KT610-KT620, KT715-KT745

Service Manual

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.

2 Safety
3 Maintenance
5 Specifications
21 Tools and Aids
24 Troubleshooting
28 Air Cleaner/Intake
30 Fuel System
49 Governor System
50 Lubrication System
52 Electrical System
59 Starter System
63 Emission Compliant Systems
66 Disassembly/Inspection and Service
79 Reassembly

32 690 03 Rev. L KohlerEngines.com 1

Safety

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

WARNING WARNING CAUTION

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

2 KohlerEngines.com 32 690 03 Rev. L

 Maintenance

MAINTENANCE INSTRUCTIONS

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

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.
MAINTENANCE SCHEDULE

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

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

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

Every 100 Hours¹

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

Every 100 Hours

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

Every 300 Hours3

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

Every 500 Hours²

● Have valve lash checked/adjusted. Reassembly

Every 500 Hours

● Replace spark plugs and set gap. Electrical System
¹ Perform these procedures more frequently under severe, dusty, dirty conditions.
² Have a Kohler authorized dealer perform this service.
3
Option only if using KOHLER® PRO oil and PRO filter.

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

32 690 03 Rev. L KohlerEngines.com 3

Maintenance

OIL RECOMMENDATIONS STORAGE

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

KOHLER PRO 10W-50

10W-30

5W-30 SAE 30

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

FUEL RECOMMENDATIONS

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

NOTE: E15, E20 and E85 are NOT approved and

should NOT be used; effects of old, stale or
contaminated fuel are not warrantable.
Fuel must meet these requirements:
● Clean, fresh, unleaded gasoline.
● Octane rating of 87 (R+M)/2 or higher.
● Research Octane Number (RON) 90 octane minimum.
● Gasoline up to 10% ethyl alcohol, 90% unleaded is
acceptable.
● Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blend (max 15% MTBE by volume) are
approved.
● Do not add oil to gasoline.
● Do not overfill fuel tank.
● Do not use gasoline older than 30 days.

4 KohlerEngines.com 32 690 03 Rev. L

 Specifications

Engine Dimensions with Low Profile or High Performance Air Cleaner-Flywheel Side

M
C
B

H K
E
J L
F
I
G

A 423.0 mm (16.65 in.) B 136.7 mm (5.38 in.) C 89.6 mm (3.53 in.) D 50.1 mm (1.97 in.)
Oil Fill and Dipstick Fuel Line Connection
E F G Mounting Hole "A" H 136.9 mm (5.39 in.)
(Yellow) Point
7.2 mm (0.28) Center
I 141.5 mm (5.57 in.) J 89.7 mm (3.53 in.) K 307.9 mm (12.12 in.) L of Gravity
45.5 mm (1.79 in.)
M Center of Gravity

32 690 03 Rev. L KohlerEngines.com 5

Specifications

Engine Dimensions with Low Profile or High Performance Air Cleaner-Oil Filter Side

J
A I
B

C L
H M

D E
F

355.1 mm (13.98 in.) 329.1 mm (12.96 in.) 159.4 mm (6.28 in.) Engine Mounting
A Low Profile Air B Top of Low Profile C D
Center of Gravity Surface
Cleaner Removal Air Cleaner
134.0 mm (5.28 in.)
80.3 mm (3.16 in.) 51.2 mm (2.02 in.)
E F Mounting Hole "A" G H Spark Plug Center
Oil Filter Oil Filter Line
392.1 mm (15.44 in.)
High Performance
I 340.9 mm (13.42 in.) J 380.7 mm (14.99 in.) K Optional Fixed Guard L Air Cleaner
Removal
354.2 mm (13.94 in.)
Top of High
M Performance Air
Cleaner

6 KohlerEngines.com 32 690 03 Rev. L

 Specifications

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

A
B B C
D E

G
G

H I
U

T K
J

S L

O
R P
N
L L
Q
A 334.3 mm (13.16 in.) B 72.8 mm (2.87 in.) C 94.3 mm (3.71 in.) D 48.1 mm (1.89 in.)
4 X 5/16-18
Evap Connection UNC-2B in. 50.0 mm (1.97 in.)
E F G 30° H
Point 16.5 mm (0.649 in.) Exhaust Port #2
Deep No Studs
I 268.3 mm (10.56 in.) J 104.0 mm (4.10 in.) K 242.1 mm (9.53 in.) L 89.8 mm (3.54 in.)
18.0 mm (0.71 in.)
M N 116.8 mm (4.60 in.) O Mounting Hole "A" P Rotation Direction
Oil Filter Removal
4 X 9.005 mm (0.355 312.0 mm (12.28 in.)
in.) 37.0 mm (1.46
248.1 mm (9.77 in.) 93.1 mm (3.66 in.) Throttle and Choke
Q R in.) Deep on a Ø S T
Starter Stud Starter Stud Cable Mounting
254.0 mm (10.0 in.) Surface
B.C.
50.0 mm (1.97 in.)
U Exhaust Port #1

32 690 03 Rev. L KohlerEngines.com 7

Specifications

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

F G
A

B D

C E

55.8 mm (2.20 in.)

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

8 KohlerEngines.com 32 690 03 Rev. L

 Specifications

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

E
B D

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

32 690 03 Rev. L KohlerEngines.com 9

Specifications

Engine Dimensions with PRO Performance Air Cleaner-Flywheel Side

M
C
B

G L
E
J
F K
I
H

A 424.7 mm (16.72 in.) B 136.7 mm (5.38 in.) C 89.6 mm (3.53 in.) D 50.1 mm (1.97 in.)
Oil Fill and Dipstick Fuel Line Connection
E F G 136.9 mm (5.39 in.) H Mounting Hole "A"
(Yellow) Point
9.7 mm (0.38 in.)
I 141.5 mm (5.57 in.) J 89.7 mm (3.53 in.) K L 307.9 mm (12.12 in.)
Center of Gravity
47.0 mm (1.85 in.)
M Center of Gravity

10 KohlerEngines.com 32 690 03 Rev. L

 Specifications

Engine Dimensions with PRO Performance Air Cleaner-Oil Filter Side

A
K

J
B

D I

E
F
G

458.7 mm (18.06 in.) 265.2 mm (10.44 in.)

398.7 mm (15.70 in.) 166.5 mm (6.56 in.)
A Air Cleaner B C Evap Connection D
Top of Air Cleaner Center of Gravity
Removal Point
Engine Mounting 80.3 mm (3.16 in.) 51.2 mm (2.02 in.)
E F G Mounting Hole "A" H
Surface Oil Filter Oil Filter
134.0 mm (5.28 in.)
I Spark Plug Center J 340.9 mm (13.42 in.) K 380.7 mm (14.99 in.) L Optional Fixed Guard
Line
272.0 mm (10.71 in.)
M Evap Connection
Point

32 690 03 Rev. L KohlerEngines.com 11

Specifications

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

A
B B C

E
E

F
S

R
H
G

Q I

L
P O K
N N
M

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

12 KohlerEngines.com 32 690 03 Rev. L

 Specifications

Engine Dimensions with PRO Performance Air Cleaner-Starter Side

G
F
A

B D

C E

55.8 mm (2.20 in.)

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

32 690 03 Rev. L KohlerEngines.com 13

Specifications

Engine Dimensions with PRO Performance Air Cleaner-Valve Cover Side

A
F

E
B D

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

14 KohlerEngines.com 32 690 03 Rev. L

 Specifications

ENGINE IDENTIFICATION NUMBERS

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

Model . . . . . . . . . . . . . . . . . . . . . KT715
7000 Series Engine

Numerical Designation
Specification . . . . . . . . . . . . . . . KT715-0001
Serial . . . . . . . . . . . . . . . . . . . . . 4823500328
Year Manufactured Code Factory Code
Code Year
48 2018
49 2019
50 2020

KT610
GENERAL SPECIFICATIONS3,6 KT620 KT715
KT725 KT730 KT735 KT740* KT745
Bore 83 mm (3.27 in.)
61 mm 69 mm
Stroke 67 mm (2.64 in.)
(2.4 in.) (2.72 in.)
660 cc 747 cc
Displacement 725 cc (44 cu. in.)
(40.3 cu. in.) (46 cu. in.)
Oil Capacity (refill) 1.9 l (2.0 qt.)
Maximum Angle of Operation (@ full oil level)4 25°
*KT740 engines with PRO Performance Air Cleaner have 747 cc (46 cu. in.) Displacement.
KT610
TORQUE SPECIFICATIONS3,5 KT620 KT715 KT725 KT730 KT735 KT740 KT745

Auto Choke
eChoke™
Stepper Motor to Bracket Fastener 3.1 N·m (27.4 in. lb.)
Air Cleaner Base to Mounting Studs 6.2-7.3 N·m (55-65 in. lb.)
Smart-Choke™
Air Vane Deflector to Intake Manifold 1 N·m (9 in. lb.)
Air Cleaner Base to Mounting Studs 6.2-7.3 N·m (55-65 in. lb.)
Bracket Assembly Screw 5 N·m (45 in. lb.)

Baffle and Sheet Metal into Aluminum

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

Blower Housing and Sheet Metal

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

3
Values are in Metric units. Values in parentheses are English equivalents.
4
Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.
5
Lubricate threads with engine oil prior to assembly.
6
Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certified Power Ratings can be found at KohlerEngines.com.
32 690 03 Rev. L KohlerEngines.com 15
Specifications

KT610
TORQUE SPECIFICATIONS3,5 KT620 KT715 KT725 KT730 KT735 KT740 KT745

Carburetor
Mounting Nut 6.2-7.3 N·m (55-65 in. lb.)

Connecting Rod
Cap Fastener (torque in increments)
Black Coating 11.3 N·m (100 in. lb.)
Gray Metallic Coating 13.6 N·m (120 in. lb.)

Crankcase
Breather Assembly
Outer Cover Stud 6.2 N·m (55 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole

Outer Cover Hex Nut 1.3 N·m (11.5 in. lb.)

Oil Drain Plug 13.6 N·m (10 ft. lb.)

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

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

Fuel Pump
Screw 2.8 N·m (25 in. lb.)

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

Ignition
Spark Plug 27 N·m (20 ft. lb.)
Module Fastener 4.0-6.2 N·m (35-55 in. lb.)
Rectifier-Regulator Fastener 4.0 N·m (35 in. lb.)

Intake Manifold
Mounting Fastener (torque in 2 increments) first to 7.4 N·m (66 in. lb.)
finally to 9.9 N·m (88 in. lb.)

Muffler
M8 Hex Nuts 24.4 N·m (216 in. lb.)
M8 Lock Nuts 27.8 N·m (246 in. lb.)
5/16-18 Capscrew 16.9 N·m (150 in. lb.)
Bracket Screw 9.9 N·m (88 in. lb.)

Oil Pan
Fastener 24.4 N·m (216 in. lb.)

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

Oil Sentry™
Pressure Switch 4.5 N·m (40 in. lb.)
3
Values are in Metric units. Values in parentheses are English equivalents.
5
Lubricate threads with engine oil prior to assembly.
16 KohlerEngines.com 32 690 03 Rev. L
 Specifications

KT610
TORQUE SPECIFICATIONS3,5 KT620 KT715 KT725 KT730 KT735 KT740 KT745

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

Speed Control Bracket

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

Starter Assembly
Thru Bolt
Inertia Drive 4.5-5.7 N·m (40-50 in. lb.)
Solenoid Shift 5.6-9.0 N·m (49-79 in. lb.)
Mounting Screw 23.8 N·m (211 in. lb.)
Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.)

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

Valve Cover
Stamped Steel Cover Fastener 13.6 N·m (120 in. lb.)
Plastic Cover Fastener
Hex Flange 9.0 N·m (80 in. lb.)
Pan Head 6.2 N·m (55 in. lb.)

KT610
CLEARANCE SPECIFICATIONS3 KT620 KT715 KT725 KT730 KT735 KT740 KT745

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

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

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

3
Values are in Metric units. Values in parentheses are English equivalents.
5
Lubricate threads with engine oil prior to assembly.
32 690 03 Rev. L KohlerEngines.com 17
Specifications

KT610
CLEARANCE SPECIFICATIONS3 KT620 KT715 KT725 KT730 KT735 KT740 KT745

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

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

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

Governor
7 mm Hex End Cross Shaft End Play 0.25/3.15 mm (0.010/0.124 in.)
Governor Cross Shaft-to-Crankcase Running
Clearance 0.025/0.126 mm (0.0009/0.0049 in.)
Cross Shaft O.D.
New 7.949/8.000 mm (0.3129/0.3149 in.)
Max. Wear Limit 7.936 mm (0.3124 in.)
Governor Gear Shaft-to-Governor Running 0.050/0.210 mm (0.0020/0.0083 in.)
Clearance
Gear Shaft O.D.
New 5.990/6.000 mm (0.2358/0.2362 in.)
Max. Wear Limit 5.977 mm (0.2353 in.)

3
Values are in Metric units. Values in parentheses are English equivalents.
18 KohlerEngines.com 32 690 03 Rev. L
 Specifications

KT610
CLEARANCE SPECIFICATIONS3 KT620 KT715 KT725 KT730 KT735 KT740 KT745

Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Module Air Gap 0.203/0.305 mm (0.008/0.012 in.)

Piston, Piston Rings, and Piston Pin

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

Valves and Valve Tappets

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

3
Values are in Metric units. Values in parentheses are English equivalents.
7
Measure 6 mm (0.2362 in.) above bottom of piston skirt at right angles to piston pin.
32 690 03 Rev. L KohlerEngines.com 19
Specifications

GENERAL TORQUE VALUES

English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel
Grade 2 or 5 Fasteners
Into Aluminum

Size Grade 2 Grade 5 Grade 8

Tightening Torque: N·m (in. lb.) ± 20%
8-32 2.3 (20) 2.8 (25) — 2.3 (20)
10-24 3.6 (32) 4.5 (40) — 3.6 (32)
10-32 3.6 (32) 4.5 (40) — —
1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)
1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —
5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)
5/16-24 18.7 (165) 30.5 (270) — —
3/8-16 29.4 (260) — — —
3/8-24 33.9 (300) — — —

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

5/16-24 — — 40.7 (30) —
3/8-16 — 47.5 (35) 67.8 (50) —
3/8-24 — 54.2 (40) 81.4 (60) —
7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —
7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —
1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —
1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —
9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —
9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —
5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —
3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Metric Fastener Torque Recommendations for Standard Applications

Property Class Noncritical
Fasteners
Size 4.8 5.8 8.8 10.9 12.9
Into Aluminum
Tightening Torque: N·m (in. lb.) ± 10%
M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)

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

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

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

20 KohlerEngines.com 32 690 03 Rev. L

 Tools and Aids

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

TOOLS
Description Source/Part No.
Alcohol Content Tester Kohler 25 455 11-S
For testing alcohol content (%) in reformulated/oxygenated fuels.
Camshaft Endplay Plate SE Tools KLR-82405
For checking camshaft endplay.
Camshaft Seal Protector (Aegis) SE Tools KLR-82417
For protecting seal during camshaft installation.
Cylinder Leakdown Tester Kohler 25 761 05-S
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available: Design Technology Inc.
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines) DTI-731-03
Dealer Tool Kit (Domestic) Kohler 25 761 39-S
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester Kohler 25 455 01-S
Cylinder Leakdown Tester Kohler 25 761 05-S
Oil Pressure Test Kit Kohler 25 761 06-S
Rectifier-Regulator Tester (120 V AC/60Hz) Kohler 25 761 20-S
Dealer Tool Kit (International) Kohler 25 761 42-S
Complete kit of Kohler required tools.
Components of 25 761 42-S
Ignition System Tester Kohler 25 455 01-S
Cylinder Leakdown Tester Kohler 25 761 05-S
Oil Pressure Test Kit Kohler 25 761 06-S
Rectifier-Regulator Tester (240 V AC/50Hz) Kohler 25 761 41-S
Digital Vacuum/Pressure Tester Design Technology Inc.
For checking crankcase vacuum. DTI-721-01
Individual component available: Design Technology Inc.
Rubber Adapter Plug DTI-721-10
Electronic Fuel Injection (EFI) Diagnostic Software Kohler 25 761 23-S
For Laptop or Desktop PC.
EFI Service Kit Kohler 24 761 01-S
For troubleshooting and setting up an EFI engine.
Components of 24 761 01-S Design Technology Inc.
Fuel Pressure Tester DTI-019
Noid Light DTI-021
90° Adapter DTI-023
Code Plug, Red Wire DTI-027
Code Plug, Blue Wire DTI-029
Shrader Valve Adapter Hose DTI-037
Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031
Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033
K-Line Adapter Jumper Lead Wiring Harness Kohler 25 176 23-S
Kohler Wireless Diagnostic System Module (Bluetooth®) Kohler 25 761 45-S
For wireless Android EFI diagnostics.
Individual component available:
Wireless Diagnostic System Interface Cable Kohler 25 761 44-S

