoiIanmainbearingvasremovedforservicing
anevbearingshouIdbeinslaIIedallhislime
MakesurelheoiIanboreforlhemainbearingis
cIeandryandfreeofnicksorburrs
InslaIIanevbearingvilhlhenolchinlhe
ocIockosilionusingaressanddriver
MakesurelhebearingisfuIIysealedagainsllhe
angeSeeIigure
LighlIyIubricalelheinsidediameleroflhe
bearingvilhoiI
Figure 10-24. Installed Main Bearing In Oil Pan.
Oil Seal
Checklomakesurelhallherearenonicksor
burrsinlhecrankshaseaIboreoflheoiIan
AIyaIighlcoalofengineoiIlolheoulside
diameleroflheoiIseaI
InslaIIlheoiIseaIinlolheoiIanusingaseaI
driverMakesurelheoiIseaIisinslaIIedslraighl
andlrueinlheborelolhedelhshovninIigure

Figure 10-25. Installed Oil Seal in Oil Pan.

Figure 10-26. Oil Seal Depth in Oil Pan.
AIyaIighlcoalofcIeanengineoiIlolheinside
diameleroflhemainbearing
Oil Pump Assembly
TheoiIumismounledinsidelheoiIanIfservice
vasrequiredandlheoiIumvasremovedreferlo
lheassembIyroceduresunderOiIIumAssembIy
inSeclion
Main
Bearing
Notch
Oil Seal
10.8
Section 10
Reassembly
O-Ring
10
8
1
14
3
5 12
7
9
11 6
4
2
13
Install Oil Pan Assembly
MakesurelheseaIingsurfacesoflheoiIanand
crankcasearecIeandryandfreeofanynicks
orburrsInslaIIanevORinginlheoiIanSee
Iigure
Figure 10-27. O-Ring Installed.
InslaIIanevoiIangaskelonlolhecrankcase
MakesurelheoiIumandoiIickuare
inslaIIedinlheoiIan
InsurelheendoflheIockinglabvasheronlhe
governorgearisosilionedoulvardinlhe
ocIockosilioninsidelhecrankcaseSeeIigure

Figure 10-28. Locking Tab Washer Details.

OrienllhealoflheoiIumgearlomalchlhe
osilionoflhealonlhecamshaTheninslaII
lhecIosureIalelolhecrankcaseCarefuIIy
seallhecamshaandlhecrankshainlolheir
malingbearingsRolalelhecrankshasIighlIylo
heIlheoiIumandgovernorgearsmeshSee
Iigure
Figure 10-29. Installing Oil Pan.
InslaIIlhefourleenhexangescrevssecuring
lheoiIanlolhecrankcaseTorquelhefasleners
inlhesequenceshovninIigurelo
24.4 Nm (216 i n. l b)
Figure 10-30. Torquing Oil Pan Fasteners.
Figure 10-31. Oil Pan Fastener Torque Sequence.
10.9
Section 10
Reassembly
10
Crankcase
Filter
Breather Hose
Flange Nuts (4)
Gasket
Check Crankshaft End play
SellheengineasshovnanduseadiaIindicalor
lochecklhecrankshaendIayagainsllhe
secicalionIisledinSeclion
Figure 10-32. Checking Crankshaft End play.
Install Breather
MakesurelheseaIingsurfacesoflhecrankcase
andbrealhercoverarecIeanandfreeofany
nicksorburrsDo not scraelhesurfacesaslhis
couIdresuIlinIeakage
InslaIIlhebrealherchambergaskelasshovn
SeeIigureAssembIeandinslaIIbrealher
assembIycomonenlsasiIIuslraledinIigure
MakesurelheIlerdoesnolexlendabove
lhelosurfaceandaIIarlsareroerIyaIigned
Figure 10-33. Breather Chamber and Gasket.
Figure 10-34. Breather Assembly Details.
Gasket
Adapter
Studs (4)
10.10
Section 10
Reassembly
1
3
4
2
InslaIIlhefourhexangescrevsandlorque
usinglhesequenceshovninIigurelo
5.7 Nm (51 i n. l b.)
Figure 10-35. Breather Assembly Fastener Torque
Sequence.
LighlIyIubricalelheIoverendoflhebrealher
hosevilhoiIandinslaIIinlolhehoIeinbrealher
assembIyThecovershouIdbesilualedbelveen
lhelvoraisedringsoflhehose
Install Hydraulic Lifters
IeedlhehydrauIicIiersofinlernaIoiIsolhe
IungerinlheIiercanbederessedbyhand
UseanoIdculoushrodmounledinadriII
ressarborressorviceandsIovIyaIy
pressure two or three ti meslobIeedlheIiers
SeeIigureIfaviceisusedinbIeedinglhe
IiersbesureloinslaIIroleclivecoveringsover
lhe|avsloavoiddamagelolhebaseoflheIier
Figure 10-36. Push Rod Tool.
NOTI AnolherlooIforbIeedingmaybemade
fromanoIdlaelandbaIIbearing
veIdedlogelherSeeIigure
Figure 10-37. Tappet and Ball Bearing Welded
Together.
AIycamshaIubricanlseeSeclionlolhe
boomsurfaceofeachIierSeeIigure
LubricalelhehydrauIicIiersandlheIierbores
inlhecrankcasevilhengineoiIDo not pri me
thc!icrs
Figure 10-38. Applying Camshaft Lubricant to
Bottom of Lifters.
NolelhemarkorlagidenlifyinglhehydrauIic
IiersaseilherinlakeorexhauslandcyIinder
orcyIinderInslaIIlhehydrauIicIiersinlo
lheirarorialeIocalioninlhecrankcaseDo
noluseamagnelSeeIigure
10.11
Section 10
Reassembly
10
NOTI HydrauIicIiersshouIdaIvaysbe
inslaIIedinlhesameosilionasbefore
disassembIyTheexhauslIiersare
Iocaledonlheoululshasideof
lheenginevhiIelheinlakeIiersare
IocaledonlhefansideoflheengineThe
cyIindernumbersareembossedonlhe
looflhecrankcaseandeachcyIinder
headSeeIigure
Figure 10-39. Installing Hydraulic Lifters.
Figure 10-40. Match Numbers on Cylinder Barrel
and Head.
Valve Stem Seals
TheseenginesusevaIveslemseaIsonlheinlake
andexhauslvaIvesAIvaysusenevseaIsvhenever
vaIvesareremovedoriflheseaIisdelerioraledor
damagedinanyvayNeverreuseanoIdseaIIigure

