Kohler Courage 20 Service Manual - 20 - 690 - 01 - EN

SV470-SV620
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
3
5
13
16
20
21
31
33
35
44
47
50
63
Safety
Maintenance
Specifications
Tools and Aids
Troubleshooting
Air Cleaner/Intake
Fuel System
Governor System
Lubrication System
Electrical System
Starter System
Emission Compliant Systems
Disassembly/Inspection and Service
Reassembly
20 690 01 Rev. I
KohlerEngines.com
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
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.
WARNING
Rotating Parts can cause
severe injury.
Stay away while engine
is in operation.
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate engine with covers,
shrouds, or guards removed.
WARNING
Carbon Monoxide can
cause severe nausea,
fainting or death.
Avoid inhaling exhaust
fumes.
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.
WARNING
CAUTION
Accidental Starts can

cause severe injury or
death.
Disconnect and ground
spark plug lead(s) before
servicing.
Electrical Shock can

cause injury.
Do not touch wires while
engine is running.
Before working on engine or

equipment, disable engine as
follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative ()
battery cable from battery.
Damaging Crankshaft
and Flywheel can cause
personal injury.
WARNING
Hot Parts can cause
severe burns.
Do not touch engine
while operating or just
after stopping.
CAUTION
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.
Never operate engine with heat

shields or guards removed.
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 manufacturers warnings
and instructions on its proper and
safe use. Never use gasoline as a
cleaning agent.
KohlerEngines.com
20 690 01 Rev. I
Maintenance
MAINTENANCE INSTRUCTIONS
WARNING
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark plug lead(s)
before servicing.
Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative () battery cable from battery.
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 Hours or Annually
Service/replace low-profile precleaner.
Air Cleaner/Intake
Replace air cleaner element (if not equipped with precleaner).
Air Cleaner/Intake
Every 100 Hours or Annually
Replace air cleaner element (if not equipped with precleaner).
Change oil and filter.
Remove cooling shrouds and clean cooling areas.
Air Cleaner/Intake
Lubrication System
Air Cleaner/Intake
Every 100 Hours

Replace fuel filter.
Check that all fasteners are in place and components are properly secured.
Reassembly
Every 200 Hours

Have valve lash checked/adjusted.
Reassembly
Every 500 Hours

Replace spark plug and set gap.
1
Perform these procedures more frequently under severe, dusty, dirty conditions.
2
Have a Kohler authorized dealer perform this service.
Electrical System
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).
20 690 01 Rev. I
KohlerEngines.com
Maintenance
OIL RECOMMENDATIONS
We recommend use of Kohler oils for best performance.
Other high-quality detergent oils (including synthetic)
of API (American Petroleum Institute) service class SJ
or higher are acceptable. Select viscosity based on
air temperature at time of operation as shown in table
below.
STORAGE
If engine will be out of service for 2 months or more
follow procedure below.
1. Add Kohler PRO Series fuel treatment or equivalent
to fuel tank. Run engine 2-3 minutes to get stabilized
fuel into carburetor (failures due to untreated fuel are
not warrantable).
2. Change oil while engine is still warm from operation.
Remove spark plug(s) and pour about 1 oz. of
engine oil into cylinder(s). Replace spark plug(s) and
crank engine slowly to distribute oil.
3. Disconnect negative (-) battery cable.
4. Store engine in a clean, dry place.
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.
KohlerEngines.com
20 690 01 Rev. I
Specifications
Engine Dimensions
Dimensions in millimeters.
Inch equivalents shown in [ ].
VALVE COVER VIEW
20 690 01 Rev. I
KohlerEngines.com
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 . . . . . . . . . . . . . . . . . . . . . SV470
Courage Engine
Vertical Shaft
Numerical Designation
Specification . . . . . . . . . . . . . . . SV470-0001
Serial . . . . . . . . . . . . . . . . . . . . . 4223500328
Year Manufactured Code
Code
Year
42
2012
43
2013
44
2014
GENERAL SPECIFICATIONS3.6
Bore
Stroke
Displacement
Spec. 00XX:
Spec. 01XX:
Spec. 02XX or higher:
SV470/
SV471/
SV480
--84 mm (3.30 in.)
89 mm (3.50 in.)
94 mm (3.70 in.)
--Spec. 00XX: 477 cc (29.1 cu. in.)

Spec. 01XX: 535 cc (32.6 cu. in.)
Spec. 02XX or higher: 597 cc (36.4 cu. in.)
Oil Capacity (refill)

Maximum Angle of Operation (@ full oil level)4
TORQUE SPECIFICATIONS3,5
Air Cleaner Base

Hex Nut Fastener
Mounting Screw Fastener (install dry)
Balance Weight
Screw
Blower Housing and Sheet Metal
M6 Fastener
Cam Lever
Fastener
SV470/
SV471/
SV480
Factory Code
SV530/
SV590/SV591/
SV540/
SV600/SV601/
SV541
SV610/SV620
--94 mm (3.70 in.)
89 mm (3.50 in.)
------94 mm (3.70 in.)
--86 mm (3.38 in.)
--597 cc (36.4 cu. in.)
535 cc (32.6 cu. in.)
------597 cc (36.4 cu. in.)
--1.5 L (1.6 U.S. qt.)
25
SV530/
SV540/
SV541
SV590/SV591/
SV600/SV601/
SV610/SV620
5.5 Nm (48 in. lb.)

8.0 Nm (70 in. lb.) into new hole
5.5 Nm (48 in. lb.) into used hole
10.9-13.2 Nm (95.0-115.0 in. lb.)
8.0-10.5 Nm (70-94.0 in. lb.) into new hole
7.1-8.6 Nm (61.8-74.8 in. lb.) into used hole
Values are in Metric units. Values in parentheses are English equivalents.

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.
3
4
KohlerEngines.com
20 690 01 Rev. I
Specifications
SV470/
SV471/
SV480
SV530/
SV540/
SV541
Carburetor
Fuel Bowl Retaining Screw
Walbro
Nikki
5.1-6.2 Nm (45-55 in. lb.)

10.8-12.8 Nm (96-113 in. lb.)
Closure Plate
Fastener
24.5 Nm (216 in. lb.)
Connecting Rod
Cap Fastener (torque in 2 increments)
5.5, 11.5 Nm (50, 100 in. lb.)
Crankcase
Oil Drain Plug
Cylinder Head
Fastener (torque in 2 increments)
Rocker Arm Pivot Stud
Rocker Arm Adjustment Nut Set Screw
14.0 Nm (125 in. lb.)

20.5, 41.0 Nm (180, 360 in. lb.)
13.5 Nm (120 in. lb.)
5.5 Nm (50 in. lb.)
Electric Starter
Thru Bolt
Mounting Nut
Nut (top) Positive (+) Brush Lead Terminal
Nut (flange) Positive (+) Brush Lead Terminal
3.3-3.9 Nm (30-35 in. lb.)

3.6 Nm (32 in. lb.)
1.6-2.8 Nm (15-25 in. lb.)
2.2-4.5 Nm (20-40 in. lb.)
Flywheel
M12 Retaining Screw
M10 Retaining Screw
88.0 Nm (65 ft. lb.)

66.5 Nm (49 ft. lb.)
Governor
Lever Nut
Ignition
Spark Plug
Module Fastener
Rectifier-Regulator Fastener
7.0-8.5 Nm (60-75 in. lb.)

27 Nm (20 ft. lb.)
Muffler
Retaining Nuts
24.4 Nm (216 in. lb.)
Oil Filter Pad Pipe Plug

1/8 N.P.T.F.
Oil Pump
Mounting Screw
3
5
SV590/SV591/
SV600/SV601/
SV610/SV620
4.5-5.0 Nm (40-46 in. lb.)