32 690 03 Rev. L KohlerEngines.com 21

Tools and Aids

TOOLS
Description Source/Part No.
Flywheel Puller SE Tools KLR-82408
For properly removing flywheel from engine.
Flywheel Anchor Bolts, Washers, Nuts Tool Kohler 25 086 753-S
Used with Flywheel Puller for properly removing flywheel from 5400 Series engine.
Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Kohler 25 455 20-S
Used to properly remove fuel hose from engine components.
Hydraulic Valve Lifter Tool Kohler 25 761 38-S
For removing and installing hydraulic lifters.
Ignition System Tester Kohler 25 455 01-S
For testing output on all systems, including CD.
Inductive Tachometer (Digital) Design Technology Inc.
For checking operating speed (RPM) of an engine. DTI-110
Offset Wrench (K and M Series) Kohler 52 455 04-S
For removing and reinstalling cylinder barrel retaining nuts.
Oil Pressure Test Kit Kohler 25 761 06-S
For testing/verifying oil pressure on pressure lubricated engines.
Rectifier-Regulator Tester (120 volt current) Kohler 25 761 20-S
Rectifier-Regulator Tester (240 volt current) Kohler 25 761 41-S
For testing rectifier-regulators.
Components of 25 761 20-S and 25 761 41-S Design Technology Inc.
CS-PRO Regulator Test Harness DTI-031R
Special Regulator Test Harness with Diode DTI-033R
Spark Advance Module (SAM) Tester Kohler 25 761 40-S
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Starter Servicing Kit (All Starters) SE Tools KLR-82411
For removing and reinstalling drive retaining rings and brushes.
Individual component available:
Starter Brush Holding Tool (Solenoid Shift) SE Tools KLR-82416
Stepper Motor Controller Tool Kohler 25 455 21-S
For testing operation of stepper motor/Digital Linear Actuator (DLA).
Jumper Lead Tool Kohler 25 518 43-S
For use with Stepper Motor Controller Tool to test rotary stepper motor.
Triad/OHC Timing Tool Set Kohler 28 761 01-S
For holding cam gears and crankshaft in timed position while installing timing belt.
Valve Guide Reamer (K and M Series) Design Technology Inc.
For properly sizing valve guides after installation. DTI-K828
Valve Guide Reamer O.S. (Command Series) Kohler 25 455 12-S
For reaming worn valve guides to accept replacement oversize valves. Can be used
in low-speed drill press or with handle below for hand reaming.
Reamer Handle Design Technology Inc.
For hand reaming using Kohler 25 455 12-S reamer. DTI-K830

22 KohlerEngines.com 32 690 03 Rev. L

 Tools and Aids

AIDS
Description Source/Part No.
Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S
Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S
Dielectric Grease Loctite® 51360
Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S
RTV Silicone Sealant
Loctite® 5900® Heavy Body in 4 oz. aerosol dispenser. Kohler 25 597 07-S
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved Loctite® 5910®
for use. Permatex® the Right Stuff® 1 Minute Gasket™ or Loctite® Nos. 5900® or Loctite® Ultra Black 598™
5910® are recommended for best sealing characteristics. Loctite® Ultra Blue 587™
Loctite® Ultra Copper 5920™
Permatex® the Right Stuff® 1
Minute Gasket™
Spline Drive Lubricant Kohler 25 357 12-S

FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL

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

32 690 03 Rev. L KohlerEngines.com 23

Troubleshooting

TROUBLESHOOTING GUIDE
When troubles occur, be sure to check simple causes which, at first, may seem too obvious to be considered. For
example, a starting problem could be caused by an empty fuel tank.
Some general common causes of engine troubles are listed below and vary by engine specification. Use these to
locate causing factors.

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

24 KohlerEngines.com 32 690 03 Rev. L

 Troubleshooting

Engine Loses Power EXTERNAL ENGINE INSPECTION

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

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

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

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

After inspecting external condition of engine, clean

engine thoroughly before disassembly. Clean individual
components as engine is disassembled. Only clean
parts can be accurately inspected and gauged for wear
or damage. There are many commercially available
cleaners that will quickly remove grease, oil, and grime
from engine parts. When such a cleaner is used, follow
manufacturer’s instructions and safety precautions
carefully.
Make sure all traces of cleaner are removed before
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down
lubricating properties of engine oil.

32 690 03 Rev. L KohlerEngines.com 25

Troubleshooting

CRANKCASE VACUUM TEST

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

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

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

26 KohlerEngines.com 32 690 03 Rev. L

 Troubleshooting

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

32 690 03 Rev. L KohlerEngines.com 27

Air Cleaner/Intake

AIR CLEANER NOTE: Operating engine with loose or damaged air

These systems are CARB/EPA certified and components cleaner components could cause premature
should not be altered or modified in any way. wear and failure. Replace all bent or damaged
components.
Air Cleaner Components NOTE: Paper element cannot be blown out with
compressed air.
A G
Rotate air cleaner cover levers outward to unlock cover;
remove air cleaner cover.
B B or
Move bails on air cleaner cover up; remove latches from
cover; remove cover.
D H Precleaner (if equipped)
C C
1. Remove precleaner from paper element.
E E 2. Replace or wash precleaner in warm water with
detergent. Rinse and allow to air dry.
3. Lightly oil precleaner with new engine oil; squeeze
F out excess oil.
F
4. Reinstall precleaner over paper element.
Paper Element
1. Remove element from base; service precleaner.
Discard element.
2. Install precleaner over new paper element and install
on base.
B Position air cleaner cover with levers outward over air
cleaner; turn levers inward to lock.
J or
F Reinstall cover; place latches onto cover; pull down bails
K to secure cover.

K
I E

Low-Profile Air
A B Air Cleaner Cover
Cleaner (LPAC)
Air Cleaner Cover
C D LPAC Element
Lever
E Precleaner F Air Cleaner Base
High Performance High Performance
G H
Air Cleaner Element
PRO Performance PRO Performance
I J
Air Cleaner Element
K Bail

28 KohlerEngines.com 32 690 03 Rev. L

 Air Cleaner/Intake

Air Cleaner Base If air cleaner base requires removal, proceed as follows:
1. Remove mounting screws for fuel pump (if
A equipped), and blower housing.
2. Raise or remove blower housing for access to air
cleaner base.
3. Remove air cleaner components from base.
4. Remove nuts securing air cleaner base onto
mounting studs.
5. Disconnect ground lead and fuel shut-off solenoid
B lead (if equipped).
6. If equipped with eChoke™, disconnect connecter
C F from stepper motor.
7. Remove Smart-Choke™ or eChoke™ bracket
assembly (if equipped).
8. Disconnect choke linkage from carburetor assembly.
E
D 9. Disconnect breather hose from air cleaner base,
then remove base and gasket.
A 10. Reverse procedure to reassemble components.
Torque nuts to 6.2-7.3 N·m (55-65 in. lb.). Torque
blower housing screws to 4.0 N·m (35 in. lb.), and
front HI-LO screws to 2.8 N·m (25 in. lb.). Torque
Smart-Choke™ bracket assembly screw to 5 N·m (45
in. lb.).
BREATHER TUBE
Ensure both ends of breather tube are properly
connected.
AIR COOLING

WARNING
G
Hot Parts can cause severe burns.
D Do not touch engine while operating or just
after stopping.
H Never operate engine with heat shields or guards
removed.
A Air Cleaner Base B Breather Hose Proper cooling is essential. To prevent over heating,
C Ground Lead D Solenoid Lead clean screens, cooling fins, and other external surfaces
of engine. Avoid spraying water at wiring harness or any
Smart-Choke™ electrical components. Refer to Maintenance Schedule.
E F Thermostat
Bracket Assembly
eChoke™ Bracket
G H Stepper Motor
Assembly

Disassembly/Reassembly
NOTE: On engines equipped with eChoke™, stepper
motor has a special retract routine that can be
activated to ensure motor is in correct position
prior to removal or upon replacement of stepper
motor when a problem is shown to exist with
stepper motor assembly and carburetor.
Activation of this routine will occur by initiating
three (3) consecutive Key On–Off cycles. Every
Key On and Off should be > 2 seconds and <
3.5 seconds. Note that if no other connections
are disturbed, stepper motor will be repositioned
at next key ON and master module will go back
to normal choke operation mode.

32 690 03 Rev. L KohlerEngines.com 29

Fuel System

Typical carbureted fuel system and related components Performance

include:
Minimum fuel delivery rate must be 7.5 l/hr. (2 gal./hr.)
● Fuel tank. with a pressure at 0.3 psi and a fuel lift of 24 in. A
● Fuel lines. 1.3 l/hr. (0.34 gal./hr.) fuel rate must be maintained at
● In-line fuel filter. 5 Hz.
● Fuel pump.
● Carburetor. Fuel Pump Replacement
Fuel from tank is moved through in-line filter and fuel NOTE: Make sure orientation of new pump is consistent
lines by fuel pump. Fuel then enters carburetor float bowl with removed pump. Internal damage may occur
and is drawn into carburetor body and mixed with air. if installed incorrectly.
This fuel-air mixture is then burned in engine combustion To replace pulse pump follow these steps. Note
chamber. orientation of pump before removing.
FUEL RECOMMENDATIONS 1. Disconnect fuel lines from inlet, outlet, and pulse
Refer to Maintenance. fittings on fuel pump.
FUEL LINE 2. Remove screws and take off pump.
Low permeation fuel line must be installed on carbureted 3. Connect pulse line to new fuel pump and make sure
Kohler Co. engines to maintain EPA and CARB opposite end is properly connected into valve cover.
regulatory compliance. 4. Attach new fuel pump using screws. Torque screws
FUEL PUMP to 2.8 N·m (25 in. lb.).
Some engines use a pulse style fuel pump. Pumping 5. Reconnect fuel lines to inlet and outlet fittings and
action of pulse style pumps is created by oscillation of secure with clamps.
positive and negative pressures within crankcase. This AUTO CHOKE (if equipped)
pressure is transmitted to pulse pump through rubber
hose connected between pump and crankcase. Pumping If engine is equipped with Smart-Choke™ or eChoke™,
action causes diaphragm on inside of pump to pull fuel identify design and follow appropriate troubleshooting
in on its downward stroke and to push it into carburetor procedures starting on page 35 of this manual.
on its upward stroke. Two check valves prevent fuel from
going backward through pump.

FUEL SYSTEM TESTS

When engine starts hard or turns over but will not start, fuel system might be causing problems. Test fuel system by
performing following test.

1. Check for fuel in combustion chamber. 3. Check operation of fuel pump.

a. Disconnect and ground spark plug leads. a. Remove fuel line from inlet fitting of carburetor.
b. Close choke on carburetor. b. Crank engine several times and observe flow.
c. Crank engine several times.
d. Remove spark plug and check for fuel at tip.
2. Check for fuel flow from tank to fuel pump.
a. Remove fuel line from inlet fitting of fuel pump.
b. Hold line below bottom of tank. Open shut-off
valve (if equipped) and observe flow.

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

30 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

CARBURETOR Walbro One-Barrel Carburetor Components

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

Keihin One-Barrel Carburetor Components D

E
I
A
F
A Idle Speed Screw B Carburetor Body
E C
C Main Jet D Float
D Shut-off Solenoid
E Fuel Bowl F Assembly
G Choke Lever
F Engines in this series are equipped with either a Keihin
or Walbro fixed main jet carburetor. Most carburetors
utilize a fuel shut-off solenoid and feature a self-relieving
choke.

H Troubleshooting Checklist
When engine starts hard, runs rough, or stalls at low
idle speed, check these areas before adjusting or
G disassembling carburetor.
1. Make sure fuel tank is filled with clean, fresh
gasoline.
A Idle Speed Screw B Carburetor Body 2. Make sure fuel tank cap vent is not blocked and is
operating properly.
C Idle Jet D Plug
E Main Jet F Float 3. Make sure fuel is reaching carburetor. This includes
checking fuel shut-off valve, fuel tank filter screen,
Shut-off Solenoid in-line fuel filter, fuel lines and fuel pump for
G H Fuel Bowl
Assembly restrictions or faulty components as necessary.
I Choke Lever 4. Make sure air cleaner base and carburetor are
securely fastened to engine using gaskets in good
condition.
5. Make sure air cleaner element (including precleaner
if equipped) is clean and all air cleaner components
are fastened securely.
6. Make sure ignition system, governor system,
exhaust system, and throttle and choke controls are
operating properly.

32 690 03 Rev. L KohlerEngines.com 31

Fuel System

Troubleshooting-Carburetor Related Causes

Condition Possible Cause Conclusion
Engine runs rich (indicated by black, Clogged air cleaner. Clean or replace air cleaner.
sooty exhaust smoke, misfiring, loss Choke partially closed during Check choke lever/linkage to ensure
of speed and power, governor operation. choke is operating properly.
hunting, or excessive throttle
opening). Float level is set too high. Adjust float (Keihin only, Walbro not
adjustable).
Dirt under fuel inlet needle. Remove needle; clean needle and
seat and blow with compressed air.
Bowl vent or air bleeds plugged. Clean vent, ports, and air bleeds.
Blow out all passages with
compressed air.
Leaky, cracked, or damaged float. Submerge float to check for leaks.
Engine runs lean (indicated by Float level is set too low. Adjust float (Keihin only, Walbro not
misfiring, loss of speed and power, adjustable).
governor hunting, or excessive Idle holes plugged; dirt in fuel delivery Clean main fuel jet and all passages;
throttle opening). channels. blow out with compressed air.
Fuel leaks from carburetor. Float level set too high. Adjust float (Keihin only, Walbro not
adjustable).
Dirt under fuel inlet needle. Remove needle; clean needle and
seat and blow with compressed air.
Bowl vents plugged. Blow out with compressed air.
Carburetor bowl gasket leaks. Replace gasket.
FUEL SYSTEM Carburetor Circuits
Fuel Shut-off Solenoid Float
Fuel level in bowl is maintained by float and fuel inlet
Most carburetors are equipped with a fuel shut-off needle. Buoyant force of float stops fuel flow when
solenoid. Solenoid is attached to fuel bowl. Solenoid has engine is at rest. When fuel is being consumed, float will
a spring-loaded pin that retracts when 12 volts is applied drop and fuel pressure will push inlet needle away from
to lead, allowing fuel flow to main jet. When current is seat, allowing more fuel to enter bowl. When demand
removed, pin extends blocking fuel flow. ceases, buoyant force of float will again overcome fuel
Below is a simple test, performed with engine off, that pressure, rising to predetermined setting and stop flow.
can determine if solenoid is functioning properly: Slow and Mid-Range
1. Shut off fuel and remove solenoid from carburetor. At low speeds engine operates only on slow circuit. As
When solenoid is loosened and removed, gas will a metered amount of air is drawn through slow air bleed
leak out of carburetor. Have a container ready to jets, fuel is drawn through main jet and further metered
catch fuel. through slow jet. Air and fuel are mixed in body of slow
2. Wipe tip of solenoid with a shop towel or blow with jet and exit to idle progression (transfer port) chamber.
compressed air to remove any remaining fuel. Take From idle progression chamber, air fuel mixture is
solenoid to a location with good ventilation and no metered through idle port passage. At low idle air/fuel
fuel vapors present. You will also need a 12 volt mixture is controlled by setting of idle fuel adjusting
power source that can be switched on and off. screws. This mixture is then mixed with main body of
air and delivered to engine. As throttle plate opening
3. Be sure power source is switched OFF. Connect increases, greater amounts of air/fuel mixture are drawn
positive power source lead to red lead of solenoid. in through fixed and metered idle progression holes.
Connect negative power source lead to solenoid As throttle plate opens further, vacuum signal becomes
body. great enough at venturi so main circuit begins to work.
4. Turn power source ON and observe pin in center of Main (high-speed)
solenoid. Pin should retract with power ON and At high speeds/loads engine operates on main circuit.
return to its original position with power OFF. Test As a metered amount of air is drawn through air jet,
several times to verify operation. fuel is drawn through main jet. Air and fuel are mixed
in main nozzles then enters main body of airflow where
further mixing of fuel and air occurs. This mixture is then
delivered to combustion chamber. Carburetor has a fixed
main circuit; no adjustment is possible.

32 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

Carburetor Adjustments Float Setting (Keihin Only)

NOTE: Carburetor adjustments should be made only A
after engine has warmed up.
Carburetor is designed to deliver correct fuel-to-air
mixture to engine under all operating conditions. Main
fuel jet is calibrated at factory and is not adjustable. Idle
fuel adjusting needles are also set at factory and are not
adjustable.
Idle Speed (RPM) Adjustment
1. Hold governor lever away from carburetor so throttle
lever is against idle speed (RPM) adjustment screw
of carburetor. Start engine and allow to warm up,
then adjust screw to set approximately 1450 RPM.
Check speed using a tachometer. Turn adjustment
screw (inner) clockwise (in) to increase or
counterclockwise (out) to decrease speed.
2. Release governor lever and check that throttle lever
is in idle position. Obtain equipment manufacturer’s
recommended idle speed (1750 RPM). All engines A 12 mm (0.472 in.)
have a bendable tab that is used to set this speed. A NOTE: Inlet needle center pin is spring loaded. Make
pliers should be used to bend this tab to achieve sure float assembly rests against fuel inlet
recommended speed. Governed idle speed (RPM) is needle, without depressing center pin.
typically 300 RPM (approximate) higher than low idle
speed. 1. Perform removal procedures for appropriate air
cleaner and carburetor outlined in Disassembly.
3. Move throttle lever to wide-open/full throttle position
and hold in this position. Turn high speed screw to 2. Clean exterior surfaces of dirt or foreign material
obtain intended high speed no-load RPM. Governed before disassembling carburetor. Remove bowl
idle speed must be set before making this retaining screws, or solenoid assembly, and carefully
adjustment. separate fuel bowl from carburetor. Do not damage
fuel bowl O-rings. Transfer any remaining fuel into
High Speed (RPM) Adjustment an approved container. Save all parts.
1. With engine running, move throttle control to fast.
3. Remove float pin (some carburetors may have a
2. Turn inner adjustment screw outward to decrease, or screw which requires removal), and inlet needle.
inward to increase RPM speed. Seat for inlet needle is not serviceable and should
not be removed.
Carburetor Servicing
4. Remove two screws securing top cover, gasket, and
ground lead (Keihin carburetors only). Discard
WARNING gasket and screws only.
5. Remove idle speed adjusting screw and spring from
Accidental Starts can cause severe injury or carburetor. Discard parts.
death.
6. Clean carburetor bowl and inlet seat areas as
Disconnect and ground spark plug lead(s) required.
before servicing.
7. Carefully remove main jet from carburetor. After
main jet is removed, on some carburetors, main
Before working on engine or equipment, disable nozzle can be removed through bottom of main
engine as follows: 1) Disconnect spark plug lead(s). 2) tower. Note orientation/direction of nozzle. Save
Disconnect negative (–) battery cable from battery. parts for cleaning and reuse.
8. Position of slow jet varies and is removable only on
NOTE: Main and slow jets are fixed and size specific some styles of carburetors. See correct illustration
and can be removed if required. Fixed jets for for corresponding style of carburetor showing
high altitudes are available. location. Save parts for cleaning and reuse unless a
● Inspect carburetor body for cracks, holes, and other jet kit is also being installed. Clean slow jet using
wear or damage. compressed air. Do not use wire or carburetor
● Inspect float for cracks, holes, and missing or cleaner.
damaged float tabs. Check float hinge and shaft for 9. Carburetor is now disassembled for appropriate
wear or damage. cleaning and installation of parts in overhaul kit.
● Inspect fuel inlet needle and seat for wear or damage. Further disassembly is not necessary. Throttle shaft
● Inspect spring loaded choke plate to make sure it assembly, fuel inlet seat and idle fuel adjustment
moves freely on shaft. screw are non-serviceable items and should not be
removed. Choke shaft assembly is serviceable,
however it should not be removed unless a choke
repair kit will be installed.