Figure 10-41. Valve Stem Seals.

Assemble Cylinder Heads
IriorloinslaIIalionIubricaleaIIcomonenlsvilh
engineoiIayingarlicuIaraenlionlolheIioflhe
vaIveslemseaIvaIveslemsandvaIveguidesInslaII
lhefoIIovingilemsinlheorderIisledbeIovusinga
vaIvesringcomressorSeeIiguresand
InlakeandexhauslvaIves
VaIvesringrelainers
VaIvesrings
VaIvesringkeeers
VaIveSlemSeaIs
GuideIIale
IivolSluds
Figure 10-42. Valve Components.
Valve Stem Seals
Match
Numbers
Guide Plate
Pivot
Studs
Valve
Spring
Retainer
Keepers
10.12
Section 10
Reassembly
Spacer
Washers
2
2
4
5 5 4
1 3 3 1
No. 1 No. 2
Figure 10-43. Installing Valves with Valve Spring
Compressor.
Install Cylinder Heads
Checklomakesurelherearenonicksorburrs
onlheseaIingsurfacesoflhecyIinderheadorlhe
crankcase
ChecklhallhedoveIinsareinIaceinlhelvo
IoverIocalionsandinslaIIanevcyIinderhead
gaskelvilhrinlinguSeeIigure
Figure 10-44. Installing New Head Gaskets.
NOTI Malchlhenumbersembossedonlhe
cyIinderheadsandcrankcaseSeeIigure

InslaIIlhecyIinderheadMakesurelheheadis
alonlhegaskelanddoveIinsInslaIIaal
vasheronlhescrevsinlhel ower two l ocati ons
(1 and 3)andlheIocalion cl osest lolheexhausl
orl(l ocati on 5)SeeIiguresand
Slarllhevehexangescrevs
Figure 10-45. Washers and Spacer Locations on
Cylinder Head Screws.
Torquelhehexangescrevsinlvoslagesrsl
lo22.6 Nm (200 i n. l b.)naIIylo45.2 Nm
(400 i n. l b.)foIIovinglhesequenceinIigure