5.0-7.5 Nm (44.4-66.0 in. lb.) into new hole
3.8-4.6 Nm (33.3-40.3 in. lb.) into used hole

20 690 01 Rev. I
KohlerEngines.com
Specifications
SV470/
SV471/
SV480
SV530/
SV540/
SV541
Oil Sentry
Pressure Switch
4.5-5.0 Nm (40-45 in. lb.)
Speed Control
Bracket Assembly Fastener

Stator
Mounting Screw

Valve Cover
Fastener

CLEARANCE SPECIFICATIONS3
SV470/
SV471/
SV480
Balance Weight
Bearing Surface I.D.
New
Max. Wear Limit
Pin O.D.
New
Max. Wear Limit
Guide Shoe Width
New
Max. Wear Limit
Guide Shoe Hole I.D.-First Generation Balance
Weight
New
Max. Wear Limit
Linkage Pin O.D. (Crankcase)-Second Generation
Balance Weight
New
Max. Wear Limit
Balance Weight Linkage-Second Generation
Balance Weight
New
Max. Wear Limit
SV530/
SV540/
SV541
3
5
SV590/SV591/
SV600/SV601/
SV610/SV620
67.011/67.086 mm (2.6382/2.6412 in.)

67.140 mm (2.6430 in.)
11.950/11.975 mm (0.4705/0.4715 in.)
11.900 mm (0.4685 in.)
17.85/17.90 mm (0.703/0.705 in.)
17.75 mm (0.6988 in.)
12.000/12.025 mm (0.4724/0.4734 in.)
12.050 mm (0.4744 in.)
11.964/11.975 mm (0.4710/0.4715 in.)
11.900 mm (0.4685 in.)
11.985/12.010 mm (0.4719/0.4728 in.)
12.035 mm (0.4738 in.)
Cam Gears
End Play
Running Side Clearance
Cam Gear-to-Cam Shaft Running Assembly
Closure Plate
Balance Weight Guide Channel Width
New
Max. Wear Limit
SV590/SV591/
SV600/SV601/
SV610/SV620
0.5/1.5 mm (0.019/0.059 in.)

0.02/0.13 mm (0.001/0.005 in.)
0.02/0.10 mm (0.001/0.004 in.)
17.95/18.05 mm (0.707/0.711 in.)

18.13 mm (0.714 in.)

KohlerEngines.com
20 690 01 Rev. I
Specifications
SV470/
SV471/
SV480
SV530/
SV540/
SV541
SV590/SV591/
SV600/SV601/
SV610/SV620
Connecting Rod
Connecting Rod-to-Crankpin Running Clearance
New
Max. Wear Limit
Connecting Rod-to-Crankpin Side Clearance
Connecting Rod-to-Piston Pin Running Clearance
0.03/0.055 mm (0.0012/0.0022 in.)

0.07 mm (0.0025 in.)
0.25/0.59 mm (0.0098/0.0232 in.)
0.015/0.028 mm (0.0006/0.0011 in.)
Crankcase
Governor Cross Shaft Bore I.D.
New
Max. Wear Limit
6.025/6.05 mm (0.2372/0.2382 in.)

6.063 mm (0.2387 in.)
Crankshaft
End Play (free)
Bore in Crankcase I.D.
New
Max. Wear Limit
Bore in Closure Plate I.D.
New
Max. Wear Limit
Flywheel End Main Bearing Journal O.D.
New, Before Serial No. 3703200003
New, After Serial No. 3703200013
O.D., Max. Wear Limit
Max. Taper
Max. Out of Round
PTO End Main Bearing Journal O.D.
O.D., Max. Wear Limit
Max. Taper
Max. Out of Round
Bore in Closure Plate Running Clearance
Bore in Crankcase Running Clearance
Connecting Rod Journal O.D.
New
Max. Wear Limit
Max. Taper
Max. Out of Round
T.I.R.
PTO End, Crankshaft in Engine
Entire Crankshaft , in V-Blocks
Eccentrics O.D.
New
Max. Wear Limit
0.225/1.025 mm (0.0089/0.040 in.)

41.965/41.990 mm (1.6521/1.6531 in.)
42.016 mm (1.654 in.)
44.965/44.990 mm (1.7703/1.7713 in.)
45.016 mm (1.7723 in.)
44.913/44.935 mm (1.7682/1.7691 in.)
44.870/44.895 mm (1.7665/1.7675 in.)
44.84 mm (1.765 in.)
0.0220 mm (0.0009 in.)
0.025 mm (0.001 in.)
41.913/41.935 mm (1.6501/1.6510 in.)
41.855/41.880 mm (1.6478/1.6488 in.)
41.83 mm (1.647 in.)
0.020 mm (0.0008 in.)
0.025 mm (0.001 in.)
0.030/0.077 mm (0.0012/0.0030 in.)
0.070/0.120 mm (0.0027/0.0047 in.)
0.030/0.077 mm (0.0012/0.0030 in.)
0.085/0.135 mm (0.0033/0.0053 in.)
40.982/41.000 mm (1.6134/1.6141 in.)
40.964 mm (1.612 in.)
0.012 mm (0.0005 in.)
0.025 mm (0.001 in.)
0.15 mm (0.0059 in.)
0.10 mm (0.0039 in.)
66.940/66.970 mm (2.6354/2.6366 in.)
66.89 mm (2.633 in.)
20 690 01 Rev. I
KohlerEngines.com
Specifications
Cylinder Bore
Cylinder Bore I.D.
New
Max. Wear Limit
SV470/
SV471/
SV480
SV530/
SV540/
SV541
---
---
Spec. 00XX: 84.010/84.035 mm

(3.307/3.308 in.)
Spec. 01XX: 89.010/89.035 mm
(3.504/3.505 in.)
Spec. 02XX or higher: 94.010/94.035 mm
(3.701/3.702 in.)
--Spec. 00XX:
Spec. 01XX:
Spec. 02XX or higher:
84.073 mm
(3.310 in.)
89.073 mm
(3.507 in.)
94.073 mm
(3.704 in.)
Max. Taper
Max. Out of Round
89.010/89.035 mm
(3.504/3.505 in.)
--94.010/94.035 mm
(3.701/3.702 in.)
--89.073 mm
(3.507 in.)
---
94.010/94.035 mm
(3.701/3.702 in.)
------94.073 mm
(3.704 in.)
-----
94.073 mm
(3.704 in.)
0.05 mm (0.002 in.)
0.12 mm (0.0047 in.)
Cylinder Head
Max. Out-of-Flatness
---
0.8 mm (0.003 in.)
Governor
Governor Cross Shaft -to-Crankcase Running
Clearance
Cross Shaft O.D.
New
Max. Wear Limit
Governor Gear Shaft -to-Governor Gear Running
Clearance
Gear Shaft O.D.
New
Max. Wear Limit
Ignition
Spark Plug Gap
Module Air Gap
0.013/0.075 mm (0.0005/0.003 in.)

5.975/6.012 mm (0.2352/0.2367 in.)
5.962 mm (0.2347 in.)
0.09/0.16 mm (0.0035/0.0063 in.)
5.99/6.00 mm (0.2358/0.2362 in.)
5.977 mm (0.02353 in.)
0.76 mm (0.030 in.)
0.203/0.305 mm (0.008/0.012 in.)
Oil Pump
Pump Gears-to-Crankcase Side Clearance
0.165/0.315 mm (0.0065/0.0124 in.)
Piston, Piston Rings, and Piston Pin

Pin Bore I.D.
New
Max. Wear Limit
Pin O.D.
New
Max. Wear Limit
Top Compression Ring-to-Groove Side Clearance
Middle Compression Ring-to-Groove Side
Clearance
SV590/SV591/
SV600/SV601/
SV610/SV620
22.006/22.012 mm (0.8685/0.8666 in.)