32 690 03 Rev. L KohlerEngines.com 33

Fuel System

For Keihin Carburetors Only 28. Correct float height adjustment is 12.0 mm
To install choke repair kit go to step 10, otherwise go (0.472 in.) measured from float bottom to body of
to step 21. carburetor. Adjust float height by carefully bending
10. Remove and discard plastic cap from top of choke metal tang of float.
lever/shaft assembly. 29. When proper float height is obtained, carefully install
11. Note position of spring legs and choke plate for new O-ring for fuel bowl.
correct reassembly later. 30. Install fuel bowl onto carburetor. Secure with four
12. Remove two screws attaching choke plate to choke original screws. Torque screws to 2.5 ± .3 N·m
shaft. Pull shaft out of carburetor body and discard (23 ± 2.6 in. lb.).
removed parts. 31. Install new cover gasket and top cover on
13. Use a screw extractor (easy out) and remove carburetor. Secure with two large-head screws and
original choke shaft bushing with old choke lever attach ground lead (if equipped with a fuel solenoid),
from carburetor housing. Save bushing to use as a to original screw location. Torque top cover screws
driver for installing new bushing. Discard old lever. to 2.5 ± .3 N·m (23 ± 2.6 in. lb.).
14. Clean I.D. of both choke shaft bores as required. 32. Place new spring onto idle speed adjusting screw
and install into carburetor. Thread in until 3 or 4
15. Insert new bushing through new choke lever from threads are exposed, as an initial adjustment.
outside, and start bushing in outer shaft bore. 33. Reinstall carburetor using appropriate new
Position choke lever so that protruding boss on carburetor and air cleaner base gaskets.
carburetor housing is between two stops formed in
choke lever. 34. Reconnect spark plug lead(s) and negative (–)
16. Turn old bushing upside down and use it as a driver battery cable. Start engine and perform Idle Speed
to carefully press or tap new bushing into carburetor (RPM) Adjustment.
body until it bottoms. Check that choke lever pivots For Walbro Carburetors Only
freely without restriction or binding. 10. Clean carburetor body, jets, vent ports, seats, etc.,
17. Install new return spring onto new choke shaft, so using a good commercially available carburetor
upper leg of spring is between two formed stops on solvent. Use clean, dry compressed air to blow out
end of choke shaft. internal channels and ports. Inspect and thoroughly
check carburetor for cracks, wear, or damage.
18. Slide choke shaft and spring, into carburetor. Pivot Inspect fuel inlet needle seat for wear or damage.
(preload) shaft and set inner leg of spring, against Check spring loaded choke plate to make sure it
formed stop within choke lever, as originally moves freely on shaft.
assembled. Opposing leg of spring must still be 11. Clean carburetor float bowl as required.
between formed stops of choke shaft.
19. Place a drop of Loctite® on threads of each new 12. Install main nozzle and main jet into tower of
screw. Install new choke plate to flat side of choke carburetor body.
shaft and start two screws. Larger cutout must be on 13. Install new solenoid gasket on solenoid.
right. Close choke and check plate alignment within Reassemble fuel bowl and solenoid.
carburetor throat, then tighten screws securely. Do 14. Reinstall carburetor using appropriate new
not overtighten. carburetor and air cleaner base gaskets.
20. Check for proper operation and free movement of 15. Reconnect spark plug lead(s) and negative (–)
parts. Install new cap. battery cable. Start engine and perform Idle Speed
21. Clean carburetor body, jets, vent ports, seats, etc., (RPM) Adjustment.
using a good commercially available carburetor
solvent. Use clean, dry compressed air to blow out High Altitude Operation
internal channels and ports. Inspect and thoroughly
check carburetor for cracks, wear, or damage. If this engine is operated at an altitude of 4000 ft.
Inspect fuel inlet needle seat for wear or damage. (1219 meters) or above, a high altitude carburetor
Check spring loaded choke plate to make sure it kit is required. To obtain high altitude carburetor kit
moves freely on shaft. information or to find a Kohler authorized dealer, visit
22. Clean carburetor float bowl as required. KohlerEngines.com or call 1-800-544-2444 (U.S. and
23. Install main nozzle and main jet into tower of Canada).
carburetor body. This engine should be operated in its original
24. Install slow jet and new plug into end of slow jet configuration below 4000 ft. (1219 meters).
tube. Operating this engine with the wrong engine
25. Attach inlet needle to metal tang of float with wire configuration at a given altitude may increase its
clip. Formed 90° lip of metal tang should point up, emissions, decrease fuel efficiency and performance,
with needle valve hanging down. and result in damage to the engine.
26. Install new float and new inlet needle down into seat
and carburetor body. Insert new pivot pin through
float hinge and secure with new retaining screw.
27. Hold carburetor body so float assembly hangs
vertically and rests lightly against fuel inlet needle.
Inlet needle should be fully seated but center pin of
needle (on retainer clip end) should not be
depressed. Check float height adjustment.

34 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

Smart-Choke™
An air vane deflector assembly that operates by air from cooling fan opens choke partially when engine is running.
When engine is cold, a spring on air vane deflector assembly, in conjunction with a bimetallic spring, holds choke
closed for starting. A bimetallic spring reacts to heat generated by electrical resistance as engine is running and
opens choke plate position. When engine is warm, bimetallic spring holds choke completely open, while engine
is running. Choke will be 2/3 closed when warm and not running. These two elements work together to operate a
smooth choke system that facilitates easy reliable starting.
Smart-Choke™ Components

A M

H
N
K
J L
F G
C

D
E

F I

A Precleaner B Paper Element C Air Cleaner Base D Evap Hose

Smart-Choke™
E F Thermostat G Solenoid Lead H Air Cleaner Gasket
Bracket Assembly
I Control Assembly J Breather Hose K Stud L Intake Manifold
Choke Unloader
M N Ignition Module O Deflector Support Tab P Air Vane Deflector
Linkage

32 690 03 Rev. L KohlerEngines.com 35

Fuel System

Troubleshooting Smart-Choke™ Related Causes

Condition Possible Cause Conclusion
Engine starts hard, runs rough, or Choke not closing. Check choke lever/linkage to ensure
stalls at idle speed. choke is operating properly.
Check that bimetallic spring actuates
freely.
Engine runs rich (indicated by black, Choke partially closed during Check choke lever/linkage to ensure
sooty exhaust smoke, misfiring, loss operation. choke is operating properly.
of speed and power, governor Check that air vane is operating
hunting, or excessive throttle freely.
opening).
Choke not opening. Check choke lever/linkage to ensure
choke is operating properly.
Check that air vane is operating
freely.
Check choke thermostat bracket
assembly.

Smart-Choke™ System Troubleshooting 1. Remove air cleaner cover, and air cleaner from air
cleaner base.
Oil Pressure Switch 2. Choke plate should be fully closed when engine is
cold.
3. There should be light spring tension holding choke
A closed.
4. There should not be any binding when choke shaft
B assembly is rotated, which could cause choke to
remain partially open.
5. Remove blower housing.
6. Check choke linkage and air vane deflector
assembly for binding or debris build up. Gently
actuate linkage and observe that choke plate has full
range of movement (open and close).
7. Unplug red wire with black tracer power lead of
bimetallic spring assembly. Measure heat circuit
resistance of choke thermostat assembly, with a volt
ohm meter at room temperature (68°F/20°C).
8. Attach one wire of meter to red wire w/yellow tracer
terminal of assembly, and other wire to ground of
bracket or to ground strip of assembly body.
A Power In Terminal Thermostat resistance should read 15 ohms (+/- 10
ohms). If assembly is warm, allow unit to cool to
B Power Out Terminal room temperature (68°F/20°C) for accurate testing.
These procedures are to be performed on a cold engine. If an infinite (open) reading is found, replace
bimetallic spring choke bracket assembly. Air vane
NOTE: Bimetallic spring assembly is pre-set at factory. linkage will not open choke plate fully when cold and
DO NOT attempt to adjust/change its settings. will not close choke plate fully when engine is warm.
NOTE: Do not remove or loosen thermostat screws. 9. Reinstall blower housing.
Position is set at factory.
10. Start engine. Upon start up, choke plate should be
NOTE: Thermostat temperature must be at room 1/3 closed. Choke plate should gradually change to
temperature before testing. full open position after 2 to 2-1/2 minutes of running.
This action is performed by bimetallic spring
assembly being heated. If choke plate fails to open,
recheck linkage for binding.

36 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

11. With engine running, check voltage at bimetallic 13. If linkage is free and choke plate fails to open fully
spring choke bracket assembly. Using a DVOM, after 2 minutes, check spring tension of bimetallic
attach black lead of meter to ground screw on assembly. If necessary, replace bimetallic spring
assembly bracket, and red lead of meter to red wire choke bracket assembly.
w/black tracer. 14. Reinstall air cleaner element and secure cover.
12. Select DC VOLTS on your meter. You should see a
minimum of 12 volts DC. Thermostat
If no voltage is present, test for voltage at oil Different styles of thermostats are used. Identify style
pressure switch. on engine and follow appropriate procedure to reset or
If voltage is present at power in terminal but not at install.
power out terminal when engine is running, pressure
switch is potentially faulty. Remove switch and install Thermostat Identification
a pressure test gauge and start engine. Consult
troubleshooting section of this manual for oil
pressure testing instructions. If adequate pressure is
found, replace pressure switch and confirm
operation/voltage readings.

A Adjustable Thermostat
B Dual Position Thermostat

32 690 03 Rev. L KohlerEngines.com 37

Fuel System

Adjustable Thermostat

G
A

D D
E E

C
B
F
F

High Position of
Spring Tab Must be Models KT725, Models KT740,
A B C D Adjustment
Located in Lever Slot KT735 KT745 Range
This Edge of Metallic
Low Position of Ground Strap Must
E Adjustment F G Lever Slot
Fall Within
Range Adjustment Range

Adjustable Thermostat Reset

NOTE: Do not remove or loosen thermostat screws. Position is set at factory.
NOTE: Thermostat temperature must be at room temperature before testing.
If thermostat is loosened or removed, use following procedure to reset position.
1. Unplug thermostat wire.
2. Thermostat position should be set to low position of adjustment range (E).
3. Once thermostat position is set, engine must be started at idle with thermostat wire disconnected to test system
function.
4. If engine runs correctly, no further adjustment is needed.
5. If engine speed does not increase to idle speed on start up, thermostat position must be adjusted by rotating
housing clockwise in 1 mm increments and retested. Position should not exceed high adjustment range shown
(D).
6. Plug in thermostat wire.

38 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

Dual Position Thermostat

A B

E
D

CDI Ignition Module MDI Ignition Module

A B C CDI Position D MDI Position
(Top View) (Top View)
Spring Tab Must be
E F Lever Slot
Located in Lever Slot

Dual Position Thermostat Installation

NOTE: Thermostat temperature must be at room temperature before testing.
1. Determine operating position of thermostat. Thermostat position is determined by ignition system: Capacitive
Discharge Ignition (CDI) or Magnetic Discharge Ignition (MDI).
For CDI systems secure thermostat in position (C).
For MDI systems secure thermostat in position (D).
2. Install Smart-Choke™ bracket assembly with thermostat in proper position. Do not plug thermostat wire at this
time.
3. Engine must be started at idle with thermostat wire disconnected to test system function.
4. If engine runs correctly, no further adjustment is needed.
5. If engine speed does not increase to idle speed on start up, ensure spring tab (E) is engaged in lever slot (F) and
thermostat is in proper position for ignition system of engine.
6. Retest system function.
7. Plug in thermostat wire.

32 690 03 Rev. L KohlerEngines.com 39

Fuel System

Starting an Engine Equipped with Smart-Choke™

NOTE: Do not crank engine continuously for more than 10 seconds at a time. If engine does not start, allow a 60
second cool down period between starting attempts. Failure to follow these guidelines can burn out starter
motor.
NOTE: If engine develops sufficient speed to disengage starter but does not keep running (a false start), engine
rotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engaged
while flywheel is rotating, starter pinion and flywheel ring gear may clash, resulting in damage to starter.
1. Smart-Choke™ system will automatically control choke plate position for starting.
2. Make sure equipment is in neutral.
3. Activate starter switch. Release switch as soon as engine starts.
If starter does not turn engine over, shut starter off immediately. Do not make further attempts to start engine until
condition is corrected. Do not jump start using another battery. See your Kohler authorized dealer for trouble
analysis.
4. For operation, after engine starts, move throttle and set desired engine operating speed.

40 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

Electronic Choke (eChoke™)

eChoke™ is an integrated control system that checks ambient and engine temperatures and monitors engine speed.
This system is integrated through wiring to a master ignition/control module. Extended cranking (beyond 10 seconds)
is not necessary, nor will it improve engine starting.
Calculations and unique software routines developed specifically for this Kohler engine operate a carburetor choke
lever through an assembly (bracket, linkage) to control a stepper motor. Power and ground are supplied to master
control and ignition module (Cylinder 2) which provides a signal for stepper motor by way of a control harness that is
routed through cylinder #2 baffle. An interconnection harness between two modules may exist (model dependent).
eChoke Components (Includes ignition due to integrated system)
● Master & slave ignition modules (with interface cables)
● Stepper motor
● Stepper motor bracket, linkage, and associated fasteners
● Wire harness (for power and ground)

eChoke™ Components

A
H I

J K
B

D
L
E
F

G
M
D

Stepper Motor
A Precleaner B Paper Element C Bracket and D Stepper Motor
Hardware
Ignition Module
E Air Cleaner Base F Carburetor G Intake Manifold H Lead #2 Cylinder
Red/Green Stripe to
Ignition Module Master Ignition Slave Ignition
I J K L Constant Battery B+
Lead #1 Cylinder Module Module Power
Master Controller
M Stepper Motor
Harness/Connector

32 690 03 Rev. L KohlerEngines.com 41

Fuel System

eChoke™ System Standard Checks Blink Codes

NOTE: Procedures and troubleshooting may be easier NOTE: Use of any other type of lamp, other than LED,
to perform with engine cover removed. Refer to could damage components.
Disassembly/Inspection and Service and eChoke™ system is equipped with an MIL connector that
Reassembly procedure. will allow connection of an LED lamp to show normal
Use these procedures and guides to troubleshoot this eChoke™ operation or specific error codes. This lead
system and its components. Perform a system reset (white/red stripe) with a bullet connector next to stepper
prior to troubleshooting to verify problem still exists. Start motor to which an LED (connected to lead and +12 volt
with key switch in OFF position, operate through On-Off- power line) can be connected to review operation or
On sequence and restart engine. look for error codes. Once a lamp is connected, operator
There are standard checks that should be made initially can attempt to run through a normal start/crank/run/
to help isolate possible problems: off sequence and monitor blink codes to determine if
controller operation is correct.
1. Check choke assembly to ensure choke is properly
connected. (Link connected to carburetor and Both normal operation and error code indication is listed
stepper motor.) in blink code table that follows. Note that code changes
for each level of operation.
2. Make sure link is located and connected properly.
Table shows both normal operation and failure mode
3. Check for battery voltage (nonoperating), must be blinks codes. Normal operation blink codes will be
greater than 12.2 VDC open circuit. displayed when no failure modes are detected during
(Low battery voltage may prevent proper operation operation. These codes will only appear if there is no
of stepper motor.) captured failure blink code. Failure mode blink codes are
specific to integrated sensors associated with master
4. Check that constant power line (RED/GREEN stripe) controller/ignition module.
connection is connected directly to battery B+.
Operational blink sequence only occurs when routine
5. Check for continuity through constant power line associated to it is completed, until then LED will continue
(possible fusible link failure). blinking to previously completed routine.
6. Check for presence of constant (battery voltage) and eChoke Diagnostics and Failure Mode Subroutines
switched power at harness. (Blower housing must be ● DELAY=LED OFF 2 seconds
removed.) ● ON=LED ON 0.5 second
7. Check that choke stepper motor is functioning. ● OFF=LED OFF 0.5 second
(Remove air cleaner cover and element. Operate
key switch through On-Off-On sequence to inspect
for any choke movement.)
8. If blink codes indicate a temperature read failure or
RPM failure (see blink code info), then master
controller/ignition is at fault and needs to be
replaced.
9. If all standard checks are correct, proceed to Blink
Codes.