ReeallherocedureforlheoosilecyIinder
Figure 10-46. Torquing Cylinder Head Fasteners.
Figure 10-47. Cylinder Head Fastener Torque
Sequence.
10.13
Section 10
Reassembly
10
MakesurelhelhreadsoflheieIugsforlhe
cyIinderheadsarecIeananddryInslaIIaIug
inloeachcyIinderheadabovelheNoscrev
Iocalionandlorquelo29.3 Nm (260 i n. l b.)See
Iigure
Figure 10-48. Installing Pipe Plug in Cylinder
Heads.
Install Guide Plate, Pivot Studs, Push
Rods and Rocker Arms
InslaIIlheushrodguideIaleandrockerarm
ivolsludsonlolhecyIinderheadsifremoved
reviousIyTorquelheivolsludslo12.4 Nm
(110 i n. l b.). SeeIigure
NOTI InslaIIlheushrodguideIalesolhe
angeisdown lovardscyIinderonlhe
No. 1 si deandup avayfromcyIinder
onlheNo. 2 si de
Nolelhemarkorlagidenlifyinglheushrodas
eilherinlakeorexhauslandcyIinderorDi
lheendsoflheushrodsinengineoiIandinslaII
makingsurelhaleachushrodbaIIsealsinils
hydrauIicIiersockelSeeIigure
Figure 10-49. Installing Guide Plate, Pivot Studs
and Push Rods.
NOTI IushrodsshouIdaIvaysbeinslaIIedin
lhesameosilionasbeforedisassembIy
AIygreaselolheconlaclsurfacesoflherocker
armsandrockerarmivolsInslaIIlherocker
armsrockerarmivolsandad|uslersonlhe
cyIinderhead
Figure 10-50. Installing Rocker Arms, Pivots and
Adjusters.
Adjust Valve Clearance
WilhIreIedLierseforeInslaIIalion
Turnlhead|uslersinlherockerarmsbyhand
cl ockwi sedovnonIyenoughlocalureush
rodsinlherecessesSeeIigure
Figure 10-51. Turning Adjusters In To Retain Push
Rods.
RolalelhecrankshaloeslabIishToDead
CenlerTDConlheComressionSlrokefor
lhecyIinder
Pipe
Plug
Rocker Arms
Pivots
Adjusters
Turn Adjusters (Clockwise)
Push Rods
Pivot
Studs
Guide
Plate
10.14
Section 10
Reassembly
Checkfor
a ComressionviIIbefeIllhroughlhesark
IughoIe
b KeyvayofcrankshaviIIbeaIignedvilh
cyIinder
c Norockerarmushrodmovemenlif
crankshaisrolaledsIighlIybackandforlh
Iflheyaremovingrolalelhecrankshaone
fuIIrevoIulion
Prcb!cdLicrsAIydovnvardressurelo
lheushrodsideofrockerarmlocomresslhe
IierandboomlheinlernaIIungerSeveraI
manuaIcomressionsmaybenecessaryHol d
i n thi s posi ti on f or Step 4.
Nnnb!cdLicrsIoIIovlhevaIvecIearance
ad|uslmenlrocedureNcnB|c!IicrsWncn
Cq|in!crHca!san!IicrsarcNci|cnctc!
NOTI IllakeslvohandslomakelheIash
ad|uslmenlAcIamingdeviceoran
assislanllohoIdlheIiercomressed
vhiIemakinglhead|uslmenlviIImake
lhisnoliceabIyeasier
Inserla0.127 mm (0.005 i n.)feeIergaugebelveen
lheendofonevaIveandlherockerarmTurn
lhead|uslerunliIasIighldragisfeIlHoIdlhe
ad|uslerinlhisosilionandlighlenlheIocking
selscrevTorquelheselscrevlo7.3 Nm
(65 i n. l b.). Aerlighleningrechecklhe
ad|uslmenlIroervaIvecIearanceis
0.101/0.152 mm (0.004/0.006 i n.)SeeIigure
Figure 10-52. Adjusting Valve Clearance.
ReeallherocedureforlheolhervaIveonlhis
side
VievedfromlheITOendrolalelhecranksha
lurncountercl ockwi se and al i gn
lhecrankshakeyvayvilhlhecyIinder
vhichnovulslhalcyIinderalTDConlhe
comressionslroke
ReealslesforseinglhevaIvecIearanceon
lheside
Rolalelhecrankshalocheckforfreeoeralion
oflhevaIvelrainCheckforcIearancebelveen
lhevaIvesringcoiIsalfuIIIiorbending
ofushrodscanoccurMinimumaIIovabIe
cl earance i s 0.25 mm (0.010 i n.)
Check Assembly
I mportant: Rolalelhecrankshaaminimumoflvo
revoIulionslocheckassembIyandoveraIIroer
oeralion
Adjust Valve Clearance
NnnB!cdLicrsWhenCyIinderHeadsandLiers
areNolRemoved
Turnlhead|uslersinlherockerarmsdovn
cIockviseonIyenoughlocalurelheush
rodsinlherecessesSeeIigure
RolalelhecrankshaloeslabIishToDead
CenlerTDConlheComressionSlrokefor
lhecyIinder
Checkfor
a ComressionviIIbefeIllhroughlhesark
IughoIe
b KeyvayofcrankshaviIIbeaIignedvilh
cyIinder
c Norockerarmushrodmovemenlif
crankshaisrolaledsIighlIybackandforlh
Iflheyaremovingrolalelhecrankshaone
fuIIrevoIulion
Turnoneoflhesiderockerarmad|uslingnuls
dovnunliIushrodissnugbulcanberolaled
vilhdragThisisIashSeeIigure
Push Down to "Bottom"
Lifter Plunger and Hold
Adjust
Feeler Gauge
10.15
Section 10
Reassembly
10
Figure 10-53. Establishing the "0" Lash Point.
Markornolelheseingoflhead|uslmenlnul
lhenlurnlighlenlhead|uslernulf our (4)
compl ete revol uti ons cl ockwi sep!usnncatnI
nut (1/6 turn), or a total of 4-1/6 turns
Figure 10-54. Setting Valve Lash (Non-Bled Lifters).
HoIdlhead|uslernulinlhisosilionandlighlen
lheIockingselscrevTorquelheselscrevlo
7.3 Nm (65 i n. l b.)
ReeallherocedureforlheolhervaIveonlhe
lhisside
VievedfromlheITOendrolalelhecranksha
lurncountercl ockwi se and al i gn the
crankshakeyvayvilhlhecyIindervhich
novulslhalcyIinderalTDConlhecomression
slroke
ReealslesforseinglhevaIvecIearanceon
lheside
Rolalelhecrankshalocheckforfreeoeralion
oflhevaIvelrainChecklhecIearancebelveenlhe
vaIvesringcoiIsalfuIIIiMinimumaIIovabIe
cl earance i s 0.25 mm (0.010 i n.).
Check Assembly
I mportant: Checkifenginecanbelurnedover
comIeleIyandcomressionisnoledIfilcannol
IocksualsomeoinlrelurnlheislonloTDC
belveenlheinlakeandexhauslslrokesrslforone
cyIinderandlhenlheolhervailinglenminules
loaIIovIierslobIeeddovnlhencheckfor
comressionagain
Install Valve Covers
MakesurelheseaIingsurfacesarecIeanandfree
ofanynicksorburrs
InslaIIandroerIyseallheseaIonloeachoflhe
vaIvecoversSeeIigure
Figure 10-55. Installing Seal on Valve Cover.
InslaIIlhevaIvecoversonlhesamesidesas
originaIIyinslaIIed
InslaIIanevgrommeloneachvaIvecover
mounlingscrevSlarleachscrev
Checklheosilionofeachcoverandgaskellhen
lorqueeachscrevlo7.9 Nm (70 i n. l b.)See
Iigure
Figure 10-56. Torquing Valve Cover Screw.
Turn Adjuster
Rotate Push Rod
and Feel for
Drag
Turn 4-1/6
Revolutions
From "0" Lash
Seal
10.16
Section 10
Reassembly
Spring
Install Spark Plugs
UsenevChamion