22.025 mm (0.8671 in.)
21.995/22.0 mm (0.8659/0.8661 in.)
21.994 mm (0.8658 in.)
0.04 mm (0.0016 in.)
0.04 mm (0.0016 in.)
10
KohlerEngines.com
20 690 01 Rev. I
Specifications
SV470/
SV471/
SV480
SV530/
SV540/
SV541
SV590/SV591/
SV600/SV601/
SV610/SV620
Piston, Piston Rings, and Piston Pin (Continued)

Top and Middle Compression Ring End Gap New
Bore
Top Ring
0.15/0.40 mm (0.006/0.016 in.)
Middle Ring
0.30/0.55 mm (0.012/0.022 in.)
Used Bore (max.)
0.77 mm (0.030 in.)
7
----93.928/93.942 mm
Thrust Face O.D.
New
(3.6980/3.6985 in.)
Spec. 00XX: 83.948/83.962 mm 88.948/88.962 mm
--(3.3050/3.3056 in.) (3.5018/3.5024 in.)
Spec. 01XX: 88.948/88.962 mm
----(3.5018/3.5024 in.)
Spec. 02XX or higher: 93.928/93.942 mm 93.928/93.942 mm
--(3.6980/3.6985 in.) (3.6980/3.6985 in.)
Max. Wear Limit
----93.828 mm
(3.6940 in.)
Spec. 00XX:
83.828 mm
88.828 mm
--(3.3003 in.)
(3.4972 in.)
Spec. 01XX:
88.828 mm
----(3.4972 in.)
93.828 mm
--Spec. 02XX or higher:
93.828 mm
(3.6940 in.)
(3.6940 in.)
Piston Thrust Face-to-Cylinder Bore7 Running
0.045 mm (0.0018 in.)
0.0880 mm
Clearance
(0.0035 in.)
Valves and Valve Lifters
Intake Valve Lash8
Exhaust Valve Lash8
Intake Valve Minimum Lift
Exhaust Valve Minimum Lift
Nominal Valve Seat Angle
Intake Valve Stem-to-Valve Guide Running
Clearance
Exhaust Valve Stem-to-Valve Guide Running
Clearance
Intake Valve Guide I.D.
New
Max. Wear Limit
Intake Valve Stem Diameter
New
Exhaust Valve Guide I.D.
New
Max. Wear Limit
Exhaust Valve Stem Diameter
New
0.127 mm (0.005 in.)

0.178 mm (0.007 in.)
8.9 mm (0.350 in.)
8.9 mm (0.350 in.)
45
0.038/0.076 mm (0.0015/0.003 in.)
0.050/0.088 mm (0.0020/0.0035 in.)
6.038/6.058 mm (0.2377/0.2385 in.)
6.135 mm (0.2415 in.)
5.982/6.0 mm (0.2355/0.2362 in.)
6.038/6.058 mm (0.2377/0.2385 in.)
6.160 mm (0.2425 in.)
5.970/5.988 mm (0.235/0.2357 in.)

Measure 8 mm (0.314 in.) above bottom of piston skirt at right angles to piston pin.
8
Check valve lash every 200 hours, adjust as required.
3
7
20 690 01 Rev. I
KohlerEngines.com
11
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
Tightening Torque: Nm (in. lb.) 20%
8-32
2.3 (20)
10-24
3.6 (32)
10-32
3.6 (32)
1/4-20
7.9 (70)
1/4-28
9.6 (85)
5/16-18
17.0 (150)
5/16-24
18.7 (165)
3/8-16
29.4 (260)
3/8-24
33.9 (300)
Grade 5
Grade 8
2.8 (25)
4.5 (40)
4.5 (40)
13.0 (115)
15.8 (140)
28.3 (250)
30.5 (270)
18.7 (165)
22.6 (200)
39.6 (350)
2.3 (20)
3.6 (32)
7.9 (70)
17.0 (150)
Tightening Torque: Nm (ft. lb.) 20%

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

Property Class
Size
4.8
5.8
Noncritical
Fasteners
Into Aluminum
8.8
10.9
12.9
Tightening Torque: Nm (in. lb.) 10%

M4
1.2 (11)
1.7 (15)
M5
2.5 (22)
3.2 (28)
M6
4.3 (38)
5.7 (50)
M8
10.5 (93)
13.6 (120)
2.9 (26)
5.8 (51)
9.9 (88)
24.4 (216)
4.1 (36)
8.1 (72)
14.0 (124)
33.9 (300)
5.0 (44)
9.7 (86)
16.5 (146)
40.7 (360)
2.0 (18)
4.0 (35)
6.8 (60)
17.0 (150)
Tightening Torque: Nm (ft. lb.) 10%

M10
21.7 (16)
27.1 (20)
M12
36.6 (27)
47.5 (35)
M14
58.3 (43)
76.4 (56)
47.5 (35)
82.7 (61)
131.5 (97)
66.4 (49)
116.6 (86)
184.4 (136)
81.4 (60)
139.7 (103)
219.7 (162)
33.9 (25)
61.0 (45)
94.9 (70)
Torque Conversions
Nm = in. lb. x 0.113
in. lb. = Nm x 8.85
Nm = ft. lb. x 1.356
ft. lb. = Nm x 0.737
12
KohlerEngines.com
20 690 01 Rev. I
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, youll increase your service
capabilities and customer satisfaction by decreasing engine downtime.
Here is a list of tools and their source.
SEPARATE TOOL SUPPLIERS
Kohler Tools
Contact your local Kohler source of
supply.
SE Tools
415 Howard St.
Lapeer, MI 48446
Phone 810-664-2981
Toll Free 800-664-2981
Fax 810-664-8181
Design Technology Inc.

768 Burr Oak Drive
Westmont, IL 60559
Phone 630-920-1300
Fax 630-920-0011
TOOLS
Description
Alcohol Content Tester
For testing alcohol content (%) in reformulated/oxygenated fuels.
Camshaft Endplay Plate
For checking camshaft endplay.
Camshaft Seal Protector (Aegis)
For protecting seal during camshaft installation.
Cylinder Leakdown Tester
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available:
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)
Dealer Tool Kit (Domestic)
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester
Oil Pressure Test Kit
Rectifier-Regulator Tester (120 V AC/60Hz)
Dealer Tool Kit (International)
Complete kit of Kohler required tools.
Rectifier-Regulator Tester (240 V AC/50Hz)
Digital Vacuum/Pressure Tester
For checking crankcase vacuum.
Rubber Adapter Plug
Electronic Fuel Injection (EFI) Diagnostic Software
For Laptop or Desktop PC.
EFI Service Kit
For troubleshooting and setting up an EFI engine.
Fuel Pressure Tester
Noid Light
90 Adapter
In-line "T" Fitting
Code Plug, Red Wire
Code Plug, Blue Wire
Shrader Valve Adapter Hose
Flywheel Holding Tool (CS)
For holding flywheel of CS series engines.
Flywheel Puller
For properly removing flywheel from engine.
Flywheel Strap Wrench
For holding flywheel during removal.
20 690 01 Rev. I
KohlerEngines.com
Source/Part No.
Kohler 25 455 11-S
SE Tools KLR-82405
SE Tools KLR-82417
Kohler 25 761 05-S
DTI-731-03
Kohler 25 761 39-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 20-S
Kohler 25 761 42-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 41-S
DTI-721-01
DTI-721-10
Kohler 25 761 23-S
Kohler 24 761 01-S
DTI-019
DTI-021
DTI-023
DTI-035
DTI-027
DTI-029
DTI-037
SE Tools KLR-82407
SE Tools KLR-82408
SE Tools KLR-82409
13
Tools and Aids