42 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

Operational Tests
Test Step Description of What is happening at
Operation MIL Lamp Status
Number Operation eChoke™
Choke system will cycle
Remove and reconnect
1 Power Cycle ON to complete open and
engine connector. then complete close.
System activated,
temperature read, waiting
1A Apply Power Turn key from OFF to ON. for engine to crank &
ON OFF ON DELAY start. Other MIL lamp
sequence indicates
failure mode 2B.
Looking for starting
engine speed. IF engine
Turn key from RUN to does not start, go to
2A Crank to Start ON OFF ON DELAY
CRANK. Failure Mode description
1B or 3B based on MIL
lamp code.
Engine started, release ON OFF ON OFF ON eChoke™ moving to open
3A Choke Adjusting Key to RUN position. DELAY position.
Choke operation eChoke™ stays in open
4A Normal ON
completed. position.

Turn Key from RUN to Once engine has come

5A Engine Shutdown ON DELAY to a stop, choke will fully
OFF.
close.
System goes into power
saver mode after 30
minutes of non use due
to shut down by seat
System will switch to switch activation or when
power saver mode after 30
6A Power Saver Mode OFF key switch moved to
minutes without engine OFF. If activated by
speed reading. safety switch shutdown,
operator MUST move to
key OFF to reset
sequence.

32 690 03 Rev. L KohlerEngines.com 43

Fuel System

Failure Modes
Pause at RUN and attempt to CRANK
engine.
Limit cranking time to about 5 seconds.
For first 4 failed crank attempts, choke
1B Failure to Start ON will reposition at each attempt. After
four (4) attempts, key OFF and make
one final attempt to start.
Check other components (spark plug,
ignition, carburetor, fuel solenoid).
Faulty temperature sensor. System will
keep choke closed at Key ON and
2B Temperature Read Failure ON OFF ON OFF ON OFF ramp to open within 10 seconds of
ON OFF ON DELAY engine starting if this is root failure.
Replace Master controller/ignition.
System defaults to this failure after 30
seconds of being in Key ON and no
3B RPM Read Failure ON OFF ON OFF ON OFF RPM.
Choke will open to half position.
ON DELAY Error clears if system reads RPM when
engine is cranking.
Replace Master controller/ignition.

44 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

Troubleshooting eChoke™ Related Causes

Condition Possible Cause Conclusion
Engine starts hard, runs rough, or Choke not closing/moving Stepper motor/bracket/link assembly
stalls at idle speed. a. Incorrect set up of stepper must allow for full travel, make sure
motor/link/bracket to link is located properly and
carburetor. connected.
b. Broken or missing link.
c. Loss of constant power or Bad wire harness connection, fusible
switched power. link failure.
d. Loss of system ground.
Component failure in Master
e. Fusible link is open. controller/ignition.
f. Stepper motor not functioning
or shaft has fallen out of Bad Master Controller harness.
motor.
g. Electronic component in
Master ignition/control module
is not functioning.
Engine runs rich (indicated by black, Choke partially closed during Stepper motor/bracket/link assembly
sooty exhaust smoke, misfiring, loss operation. must allow for full travel, make sure
of speed and power, governor a. Incorrect set up of stepper link is located properly and
hunting, or excessive throttle motor/link/bracket to connected.
opening). carburetor.
b. Broken or missing link.
c. Loss of constant power or Bad wire harness connection, fusible
switched power. link failure.
d. Loss of system ground.
Component failure in Master
e. Fusible link is open. controller/ignition.
f. Stepper motor not functioning
or shaft has fallen out of Bad Master Controller harness.
motor.
g. Electronic component in
Master ignition/control module
is not functioning.
Engine runs lean (indicated by Key integrated component in Master Bad ignition module on specific
misfiring, loss of speed and power, ignition/control module is not cylinder.
governor hunting, or excessive functioning.
throttle opening). Incorrect set up of stepper motor/link/ Stepper motor/bracket/link assembly
bracket to carburetor. must allow for full travel, make sure
link is located properly and
connected.

32 690 03 Rev. L KohlerEngines.com 45

Fuel System

Starting an Engine Equipped with eChoke™ 10. If movement is noted, attempt to crank and start
engine. (Do not exceed 10 seconds of cranking.)
1. This eChoke™ system automatically controls choke
plate position for starting. 11. If engine does not start:
2. Make sure equipment is in neutral and brake is Release key to RUN position, (do not shut OFF),
engaged. pause, movement of choke should be noted.
3. Activate starter switch. Release switch as soon as Repeat from beginning of step 10 (this routine can
engine starts. be attempted 4 times). Choke should be fully
relieved after final attempt. If eChoke™ assembly
4. For operation, after engine starts, move throttle and moves choke plate through each attempt, but engine
set desired engine operating speed. still did not start, problem is not associated with
5. If engine does not start, remove air cleaner cover, eChoke™, but is rather another system or component
and air cleaner from air cleaner base. issue.
6. Confirm connection of stepper motor assembly to
carburetor.
7. With key switch set to OFF, choke plate should
nearly fully closed, stepper motor for eChoke should
be near full extension (expanded bellows).
8. With engine/ambient temperature above 40°F (4°C),
turn key switch from OFF to RUN. There should be a
noticeable movement of choke plate.
9. If no movement:
a. Shut off key switch and test for full travel of
actuator by disconnection and reconnection of
constant power (RED/GREEN STRIPE) at engine
connector.
b. If there is still no movement, separate tests to
validate battery voltage and power and ground
connection to master controller need to be
performed.

46 KohlerEngines.com 32 690 03 Rev. L

 Fuel System

Governor/Throttle Control Connections

A C
H E

H
F

K M
A

E E

B G

D C
F B C

A Left Side Pull B Cable Clamp C Speed Control Lever D Speed Setting Lever
E Choke Lever F Right Side Pull G Contact Point H Choke Control Cable
Dual Control High Speed High Speed Adjusting
I Throttle Control Cable J Lever Stop Screw (Do K L Choke Linkage
Screw
Not Remove)
High Speed Control
M Lever

32 690 03 Rev. L KohlerEngines.com 47

Fuel System

UNITIZED THROTTLE AND CHOKE CONTROL Starting an Engine Equipped with Unitized Throttle
Some engines are equipped with a unitized throttle and and Choke Control
choke control. This assembly controls choke and engine NOTE: Do not crank engine continuously for more than
speed with a single lever. Engines with a unitized throttle 10 seconds at a time. If engine does not start,
and choke control will have either a left side pull or a allow a 60 second cool down period between
right side pull. starting attempts. Failure to follow these
guidelines can burn out starter motor.
Throttle Cable Adjustment
NOTE: If engine develops sufficient speed to disengage
NOTE: Choke is placed ON by moving throttle control starter but does not keep running (a false start),
slightly past fast position. If throttle control does engine rotation must be allowed to come to a
not have a designated choke ON position, be complete stop before attempting to restart
sure to leave sufficient throttle control travel past engine. If starter is engaged while flywheel is
fast position. This will enable choke to be placed rotating, starter pinion and flywheel ring gear
ON. may clash, resulting in damage to starter.
1. Loosen control cable clamp. 1. For a Cold or Warm Engine – Place throttle/choke
2. Place throttle control lever of equipment into fast or control into fast/choke ON position. This will also
high speed position. place choke into ON position.
3. Pull on outer shield of throttle control cable until 2. Make sure equipment is in neutral.
speed control lever rotates and makes contact with 3. Activate starter switch. Release switch as soon as
choke lever. Tighten cable clamp securely. engine starts.
If starter does not turn engine over, shut starter off
immediately. Do not make further attempts to start
engine until condition is corrected. Do not jump start
using another battery. See your Kohler authorized dealer
for trouble analysis.
4. For Operation – After engine starts, move throttle/
choke control from fast/choke ON position and set
desired engine operating speed (between slow and
fast position).

48 KohlerEngines.com 32 690 03 Rev. L

 Governor System

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

J
I F
B
K

L D H
A
M

Inside Engine

C
G
E
D

A Throttle Lever B Throttle Linkage C Nut D Governor Lever

Round Cross Shaft 7 mm Hex Cross
E Governor Spring F Choke Linkage G H
End Shaft End
Locking Tab
I Flyweight J Regulating Pin K Governor Gear L Thrust Washer
M Shaft
This governor design works as follows: Governor Adjustments
● Centrifugal force acting on rotating governor gear NOTE: Do not tamper with governor setting. Overspeed
assembly causes flyweights to move outward as is hazardous and could cause personal injury.
speed increases. Governor spring tension moves
them inward as speed decreases. Initial Adjustment Procedure
● As flyweights move outward, they cause regulating pin Make this adjustment whenever governor arm is
to move outward. loosened or removed from cross shaft. To ensure proper
● Regulating pin contacts tab on cross shaft causing adjustment, make sure throttle linkage is connected
shaft to rotate. to both governor arm and throttle lever on carburetor.
● One end of cross shaft protrudes through crankcase. Adjust as follows:
Rotating action of cross shaft is transmitted to throttle 1. Make sure throttle linkage is connected to governor
lever of carburetor through external throttle linkage. arm and throttle lever on carburetor.
● When engine is at rest, and throttle is in fast position,
tension of governor spring holds throttle plate open. 2. Loosen nut holding governor lever to cross shaft.
When engine is operating, governor gear assembly is 3. Move governor lever toward carburetor as far as it
rotating. Force applied by regulating pin against cross will go (wide open throttle) and hold in this position.
shaft tends to close throttle plate. Governor spring
tension and force applied by regulating pin balance 4. Round Cross Shaft End: Insert a long thin rod or
each other during operation, to maintain engine tool into hole on cross shaft and rotate shaft
speed. counterclockwise (viewed from end) as far as it will
● When load is applied and engine speed and governor turn, then torque nut to 6.8 N·m (60 in. lb.).
gear speed decreases, governor spring tension moves 7 mm Hex Cross Shaft End: Use 7 mm hex socket
governor arm to open throttle plate wider. This allows on end of cross shaft and rotate shaft
more fuel into engine, increasing engine speed. As counterclockwise (viewed from end) as far as it will
speed reaches governed setting, governor spring turn, then torque nut to 6.8 N·m (60 in. lb.).
tension and force applied by regulating pin will again
offset each other to hold a steady engine speed.
32 690 03 Rev. L KohlerEngines.com 49
Lubrication System

This engine uses a combination pressure/splash lubrication system, delivering oil under pressure to crankshaft,
connecting rod and main bearing surfaces. Other component areas are splash lubricated.
A high-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating
temperatures. A pressure relief valve limits maximum pressure of system. Oil pan must be removed to service oil
pickup and oil pump.
Lubrication Components

A
A

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

OIL RECOMMENDATIONS CHANGE OIL AND FILTER

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

50 KohlerEngines.com 32 690 03 Rev. L

 Lubrication System

OIL SENTRY™ (if equipped) Installation

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

32 690 03 Rev. L KohlerEngines.com 51

Electrical System

SPARK PLUGS Inspection

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

A
B

Plug taken from an engine operating under normal

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

C D

A Wire Gauge B Spark Plug

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

52 KohlerEngines.com 32 690 03 Rev. L

 Electrical System

Carbon Fouled Battery Maintenance

Regular maintenance is necessary to prolong battery
life.
Battery Test
To test battery, follow manufacturer's instructions.
ELECTRONIC IGNITION SYSTEMS
All ignition systems are designed to be trouble free for
life of engine. Other than periodically checking/replacing
spark plugs, no maintenance or timing adjustments
are necessary or possible. Mechanical systems do
Soft, sooty, black deposits indicate incomplete occasionally fail or break down. Refer to Troubleshooting
combustion caused by a restricted air cleaner, over rich to determine root of a reported problem.
carburetion, weak ignition, or poor compression. Reported ignition problems are most often due to poor
Overheated connections. Before beginning test procedure, check
all external wiring. Be certain all ignition-related wires
are connected, including spark plug leads. Be certain all
terminal connections fit snugly. Make sure ignition switch
is in run position.

Chalky, white deposits indicate very high combustion

temperatures. This condition is usually accompanied
by excessive gap erosion. Lean carburetor settings,
an intake air leak, or incorrect spark timing are normal
causes for high combustion temperatures.
BATTERY
A 12-volt battery with 400 cold cranking amps (cca) is
generally recommended for starting in all conditions. A
smaller capacity battery is often sufficient if an
application is started only in warmer temperatures. Refer
to following table for minimum capacities based on
anticipated ambient temperatures. Actual cold cranking
requirement depends on engine size, application, and
starting temperatures. Cranking requirements increase
as temperatures decrease and battery capacity shrinks.
Refer to equipment's operating instructions for specific
battery requirements.
Battery Size Recommendations
Temperature Battery Required
Above 32°F (0°C) 200 cca minimum
0°F to 32°F (-18°C to 0°C) 250 cca minimum
-5°F to 0°F (-21°C to -18°C) 300 cca minimum
-10°F (-23°C) or below 400 cca minimum
If battery charge is insufficient to turn over engine,
recharge battery.

32 690 03 Rev. L KohlerEngines.com 53

Electrical System

Ignition Systems
These systems use a capacitive discharge (CD) coil. With CDI fixed timing, ignition timing and spark remains constant
regardless of engine speed. Timing of spark is controlled by location of flywheel magnet group as referenced to
engine TDC. MDI adjustable timing uses a digital microprocessor which is located in ignition modules. Ignition timing
varies depending upon engine speed with this system.
A typical fixed ignition system consists of:
● 1 magnet assembly which is permanently affixed to flywheel.
● 2 electronic capacitive-discharge or magnetic discharge ignition modules which mount on engine crankcase.
● 1 kill switch (or key switch) which grounds modules to stop engine.
● 2 spark plugs.

Wiring Diagram-Electronic Ignition System Diagram

AF AC AG
Z Q AF
AB G
AC
T
AA S D
AB
Q D AE
S M AD
Y
N

X
R
Q
O
W
L

K
P

J
V
U
A I H
H
G
B

E
F
C D

Solenoid Shift Inertia Driver

A Starter Solenoid Tang B C D Green
Starter Assembly Starter Assembly
E Violet (Charging) F Oil SentryTM (Optional) White
G Spark Plug(s) H (AC Charging Leads)
Rectifier-Regulator Flywheel Stator
I J Rectifier-Regulator K L Ignition Module(s)
Connector Assembly
M Intake Manifold Screw N Ground O Carburetor P White (Ignition Kill)
Q Red R Solenoid Lead S Orange T Connector
Relay Cranking
U Blue V Starter Solenoid Stud W Relay Stud X (Customer Supplied)
Violet (shown)
Y Battery Negative Z Battery AA Battery Positive AB or Orange
Orange (shown)
AC White AD AE Blue (shown) or Red AF Polarity Rib
or Red
Solenoid Shift Starter
AG Assembly (Optional)

54 KohlerEngines.com 32 690 03 Rev. L

 Electrical System

Wiring Diagram-Electronic Ignition System with Smart-Choke™ System*

AF AC
AG
Z Q AF
AB AC G
T
AA S D
Q AB D AE
M AD
Y S
N
X
R
Q
O
W
L

K
P

V J
U

A I
H
AI
G
B H

E F
D
C

AJ
AH
Solenoid Shift Inertia Driver
A Starter Solenoid Tang B C D Green
Starter Assembly Starter Assembly
E Violet (Charging) F Oil SentryTM (Optional) White
G Spark Plug(s) H (AC Charging Leads)
Rectifier-Regulator Flywheel Stator
I J Rectifier-Regulator K L Ignition Module(s)
Connector Assembly
M Intake Manifold Screw N Ground O Carburetor P White (Ignition Kill)
Q Red R Solenoid Lead S Orange T Connector
Relay Cranking
U Blue V Starter Solenoid Stud W Relay Stud X (Customer Supplied)
Violet (shown)
Y Battery Negative Z Battery AA Battery Positive AB or Orange
Orange (shown)
AC White AD AE Blue (shown) or Red AF Polarity Rib
or Red
Solenoid Shift Starter
AG AH Thermostat Assembly AI Red AJ Red w/Black Line
Assembly (Optional)

*For engines with eChoke™, refer to component illustrations in Fuel Section of this manual.

32 690 03 Rev. L KohlerEngines.com 55

Electrical System

Electronic Ignition Systems Tests

NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate
findings. Battery on unit must be fully charged and properly connected before performing tests (a battery that
is hooked up or charged backward will crank engine but it won’t have spark). Be certain drive is in neutral and
all external loads are disconnected.
Test Ignition Systems
NOTE: If engine starts or runs during testing, you may need to ground kill lead to shut it down. Because you have
interrupted kill circuit, it may not stop using switch.
Isolate and verify trouble is within engine.
1. Locate connectors where wiring harnesses from engine and equipment are joined. Separate connectors and
remove white kill lead from engine connector. Rejoin connectors and position or insulate kill lead terminal so it
cannot touch ground. Try to start engine to verify whether reported problem is still present.
Condition Possible Cause Conclusion
Problem goes away. Electrical System Check key switch, wires, connections,
safety interlocks, etc.
Problem persists. Ignition or Electrical System Leave kill lead isolated until all testing
is completed.
Identify white kill lead of engine
wiring harness connector. Establish
a connection to a known good
ground location. Engine should kill
completely. If not or only one cylinder
is affected, test ignition modules.