XCYCorequivaIenl
sarkIugs
Sellhegaal0.76 mm (0.030 i n.)
InslaIInevIugsandlorquelo24.4-29.8 Nm
!bSeeIigure
Figure 10-57. Installing Spark Plugs.
Install Oil Filter Housing Assembly
ReassembIelheoiIIlerhousingifdisassembIed
reviousIySeeIigureslhrough
Figure 10-58. Oil Filter Housing Components.
a InslaIIlhesmaIIsringonlolherubbervaIveand
inserllhesmaIIendlhroughlhecorresonding
hoIeinlhecuunliIroerIysealedSeeIigure

b InslaIIlheIargersringinlolheIlerhousing
SeeIigure
Figure 10-59. Installing Valve and Spring to Cup.
Figure 10-60. Installing Spring into Housing.
c InserllheoiIIlercuaIigninglheculoulvilh
lhecorresondingseclioninlhehousingSee
Iigure
d InslaIIandlighlenlheniIeinlhehousingUse
aAIIenvrenchbilandlorquelo18.0 Nm
(160 i n. l b.)SeeIiguresand
Figure 10-61. Installing Cup.
Cup
Valve
Spring
Cup
Oil Filter
Housing
Valve
Spring
Cup
Spring
Nipple
10.17
Section 10
Reassembly
10
O-Rings Around
Dowel Pins
Figure 10-62. Installing Nipple into Cup and Oil
Filter Housing.
Figure 10-63. Torquing Nipple into Housing.
Installation
MakesureaIIseaIingsurfacesarecIeanandaII
lhreedoveIinsareinosilionInslaIIorcheck
lhalnevORingsarearoundaIIlhreedoveIins
oflheoiIIleradalerSeeIigure
Figure 10-64. O-Rings Installed on Crankcase for
Oil Filter Housing.
InslaIIlheIlerhousingassembIyandsecure
vilhlheMhexheadscrevMakesurelhe
housingisaloncrankcaseandORingremains
inosilionTorquelhescrevlo24.4 Nm
(216 i n. l b.)SeeIigure
Figure 10-65. Torquing Oil Filter Housing.
TheoiIIlermaybeinslaIIednovoruon
comIelionofengineassembIyasdescribedin
Seclion
Install Intake Manifold
InslaIInevinlakemanifoIdgaskelssolhe
nolchedseclionisinvardandoinlslovardlhe
yvheeIsideSeeIigure
Figure 10-66. Installed Intake Manifold Gaskets.
Notches
Mounting
Screw
Oil Filter
Housing
Nipple
Cup (with
Spring and
Valve)
Housing
10.18
Section 10
Reassembly
1
2
Cylinder 1
Cylinder 2
3
4
MounllheinlakemanifoIdlolhecyIinderheads
Makesurelhegaskelsremaininlheroer
osilionTorquelhefourscrevsinlvoslages
rsllo16.9 Nm (150 i n. l b.)naIIylo
22.6 Nm (200 i n. l b.)usinglhesequenceshovn
inIigure
Figure 10-67. Installing Intake Manifold.
Figure 10-68. Intake Manifold Torque Sequence.
InslaIIlhecarburelormounlingsludsinloinlake
manifoIdifremovedearIierUselvohexnuls
Iockedangeloangeandlighleneachoflhe
sludsunliIboomedlighl
Install Backing Shroud Assembly
ToaidassembIyinslaIIlheIoveroiIcooIerhose
onlolheoiIIlerhousingriorloinslaIIinglhe
backingshroudassembIySecurevilhacIam
osilionedasshovnSeeIigure
NOTI NevhosecIamsarerecommended
forreassembIyorifcIamshavebeen
IoosenedexandedseveraIlimeslo
avoidIeakage
Figure 10-69. Lower Oil Cooler Hose Details.
InslaIIlhebackingshroudassembIyandsecure
lolhecrankcasevilhlhefourMscrevsTorque
lhefourscrevsgoinginlolhecrankcaselo
10.7 Nm (99 i n. l b.)inlonevhoIesor7.3 Nm
(65 i n. l b.)inlousedhoIesSeeIigure
Figure 10-70. Installing Backing Shroud Assembly.
Install Stator, Wiring Harness, and
Rectier-ReguIator
AIyieseaIanlvilhTeon