TOOLS
Description
Hydraulic Valve Lifter Tool
For removing and installing hydraulic lifters.
For testing output on all systems, including CD.
Inductive Tachometer (Digital)
For checking operating speed (RPM) of an engine.
Offset Wrench (K and M Series)
For removing and reinstalling cylinder barrel retaining nuts.
For testing/verifying oil pressure on pressure lubricated engines.
Radiator Tester
For pressure testing radiator and cap on Aegis liquid-cooled engines.
Rectifier-Regulator Tester (120 volt current)
Rectifier-Regulator Tester (240 volt current)
For testing rectifier-regulators.
Components of 25 761 20-S and 25 761 41-S
CS-PRO Regulator Test Harness
Special Regulator Test Harness with Diode
Spark Advance Module (SAM) Tester
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK.
Starter Servicing Kit (All Starters)
For removing and reinstalling drive retaining rings and brushes.
Starter Brush Holding Tool (Solenoid Shift)
Triad/OHC Timing Tool Set
For holding cam gears and crankshaft in timed position while installing timing belt.
Valve Guide Reamer (K and M Series)
For properly sizing valve guides after installation.
Valve Guide Reamer O.S. (Command Series)
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
For hand reaming using Kohler 25 455 12-S reamer.
Valve Guide Service Kit (Courage, Aegis, Command, OHC)
For servicing worn valve guides.
AIDS
Description
Camshaft Lubricant (Valspar ZZ613)
Dielectric Grease (GE/Novaguard G661)
Dielectric Grease
Kohler Electric Starter Drive Lubricant (Inertia Drive)
Kohler Electric Starter Drive Lubricant (Solenoid Shift)
RTV Silicone Sealant
Loctite 5900 Heavy Body in 4 oz. aerosol dispenser.
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved
for use. Loctite Nos. 5900 or 5910 are recommended for best sealing
characteristics.
Spline Drive Lubricant
14
KohlerEngines.com
Source/Part No.
Kohler 25 761 38-S
Kohler 25 455 01-S
DTI-110
Kohler 52 455 04-S
Kohler 25 761 06-S
Kohler 25 455 10-S
Kohler 25 761 20-S
Kohler 25 761 41-S
DTI-031
DTI-033
Kohler 25 761 40-S
SE Tools KLR-82411
SE Tools KLR-82416
Kohler 28 761 01-S
DTI-K828
Kohler 25 455 12-S
DTI-K830
SE Tools KLR-82415
Source/Part No.
Kohler 25 357 14-S
Kohler 25 357 11-S
Loctite 51360
Kohler 52 357 01-S
Kohler 52 357 02-S
Kohler 25 597 07-S
Loctite 5910
Loctite Ultra Black 598
Loctite Ultra Blue 587
Loctite Ultra Copper 5920
Kohler 25 357 12-S
20 690 01 Rev. I
Tools and Aids

FLYWHEEL HOLDING TOOL
ROCKER ARM/CRANKSHAFT TOOL
A flywheel holding tool can be made out of an old junk

flywheel ring gear and used in place of a strap wrench.
1. Using an abrasive cut-off wheel, cut out a six tooth
segment of ring gear as shown.
2. Grind off any burrs or sharp edges.
3. Invert segment and place it between ignition bosses
on crankcase so tool teeth engage flywheel ring
gear teeth. Bosses will lock tool and flywheel in
position for loosening, tightening, or removing with a
puller.
A spanner wrench to lift rocker arms or turn crankshaft

may be made out of an old junk connecting rod.
1. Find a used connecting rod from a 10 HP or larger
engine. Remove and discard rod cap.
2. Remove studs of a Posi-Lock rod or grind off
aligning steps of a Command rod, so joint surface is
flat.
3. Find a 1 in. long capscrew with correct thread size to
match threads in connecting rod.
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.
20 690 01 Rev. I
KohlerEngines.com
15
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
Battery connected backwards.
Blown fuse.
Carburetor solenoid malfunction.
Choke not closing.
Clogged fuel line or fuel filter.
Diode in wiring harness failed in open circuit mode.
DSAI or DSAM malfunction.
Empty fuel tank.
Faulty electronic control unit.
Faulty ignition coil(s).
Faulty spark plug(s).
Fuel pump malfunction-vacuum hose clogged or
leaking.
Fuel shut-off valve closed.
Ignition module(s) faulty or improperly gapped.
Insufficient voltage to electronic control unit.
Interlock switch is engaged or faulty.
Key switch or kill switch in OFF position.
Low oil level.
Quality of fuel (dirt, water, stale, mixture).
SMART-SPARKTM malfunction.
Spark plug lead(s) disconnected.
Engine Will Not Crank

Battery is discharged.
Faulty electric starter or solenoid.
Faulty key switch or ignition switch.
Loose wires or connections that intermittently ground
ignition kill circuit.
Pawls not engaging in drive cup.
Seized internal engine components.
Engine Starts But Does Not Keep Running

Faulty carburetor.
Faulty cylinder head gasket.
Faulty or misadjusted choke or throttle controls.
leaking.
Intake system leak.
Restricted fuel tank cap vent.
Engine Will Not Idle

Engine overheated.
Idle fuel adjusting needle(s) improperly set.
Idle speed adjusting screw improperly set.
Inadequate fuel supply.
Low compression.
Restricted fuel tank cap vent.
Engine Starts Hard

Clogged fuel line or fuel filter.
Engine overheated.
Faulty ACR mechanism.
Faulty or misadjusted choke or throttle controls.
Flywheel key sheared.
leaking.
Low compression.
Weak spark.
16
Engine Runs But Misses

Carburetor adjusted incorrectly.
Engine overheated.
Ignition module(s) faulty or improperly gapped.
Incorrect crankshaft position sensor air gap.
Spark plug lead(s) disconnected.
Spark plug lead boot loose on plug.
Spark plug lead loose.
Engine Overheats
Cooling fan broken.
Excessive engine load.
Fan belt failed/off.
Faulty carburetor.
High crankcase oil level.
Lean fuel mixture.
Low cooling system fluid level.
Low crankcase oil level.
Radiator, and/or cooling system components clogged,
restricted, or leaking.
Water pump belt failed/broken.
Water pump malfunction.
Engine Knocks
Hydraulic lifter malfunction.
Incorrect oil viscosity/type.
Internal wear or damage.
KohlerEngines.com
20 690 01 Rev. I
Troubleshooting
Engine Loses Power
Dirty air cleaner element.
Engine overheated.
Restricted exhaust.
High crankcase oil level.
Incorrect governor setting.
Low battery.
Low compression.
Engine Uses Excessive Amount of Oil
Loose or improperly torqued fasteners.
Blown head gasket/overheated.
Breather reed broken.
Clogged, broken, or inoperative crankcase breather.
Crankcase overfilled.
Incorrect oil viscosity/type.
Worn cylinder bore.
Worn or broken piston rings.
Worn valve stems/valve guides.
Oil Leaks from Oil Seals, Gaskets
Breather reed broken.
Clogged, broken, or inoperative crankcase breather.
Loose or improperly torqued fasteners.
Piston blow by, or leaky valves.
Restricted exhaust.
EXTERNAL ENGINE INSPECTION

NOTE: It is good practice to drain oil at a location away
from workbench. Be sure to allow ample time for
complete drainage.
Before cleaning or disassembling engine, make a
thorough inspection of its external appearance and
condition. This inspection can give clues to what
might be found inside engines (and cause) when it is
disassembled.
Check for buildup of dirt and debris on crankcase,
cooling fins, grass screen, and other external surfaces.
Dirt or debris on these areas can cause overheating.
Check for obvious fuel and oil leaks, and damaged
components. Excessive oil leakage can indicate a
clogged or inoperative breather, worn or damaged
seals or gaskets, or loose fasteners.
Check air cleaner cover and base for damage or
indications of improper fit and seal.
Check air cleaner element. Look for holes, tears,
cracked or damaged sealing surfaces, or other
damage that could allow unfiltered air into engine. A
dirty or clogged element could indicate insufficient or
improper maintenance.
Check carburetor throat for dirt. Dirt in throat is further
indication that air cleaner was not functioning properly.
Check if oil level is within operating range on dipstick.
If it is above, sniff for gasoline odor.
Check condition of oil. Drain oil into a container; it
should flow freely. Check for metal chips and other
foreign particles.
Sludge is a natural by-product of combustion; a small
accumulation is normal. Excessive sludge formation
could indicate over rich fuel settings, weak ignition,
overextended oil change interval or wrong weight or
type of oil was used.
CLEANING ENGINE
WARNING
Cleaning Solvents can cause severe injury or
death.
Use only in well ventilated areas away from
ignition sources.
Carburetor cleaners and solvents are extremely
flammable. Follow cleaner manufacturers 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
manufacturers 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.
20 690 01 Rev. I
KohlerEngines.com
17
Troubleshooting
CRANKCASE VACUUM TEST
WARNING
WARNING
Carbon Monoxide can cause severe nausea,

fainting or death.
Avoid inhaling exhaust fumes.
Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide is odorless, colorless,
and can cause death if inhaled.
Rotating Parts can cause severe injury.