Test for Spark

NOTE: If 2 testers are available, testing can be performed simultaneously for both cylinders. However, if only 1 tester
is available, 2 individual tests must be performed. Side not being tested must have spark plug lead connected
or grounded. Do not crank engine or perform tests with 1 spark plug lead disconnected and not grounded, or
permanent system damage may occur.
1. With engine stopped, disconnect 1 spark plug lead. Connect spark plug lead to post terminal of spark tester and
attach tester clip to a good engine ground.
2. Crank engine over, establishing a minimum of 550-600 RPM, and observe tester(s) for spark.
3. Repeat spark test on opposite cylinder if cylinders are being tested individually.
Condition Possible Cause Conclusion
One side is not firing. Wiring and Connections Check all wiring, connections, and
terminals on that side. If wiring is
okay, replace ignition module and
retest for spark.
Tester shows spark but engine Spark Plug(s) Try new spark plug(s).
misses or won’t run on that cylinder.
Neither side is firing. Ignition Switch Recheck position of ignition switch
and check for shorted kill lead.
Both cylinders have good spark but Spark Plug(s) Install new spark plug(s) and retest
engine runs poorly or existing plug engine performance.
condition is questionable.
1 cylinder has good spark and other Ignition Test ignition modules and
cylinder has no or intermittent spark. connections.

56 KohlerEngines.com 32 690 03 Rev. L

 Electrical System

BATTERY CHARGING SYSTEM

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

Most engines are equipped with a 12/15 amp regulated charging system. Some have a 25 amp regulated charging
system.
12/15/25 Amp Regulated Charging System
Stator
Stator is mounted on crankcase behind flywheel. Follow procedures in Disassembly and Reassembly if stator
replacement is necessary.
Rectifier-Regulator
NOTE: When installing rectifier-regulator, take note of terminal positions and install plug correctly.
NOTE: Disconnect all electrical connections attached to rectifier-regulator. Testing may be performed with rectifier-
regulator mounted or loose. Repeat applicable test procedure 2 or 3 times to determine condition of part.
Rectifier-regulator is mounted on backing shroud assembly. To replace it, disconnect plug, remove mounting screws,
and ground lead.
Testing rectifier-regulator may be performed as follows, using appropriate rectifier-regulator tester.
To test 25 amp rectifier-regulators: To test 12/15 amp rectifier-regulators:
1. Connect single lead adapter in between B+ (center) 1. Connect tester ground lead (with spring clamp) to
terminal of rectifier-regulator being tested and body of rectifier-regulator being tested.
squared single end of tandem adapter lead. 2. Connect tester red lead to B+ terminal of rectifier-
2. Connect tester ground lead (with spring clamp) to regulator and 2 black tester leads to 2 AC terminals.
body of rectifier-regulator. 3. Plug tester into proper AC outlet/power for tester
3. Connect red lead and 1 black lead to terminals on being used. Turn on power switch. POWER light
open end of tandem adapter lead (connections are should be illuminated and 1 of 4 status lights may be
not location specific). on as well. This does not represent condition of part.
4. Connect remaining black lead from tester to 1 outer 4. Press TEST button until a click is heard and then
AC terminal on rectifier-regulator. release. Momentarily 1 of 4 status lights will
5. Plug tester into proper AC outlet/power for tester illuminate indicating condition of part.
being used. Turn on power switch. POWER light
should be illuminated and 1 of 4 status lights may be
on as well. This does not represent condition of part.
6. Press TEST button until a click is heard and then
release. Momentarily 1 of 4 lights will illuminate
indicating partial condition of part.

Condition Conclusion
25 amp 12/15 amp
OK (green) light comes on and stays steady. Disconnect tester black lead Part is good and may be used.
attached to 1 AC terminal and
reconnect it to other AC terminal.
Repeat test. If OK (green) light
comes on again, part is good
and may be used.
NOTE: A flashing LOW light can also occur as Rectifier-regulator is faulty and should not be used.
a result of an inadequate ground lead
connection. Make certain connection
location is clean and clamp is secure.
Other lights come on.

32 690 03 Rev. L KohlerEngines.com 57

Electrical System

12/15/25 Amp Battery Charging Systems

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

2. Remove connector from rectifier-regulator. With

engine running at 3600 RPM, measure AC voltage
across stator leads using an AC voltmeter.
Condition Conclusion
Voltage is 28 volts or Stator is OK. Rectifier-
more. regulator is faulty; replace.
Voltage is less than 28 Stator is faulty; replace.
volts. Test stator further using an
ohmmeter (steps 3 and 4).

3. With engine stopped, measure resistance across

stator leads using an ohmmeter.
Condition Conclusion
Resistance is 0.064/0.2 Stator is OK.
ohms.
Resistance is 0 ohms. Stator is shorted; replace.
Resistance is infinity Stator is open; replace.
ohms.

4. With engine stopped, measure resistance from each

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

58 KohlerEngines.com 32 690 03 Rev. L

 Starter System

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

INERTIA DRIVE ELECTRIC STARTERS

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

32 690 03 Rev. L KohlerEngines.com 59

Starter System

SOLENOID SHIFT STARTERS Starter Disassembly

Solenoid Shift Starter Components NOTE: Do not reuse old retainer.
NOTE: Do not soak armature or use solvent when
H I cleaning. Wipe clean using a soft cloth, or use
compressed air.
J 1. Remove hex nut and disconnect positive (+) brush
lead/bracket from solenoid terminal.
G
K 2. Remove head screws securing solenoid to starter.
F 3. Unhook plunger pin from drive lever. Remove gasket
L from recess in housing.
E
4. Remove thru (larger) bolts.
D M
5. Remove commutator end plate assembly, containing
N brush holder, brushes, springs, and locking caps.
Remove thrust washer from inside commutator end.
C
O 6. Remove frame from armature and drive end cap.
7. Remove drive lever pivot bushing and backing plate
(if equipped) from end cap.
8. Take out drive lever and pull armature out of drive
P end cap.
9. Remove thrust washer from armature shaft.
10. Push stop collar down to expose retaining ring.
B Q 11. Remove retainer from armature shaft. Save stop
collar.
R 12. Remove drive pinion assembly from armature.
13. Clean parts as required.
S
Inspection
A T Drive Pinion
Check and inspect following areas:
U ● Pinion teeth for abnormal wear or damage.
● Surface between pinion and clutch mechanism for
nicks or irregularities which could cause seal damage.
A Tube B Washer ● Check drive clutch by holding clutch housing and
C Armature D Drive rotating pinion. Pinion should rotate in only 1 direction.
E Stop F Retaining Ring Brushes and Springs
G Collar H Drive End Cap Detail
I Screw J Plunger
K Spring L Lever
M Plate N Plug
O Solenoid P Frame and Field A
Q Brush Holder R Nut
Commutator End
S T Screw
Plate
U Bolt
When power is applied to starter electric solenoid moves
drive pinion out onto drive shaft and into mesh with
flywheel ring gear. When pinion reaches end of drive
shaft it rotates flywheel and cranks engine.
When engine starts and start switch is released, starter A Wear Limit Length
solenoid is deactivated, drive lever moves back, and Inspect both springs and brushes for wear, fatigue, or
drive pinion moves out of mesh with ring gear into damage. Measure length of each brush. Minimum length
retracted position. for each brush is 7.6 mm (0.300 in.). Replace brushes if
they are worn, undersize, or condition is questionable.

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 Starter System

Armature Starter Reassembly

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

32 690 03 Rev. L KohlerEngines.com 61

Starter System

c. Install brush springs and snap on retainer caps.

d. Hold starter assembly vertically on end housing, and carefully place tool (with extension) and assembled
original brush holder assembly onto end of armature shaft. Slide brush holder assembly down into place
around commutator, install positive (+) brush lead grommet in cutout of frame.
11. Install end cap onto armature and frame, aligning thin raised rib in end cap with corresponding slot in grommet of
positive (+) brush lead.
12. Install thru bolts and brush holder mounting screws. Torque bolts to 5.6-9.0 N·m (49-79 in. lb.) and brush holder
mounting screws to 2.5-3.3 N·m (22-29 in. lb.).
13. Hook plunger behind upper end of drive lever and install spring into solenoid. Insert mounting screws through
holes in drive end cap. Use these to hold solenoid gasket in position, then mount solenoid. Torque screws to
4.0-6.0 N·m (35-53 in. lb.).
14. Connect positive (+) brush lead/bracket to solenoid and secure with nut. Torque nut to 8-11 N·m (71-97 in. lb.). Do
not overtighten.
Solenoid Tests
NOTE: DO NOT leave 12 volt test leads connected to solenoid for any time over what is necessary for performing
each of individual tests. Internal damage to solenoid may occur.
Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal. Remove mounting
hardware and separate solenoid from starter for testing.
To test solenoid pull-in coil/plunger:
Actuation
1. Use a 12 volt power supply and 2 test leads.
2. Connect 1 lead to flat spade S/start terminal on solenoid. Momentarily connect other lead to lower large post
terminal.
When connection is made solenoid should energize (audible click) and plunger retract. Repeat test several times.
Continuity
1. Use an ohmmeter set to audible or Rx2K scale, and connect 2 ohmmeter leads to 2 large post terminals.
2. Perform solenoid pull-in coil/plunger actuation test and check for continuity. Ohmmeter should indicate continuity.
Repeat test several times.
To test solenoid hold-in coil:
Function
1. Connect a 12 volt test lead to flat spade S/start terminal on solenoid and other lead to body or mounting surface of
solenoid.
2. Manually push plunger IN and check if coil holds plunger retracted. Do not allow test leads to remain connected to
solenoid for a prolonged period of time.
Continuity
1. Use an ohmmeter set to audible or Rx2K scale, and connect 2 ohmmeter leads to 2 large post terminals.
2. Perform preceding solenoid hold-in coil function test and check for continuity. Meter should indicate continuity.
Repeat test several times.
Condition Conclusion
Solenoid fails to activate. Replace solenoid.
No continuity is indicated.
Plunger fails to stay retracted.

62 KohlerEngines.com 32 690 03 Rev. L

 Emission Compliant Systems

EVAPORATIVE EMISSION COMPLIANT SYSTEM

Carbon Canister System

D
A

Roll Over Valve

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

32 690 03 Rev. L KohlerEngines.com 63

Emission Compliant Systems

SECONDARY EMISSION COMPLIANT SYSTEM

Twin Secondary Air Induction System

A
C

D
C

Hose To Exhaust Secondary Air

A B Inlet Screen C D Hose To Carburetor
Manifold Valve Assembly
Hose To Exhaust
E Manifold

Single Secondary Air Induction System

G
F

Secondary Air Hose To Exhaust

F G H Hose To Carburetor I Inlet Screen
Valve Assembly Manifold
For engine to be Tier III compliant, it may be fitted with a secondary air induction system (SAI).
Operation Maintenance
Intake pulse of engine activates secondary air valve. Air inlet screen in secondary air valve can be removed,
Air is drawn through an inlet screen of secondary air cleaned, and reinstalled. If inspection of system reveals
valve. Air is then drawn into exhaust manifold and any damage or decomposition of hoses, secondary air
muffler where it mixes with any unburned hydrocarbons, valve, or exhaust system, parts should be replaced.
which then burn in heat of muffler. A hose is connected
between a carburetor port and a diaphragm chamber
in secondary air valve. Carburetor vacuum moves
diaphragm to close valve when air induction is not
required, primary idle.

64 KohlerEngines.com 32 690 03 Rev. L

 Emission Compliant Systems

Remove Inlet Screen

Inlet Components

A
B

A Secondary Air Valve Assembly B Barb C Inlet Screen

1. Remove inlet screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away
from valve assembly.
2. Use a soft brush to remove debris from screen.
3. Run water through inlet screen in reverse direction.
4. To reinstall, push inlet screen onto barb of secondary air valve assembly. An audible click will be heard when inlet
screen is properly reinstalled.

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Disassembly/Inspection and Service

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

External Engine Components

A
R
B

E C

E S

H D B
G R

E
I S
V P Q
H
W

U
N O
T

J
K

A Fixed Guard B Air Cleaner Cover C Debris Screen D Blower Housing

E Hose Clamp F Fuel Pump G Hose Clip H Fuel Line
I Fuel Filter J Oil Filter K Outer Baffle L Electric Starter
M Inner Baffle N Ignition Module O Intake Manifold P Carburetor
Q Gasket R Air Cleaner Base S Air Cleaner Element T Rectifier-Regulator
U Dipstick Tube V Oil Fill/Dipstick W Breather Hose
66 KohlerEngines.com 32 690 03 Rev. L
 Disassembly/Inspection and Service

Clean all parts thoroughly as engine is disassembled. Remove Throttle Controls

Only clean parts can be accurately inspected
and gauged for wear or damage. There are many Control Bracket Components
commercially available cleaners that will quickly remove
grease, oil and grime from engine parts. When such a
cleaner is used, follow manufacturer’s instructions and A
safety precautions carefully.
Make sure all traces of cleaner are removed before B
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down
lubricating properties of engine oil. C
F E
Disconnect Spark Plug Leads
NOTE: Pull on boot only, to prevent damage to spark
plug lead.
1. Disconnect leads from spark plugs.
2. Shut off fuel supply.
D
Drain Oil From Crankcase and Remove Oil Filter
1. Remove oil fill/dipstick and oil drain plug. C
2. Allow ample time for oil to drain from crankcase and
oil filter.
3. Remove and appropriately discard oil filter.
Remove Muffler G
Remove exhaust system and attaching hardware from C
engine.
D
Remove Fuel Pump (if equipped)
A Choke Linkage B Throttle Linkage
WARNING C Governor Lever D Governor Spring
Explosive Fuel can cause fires and severe E Cross Shaft F Control Bracket
burns.
Do not fill fuel tank while engine is hot or G Dampener Spring
running. 1. Remove screws securing throttle control bracket to
Gasoline is extremely flammable and its vapors can cylinder heads.
explode if ignited. Store gasoline only in approved 2. Disconnect choke linkage from choke actuator lever.
containers, in well ventilated, unoccupied buildings, Unhook governor spring, and dampener spring from
away from sparks or flames. Spilled fuel could ignite governor lever. Note hole locations for reassembly.
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent. Remove External Governor Controls
1. Disconnect pulse (vacuum) hose and outlet fuel line Loosen nut and remove governor lever from cross shaft.
from fuel pump. Leave lever attached to throttle linkage.
2. Remove mounting screws, unhook outlet hose from
blower housing clip, and remove fuel pump from
blower housing.
Remove Blower Housing and Outer Baffles
1. Remove air cleaner cover.
2. Remove screws securing blower housing.
3. Remove blower housing from engine.
4. Remove M5 and M6 screws securing baffles to
cylinders, heads and backing plate.

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Disassembly/Inspection and Service

Remove Air Cleaner and Carburetor Smart-Choke™

E F Thermostat
Bracket Assembly
WARNING
eChoke™ Bracket
Explosive Fuel can cause fires and severe G H Stepper Motor
burns. Assembly
Do not fill fuel tank while engine is hot or NOTE: On engines equipped with eChoke™, stepper
running. motor has a special retract routine that can be
activated to ensure motor is in correct position
Gasoline is extremely flammable and its vapors can prior to removal or upon replacement of stepper
explode if ignited. Store gasoline only in approved motor when a problem is shown to exist with
containers, in well ventilated, unoccupied buildings, stepper motor assembly and carburetor.
away from sparks or flames. Spilled fuel could ignite Activation of this routine will occur by initiating
if it comes in contact with hot parts or sparks from three (3) consecutive Key On–Off cycles. Every
ignition. Never use gasoline as a cleaning agent. Key On and Off should be > 2 seconds and <
3.5 seconds. Note that if no other connections
Smart-Choke™ and eChoke™ Carburetor/Air Cleaner are disturbed, stepper motor will be repositioned
Components at next key ON and master module will go back
to normal choke operation mode.
NOTE: Do not remove or loosen thermostat screws.
A Position is set at factory.
1. Remove carburetor/air cleaner base mounting nuts
and disconnect breather hose.
2. Remove air cleaner element and precleaner (if
equipped) from air cleaner base for servicing.
3. Disconnect ground lead and fuel shut-off solenoid
lead (if equipped).
B 4. Remove Smart-Choke™ or eChoke™ bracket
assembly (if equipped). Remove air cleaner base
and gasket.
C F
5. Remove carburetor, throttle linkage and governor
lever as an assembly.
6. Remove carburetor gasket.
E 7. If necessary, carburetor, throttle linkage and
D
governor lever can be separated. Reattach bushings
to linkage following separation to avoid losing them.
Remove Electric Starter Motor
A 1. Disconnect leads from starter.
2. Remove screws and starter.
Remove Inner Baffles
Remove mounting screws securing inner baffles to
crankcase. Note position of any lifting bracket(s).
Remove inner baffles.
Remove Ignition Modules
NOTE: Engines equipped with Smart-Choke™ have a
deflector support tab on #2 cylinder ignition
module. Note position for reassembly.
G
1. Rotate flywheel so magnet is away from modules.
D 2. Disconnect lead from each ignition module.
3. Remove mounting screws and ignition modules.
H Note position of ignition modules.

A Air Cleaner Base B Breather Hose

C Ground Lead D Solenoid Lead

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 Disassembly/Inspection and Service

Remove Intake Manifold and Rectifier-Regulator 4. Remove screws securing rectifier-regulator to

backing plate and disconnect plug.
1. Remove screws securing intake manifold to cylinder
heads. Note which screws hold wiring clamp(s). 5. Use tip of a small screwdriver or similar small flat
tool to bend locking tang, then remove B+ (center
2. On engines equipped with Smart-Choke™, lead) from terminal plug. This will allow intake
disconnect choke unloader linkage from carburetor. manifold to be removed with wiring harness intact.
Unless air vane deflector is damaged or
malfunctioning, disassembly from intake manifold is
not necessary.
3. Remove intake manifold and O-rings. Leave wiring
harness attached to manifold.