Loclile

No
orequivaIenllolheslalormounlinghoIes
IosilionlheslaloraIigninglhemounlinghoIes
solheIeadsareallheboomandlovardlhe
reclierreguIalormounlonlheNoside
InslaIIandlorquelhelvohexangescrevslo
6.2 Nm (55 i n. l b.)SeeIigure
RoulelheslalorviresunderlhelvomoIded
cIisinbackingshroudassembIySeeIigure

10.19
Section 10
Reassembly
10
Figure 10-71. Installing Stator.
ChecklhelerminaIonlheendoflhefused
chargingIeadlobesurelheIockinglangis
angIeduvardifremovedearIierInserllhe
lerminaIinlolhecenlerIocalionoflheconneclor
unliIilIocksinloIace
Figure 10-72. B+ Charging Lead Details.
InslaIIlheviringharnessunderlhelvomoIded
cIisinlhebackingshroudassembIySee
Iigure
Figure 10-73. Installing Wiring Harness.
IosilionlhereclierreguIaloronlolhemounling
oslsvilhlhecooIingnsuAachlhe
groundIeadlolheoulerscrevandvasherlhen
lorquelhemounlingscrevslo
2.0 Nm (18 i n l b.)ConnecllheIuglolhe
reclierreguIalorSeeIigure
Figure 10-74. InstaIIing Rectier-ReguIator.
Install Flywheel
WARNING: Damaging Crankshaft and
Flywheel Can Cause Personal Injury!
Usinginprcpcrprccc!urcsicinsia||incquncc|cancrack
cr!anagcinccranksnaan!crquncc|Tnisncicn|q
causcscxicnsitccnginc!anagc|uicana|sccauscpcrscna|
injurqsincc|rckcnjragncnisccu|!|cinrcunjrcninc
cngincA|uaqsc|scrtcan!uscincjc||cuingprccauiicns
an!prccc!urcsuncninsia||ingincquncc|
NOTI eforeinslaIIinglheyvheeImakesure
lhecrankshalaerandlheyvheeIhub
arecIeandryandcomIeleIyfreeofany
IubricanlsTheresenceofIubricanlscan
causelheyvheeIlobeoverslressedand
damagedvhenlhehexangescrevis
lorquedlosecicalions
Figure 10-75. Clean and Dry Taper of Crankshaft.
B+
Lead
Tabs
Mounting Screws
Molded Clips
Ground
Lead
Plug
Rectier-
Regulator
10.20
Section 10
Reassembly
Figure 10-76. Clean and Dry Flywheel Hub.
Figure 10-77. Installed Flywheel Key.
NOTI MakesurelheyvheeIkeyisinslaIIed
roerIyinlhekeyvayTheyvheeIcan
becomecrackedordamagediflhekeyisnol
roerIyinslaIIed
InslaIIlhevoodrukeyinlolhekeyvayoflhe
crankshaMakesurelhallhekeyisroerIy
sealedandaraIIeIvilhlheshalaer
InslaIIlheyvheeIonlolhecrankshabeing
carefuInolloshilhevoodrukey
InslaIIlhehexangescrevandvasher
UseayvheeIslravrenchorhoIdinglooIlo
hoIdlheyvheeITorquelhehexangescrev
securinglheyvheeIlolhecrankshalo
Nm!bSeeIigure
Figure 10-78. Installing and Torquing Flywheel
Fastener.
Install Ignition Modules
RolalelheyvheeIloosilionlhemagnelavay
fromlheignilionmoduIebosses
ConnecllhegroundIeadlolhesingIekiIIlaband
inslaIIlhemoduIesonlolhecrankcasebossesso
lhelabisavayfromyouinThesarkIugIead
shouIdbelovardsyououlMounllheviring
harnesscIamvilhlheIoouponlheslarler
NosideinnermoduIescrevandroulelhe
harnesslhroughilAachlhereclierreguIalor
groundIeadlolheoulerscrevSeeIigure
Figure 10-79. Ignition Module Mounting Details.
SIidelhemoduIesuasfaravayfromlhe
yvheeIasossibIeandsnuglhescrevslohoId
lheminlhalosilion
RolalelheyvheeIloosilionlhemagnel
direclIyunderoneignilionmoduIe
Clip
Kill
Lead
10.21
Section 10
Reassembly
10
Inserla0.30 mm (0.012 i n.)alfeeIergauge
belveenlhemagnelandlheignilionmoduIe
SeeIigureDSAIenginesdonolrequire
orhaveanairgaseingLoosenlhescrevs
enoughloaIIovlhemagnellouIIlhemoduIe
dovnagainsllhefeeIergauge
Figure 10-80. Setting Ignition Module Air Gap.
Torquelhescrevslo6.2 Nm (55 i n. l b.)inlonev
hoIesor4.0 Nm (35 i n. l b.)inlousedhoIes
Reealsleslhroughforlheolherignilion
moduIe
RolalelheyvheeIbackandforlhchecking
forcIearancebelveenlhemagnelandignilion
moduIesMakesurelhemagneldoesnol
slrikelhemoduIesChecklhegavilhafeeIer
gaugeandread|uslifnecessaryIinaIAirGa
0.280/0.330 mm (0.011/0.013 i n.)
MakesurelheIeadsareunderlhemoIdedcIi
onlheslarlersideSeeIigure
Figure 10-81. Lead Routing Details.
InstaII Outer CyIinder Bafes
InslaIIlheoulercyIinderbaesMakesure
lhesarkIugIeadisrouledlhroughlhe
corresondingoeningineachbaeSlarleach
oflhescrevsTorquelheMshouIderscrevs
goinglhroughlhebackingshroudassembIyinlo
lheexlrudedhoIesinlhebaeslo
4.0 Nm (35 i n. l b.) foriniliaIinslaIIalionsor
2.0 Nm (17.7 i n. l b.) anylimelhereaerTorque
lheMscrevsgoinginlolhecyIinderheadand
crankcaselo10.7 Nm (95 i n. l b.) fornevhoIes
or7.3 Nm (65 i n. l b.) forusedhoIes
Figure 10-82. InstaIIing Outer CyIinder Bafes.
Figure 10-83. InstaIIing CyIinder Bafe Inner
Screws.
Molded
Clip
Mounting
Screws
Feeler
Gauge
Cylinder
Bafe
Mounting
Screws
10.22
Section 10
Reassembly
Install Oil Cooler
ConnecllhelvooiIcooIerhosesbelveenlheoiI
IleradalerandlheoiIcooIerSecurevilhnev
cIamsSeeIigure
Figure 10-84. Connecting Oil Cooler Hoses.
AIignlheoiIcooIervilhlhebossesinlhebacking
shroudassembIySecurevilhlhelvoscrevs
andvashersSeeIigure
Figure 10-85. Installing Oil Cooler.
Install Cooling Fan and Grass Screen
CAUTION:
|ai|urcicuii|izccrrcasscn||cincgrassscrccnas!csignc!
ccu|!rcsu|iingrassscrccnjai|urcan!scricuspcrscna|
injurq
IosilionlhecooIingfanonlolheyvheeI
aIigninglhemounlingIocalionsAIyasmaII
amounlofLoclile