Stay away while engine is in operation.
Keep hands, feet, hair, and clothing away from all
moving parts to prevent injury. Never operate engine
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:
1. Insert rubber stopper into oil fill hole. Be sure pinch
clamp is installed on hose and use tapered adapters
to connect hose between stopper and one
manometer tube. Leave other tube open to
atmosphere. Check that water level in manometer is
at 0 line. Make sure pinch clamp is closed.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube.
Level in engine side should be a minimum of 10.2
cm (4 in.) above level in open side.
If level in engine side is less than specified (low/no
vacuum), or level in engine side is lower than level in
open side (pressure), check for conditions in table
below.
4. Close pinch clamp before stopping engine.
To test crankcase vacuum with vacuum/pressure gauge:

1. Remove dipstick or oil fill plug/cap.
2. Install adapter into oil fill//dipstick tube opening,
upside down over end of a small diameter dipstick
tube, or directly into engine if a tube is not used.
Insert barbed gauge fitting into hole in stopper.
3. Run engine and observe gauge reading.
Analog testerneedle movement to left of 0 is a
vacuum, and movement to right indicates a pressure.
Digital testerdepress test button on top of tester.
Crankcase vacuum should be a minimum of 10.2 cm
(4 in.) of water. If reading is below specification, or if
pressure is present, check table below for possible
causes and conclusions.
Condition
Crankcase breather clogged or inoperative.
Conclusion
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.
18
KohlerEngines.com
20 690 01 Rev. I
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
Air escaping from crankcase breather.
Air escaping from exhaust system.
Air escaping from intake.
Gauge reading in low (green) zone.
Gauge reading in moderate (yellow) zone.
Gauge reading in high (red) zone.
20 690 01 Rev. I
Conclusion
Ring or cylinder worn.
Defective exhaust valve/improper seating.
Defective intake valve/improper seating.
Piston rings and cylinder in good condition.
Engine is still usable, but there is some wear present.
Customer should start planning for overhaul or
replacement.
Rings and/or cylinder have considerable wear. Engine
should be reconditioned or replaced.
KohlerEngines.com
19
Air Cleaner/Intake
AIR CLEANER
These systems are CARB/EPA certified and components
should not be altered or modified in any way.
Air Cleaner Components
A
Paper Element
1. Remove element from base; replace element.
2. Install element with pleated side out and seat rubber
seal onto edges of base.
Reinstall air cleaner cover and secure with knobs.
BREATHER TUBE
Ensure both ends of breather tube are properly
connected.
AIR COOLING
WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating or just
after stopping.
Never operate engine with heat shields or guards
removed.
Proper cooling is essential. To prevent over heating,
clean screens, cooling fins, and other external surfaces
of engine. Avoid spraying water at wiring harness or any
electrical components. Refer to Maintenance Schedule
C
D
B
E
D
A
C
E
Air Cleaner Base

Precleaner
Air Cleaner Knob
B
D
Paper Element
Air Cleaner Cover
NOTE: Operating engine with loose or damaged air

cleaner components could cause premature wear and
failure. Replace all bent or damaged components.
NOTE: Paper element cannot be blown out with
compressed air.
Loosen knobs and remove air cleaner cover.
Precleaner (if equipped)
1. Remove precleaner.
2. Replace or wash precleaner in warm water with
detergent. Rinse and allow to air dry.
3. Saturate precleaner with new engine oil; squeeze
out excess oil.
4. Reinstall precleaner into cover, aligning hole in
precleaner with upper cover knob.
20
KohlerEngines.com
20 690 01 Rev. I
Fuel System
Typical carbureted fuel system and related components
include:
Fuel tank.
Fuel lines.
In-line fuel filter.
Fuel pump.
Carburetor.
Fuel from tank is moved through in-line filter and fuel
lines by fuel pump. Fuel then enters carburetor float bowl
and is drawn into carburetor body and mixed with air.
This fuel-air mixture is then burned in engine combustion
chamber.
FUEL RECOMMENDATIONS
Refer to Maintenance.
FUEL LINE
Low permeation fuel line must be installed on carbureted
Kohler Co. engines to maintain EPA and CARB
regulatory compliance.
FUEL PUMP
Some engines are equipped with one of two optional
pulse fuel pumps. One is mounted to speed control
bracket, and other is mounted to air cleaner base.
Fuel pump has two internal chambers separated by
a diaphragm. Air chamber is connected to engine
crankcase by a rubber hose. Fuel chamber has an inlet
from fuel tank, and an outlet to carburetor. Inlet and
outlet each have an internal, one-way check valve.
Alternating negative and positive pressures in crankcase
activate pump. When piston moves upward in cylinder,
negative pressure (vacuum) is created in crankcase
and in air chamber of pump. Diaphragm flexes toward
negative pressure, and suction draws fuel past inlet
check valve, into fuel chamber. Downward movement
of piston causes a positive pressure in crankcase and
air chamber, pushing diaphragm in opposite direction,
putting pressure on fuel. Inlet check valve has now
closed, so fuel is forced past outlet check valve, to
carburetor.
20 690 01 Rev. I
Repair
Pulse fuel pumps are not serviceable and must be
replaced when faulty.
Removal
Speed Control Bracket Mounted Fuel Pump
1. Disconnect inlet, outlet, and pulse lines from fuel
pump. Mark lines for proper reassembly.
2. Remove screws attaching fuel pump.
Air Cleaner Base Mounted Fuel Pump
1. Remove dipstick and blower housing.
pump. Mark lines for proper reassembly.
3. Remove fuel pump from bracket.
Installation
Speed Control Bracket Mounted Fuel Pump
1. Install new fuel pump, and secure with hex flange
screws. Torque screws to 5.9 Nm (52 in. lb.). Do not
over tighten.
2. Connect inlet, outlet, and pulse lines to their
respective fittings on pump. Secure with clamps.
Air Cleaner Base Mounted Fuel Pump
1. Install new fuel pump, pressing fuel pump onto
bracket past locking tabs.
2. Connect inlet, outlet, and pulse lines to their
respective fittings on pump. Secure with clamps.
KohlerEngines.com
21
Fuel System
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.
a. Disconnect and ground spark plug lead.
b. Close choke on carburetor.
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
Fuel at tip of spark plug.
No fuel at tip of spark plug.
Fuel flows from fuel line.
No fuel flow from fuel line.