Cylinder Head Components

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

M P
N
Q

A Gasket B Valve C Cylinder Head D Valve Spring Cap

E Valve Stem Seal F Valve Spring G Valve Spring Keeper H Stud
I Spark Plug J Guide Plate K Push Rod L Rocker Arm
Stamped Steel Valve
M Rocker Arm Pivots N Adjusters O Washer P Cover (RTV)
Plastic Valve Cover
Q R O-Ring
(O-Ring)

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Disassembly/Inspection and Service

Remove Spark Plugs Remove Cylinder Heads

Remove spark plug from each cylinder head. NOTE: Exhaust side is located on output shaft side of
engine, while intake side is located on fan side
Remove Valve Covers and Cylinder Heads of engine. Cylinder head number is embossed
Plastic Valve Covers with O-Rings on outside of each cylinder head.
Remove screws securing each valve cover. Most valve 1. Loosen inner setscrews (T25 Torx), and back off
covers have screw hole spacers molded in place. adjusters.
Remove valve covers and O-rings. 2. Mark location of push rods as either intake or
Stamped Steel Valve Covers with RTV Sealant exhaust and cylinder 1 or 2. Push rods should
always be installed in same positions.
NOTE: Valve cover is sealed to cylinder head using
RTV silicone sealant. When removing valve 3. Remove screws securing each cylinder head.
cover, use care not to damage gasket surfaces 4. Remove cylinder head and head gasket.
of cover and cylinder head. To break RTV seal,
hold a block of wood against 1 flat face of valve Disassemble Cylinder Heads
cover. Strike wood firmly with a mallet. If seal NOTE: Use a new valve stem seal whenever valve is
doesn't break loose after 1 or 2 attempts, repeat removed or if valve stem seal is deteriorated or
procedure on other side. damaged. Never reuse an old valve stem seal.
1. Remove Torx screws securing each valve cover. 1. Remove adjusters, pivots, rocker arms, studs and
2. Using a brass wire brush and gasket remover or guide plate from cylinder head.
similar solvent, clean old RTV from surface of 2. Compress valve springs using a valve spring
cylinder head and valve cover. compressor.
3. Sealing surface of stamped steel valve covers must 3. Once valve spring is compressed, remove following
be checked for flatness prior to reinstallation. Hold items.
valve cover down firmly against a flat, level surface
or piece of glass, and check around entire perimeter ● Valve spring keepers.
that a 0.012 in. (0.30 mm) feeler gauge cannot be ● Valve spring caps.
inserted anywhere. If gauge goes in anywhere, ● Valve springs.
cover needs to be replaced. ● Intake and exhaust valves (mark position).
● Valve stem seal.
● Washer (intake valve only).
4. Repeat above procedure for other cylinder head. Do
not interchange parts from 1 cylinder head to
another.

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 Disassembly/Inspection and Service

Inspection and Service

Valve Details

Exhaust Insert

F B F
E C A E

G D G

H H

Exhaust Valve A Intake Valve

B

Intake Insert
Dimension Intake Exhaust
A Seat Angle 89° 89°
B Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.)
C Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.)
D Guide I.D. 7.040/7.060 mm (0.2772/0.2780 in.) 7.040/7.060 mm (0.2772/0.2780 in.)
E Valve Head Diameter 33.37/33.63 mm (1.3138/1.3240 in.) 29.37/29.63 mm (1.1563/1.1665 in.)
F Valve Face Angle 45° 45°
G Valve Margin (Min.) 1.5 mm (0.0591 in.) 1.5 mm (0.0591 in.)
H Valve Stem Diameter 6.982/7.000 mm (0.2749/0.2756 in.) 6.970/6.988 mm (0.2744/0.2751 in.)
After cleaning, check flatness of cylinder head and corresponding top surface of crankcase, using a surface plate or
precision straight edge and feeler gauge. Maximum allowable out of flatness is 0.076 mm (0.003 in.).
Carefully inspect valve mechanism parts. Inspect valve To check valve guide-to-valve stem clearance,
springs and related hardware for excessive wear or thoroughly clean valve guide and, using a split-ball
distortion. Check valves and valve seat area or inserts gauge, measure inside diameter of guide. Then, using
for evidence of deep pitting, cracks, or distortion. an outside micrometer, measure diameter of valve stem
Check clearance of valve stems in guides. See valve at several points on stem where it moves in valve guide.
details and specifications. Use largest stem diameter to calculate clearance by
subtracting stem diameter from guide diameter. If intake
Hard starting, or loss of power accompanied by high clearance exceeds 0.040/0.078 mm (0.0016/0.0031 in.)
fuel consumption may be symptoms of faulty valves. or exhaust clearance exceeds 0.052/0.090 mm
Although these symptoms could also be attributed to (0.0020/0.0035 in.), determine whether valve stem or
worn rings, remove and check valves first. After removal, guide is responsible for excessive clearance.
clean valve heads, faces, and stems with a power wire
brush. Then, carefully inspect each valve for defects Maximum (I.D.) wear on intake valve guide is 7.140 mm
such as warped head, excessive corrosion, or worn stem (0.2811 in.) while 7.160 mm (0.2819 in.) is maximum
end. Replace valves found to be in bad condition. allowed on exhaust guide. Guides are not removable but
can be reamed 0.25 mm (0.010 in.) oversize. Valves with
Valve Guides 0.25 mm oversize stems must then be used.
If a valve guide is worn beyond specifications, it will not
guide valve in a straight line. This may result in burnt If guides are within limits but valve stems are worn
valve faces or seats, loss of compression, and excessive beyond limits, install new valves.
oil consumption.

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Disassembly/Inspection and Service

Valve Seat Inserts Flywheel/Ignition/Breather Components

Hardened steel alloy intake and exhaust valve seat
inserts are press-fitted into cylinder head. Inserts are
not replaceable but can be reconditioned if not too badly A
pitted or distorted. If cracked or badly warped, cylinder C
head should be replaced.
D
Recondition valve seat inserts following instructions
provided with valve seat cutter being used. Final cut
should be made with an 89° cutter as specified for
valve seat angle. Cutting proper 45° valve face angle,
as specified, and proper valve seat angle (44.5°, half of
full 89° angle), will achieve desired 0.5° (1.0° full cut) B
interference angle where maximum pressure occurs on
outside diameters of valve face and seat.
Lapping Valves
NOTE: Exhaust valves that are black in color cannot be
ground and do not require lapping.
Reground or new valves must be lapped in, to provide E
fit. Use a hand valve grinder with suction cup for F
final lapping. Lightly coat valve face with fine grade
of grinding compound, then rotate valve on seat with
grinder. Continue grinding until smooth surface is
obtained on seat and on valve face. Thoroughly clean
cylinder head in soap and hot water to remove all traces
of grinding compound. After drying cylinder head, apply G
a light coating of SAE 10 oil to prevent rusting.
Intake Valve Stem Seal
Always use a new seal when valves are removed
from cylinder head. Seals should also be replaced if H
deteriorated or damaged in any way. Never reuse an old
seal.

I
J
K
L
M

A Flywheel Screw B Fan

C Washer D Fan Mounting Plate
E Magnet F Flywheel
G Stator H Backing Plate
I Breather Reed Cover J Stud
K Retainer L Breather Reed
M Flywheel Key

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 Disassembly/Inspection and Service

Remove Debris Screen, Fan, and Flywheel Crankshaft/Governor Gear/Oil Pump Components
NOTE: Always use a flywheel strap wrench or flywheel E
holding tool (see Tools and Aids) to hold flywheel
when loosening or tightening flywheel and fan
retaining fasteners. Do not use any type of bar C
or wedge between fins of cooling fan, as fins A B
could become cracked or damaged.
D
NOTE: Always use a puller to remove flywheel from
crankshaft. Do not strike crankshaft or flywheel,
as these parts could become cracked or A
damaged. Striking puller or crankshaft can
cause crank gear to move, affecting crankshaft
endplay.
1. Unsnap debris screen from cooling fan.
2. Remove retaining screw, washer, and fan mounting
plate, securing fan and flywheel to crankshaft.
3. Lift cooling fan to disengage 2 drive pins and remove
it from flywheel. Two plastic retainers may remain in
fan.
4. Remove flywheel from crankshaft by pulling from F
under ring gear with large gear puller.
5. Remove flywheel key from crankshaft.
Flywheel Inspection
Inspect flywheel for cracks, and flywheel keyway for
damage. Replace flywheel if it is cracked. Replace
flywheel, crankshaft, and key if flywheel key is sheared G
or keyway is damaged.
Inspect ring gear for cracks or damage. Kohler does P
not provide ring gears as a serviceable part. Replace H
flywheel if ring gear is damaged. T
Q I
Remove Backing Plate and Stator
1. Remove mounting screws and backing plate from V J
crankcase. S K
2. Remove screws and stator. Note routing of stator
leads. R L

Remove Breather Reed Assembly U

1. RTV sealant is used between breather reed cover M
and crankcase. Remove nut and sealing (flat)
washer securing breather reed cover to crankcase.
Carefully pry under small tab of cover flange to
separate and remove. Do not bend or distort cover.
2. Unscrew and remove mounting stud, retainer and
breather reed.
N

Governor Cross
A B Lower Washer
Shaft
Push-on Retaining
C Nylon Washer D Ring
E E-Clip F Crankshaft
G Valve Tappets H Camshaft
I Regulating Pin J Shaft

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Disassembly/Inspection and Service

Locking Tab Thrust NOTE: Governor gear is held onto shaft by small
K Governor Gear L molded tabs in gear. When gear is removed from
Washer
shaft, these tabs are destroyed and gear must
M Oil Pan N Drain Plug be replaced. Therefore, remove gear only if
O Oil Seal P Oil Pump absolutely necessary.
Governor gear must be replaced once it is removed from
Q Oil Sentry™ R Ball oil pan.
S Spring T Oil Pick-up Screen 1. Use 2 small screwdrivers and carefully pry upward to
Ground Strap remove regulating pin and governor gear assembly.
U V Outer Gerotor Gear
Location 2. Remove locking tab thrust washer located under
governor assembly.
Remove Oil Pan Assembly 3. Carefully inspect governor gear shaft and replace it
1. Remove screws securing oil pan to crankcase. only if it is damaged. After removing damaged shaft,
2. Locate splitting tab cast into perimeter of oil pan. press or lightly tap replacement shaft into oil pan to
Insert drive end of a 1/2” breaker bar between depth shown.
splitting tab and crankcase and turn it to break RTV Reassembly
seal. Do not pry on sealing surfaces as this can 1. Install locking tab thrust washer on governor gear
cause leaks. shaft with tab down.
Inspection 2. Position regulating pin within governor gear/
Inspect oil seal in oil pan and remove it if it is worn flyweights assembly and slide both onto governor
or damaged. New oil seal is installed after oil pan is shaft until assembly locks into place.
assembled to crankcase. See Reassembly, Oil Seal in
Oil Pan. Oil Pump Assembly
Inspect main bearing surface for wear or damage (refer Oil pump is mounted inside oil pan. If service is required,
to Specifications). Replace oil pan assembly if required. continue with Disassembly, Inspection, and Reassembly.
Disassembly
Governor Assembly 1. Remove screws.
Governor gear assembly is located inside oil pan. If 2. Lift oil pump assembly from oil pan. Remove outer
service is required, continue following steps. gerotor gear from oil pan.
Inspection 3. Ensure ball and spring remain installed in pressure
Inspect governor gear teeth. Replace gear if it is worn, relief hole of oil pan. If ball and spring fall out of
chipped, or if any teeth are missing. Inspect governor pressure relief hole, see reassembly for correct
weights. They should move freely in governor gear. installation.
Disassembly Inspection
Governor Shaft Component and Details Inspect oil pump housing, gear, and rotors for nicks,
burrs, wear, or any visible damage. If any parts
C are worn or damaged, replace oil pump assembly.
Check oil pickup screen for damage or restriction,
replace if necessary. Disassembly of oil pump is not
recommended.
B Reassembly
1. Lubricate outer gerotor gear with oil. Install outer
A gerotor gear through shaft of oil pump, around inner
gerotor gear. Matching molding dots on inner and
outer gerotor gears is not necessary and will not
affect oil pump efficiency.
2. Reinstall ball, then spring into pressure relief hole of
oil pan.
3. Install oil pump inserting center shaft into
corresponding recess in oil pan. Secure oil pump by
torquing screws (in no specific sequence) to 9.9 N·m
(88 in. lb.).
4. After torquing, rotate gear and check for freedom of
movement. Make sure there is no binding. If binding
occurs, loosen screws, reposition pump, retorque
screws and recheck movement.
34.0 mm (1.3386 in.)
A B 19.40 mm (0.7638 in.)
33.5 mm (1.3189 in.)
C Gear Shaft

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 Disassembly/Inspection and Service

Remove Camshaft and Valve Tappets Connecting Rods/Piston/Breather Components

1. Position crankcase so flywheel side is down. B
Remove camshaft and shim.
D C
2. Remove valve tappets from crankcase and mark I
them by their location, as either intake or exhaust
and cylinder 1 or 2. Tappets should always be
reinstalled in same position. B
Camshaft Inspection and Service
Check lobes of camshaft for wear or damage. See
Specifications for minimum lift specifications. Inspect A F
cam gear for badly worn, chipped or missing teeth.
Replacement of camshaft will be necessary if any of E
these conditions exist.
Valve Tappets Inspection G
Check base surface of valve tappet(s) for wear or H
damage. Replace tappet(s) if condition is questionable
in any way. Corresponding camshaft lobe(s) should also A Piston Ring Set B Piston Pin Retainer
be checked for wear or damage. Whenever tappets are C Piston D Piston Pin
replaced, apply a liberal coating of Kohler lubricant to
base of each new tappet before it is installed. Connecting Rod
E Connecting Rod F End Cap
Remove Governor Cross Shaft
Breather
Governor Cross Shaft Oil Seal Details G Breather Filter H Cover
A B I Oil Seal
Remove Breather Assembly
Breather system is designed to control amount of oil
in head area and still maintain necessary vacuum in
crankcase.
When pistons move downward, crankcase gases are
pushed past reed through breather filter into intake
system. Upward travel of pistons closes reed and
creates a low vacuum in lower crankcase. Any oil
separated out through filter drains back into crankcase.
1. Remove screws securing breather cover to
crankcase.
2. Carefully remove cover and breather filter. Make
Governor Cross sure drain back hole is not plugged or restricted.
A 2.0 mm (0.0787 in.) B Shaft Seal
Remove Connecting Rods with Pistons and Rings
1. Round Cross Shaft End: Remove push-on NOTE: If a carbon ridge is present at top of either
retaining ring and nylon washer from governor cross cylinder bore, use a ridge reamer tool to remove
shaft. it before attempting to remove piston.
7 mm Hex Cross Shaft End: Remove E-Clip and NOTE: Cylinders are numbered on crankcase. Use
nylon washer from governor cross shaft. numbers to mark each end cap, connecting rod
2. Remove cross shaft with lower washer through and piston for reassembly. Do not mix end caps
inside of crankcase. and connecting rods.
3. Remove governor shaft seal from crankcase. 1. Remove screws securing closest connecting rod end
cap. Remove end cap.
If governor cross shaft seal is damaged and/or leaks,
replace it using following procedure. 2. Carefully remove connecting rod and piston
assembly from cylinder bore.
Remove oil seal from crankcase and replace it with a
new one. Install new seal to depth shown. 3. Repeat above procedure for other connecting rod
and piston assembly.
Connecting Rods
Offset, stepped-cap connecting rods are used in all
these engines.

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Disassembly/Inspection and Service

Inspection and Service Ring failure is usually indicated by excessive oil

Check bearing area (big end) for excessive wear, score consumption and blue exhaust smoke. When rings fail,
marks, running and side clearances (See Specifications). oil is allowed to enter combustion chamber where it is
Replace rod and cap if scored or excessively worn. burned along with fuel. High oil consumption can also
Service replacement connecting rods are available in occur when piston ring end gap is incorrect because
STD size and 0.25 mm (0.010 in.) undersize. Undersized ring cannot properly conform to cylinder wall under this
rods, 0.25 mm (0.010 in.), have an identification marking condition. Oil control is also lost when ring gaps are not
on lower end of rod shank. Always refer to appropriate staggered during installation.
parts information to ensure correct replacements are When cylinder temperatures get too high, lacquer and
used. varnish collect on pistons causing rings to stick, which
results in rapid wear. A worn ring usually takes on a
Piston and Rings shiny or bright appearance.
Inspection Scratches on rings and pistons are caused by abrasive
Piston and Rings Components and Details material such as carbon, dirt, or pieces of hard metal.
A Detonation damage occurs when a portion of fuel charge
ignites spontaneously from heat and pressure shortly
after ignition. This creates 2 flame fronts, which meet
and explode to create extreme hammering pressures on
B a specific area of piston. Detonation generally occurs
from using low octane fuels.
C Pre-ignition or ignition of fuel charge before timed spark
can cause damage similar to detonation. Pre-ignition
damage is often more severe than detonation damage.
Pre-ignition is caused by a hot spot in combustion
chamber such as glowing carbon deposits, blocked
cooling fins, an improperly seated valve, or wrong spark
plug(s).
Replacement pistons are available in STD bore size,
D and 0.25 mm (0.010 in.) oversize. Replacement pistons
include new piston ring sets and new piston pins.
E Replacement ring sets are also available separately for
STD, and 0.25 mm (0.010 in.) oversize pistons. Always
use new piston rings when installing pistons. Never use
old rings.
F
Some important points to remember when servicing
piston rings:
1. Cylinder bore must be de-glazed before service ring
G sets are used.
2. If cylinder bore does not need re-boring and if old
piston is within wear limits and free of score or scuff
H marks, old piston may be reused.
A Piston Ring B End Gap 3. Remove old rings and clean up grooves. Never
reuse old rings.
C Identification Mark D Piston
4. Before installing new rings on piston, place top 2
Top Compression Middle Compression rings, each in turn, in its running area in cylinder
E F
Ring Ring bore and check end gap. Top compression ring end
G Rails H Expander gap clearance is 0.189/0.277 mm (0.0074/0.0109 in.)
for a new bore, or 0.531 mm (0.0209 in.) for a used
Scuffing and scoring of pistons and cylinder walls occurs bore. Middle compression ring end cap is
when internal engine temperatures approach welding 1.519/1.797 mm (0.0598/0.0708 in.) for a new bore,
point of piston. Temperatures high enough to do this are or 2.051 mm (0.0808 in.) for a used bore.
created by friction, which is usually attributed to improper
lubrication and/or overheating of engine. 5. After installing new compression (top and middle)
rings on piston, make sure top compression ring-to-
Normally, very little wear takes place in piston boss- groove side clearance and is 0.030/0.070 mm
piston pin area. If original piston and connecting rod can (0.0010/0.0026 in.) and middle compression ring-to-
be reused after new rings are installed, original pin can groove side clearance 0.030/0.070 mm
also be reused but new piston pin retainers are required. (0.0010/0.026 in.). If side clearance is greater than
A piston pin is included as part of piston assembly – if specified, a new piston must be used.
pin boss in piston or pin are worn or damaged, a new
piston assembly is required.