Nololhelhreadsand
inslaIIlhelhreeIongmounlingscrevsTorque
lhescrevslo9.9 Nm (88 i n. l b.)SeeIigure

AIyasmaIIamounlofLoclile

Nololhe
exlernaIlhreadedseclionunIessnevarlsvilh
reaIiedIockingcomoundarebeingused
Threadlhefourhexgrassscreensludsinlolhe
mounlinghoIesinlheyvheeITorqueeachslud
lo9.9 Nm (88 i n. l b.)SeeIigure
InslaIIlheslienerfoIIovedbylhemelaIgrass
screenonlolhefourhexsludsSecurevilhlhe
fourseciaIvashersandmounlingscrevsusing
Loclile

NoonlhelhreadsTorquelhe
screvslo9.9 Nm (88 i n. l b.). SeeIigure
Figure 10-86. Cooling Fan and Grass Screen
Assembly Details.
Install Electric Starter
InslaIIlheeIeclricslarlermolorusinglhelvohex
angescrevsSeeIigure
Torquelhelvohexangescrevslo15.3 Nm
(135 i n. l b.)
Figure 10-87. Installing Electric Starter Motor.
Hoses
Mounting
Screws
Mounting
Screws
Mounting Studs
Stiffener
Fan Screws
Fan
Grass Screen
Screws
Special
Washers
10.23
Section 10
Reassembly
10
ConnecllheIeadslolhesoIenoidSeeIigure

Figure 10-88. Connecting Leads to Starting Motor.