Fuel line condition.
22
3. Check operation of fuel pump.

a. Remove fuel line from inlet fitting of carburetor.
b. Crank engine several times and observe flow.
Conclusion
Fuel is reaching combustion chamber.
Check fuel flow from fuel tank (step 2).
Check for faulty fuel pump (step 3).
If fuel pump is working, check for faulty carburetor. Refer
to Carburetor.
Check fuel tank cap vent, fuel pickup screen, in-line
filter, shut-off valve, and fuel line. Correct any observed
problem and reconnect line.
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.
KohlerEngines.com
20 690 01 Rev. I
Fuel System
CARBURETOR
WARNING
burns.
running.
Nikki One-Barrel Carburetor Components

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.
Walbro One-Barrel Carburetor Components
A
A
B
K
C
D
J
D
E
H
H
F
F
G
Choke Return Spring
Choke Lever and

Shaft
Choke Plate
Float Pin
Fuel Inlet Needle

Bowl Retaining Screw
Gasket
Fuel Bowl
Fuel Bowl
Bowl Gasket
Fuel Shut-Off
Solenoid
Float
Low Idle Speed
Adjusting Spring and
Screw
Bowl Gasket
Choke Return Spring
Choke Lever and

Shaft
Choke Plate
Float Pin
Fuel Inlet Needle

Gasket
Fuel Shut-Off
Solenoid
Float
Low Idle Speed
Adjusting Spring and
Screw
H
J
I
K
20 690 01 Rev. I
KohlerEngines.com
23
Fuel System
These engines are equipped with either a Walbro or
Nikki fixed main jet carburetor. Carburetors will have a
low idle speed adjustment screw, and either fixed idle, or
a limiter cap on idle fuel adjustment needle.
Troubleshooting Checklist
When engine starts hard, runs rough, or stalls at low
idle speed, check these areas before adjusting or
disassembling carburetor.
1. Make sure fuel tank is filled with clean, fresh
gasoline.
2. Make sure fuel tank cap vent is not blocked and is
operating properly.
3. Make sure fuel is reaching carburetor. This includes

checking fuel shut-off valve, fuel tank filter screen,
in-line fuel filter, fuel lines and fuel pump for
restrictions or faulty components as necessary.
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.
Troubleshooting-Carburetor Related Causes

Condition
Engine starts hard, runs rough, or
stalls at idle speed.
Engine runs rich (indicated by black,
sooty exhaust smoke, misfiring, loss
of speed and power, governor
hunting, or excessive throttle
opening).
Possible Cause
Low idle fuel mixture/speed
improperly adjusted.
Improper choke adjustment.
Choke partially closed during
operation.
Low idle fuel mixture is improperly
adjusted.
Dirt under fuel inlet needle.
Bowl vent or air bleeds plugged.
Fuel bowl gasket leaks.

Engine runs lean (indicated by
misfiring, loss of speed and power,
governor hunting, or excessive
throttle opening).
Fuel leaks from carburetor.
24
Conclusion
Adjust low idle speed screw, then
adjust low idle fuel needle.
Correct choke adjustment.
Check choke lever/linkage to ensure
choke is operating properly.
Adjust low idle fuel needle.
Remove needle; clean needle and
seat and blow with compressed air.
Remove fuel bowl, low idle fuel
adjusting needle, and welch plugs.
Clean vent, ports, and air bleeds.
Blow out all passages with
compressed air.
Remove fuel bowl and replace
gasket.
Submerge float to check for leaks.
Adjust low idle fuel needle.
Leaky, cracked, or damaged float.

Low idle fuel mixture is improperly
adjusted.
Idle holes plugged; dirt in fuel delivery Remove fuel bowl, low idle fuel
channels.
Clean main fuel jet and all passages;
blow out with compressed air.
Dirt under fuel inlet needle.
Remove fuel bowl, low idle fuel
Clean vent, ports, and air bleeds.
Blow out all passages with
compressed air.
Float is cracked or damaged.
Replace float.
Bowl retaining screw gasket
Replace gasket.
damaged.
Bowl retaining screw loose.
Torque screw to specifications.
Walbro 5.1-6.2 Nm (45-55 in. lb.) or
Nikki 10.8-12.8 Nm (96-113 in. lb.).
KohlerEngines.com
20 690 01 Rev. I
Fuel System
FUEL SYSTEM
Fuel Shut-off Solenoid
Most carburetors are equipped with a fuel shut-off
solenoid. Solenoid is attached to fuel bowl. Solenoid has
a spring-loaded pin that retracts when 12 volts is applied
to lead, allowing fuel flow to main jet. When current is
removed, pin extends blocking fuel flow.
Below is a simple test, performed with engine off, that
can determine if solenoid is functioning properly:
1. Shut off fuel and remove solenoid from carburetor.
When solenoid is loosened and removed, gas will
leak out of carburetor. Have a container ready to
catch fuel.
2. Wipe tip of solenoid with a shop towel or blow with
compressed air to remove any remaining fuel. Take
solenoid to a location with good ventilation and no
fuel vapors present. You will also need a 12 volt
power source that can be switched on and off.
3. Be sure power source is switched OFF. Connect
positive power source lead to red lead of solenoid.
Connect negative power source lead to solenoid
body.
4. Turn power source ON and observe pin in center of
solenoid. Pin should retract with power ON and
return to its original position with power OFF. Test
several times to verify operation.
Carburetor Circuits
Float
Fuel level in bowl is maintained by float and fuel inlet
needle. Buoyant force of float stops fuel flow when
engine is at rest. When fuel is being consumed, float will
drop and fuel pressure will push inlet needle away from
seat, allowing more fuel to enter bowl. When demand
ceases, buoyant force of float will again overcome fuel
pressure, rising to predetermined setting and stop flow.
Slow and Mid-Range
At low speeds engine operates only on slow circuit. As
a metered amount of air is drawn through slow air bleed
jets, fuel is drawn through main jet and further metered
through slow jet. Air and fuel are mixed in body of slow
jet and exit to idle progression (transfer port) chamber.
From idle progression chamber, air fuel mixture is
metered through idle port passage. At low idle air/fuel
mixture is controlled by setting of idle fuel adjusting
screws. This mixture is then mixed with main body of
air and delivered to engine. As throttle plate opening
increases, greater amounts of air/fuel mixture are drawn
in through fixed and metered idle progression holes.
As throttle plate opens further, vacuum signal becomes
great enough at venturi so main circuit begins to work.
Main (high-speed)
At high speeds/loads engine operates on main circuit.
As a metered amount of air is drawn through air jet,
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.
20 690 01 Rev. I
Carburetor Adjustments
NOTE: Carburetor adjustments should be made only
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
normally do not need adjustment.
Low Idle Speed (RPM) Adjustment
NOTE: Actual low idle speed depends on application.
Refer to equipment manufacturers
recommendations. Low idle speed for basic
engines is 1200 RPM.
Place throttle control into idle or slow position. Turn low
idle speed adjusting screw in or out to obtain allow idle
speed of 1200 RPM ( 75 RPM).
Governed Idle Speed Adjustment (if equipped)
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 1200 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. Turn governed idle adjustment
screw to obtain equipment manufacturers
recommended idle speed (1500-1800 RPM). Some
engines have a bendable tab that is used to set this
speed. A pliers should be used to bend this tab to
achieve recommended speed. Governed idle speed
(RPM) is typically 300 RPM (approximate) higher
than low idle speed.
3. Move throttle lever to wide-open/full throttle position
and hold in this position. Turn high speed screw to
obtain intended high speed no-load RPM. Governed
idle speed must be set before making this
adjustment.
Low Idle Fuel Adjustment
Optimum Low Idle Fuel Setting
B
Rich
Lean
Midpoint
Left Side
Right Side
NOTE: Engines will have fixed low idle or limiter caps