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 Disassembly/Inspection and Service

Install New Piston Rings Check cylinder bore for scoring. In severe cases,
NOTE: Rings must be installed correctly. Ring unburned fuel can cause scuffing and scoring of cylinder
installation instructions are usually included with wall. It washes necessary lubricating oils off piston and
new ring sets. Follow instructions carefully. Use cylinder wall. As raw fuel seeps down cylinder wall,
a piston ring expander to install rings. Install piston rings make metal to metal contact with wall.
bottom (oil control) ring first and top Scoring of cylinder wall can also be caused by localized
compression ring last. hot spots resulting from blocked cooling fins or from
inadequate or contaminated lubrication.
To install new piston rings, proceed as follows:
If cylinder bore is badly scored, excessively worn,
1. Oil control ring (bottom groove): Install expander and tapered, or out-of-round, resizing is necessary. Use an
then rails. Make sure ends of expander are not inside micrometer to determine amount of wear (refer
overlapped. to Specifications). A 0.25 mm (0.010 in.) oversize piston
2. Middle compression ring (center groove): Install is available if resizing is selected. Initially, resize using
center ring using a piston ring expander tool. Make a boring bar, then use these following procedures for
sure identification mark is up or colored dye stripe (if honing cylinder.
contained) is to left of end gap. Honing
3. Top compression ring (top groove): Install top ring Details
using a piston ring expander tool. Make sure
identification mark is up or colored dye stripe (if
contained) is left of end gap. A
Remove Crankshaft
Carefully pull crankshaft from crankcase.
Inspection and Service
Inspect gear teeth of crankshaft. If teeth are badly worn,
chipped, or some are missing, replacement of crankshaft
will be necessary.
Inspect crankshaft bearing surfaces for scoring,
grooving, etc. Measure running clearance between
crankshaft journals and their respective bearing bores.
Use an inside micrometer or telescoping gauge to
measure inside diameter of both bearing bores in vertical
and horizontal planes. Use an outside micrometer to
measure outside diameter of crankshaft main bearing
journals. Subtract journal diameters from their respective A 23°-33° Crosshatch
bore diameters to get running clearances. Check results
against values in Specifications. If running clearances NOTE: Kohler pistons are custom-machined to exacting
are within specification, and there is no evidence of tolerances. When over-sizing a cylinder, it
scoring, grooving, etc., no further reconditioning is should be machined exactly 0.25 mm (0.010 in.)
necessary. If bearing surfaces are worn or damaged, over new diameter (refer to Specifications).
crankcase and/or oil pan will need to be replaced. Oversize Kohler replacement piston will then fit
correctly.
Inspect crankshaft keyways. If worn or chipped,
replacement of crankshaft will be necessary. While most commercially available cylinder hones can
be used with either portable drills or drill presses, use
Inspect crankpin for score marks or metallic pickup. of a low speed drill press is preferred as it facilitates
Slight score marks can be cleaned with crocus cloth more accurate alignment of bore in relation to crankshaft
soaked in oil. If wear limits are exceeded, as stated in crossbore. Honing is best accomplished at a drill speed
Specifications, it will be necessary to replace crankshaft. of about 250 RPM and 60 strokes per minute. After
installing coarse stones in hone, proceed as follows:
Remove Flywheel and PTO End Oil Seals
1. Lower hone into bore and after centering, adjust so
Remove oil seals from crankcase and oil pan. stones are in contact with cylinder wall. Use of a
commercial cutting-cooling agent is recommended.
Crankcase
2. With lower edge of each stone positioned even with
Inspection and Service lowest edge of bore, start drill and honing process.
Check all gasket surfaces to make sure they are free of Move hone up and down while resizing to prevent
gasket fragments. Gasket surfaces must also be free of formation of cutting ridges. Check size frequently.
deep scratches or nicks.

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Disassembly/Inspection and Service

3. When bore is within 0.064 mm (0.0025 in.) of Measuring Piston-to-Bore Clearance

desired size, remove coarse stones and replace Piston Detail
them with burnishing stones. Continue with
burnishing stones until bore is within 0.013 mm
(0.0005 in.) of desired size and then use finish
stones (220-280 grit) and polish bore to its final size. A
A crosshatch should be observed if honing is done
correctly. Crosshatch should intersect at
approximately 23°-33° off horizontal. Too flat an
angle could cause rings to skip and wear
excessively, and too steep an angle will result in high
oil consumption.
A 6 mm (0.2362 in.)
4. After resizing, check bore for roundness, taper, and
size. Use an inside micrometer, telescoping gauge, NOTE: Do not use a feeler gauge to measure piston-to-
or bore gauge to take measurements. These bore clearance, it will yield inaccurate
measurements should be taken at 3 locations in measurements. Always use a micrometer.
cylinder – at top, middle, and bottom. Two Before installing piston into cylinder bore, it is necessary
measurements should be taken (perpendicular to that clearance be accurately checked. This step is
each other) at 3 locations. often overlooked, and if clearances are not within
Clean Cylinder Bore After Honing specifications, engine failure will usually result.
Proper cleaning of cylinder walls following boring and/ Use following procedure to accurately measure piston-
or honing is very critical to a successful overhaul. to-bore clearance:
Machining grit left in cylinder bore can destroy an engine 1. Use a micrometer and measure diameter of piston
in less than 1 hour of operation after a rebuild. 6 mm (0.2362 in.) above bottom of piston skirt and
Final cleaning operation should always be a thorough perpendicular to piston pin.
scrubbing with a brush and hot, soapy water. Use a 2. Use an inside micrometer, telescoping gauge, or
strong detergent capable of breaking down machining bore gauge and measure cylinder bore.
oil while maintaining a good level of suds. If suds break Measurement approximately 63.5 mm (2.5 in.) below
down during cleaning, discard dirty water and start again top of bore and perpendicular to piston pin.
with more hot water and detergent. Following scrubbing,
rinse cylinder with very hot, clear water, dry it completely, 3. Piston-to-bore clearance is difference between bore
and apply a light coating of engine oil to prevent rusting. diameter and piston diameter (step 2 minus step 1).

78 KohlerEngines.com 32 690 03 Rev. L

 Reassembly

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

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

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Reassembly

Crankshaft/Governor Gear/Oil Pump Components Locking Tab Thrust

K Governor Gear L Washer
E
M Oil Pan N Drain Plug
C O Oil Seal P Oil Pump
A B Q Oil Sentry™ R Ball
D S Spring T Oil Pick-up Screen
Ground Strap
U V Outer Gerotor Gear
Location
A
Install Governor Cross Shaft
1. Lubricate governor cross shaft bearing surfaces in
crankcase with engine oil.
2. Slide lower washer onto governor cross shaft and
install cross shaft from inside of crankcase.
3. Round Cross Shaft End: Install nylon washer onto
governor cross shaft, then start push-on retaining
ring. Hold cross shaft up in position, place a 0.50
F mm (0.020 in.) feeler gauge on top of nylon washer,
and push retaining ring down shaft to secure.
Remove feeler gauge, which will have established
proper end play.
7 mm Hex Cross Shaft End: Install nylon washer
onto governor cross shaft. Install E-clip into groove
on cross shaft. Use a 0.25 mm (0.010 in.) feeler
G gauge to make sure gap between washer and clip is
at least 0.25 mm (0.010 in.).
P
H Install Crankshaft
T 1. Lubricate flywheel side main bearing surface and
Q I lips of oil seal in crankcase with clean engine oil.
V 2. Carefully slide flywheel end of crankshaft through
J main bearing in crankcase.
S K
R L
U
M

Governor Cross
A B Lower Washer
Shaft
Push-on Retaining
C Nylon Washer D Ring
E E-Clip F Crankshaft
G Valve Tappets H Camshaft
I Regulating Pin J Shaft

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 Reassembly

Install Connecting Rods with Pistons and Rings 4. Make sure FLY stamping on piston is facing toward
flywheel side of engine. Use a hammer with a rubber
Piston and Connecting Rod Details or wood grip and gently tap piston into cylinder. Be
careful oil ring rails do not spring free between
bottom of ring compressor and top of cylinder.
5. Install inner rod cap to connecting rod using screws.
Two different types of coatings on connecting rod
screws have been used. If black coating, torque in
increments to 11.3 N·m (100 in. lb.). If gray metallic
coating, it is not necessary to lubricate this screw,
torque in increments to 13.6 N·m (120 in. lb.).
B Illustrated instructions are provided in service rod
package.
6. Repeat above procedure for other connecting rod
and piston assembly.

A Install Valve Tappets and Camshaft

NOTE: Exhaust valve tappets are located on output
A Side 1 B Side 2 shaft side of engine, while intake valve tappets
are located on fan side of engine. Cylinder
Connecting Rod Screw Details number is embossed on outside of each cylinder
on crankcase. Valve tappets should always be
installed in same position as before disassembly.
A 1. Apply camshaft lubricant to contact surface of valve
tappets. Note mark or tag identifying tappets and
install them in their appropriate crankcase locations.
A small amount of grease applied to stems will hold
valve tappets up until camshaft is installed.
2. Liberally apply camshaft lubricant to lobes of
camshaft. Lubricate camshaft bearing surfaces of
B crankcase and camshaft with engine oil.
3. Position timing mark of crankshaft gear at 12 o’clock
position.
4. Turn governor cross shaft clockwise until lower end
Type Torque (blade) is laying against bottom of cylinder. Make
A Black Coating 11.3 N·m (100 in. lb.) sure cross shaft remains in this position while
installing camshaft.
Gray Metallic
B 13.6 N·m (120 in. lb.) 5. Slide camshaft into bearing surface of crankcase,
Coating
positioning timing mark of camshaft gear at 6 o’clock
NOTE: Cylinders are numbered on crankcase. Make position. Make sure camshaft gear and crankshaft
sure to install piston, connecting rod, and end gear mesh with both timing marks aligned.
cap into its appropriate cylinder bore as
previously marked during disassembly. Do not Oil Pump Assembly
mix end caps and connecting rods. Oil pump is mounted inside oil pan. If service
NOTE: Proper orientation of piston/connecting rod was required and oil pump was removed, refer to
assemblies inside engine is extremely important. Disassembly/Inspection and Service procedure.
Improper orientation can cause extensive wear
or damage. Be certain pistons and connecting Governor Assembly
rods are assembled exactly as shown. Governor assembly is located inside oil pan. If service
NOTE: Align chamfer of connecting rod with chamfer of was required and governor was removed, refer to
its mating end cap. When installed, flat faces of Disassembly/Inspection and Service procedure.
connecting rods should face each other. Faces
with raised rib should be toward outside.
1. Stagger piston rings in grooves until end gaps are
120° apart. Oil ring rails should also be staggered.
2. Lubricate cylinder bore, piston, and piston rings with
engine oil. Compress rings using a piston ring
compressor.
3. Lubricate crankshaft journals and connecting rod
bearing surfaces with engine oil.

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Reassembly

Install Oil Seal in Oil Pan RTV sealant is used as a gasket between oil pan
and crankcase. Refer to Tools and Aids for a listing of
Oil Seal Component and Detail approved sealants. Always use fresh sealant. Using
outdated sealant can result in leakage.
1. Be sure sealing surfaces have been cleaned and
A prepared as described at beginning of Reassembly.
2. Check to make sure there are no nicks or burrs on
sealing surfaces of oil pan or crankcase.
B 3. Apply a 1.5 mm (1/16 in.) bead of black RTV sealant
to sealing surface of oil pan. See sealant pattern. Oil
pan must be installed within 5 minutes of sealant
being applied for proper sealing to occur.
4. Make sure end of governor cross shaft is lying
against bottom of cylinder inside crankcase.
5. Install oil pan to crankcase. Carefully seat camshaft
with shim and crankshaft into their mating bearings.
Rotate crankshaft to help engage oil pump and
governor gear meshes.
A 6.5 mm (0.255 in.) B Oil Seal
6. Install 10 screws securing oil pan to crankcase.
1. Check to make sure there are no nicks or burrs in Torque fasteners in sequence shown to 24.4 N·m
crankshaft bore of oil pan. (216 in. lb.).
2. Apply a light coat of engine oil to outside diameter of
oil seal.
3. Drive oil seal into oil pan using a seal driver. Make
sure oil seal is installed straight and true in bore, to
depth shown.
Install Oil Pan Assembly
Sealant Pattern

Fastener Torque Sequence

1
3
10
5
8

9
2 4

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 Reassembly

Flywheel/Ignition/Breather Components Install Breather Reed and Breather Reed Cover

Breather Reed Cover Sealant
A
C A
D

E F A Sealant Bead
NOTE: RTV sealant should be allowed to cure a
minimum of 1 hour before engine is started.
1. Install breather reed, followed by retainer over
passage hole and mounting hole in crankcase. Hold
G in position and secure with mounting stud. Torque
stud to 6.2 N·m (55 in. lb.) into a new, cored hole, or
4.0 N·m (35 in. lb.) into a used hole.
2. Invert breather reed cover and apply a 1.5 mm
H (1/16 in.) bead of RTV sealant to perimeter flange of
cover as shown. Use Loctite® 5900TM or 5910TM.
3. Immediately install breather reed cover over
mounting stud and onto crankcase. Do not allow
I RTV sealant to come in contact with breather reed,
or reed sealing surface.
J
4. Secure with a new sealing washer and M5 nut.
K Torque nut to 1.3 N·m (12 in. lb.). Check that a
L complete seal has occurred by RTV sealant being
M squeezed out around entire flange perimeter.
Install Stator and Backing Plate
1. Apply pipe sealant with Teflon® (Loctite® PST® 592TM
or equivalent) to stator mounting holes.
2. Position stator aligning mounting holes so leads are
at bottom, toward crankcase.
3. Install and torque screws to 8.8 N·m (78 in. lb.).
4. Install backing plate. Secure with screws. Torque
screws in a crisscross pattern to 7.3 N·m (65 in. lb.).
Install Flywheel and Fan
A Flywheel Screw B Fan
C Washer D Fan Mounting Plate CAUTION
E Magnet F Flywheel Damaging Crankshaft and Flywheel can
cause personal injury.
G Stator H Backing Plate
I Breather Reed Cover J Stud
K Retainer L Breather Reed
M Flywheel Key Using improper procedures can lead to broken
fragments. Broken fragments could be thrown from
engine. Always observe and use precautions and
procedures when installing flywheel.