InstaII VaIIey Bafes
InslaIIlhelvovaIIeybaesandsecurevilh
lhemounlingscrevsTheIoverseclionshouId
lunderlheoulerbaeTorquelheMscrevs
goinginlolhecyIinderheadlo10.7 Nm (95 i n.
l b.) fornevhoIesor7.3 Nm (65 i n. l b.) forused
hoIesTorquelheMscrevgoinginlolheIover
bIoverhousingmounlingcIilo3.9 Nm
(35 i n. l b.)SeeIigure
Figure 10-89. InstaIIing VaIIey Bafes.
Install Carburetor
WARNING: Explosive Fuel!
Gasc|incnaq|cprcscniininccar|urcicran!juc|sqsicn
Gasc|inciscxircnc|qanna||can!iistapcrscancxp|c!c
ijigniic!Kccpsparksan!cincrscurccscjigniiicnauaq
jrcninccnginc
InslaIIanevcarburelorgaskelonlolheinlake
manifoIdvilhlhelabupMakesureaIIhoIes
aIignandareoen
AachlhelhroIeandchokeIinkageslolhe
carburelorifdisconnecledreviousIyInslaII
lhecarburelorvilhlheIinkagesaachedasan
assembIySeeIigure
Figure 10-90. Installing Carburetor onto Manifold.
Install Governor Lever
InslaIIlhegovernorIeveronlolhegovernorsha
andconnecllhelhroIeIinkagevilhlhebIack
cIiDonollighlenlhegovernorIeverallhis
lime
Figure 10-91. Installing Governor Lever.
Valley
Bafes
Mounting
Screw
Governor
Lever
Governor
Cross Shaft
Carburetor
Gasket
(Tab "Up")
Throttle
Linkage
Choke
Linkage
10.24
Section 10
Reassembly
1, 5
4
3
2
Mounting
Screws
Install Control Bracket and Air Cleaner
Assembly
IosilionlheconlroIbrackelassembIyonlo
lhelhreeinlakemanifoIdbossesaIigninglhe
mounlinghoIesSeeIigure
Figure 10-92. Installing Control Bracket.
InslaIIanevaircIeanereIbovgaskelonlolhe
mounlingsluds
SIidelheaircIeanerassembIyonlolhefour
carburelormounlingsludsaachlheground
Ieadvilhslarvasherifusedandngerlighlen
lhehexangenulsAIignlhelvoforvard
mounlinghoIesinlhebasevilhlhemounling
hoIesbossesoflheinlakemanifoIdandconlroI
brackellhenslarllhelvohexangescrevs
CheckosilionsofaIIarlslhenlorquelhe
fourhexangenulslo7.9 Nm (70 i n. l b.) i n
lhesequenceiIIuslraledandlhelvohexange
screvslo9.9 Nm (88 i n. l b.)SeeIigures
and
Figure 10-93. Installing Air Cleaner.
Figure 10-94. Torque Sequence for Air Cleaner
Mounting Nuts.
Figure 10-95. Installing AIr Cleaner Mounting
Screws .
Connecllhebrealherhoselolheingonlhe
oulIeloflheaircIeanerandconnecllhefueI
soIenoidIead
ConnecllheformedvenlhoselolheaircIeaner
housingandlhevenlorlonlhecarburelor
ConnecllhechokeIinklolheconlroIivolin
ReinslaIIlhevasherandsecurevilhanew ush
onaInulSeeIigure
Mounting
Locations
Control
Bracket
Mounting
Nuts
Breather
Hose Port
Vent
Hose
Ground
Lead
Location
10.25
Section 10
Reassembly
10
Fuel Pump
Outlet Hose
Pulse
Hose
Inlet
Hose
Figure 10-96. Installing Choke Link and Push-On
Nut.
Install Throttle and Choke Linkages
IflheindividuaIlhroIechokeconlroIIinkagesvere
disconnecledduringdisassembIyreconnecllhem
basedonlheoeralingdireclionoflheconlroIcabIes
lobeused
On Control Levers:
HoIeAisusedforOut er Pul l conlroIcabIe
aclualion
HoIeB isusedforI nner Pul l conlroIcabIe
aclualionSeeIiguresand
ConnecllhechokeIinkagelolhearorialehoIe
inlhechokeIeverandsecurevilhlhesmaIIcIi
Figure 10-97. Throttle/Choke Linkage Details for
"Outer Pull" Actuation.
ConnecllhelhroIeIinkagelolhearoriale
hoIeinlhelhroIeIeverandsecurevilhlhe
smaIIcIi
Figure 10-98. Throttle/Choke Linkage Details for
"Inner Pull" Actuation.
Install Fuel Pump
InslaIIlhefueIumvilhhoseslolheconlroI
brackelifremovedearIierTorquelhemounling
screvslo4.0 Nm (35 i n. l b.)
ConnecllheoulIelfueIIinelolhecarburelorinIel
andsecurevilhacIam
InslaIIlheuIsehoseandinIelhosesinlheir
roerIocalionsSeeIigure
Figure 10-99. Fuel Pump Mounting and Hose
Details.
Links Connected
Here
(A)
(A)
Choke Control
Clamp Location
Throttle Control
Clamp Location
Links Connected
Here
(B)
(B)
Control Cable Clamp Locations
Choke Linkage
Push-on Nut
10.26
Section 10
Reassembly
Oil Pan
Adjusting Governor
IosilionlhegovernorIeversolhecIamingarea
isinboardbulcomIeleIyonlheknurIedareaof
governorcrossshaSeeIigure
Figure 10-100. Brushed/Knurled Area.
MovelhegovernorIever toward lhecarburelor
asfarasilviIIgovideoenlhroIeandhoId
inosilionSeeIigure
InserlaIonglhinrodorlooIinlolhehoIeonlhe
crossshaandrolalelheshacIockvisevieved
fromlheendasfarasilviIIlurnlhenlorque
lhehexnullo7.3 Nm (65 i n. l b.)SeeIigure

Figure 10-101. Adjusting Governor.

InsurelhallhecorreclcoIoredsringsareused
ConnecllhegovernorsringvilhIongIooed
endlolheinnerhoIeonlhegovernorIeverand
conlroIbrackelConnecllhegovernedidIesring
lolheoulergovernorIeverhoIeandconlroI
brackelTheIongendofeachsringmuslbe
lovardlhegovernorIeverChecklhallhesrings
donolconlacllhevaIIeybaeSeeIigure
Figure 10-102. Governor Springs Installed.
Governor Spring/RPM Chart
Figure 10-103. Governor Spring/RPM Chart.
Install Oil Sentry