on idle fuel adjusting needles. Step 2 can only
be performed within limits allowed by cap. Do
not attempt to remove limiter caps.
KohlerEngines.com
25
Fuel System
1. Place throttle control into idle or slow position. Adjust
low idle speed to 1200 RPM. Follow Low Idle Speed
(RPM) Adjustment.
2. Low idle fuel needle(s) setting: place throttle into idle
or slow position.
a. Turn 1 low idle fuel adjusting needle out
(counterclockwise) from preliminary setting until
engine speed decreases (rich). Note position of
needle. Now turn adjusting needle in (clockwise).
Engine speed may increase, then it will decrease
as needle is turned in (lean). Note position of
needle. Set adjusting needle midway between
rich and lean settings.
b. Repeat procedure on other low idle adjustment
needle (two-barrel carburetor only).
3. Recheck/adjust Low Idle Speed (RPM) to specified
setting.
High Speed (RPM) Adjustment
1. With engine running, move throttle control to fast.
2. Turn inner adjustment screw outward to decrease, or
inward to increase RPM speed. Courage singles
require loosening screws on speed control bracket
and sliding towards carburetor to lower and away
from carburetor to increase speed.
Carburetor Servicing
NOTE: Main and slow jets are fixed and size specific
and can be removed if required. Fixed jets for
high altitudes are available.
Inspect carburetor body for cracks, holes, and other
wear or damage.
Inspect float for cracks, holes, and missing or
damaged float tabs. Check float hinge and shaft for
wear or damage.
Inspect fuel inlet needle and seat for wear or damage.
Inspect spring loaded choke plate to make sure it
moves freely on shaft.
1. Perform removal procedures for appropriate air
cleaner and carburetor outlined in Disassembly.
2. Clean exterior surfaces of dirt or foreign material
before disassembling carburetor. Remove bowl
retaining screws, or solenoid assembly on most
single cylinder engines, and carefully separate fuel
bowl from carburetor. Do not damage fuel bowl
O-rings. Transfer any remaining fuel into an
approved container. Save all parts. Fuel can also be
drained prior to bowl removal by loosening/removing
bowl drain screw.
3. Remove float pin (some carburetors may have a
screw which requires removal), and inlet needle.
Seat for inlet needle is not serviceable and should
not be removed.
4. Clean carburetor bowl and inlet seat areas as
required.
26
5. Carefully remove main jets from carburetor. For

two-barrel carburetors, note and mark jets by
location for proper reassembly. Main jets may be
size/side specific. After main jets are removed, on
some carburetors, main nozzles can be removed
through bottom of main towers. Note orientation/
direction of nozzles. End with 2 raised shoulders
should be out/down adjacent to main jets. Save
parts for cleaning and reuse.
6. Position of slow jet varies and is removable only on
some styles of carburetors. See correct illustration
for corresponding style of carburetor showing
location. (On two-barrel carburetors, slow jets may
be sized to specific side. Mark or tag jets for proper
reassembly. Note small O-ring on bottom of each
jet.) Save parts for cleaning and reuse unless a jet
kit is also being installed. Clean slow jets using
compressed air. Do not use wire or carburetor
cleaner.
Carburetor is now disassembled for appropriate cleaning
and installation of parts in overhaul kit. See instructions
provided with repair kits for more detailed information.
High Altitude Operation
Engines may require a high altitude carburetor kit to
ensure correct engine operation at altitudes above
1219 meters (4000 ft.). To obtain high altitude kit
information or to find a Kohler authorized dealer visit
KohlerEngines.com or call 1-800-544-2444 (U.S. and
Canada).
This engine should be operated in its original
configuration below 1219 meters (4000 ft.) as damage
may occur if high altitude carburetor kit is installed and
operated below 1219 meters (4000 ft.).
UNITIZED THROTTLE AND CHOKE CONTROL
Some engines are equipped with a unitized throttle and
choke control. This assembly controls choke and engine
speed with a single lever.
Throttle Cable Adjustment
Throttle/Choke Controls Details
A
A
KohlerEngines.com
Cold Engine
B
B
Warm Engine
20 690 01 Rev. I
Fuel System
Speed Control Bracket Alignment Hole Details
Choke Adjusting Screw Details
D
J
H
Cable Clamp
Early Models
Later Models
Current Models
Alignment Hole
Alignment Hole for

3000 RPM and
Higher
Alignment Hole for

Less Than 3000 RPM
Alignment Hole for

3101-3750 RPM
Alignment Hole for

2901-3100 RPM
Alignment Hole for

2400-2900 RPM
20 690 01 Rev. I
Choke Adjusting Screw
NOTE: Choke is placed ON by moving throttle control

slightly past fast position. If throttle control does
not have a designated choke ON position, be
sure to leave sufficient throttle control travel past
fast position. This will enable choke to be placed
ON.
1. Loosen control cable clamp.
2. Place throttle control lever of equipment into fast or
high speed position. Actuating tab of choke lever
should be just below end of choke adjusting screw.
3. Early Models: Early models use a single alignment
hole to set engine RPM. Align hole in throttle lever
with hole in speed control bracket by inserting a
pencil or 6.35 mm (1/4 in.) drill bit.
Later Models: Later models use a new control
assembly, identified by two opposing alignment
holes (close to throttle lever pivot), instead of one.
Based upon intended high-speed (RPM) setting,
throttle cable adjustment must be made by matching
hole in control lever with correct alignment hole. Use
lower (left side) hole for high-speed settings above
3000 RPM. Use upper (right side) hole for highspeed settings lower than 3000 RPM. Move throttle
lever to align hole in lever with correct hole in control
bracket. Insert a pencil or a 6.35 mm (1/4 in.) drill bit
to hold in position.
Current Models: Current models use a new control
assembly, identified by three alignment holes (close
to throttle lever pivot). Based upon intended highspeed (RPM) setting, throttle cable adjustment must
be made by matching hole in control lever with
correct alignment hole. Use appropriate hole for
corresponding high-speed settings. Move throttle
4. Pull on outer shield of throttle control cable to
remove any slack. Tighten cable clamp securely.
KohlerEngines.com
27
Fuel System
Starting an Engine Equipped with Unitized Throttle
and Choke Control
Starting Throttle Control Details
High Speed (RPM) Adjustment

Speed Control Bracket Details
A
A
Cold Engine or Warm Engine
NOTE: Do not crank engine continuously for more than

10 seconds at a time. If engine does not start,
allow a 60 second cool down period between
starting attempts. 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.
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.
1. For a Cold or Warm Engine Place throttle/choke
control into fast/choke ON position. This will also
place choke into ON position.
2. Make sure equipment is in neutral.
3. Activate starter switch. Release switch as soon as
engine starts.
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).
28
Speed Control Bracket Mounting Screw
Recommended maximum no-load high speed (RPM)

for most engines is 3300 RPM. Actual high speed
(RPM) depends on application. Refer to equipment
manufacturers instructions for specific information.
1. Make sure throttle cable is adjusted properly (see
Throttle Cable Adjustment).
2. Start engine and allow it to warm up. Place throttle
control lever into fast or high speed position. Turn
choke adjusting screw out/counterclockwise, so
there is clearance from choke lever, and that contact
cannot occur during Step 4.
Later Models: Later models utilize a new design
control assembly, identified by two opposing
alignment holes (close to throttle lever pivot), instead
of one. Based upon intended high speed (RPM)
setting, throttle cable adjustment must be made
matching hole in control lever with appropriate
alignment hole. Use lower (left side) hole for highspeed settings 3000 RPM and above. Use upper
(right side) hole for high-speed settings less than
3000 RPM. Move throttle lever to align hole in lever
with appropriate hole in control bracket. Insert a
pencil or a 6.35 mm (1/4 in) drill bit to hold in
position.
KohlerEngines.com
20 690 01 Rev. I
Fuel System
4. Loosen speed control bracket mounting screws.
Slide bracket forward or backward, until desired high
speed (RPM) is reached. Check speed with a
tachometer.
To increase high speed (RPM), move bracket toward
carburetor.
To decrease high speed (RPM), move bracket away
from carburetor.
5. Tighten speed control bracket mounting screws.
Recheck speed with a tachometer and readjust if
necessary.
Torque mounting screws as follows:
Into new hole 11.0 Nm (95 in. lb.).
Into used hole 7.5 Nm (65 in. lb.).
6. Adjust choke (see Choke Adjustment which follows).
Install Separate Control Cables