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Reassembly

NOTE: Before installing flywheel, make sure crankshaft taper and flywheel hub are clean, dry, and completely free of
lubricants. Presence of lubricants can cause flywheel to be overstressed and damaged when screw is torqued
to specifications.
NOTE: Make sure flywheel key is installed properly in keyway. Flywheel can become cracked or damaged if key is
not installed properly.
1. Install flywheel key into keyway of crankshaft. Make sure key is properly seated and parallel with shaft taper.
2. Install flywheel onto crankshaft being careful not to shift flywheel key.
3. Install fan onto flywheel, so locating pins fit into corresponding recesses. Drive 2 retainers down completely.
4. Install fan mounting plate onto fan, aligning 4 cutouts, followed by heavy flat washer and screw.
5. Use a flywheel strap wrench or holding tool to hold flywheel. Torque screw securing flywheel to crankshaft to 74.5
N·m (55 ft. lb.).
Cylinder Head Components

C J
O A
I E
L
S
F K
D M
G N
4 2 2 4 H

R
1 3 3 1

M P
N
#1 #2 Q

A Gasket B Valve C Cylinder Head D Valve Spring Cap

E Valve Stem Seal F Valve Spring G Valve Spring Keeper H Stud
I Spark Plug J Guide Plate K Push Rod L Rocker Arm
Stamped Steel Valve
M Rocker Arm Pivots N Adjusters O Washer P Cover (RTV)
Plastic Valve Cover
Q R O-Ring S Torque Sequence
(O-Ring)

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Assemble and Install Cylinder Heads Adjust Valve Clearance

Valve Stem Seals Adjusters Retaining Push Rods
Use a new seal whenever valve is removed, or if seal is
deteriorated or damaged. Never reuse an old seal. A
Assemble Cylinder Heads
Prior to installation, lubricate all components with engine B
oil, paying particular attention to lip of valve stem seal,
valve stems, and valve guides. Install following items in
order listed below using a valve spring compressor.
● Intake and exhaust valves.
● Valve stem seal.
● Washer (intake valve only).
● Valve springs.
● Valve spring caps.
● Valve spring keepers.
Install Cylinder Heads A Adjuster B Rocker Arm
NOTE: Match numbers embossed on cylinder heads
and crankcase. 1. Rotate crankshaft to establish TDC on compression
stroke for cylinder 1.
NOTE: Push rods should always be installed in same
position as before disassembly. Check for:
1. Check to make sure there are no nicks or burrs on a. Compression will be felt through spark plug hole.
sealing surfaces of cylinder head or crankcase. b. Keyway of crankshaft will be aligned with cylinder
Make sure dowel locating pins are in lower 2 cylinder 1.
bolt holes on each side.
c. No rocker arm/push rod movement if crankshaft
2. Install a new cylinder head gasket (with printing up) is rotated slightly back and forth. If they are
on each side. moving, rotate crankshaft 1 full revolution.
3. Install each cylinder head and start 4 screws. 2. Insert a 0.127 mm (0.005 in.) feeler gauge between
4. Torque screws in 2 stages; first to 22.6 N·m end of 1 valve and rocker arm. Turn adjuster until a
(200 in. lb.), then finally to 41.8 N·m (370 in. lb.), slight drag is felt. Hold in this position and tighten
following sequence. setscrew securely. Torque setscrew to 7.9 N·m
(70 in. lb.). After tightening recheck adjustment.
Install Rocker Arms Proper valve clearance is 0.101/0.152 mm
1. Note mark or tag identifying push rod as either (0.004/0.006 in.).
intake or exhaust and cylinder 1 or 2. Check each
push rod is straight and not bent. Dip ends of push 3. Repeat procedure for other valve on side 1.
rods in engine oil and install in their original 4. Viewed from PTO end, rotate crankshaft 270° (3/4
positions, making sure each push rod ball seats in its turn) counterclockwise and align crankshaft keyway
tappet socket. with cylinder 2, which now puts cylinder at TDC on
2. Install guide plate and studs. Torque studs to compression stroke.
11.3 N·m (100 in. lb.). 5. Repeat steps 3-4 for setting valve clearance on side
3. Apply grease to contact surfaces of adjusters, rocker 2.
arms and rocker arm pivots. Install rocker arms and 6. Rotate crankshaft to check for free operation of
rocker arm pivots onto appropriate cylinder head, valve train. Check for clearance between valve
and install adjuster finger tight. Make sure set screw spring coils at full lift, or bending of push rod(s) can
is backed out until flush with adjuster. occur. Minimum allowable clearance is 0.25 mm
(0.010 in.).
Check Assembly
Rotate crankshaft a minimum of 2 revolutions to check
longblock assembly and overall proper operation.

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Reassembly

Install Valve Covers Stamped Steel Valve Covers

Plastic valve covers contain integral bolt hole spacers Stamped Steel Valve Cover RTV Sealant
molded in place. Sealing of plastic valve covers is
accomplished using a yellow colored O-ring. In stamped
steel valve covers sealing is accomplished using RTV
sealant.
Plastic Valve Covers
Plastic Valve Cover Torque Sequence

1&5 3

A
4 2
A RTV Sealant
1. Make sure sealing surfaces of valve covers and
cylinder heads are clean and free of any nicks or
burrs. Stamped Steel Valve Cover Torque Sequence
2. Install a new O-ring in groove of each cover. Do Not
use gaskets or RTV sealant. 1&5 3
3. Position covers on cylinder heads. If a pulse style
fuel pump is used, valve cover with pulse fitting hole
must be installed on side 2. Install screws in each
cover and finger tighten.
4. Using sequence shown, torque valve cover screws
to the appropriate torque for style of screw.

Hex Flange to 9.0 N·m (80 in. lb.)

4 2

Pan Head to 6.2 N·m (55 in. lb.) NOTE: Always use fresh sealant. Using outdated
sealant can result in leakage. Refer to Tools and
Aids for information on sealant dispenser.
NOTE: To ensure proper adhesion of sealant to both
sealing surfaces, perform step 3 immediately (5
minutes maximum) after application of RTV.
RTV silicone sealant is used as a gasket between valve
cover and cylinder head. Refer to Tools and Aids for a
listing of approved sealants.
1. Prepare sealing surfaces of cylinder heads and
valve covers. Flatness of sealing surface must be
checked prior to reinstallation. See Disassembly.
2. Apply a 1.5 mm (1/16 in.) bead of sealant to valve
cover as shown.

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

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Reassembly

External Engine Components

A
R
B

E C

E S

H D B
G R

E
I S
V P Q
H
W

U
N O
T

J
K

A Fixed Guard B Air Cleaner Cover C Debris Screen D Blower Housing

E Hose Clamp F Fuel Pump G Hose Clip H Fuel Line
I Fuel Filter J Oil Filter K Outer Baffle L Electric Starter
M Inner Baffle N Ignition Module O Intake Manifold P Carburetor
Q Gasket R Air Cleaner Base S Air Cleaner Element T Rectifier-Regulator
U Dipstick Tube V Oil Fill/Dipstick W Breather Hose

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 Reassembly

Install Ignition Modules Install Intake Manifold

Torque Sequence
Smart-Choke™ Deflector Support Tab
3 4

1 2
A
B 1. On engines equipped with Smart-Choke™, install air
vane deflector into intake manifold. Torque screw to
1 N·m (9 in. lb.).
2. Install intake manifold using new O-rings, with wiring
harness attached, onto cylinder heads. Slide any
wiring harness clips onto appropriate bolts before
installing. Using sequence shown, torque screws in
2 increments, first to 7.4 N·m (66 in. lb.), then to
9.9 N·m (88 in. lb.).
3. Connect kill lead to tab terminal on standard ignition
modules.
Install Rectifier-Regulator (if equipped)
A Position tab towards crankcase. 1. Install B+ terminal/lead into center position of
B Rotate tab against module before tightening. rectifier-regulator plug so it locks in place, and
connect plug to rectifier-regulator.
NOTE: On engines equipped with Smart-Choke™, make
sure to install deflector support tab on #2 2. Attach rectifier-regulator to opening in backing plate
cylinder ignition module. from underside, and secure with mounting screws.
Torque screws to 4.0 N·m (35 in. lb.).
1. Rotate flywheel to position magnet away from
ignition module bosses. Install Inner and Outer Cylinder Baffles
2. CDI modules are installed on cylinder 1 with single 1. Attach outer cylinder baffles and secure with M6
kill tab away from cylinder/towards you, and on screw (lower cylinder location), and M5 screw into
cylinder 2 with single kill tab towards cylinder/away backing plate. Tighten screws as listed following step
from you. 2.
MDI modules are installed with flat side out/towards 2. Attach inner baffles including any lifting straps to
you. cylinder head flanges and to 2 crankcase mounting
3. Install each ignition module to crankcase bosses. bosses. Lift strap should be outside outer baffle.
Slide modules up as far away from flywheel as Secure with M5 screws. Remaining lower inner
possible and snug screws to hold them in position. baffle mounting screws will be installed later.
4. Rotate flywheel to position magnet directly under 1 Torque baffle mounting screws:
ignition module. M5 screws: 6.2 N·m (55 in. lb.) into a new cored
5. Insert a 0.25 mm (0.009 in.) flat feeler gauge hole, or 4.0 N·m (35 in. lb.) into a used hole.
between magnet and ignition module. Loosen M6 screws: 10.7 N·m (95 in. lb.) into a new cored
screws enough to allow magnet to pull module down hole, or 7.3 N·m (65 in. lb.) into a used hole.
against feeler gauge.
6. Torque screws to 4.0-6.2 N·m (35-55 in. lb.).
7. Repeat steps 4 through 6 for other ignition module.
8. Rotate flywheel back and forth checking for
clearance between magnet and ignition modules.
Make sure magnet does not strike modules. Check
gap with a feeler gauge and readjust if necessary.
Final air gap 0.203/0.305 mm (0.008/0.012 in.).

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Reassembly

Install Carburetor Choke Unloader Linkage

WARNING
Explosive Fuel can cause fires and severe
burns. A
Do not fill fuel tank while engine is hot or
running.
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Spilled fuel could ignite B
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
1. Install a new carburetor gasket. Make sure all holes
align and are open.
2. Install carburetor, throttle linkage and governor lever Choke Unloader Choke
A B
as an assembly. Linkage Lever
3. If carburetor is equipped with a fuel solenoid,
connect red (power) lead. Attach eyelet terminal of Actuator Lever Engaged with Choke Shaft Pin
ground lead to inner top carburetor cover mounting B
screw. A
Install Carburetor with Smart-Choke™

Smart-Choke™ Carburetor Components

A Actuator Lever B Choke Shaft Pin

NOTE: If thermostat was removed from assembly, refer
B to procedure in Fuel System section to install.
F 1. Install new carburetor gasket. Make sure all holes
align and are open.
C E 2. Install carburetor, throttle linkage and governor lever
G as an assembly.
3. Connect choke unloader linkage from air vane
deflector to carburetor.
A Air Cleaner Base B Breather Hose 4. If carburetor is equipped with a fuel solenoid,
C Ground Lead D Solenoid Lead connect red (power) lead. Attach eyelet terminal of
ground lead to inner top carburetor cover mounting
Smart-Choke™ screw.
E F Thermostat
Bracket Assembly 5. Install a new air cleaner base gasket and air cleaner
G Carburetor base onto mounting studs. Install Smart-Choke™
bracket assembly. Ensure actuator lever is engaged
with pin on choke shaft. Torque nuts to 6.2-7.3 N·m
(55-65 in. lb.)
6. Connect breather hose to air cleaner base and
secure with clamp.

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 Reassembly

Install Carburetor with eChoke™ Install External Governor Controls

eChoke™ Carburetor Components Control Bracket Components

A A

F C
F E

B D
D
C

A Air Cleaner Base B Solenoid Lead

G
eChoke™ Bracket
C Stepper Motor D C
Assembly
D
E Carburetor F Nuts
NOTE: On engines equipped with eChoke™, stepper A Choke Linkage B Throttle Linkage
motor has a special retract routine that can be C Governor Lever D Governor Spring
activated to ensure motor is in correct position
prior to removal or upon replacement of stepper E Cross Shaft F Control Bracket
motor when a problem is shown to exist with G Dampener Spring
stepper motor assembly and carburetor.
Activation of this routine will occur by initiating Throttle and Choke Components
three (3) consecutive Key On–Off cycles. Every
Key On and Off should be > 2 seconds and < A B
3.5 seconds. Note that if no other connections
are disturbed, stepper motor will be repositioned K
at next key ON and master module will go back
to normal choke operation mode. J C
1. Install a new carburetor gasket. Make sure all holes I
align and are open. H D
2. Install carburetor, throttle linkage and governor lever
as an assembly. E
G F
3. If carburetor is equipped with a fuel solenoid,
connect red (power) lead. Attach eyelet terminal of A Screw B Choke Lever
ground lead to inner top carburetor cover mounting
screw. Throttle Actuator
C Throttle Lever D Lever
4. Install a new air cleaner base gasket and air cleaner E Control Bracket F Choke Return Spring
base onto mounting studs. Install eChoke™ bracket
assembly. Connect eChoke™ stepper motor harness G Lock Nut M5x0.8 H Shoulder Washer
and follow routine indicated in NOTE in this section I Flat Washer J Nylon Washer
prior to setting link. K Wave Washer
5. Connect choke linkage to choke actuator lever on
main control bracket assembly. Torque nuts to
6.2-7.3 N·m (55-65 in. lb.).
6. Connect breather hose to air cleaner base and
secure with clamp.

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1. Install governor lever onto governor cross shaft if Install Electric Starter Motor
disconnected previously.
1. Install starter motor and lift bracket.
2. Make sure throttle linkage is connected to governor
lever and throttle lever on carburetor. Connect choke 2. Torque screws to 23.8 N·m (211 in. lb.).
linkage to carburetor choke lever. 3. On models with a solenoid shift starter, connect
3. Attach fuel line to carburetor and secure with a leads to solenoid.
clamp.
Install Debris Screen
4. Install a new air cleaner base gasket and air cleaner
base onto mounting studs. Torque nuts to Snap screen onto fan.
6.2-7.3 N·m (55-65 in. lb.).
Install Blower Housing
5. Connect breather hose to air cleaner base and
secure with clamp. NOTE: Do not completely tighten screws until all are
installed to allow shifting for hole alignment.
6. Move governor lever toward carburetor as far as it
will go (wide-open throttle), and hold in position. 1. Install blower housing onto engine. Start all
mounting screws. Make sure wire harness and spark
7. Round Cross Shaft End: Insert a nail or similar plug leads exit out through appropriate openings in
tool into hole on cross shaft and rotate shaft shrouding. Attach any fuel line clamps used.
counterclockwise as far as will turn, then torque nut
to 6.8 N·m (60 in. lb.). 2. Torque screws as follows:
7 mm Hex Cross Shaft End: Use 7 mm hex socket M5 Blower Housing Screws: 6.2 N·m (55 in. lb.) in a
on end of cross shaft and rotate shaft new hole, or 4.0 N·m (35 in. lb.) in a used hole.
counterclockwise (viewed from end) as far as it will M4 HI-LO Screws: 2.8 N·m (25 in. lb.).
turn, then torque nut to 6.8 N·m (60 in. lb.).
M3 HI-LO Screws: 2.3 N·m (20 in. lb.).
Install Air Cleaner Element 3. Install and secure air cleaner cover.
Install air cleaner element (with precleaner if equipped),
onto air cleaner base. Install Fixed Guard (if equipped)
Install fixed guard. Securely tighten screw (if equipped).
Install Throttle and Choke Controls
Install Dipstick Tube
Governor Lever Hole Position
1. Lubricate dipstick tube O-ring and install into
E crankcase.
D 2. Secure to backing plate using M5 screw.
C
3. Torque screw to 4.0 N·m (35 in. lb.).
B
A

A Governor Lever B Hole 1

C Hole 2 D Hole 3
E Hole 4
1. Connect choke linkage to choke actuator lever on
main control bracket assembly.
2. Install main control bracket to cylinder heads using
screws. Two lower screws should also secure inner
baffles. Torque screws to 10.7 N·m (95 in. lb.) into
new holes, or 7.3 N·m (65 in. lb.) into used holes.
3. Connect governed idle spring to governor lever and
main control bracket. Connect governor spring from
throttle control bracket to appropriate hole in
governor lever.

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Install Fuel Pump Install Oil Filter and Fill Crankcase with Oil
NOTE: Make sure oil drain plug is installed and torqued
WARNING to specification to prevent oil leakage.
Explosive Fuel can cause fires and severe 1. Install oil drain plug. Torque plug to 13.6 N·m
burns. (10 ft. lb.).
Do not fill fuel tank while engine is hot or 2. Place new filter in shallow pan with open end up. Fill
running. with new oil until oil reaches bottom of threads. Allow
Gasoline is extremely flammable and its vapors can 2 minutes for oil to be absorbed by filter material.
explode if ignited. Store gasoline only in approved 3. Apply a thin film of clean oil to rubber gasket on new
containers, in well ventilated, unoccupied buildings, filter.
away from sparks or flames. Spilled fuel could ignite 4. Refer to instructions on oil filter for proper
if it comes in contact with hot parts or sparks from installation.
ignition. Never use gasoline as a cleaning agent.
5. Fill crankcase with new oil. Level should be at top of
Fuel Pump Components indicator on dipstick.
6. Reinstall oil fill/dipstick and tighten securely.
Connect Spark Plug Leads
Connect leads to spark plugs.
F Prepare Engine for Operation
E Engine is now completely reassembled. Before starting
or operating engine, be sure to do following.
A D 1. Make sure all hardware is tightened securely.
2. Make sure oil drain plug, Oil SentryTM pressure
C switch, and a new oil filter are installed.
B
3. Adjust carburetor idle speed adjusting screw as
necessary.
Testing Engine
It is recommended engine be operated on a stand or
A Outlet Fuel Line B Pulse Hose bench prior to installation in piece of equipment.
C Inlet Fuel Line D Fuel Line Clamp 1. Run engine at idle for 2-3 minutes, then 5-6 minutes
more between idle and midrange.
E Fuel Filter F Fuel Pump
2. Adjust idle speed screw and high-speed stop as
NOTE: If a new fuel pump is being installed, make sure necessary. Make sure maximum engine speed does
orientation of new pump is consistent with not exceed 3750 RPM (no load).
removed pump. Internal damage may occur if
installed incorrectly.
1. Connect pulse hose to valve cover. Valve cover
should be situated between 2 formed lips on pulse
hose.
2. Attach pulse hose to fuel pump and secure with a
clamp. Mount fuel pump to blower housing with
screws. Torque screws to 2.8 N·m (25 in. lb.).
3. Connect inlet and outlet fuel lines to pump. Route
inlet fuel line through fuel line clamp (if used) as
shown.
Install Muffler
1. Install muffler and attaching hardware to muffler
bracket. Torque screws to 9.9 N·m (88 in. lb.).
2. Install M8 nuts or 5/16-18 head capscrews (based
on head design), to secure muffler. Torque hex nuts
to 24.4 N·m (216 in. lb.), lock nuts to 27.8 N·m (246
in. lb.), or capscrews to 16.9 N·m (150 in. lb.).

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