(If Equipped)
AIypipcsca!antwithTcnn

Loclile

No
orequivaIenllolhelhreadsoflheOiI
Senlry

svilchandinslaIIilinlolheorlin
lheoiIanSeeIigureTorquelo
10.1 Nm (90 i n. l b.)
Figure 10-104. Oil Sentry
TM
Pressure Switch
Location.
Brushed/
Knurled
Area
Governor
Lever
Pressure
Switch
Lift/Rotate
Clockwise
Move and
Hold Towards
Carburetor
Hex
Nut
Governed
Idle Spring
Governor
Spring
Governor Spring
(Color)
High Speed (RPM)
Orange 3000 - 3100 RPM
Red 3101 - 3300 RPM
Green 3301 - 3750 RPM
Purple 3751 - 3900 RPM
Governor Idle Spring
(Color)
High Speed (RPM)
Clear 1200 - 1550 RPM
Black 1551 - 1800 RPM
10.27
Section 10
Reassembly
10
Oil Fill
Tube
Lift
Bracket
Lower
Mounting
Screw
Cylinder Shrouds
Mounting
Screws
ConnecllhegreenvireIeadlolheOiISenlry

lerminaI
Install Blower Housing and Cylinder Shrouds
InslaIIlhedislicklubevilhanevIoverO
RinginlolhecrankcaseSecurevilhlheIover
mounlingscrevTorquelhescrevlo4.0 Nm
(35 i n. l b.)SeeIigure
AachlheIibrackelifusedonlocrankcase
vilhlhelvomounlingscrevsTorquelhescrevs
lo9.9 Nm (88 i n. l b.)SeeIigure
Figure 10-105. Oil Fill Tube and and Lift Bracket.
AIignandinslaIIlhebIoverhousingSecure
vilhlhefourshouIderscrevsTorquelhescrevs
lo4.0 Nm (35 i n. l b.)forinilaIinslaIIalionsor
2.0 Nm (17.7 i n. l b.) anylimelhereaer See
Iigure
Figure 10-106. Installing Blower Housing.
InslaIIlhelvocyIindershroudsandsecure
vilhlheshouIderscrevsTorquelhescrevs
lo4.0 Nm (35 i n. l b.)foriniliaIinslaIIalions
or2.0 Nm (17.7 i n. l b.) anylimelhereaer See
Iigure
Figure 10-107. Installing Cylinder Shrouds.
InstaII Mufer
InslaIIlheorlIinersifequiedAachlhe
muerandsecurevilhlhefourhexangenuls
onlolheexhauslsludsTorquelhehexange
nulslo24.4 Nm (216 i n. l b.)
InslaIIanyaachinghardvareandbrackels
TorqueMscrevslo9.9 Nm (88 i n. l b.), and M8
screvslo24.4 Nm (216 i n. l b.)
Figure 10-108. Mufer InstaIIation.
InslaIIlhesarkarreslorifused
Mounting
Locations
Underside View
Flange
Nuts (4)
10.28
Section 10
Reassembly
Install Oil Filter and Add Oil to Crankcase
InslaIIlheoiIdrainIugsSeeIigure
TorquelheIugsloNm!b
NOTI MakesurelhalbolhoiIdrainIugs
areinslaIIedandlorquedlolheabove
secicalionslorevenloiIIeakage
Figure 10-109. Reinstall Oil Drain Plugs.
InslaIIanevoiIIlerfoIIovinglheinslruclions
inSeclion
AIyalhinImofcIeanengineoiIlolherubber
gaskelonlheoiIIlerandlhreadlheIleronlo
lheadalerniIeSeeIigure
HandlighlenlheIlerunliIlherubbergaskel
conlaclslheadalerlhenlighlenlheIleran
addilionaIlurnSeeIigure
Figure 10-110. Installing and Tightening Oil Filter.
AddoiIlobringlheIeveIulolheImarkand
reinslaIIlhedislickSeeIigure
Figure 10-111. Reinstall the Dipstick in Tube.
Connect Spark Plug Leads
ConnecllheIeadslolhesarkIugsSeeIigure

Figure 10-112. Connect Spark Plug Leads.

Prepare the Engine for Operation
TheengineisnovcomIeleIyreassembIedefore
slarlingoroeralinglheenginebesurelodolhe
foIIoving
MakesureaIIhardvareislighlenedsecureIy
MakesurelheoiIdrainIugsOiISenlry

ressuresvilchandanevoiIIlerareinslaIIed
IiIIlhecrankcasevilhlhecorreclamounl
veighlandlyeofoiIReferlooiI
recommendalionsandroceduresinlheSafely
andGeneraIInformalionandLubricalion
Syslemseclions
Ad|usllhecarbureloridIefueIneedIesoridIe
seedad|uslingscrevasnecessaryReferlo
SeclionlheIueISyslemandGovernor
Drain Plug (Starter Side Shown)
10.29
Section 10
Reassembly
10
Testing the Engine
Ilisrecommendedlhallheenginebeoeraledona
leslslandorbenchriorloinslaIIalioninlheieceof
equimenl
SellheengineuonaleslslandInslaIIanoiI
ressuregaugeSlarllheengineandchecklo
becerlainlhaloiIressuresiormoreis
resenlRunlheenginealidIeforminules
lhenminulesmorebelveenidIeand
midrangeAd|usllhecarburelormixlureseings
asnecessaryasavaiIabIe
Ad|usllhegovernedidIeandhighseedRIM
lorequiredseingsMakesurelhemaximum
engineseeddoesnolexceedRIMno
Ioad
10.30
LITHO IN U.S.A.
FORM NO.: TP-2581
ISSUED: 1/09
REVISED:
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL 1-800-544-2444
KohlerEngines.com