Speed Control Bracket Alignment Hole
B
Choke Adjustment
This procedure must follow High Speed Adjustment
just described. If not already completed, perform that
operation first.
1. Turn choke adjusting screw out (counterclockwise),
until it no longer contacts choke lever.
2. Then turn it back in (clockwise), until it just makes
contact.
3. While observing choke link, move throttle control
lever to low idle (slow) position, then back to full
throttle (fast). Choke link should not move as throttle
moves through normal range. If it does, back
adjusting screw out until it no longer moves.
4. Move throttle control lever to choke position. Check
if choke has fully closed by placing your finger on
right side of lower end of choke lever/choke link and
applying gentle pressure towards carburetor. If
controls have been properly set, link should not
move.
SEPARATE THROTTLE AND CHOKE CONTROL
Some engines are equipped with separate throttle and
choke controls. This allows you to adjust choke and
throttle controls individually.
E
K
I
20 690 01 Rev. I
Throttle Cable Clamp
Early Models
Later Models
Current Models
Alignment Hole
Alignment Hole for

3000 RPM and
Higher
Alignment Hole for

Less Than 3000 RPM
Alignment Hole for

3101-3750 RPM
Alignment Hole for

2901-3100 RPM
Alignment Hole for

2400-2900 RPM
KohlerEngines.com
Choke Cable Clamp
29
Fuel System
Throttle Control Installation
1. Loosen two cable clamp screws on speed control
bracket assembly.
2. Move application throttle control lever to maximum
full (fast) throttle position, and then move it back
3/16" or 4.75 mm. Insert cable boden wire into
throttle control lever on control plate.
3. Position throttle cable under cable clamp.
Later Models: Later models utilize a new design
control assembly, identified by two opposing
alignment holes (close to throttle lever pivot), instead
of one. Based upon intended high speed (RPM)
setting, throttle cable adjustment must be made
matching hole in control lever with appropriate
alignment hole. Use lower (left side) hole for highspeed settings 3000 RPM and above. Use upper
(right side) hole for high-speed settings less than
3000 RPM. Move throttle lever to align hole in lever
with appropriate hole in control bracket. Insert a
pencil or a 6.35 mm (1/4 in.) drill bit to hold in
position.
5. Pull on outer shield of throttle control cable to
remove any slack. Tighten cable clamp securely.
6. Move application throttle lever to slow position, then
to full throttle. Check engine control to ensure it
stops against stop screw, which means it is properly
set.
Choke Control Installation
1. Connect choke cable boden wire to engine choke
control lever on speed control bracket assembly.
2. Position choke cable under cable clamp.
3. Push/move choke control to off position in
application panel until it bottoms, then pull it back
approximately 1/16 in.
4. Push on choke cable, ahead of clamp on engine
control plate, until choke lever stops. Do not force.
Then tighten cable clamp screw.
5. Move choke control until it stops (on position). Check
that choke link cannot be moved towards carburetor
by applying finger pressure on lower link/lever below
engine control plate. If choke link moves, readjust by
following steps 3 and 4.
6. Push/move choke control in/down until it bottoms.
Choke lever and link should be to right at end of its
travel, with linkage free so engine does not run on
partial choke.
30
Starting an Engine Equipped with Separate Control

Cables
1. Place throttle control midway between slow and fast
positions. Place choke control into on position.
2. Start engine.
3. For a Cold Engine Gradually return choke control
to off position after engine starts and warms up.
Engine/equipment may be operated during warm up
period, but it may be necessary to leave choke
partially on until engine warms up.
4. For a Warm Engine Return choke to off position as
soon as engine starts.
Changing High Speed (RPM) on Engines with
Separate Controls (Increase or Decrease RPM)
Speed Control Bracket Mounting Screw
1. Check that governor spring and installation matches

intended high speed RPM operating range.
2. Start engine, move application throttle lever to full
throttle/fast, and loosen mounting screws of main
speed control bracket to allow repositioning.
3. To increase RPM: Move speed control bracket,
towards carburetor. To decrease RPM: Move speed
control bracket, away from carburetor. Check RPM
with a tachometer and tighten screws when correct
setting has been obtained.
4. To ensure that RPM has been obtained, move
throttle lever to low idle/slow then back to full throttle/
fast position and check RPM with a tachometer.
Setting Low Idle RPM
1. Move application control to slow position.
2. Using a tachometer, check RPM. Then, using a
screwdriver, turn low idle speed screw inward
(clockwise) to increase RPM, and outward
(counterclockwise) to lower RPM.
KohlerEngines.com
20 690 01 Rev. I
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 closure plate and is driven off gear on crankshaft.
Governor Components
J
I
M
F
K
E
H
L
Inside Engine
G
D
C
Governor Cross Shaft
Governor Lever
Speed Control Bracket
Throttle Lever
Choke Linkage
Governor Spring
Flyweight
Regulating Pin
Throttle Linkage
Throttle Linkage
Spring
Fuel Pump
Fuel Pump Bracket
Governor Gear
This governor design works as follows:

Centrifugal force acting on rotating governor gear
assembly causes flyweights to move outward as
speed increases. Governor spring tension moves
them inward as speed decreases.
As flyweights move outward, they cause regulating pin
to move outward.
Regulating pin contacts tab on cross shaft causing
shaft to rotate.
One end of cross shaft protrudes through crankcase.
Rotating action of cross shaft is transmitted to throttle
lever of carburetor through external throttle linkage.
When engine is at rest, and throttle is in fast position,
tension of governor spring holds throttle plate open.
When engine is operating, governor gear assembly is
rotating. Force applied by regulating pin against cross
shaft tends to close throttle plate. Governor spring
tension and force applied by regulating pin balance
each other during operation, to maintain engine
speed.
When load is applied and engine speed and governor
gear speed decreases, governor spring tension moves
governor arm to open throttle plate wider. This allows
more fuel into engine, increasing engine speed. As
speed reaches governed setting, governor spring
tension and force applied by regulating pin will again
offset each other to hold a steady engine speed.
20 690 01 Rev. I
Governor Adjustments
NOTE: Do not tamper with governor setting. Overspeed
is hazardous and could cause personal injury.
Initial Adjustment Procedure
Make this adjustment whenever governor arm is
loosened or removed from cross shaft. Adjust as follows:
1. Make sure throttle linkage is connected to governor
arm and throttle lever on carburetor.
2. Loosen nut holding governor lever to cross shaft.
3. Move governor lever toward carburetor as far as it
will go (wide open throttle) and hold in this position.
4. Grasp cross shaft with a pliers, and turn shaft
counterclockwise as far as it will go. Torque nut to
7.0-8.5 Nm (60-75 in. lb.).
KohlerEngines.com
31
Governor System
Governor Sensitivity Adjustment
Governor sensitivity is adjusted by repositioning
governor spring in holes in governor lever. If speed
surging occurs with a change in load, governor is set too
sensitive. If a big drop in speed occurs when a normal
load is applied, governor should be set for greater
sensitivity.
Desired high speed setting (RPM) will determine
governor spring position in governor lever and throttle
lever, as well as spring used.
32
KohlerEngines.com
20 690 01 Rev. I
Lubrication System
This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft,
connecting rod bearing surfaces, and hydraulic valve lifters.
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. Closure plate must be removed to service
oil pickup, pressure relief valve, and oil pump.
Lubrication Components
C
A
Oil Fill/Dipstick
Oil Filter
OIL RECOMMENDATIONS
Refer to Maintenance.
CHECK OIL LEVEL
NOTE: To prevent extensive engine wear or damage,
never run engine with oil level below or above
operating range indicator on dipstick.
Ensure engine is cool. Clean oil fill/dipstick areas of any
debris.
1. Remove dipstick; wipe oil off.
2. Reinsert dipstick into tube; press completely down.
3. Remove dipstick; check oil level. Level should be at
top of indicator on dipstick.
4. If oil is low on indicator, add oil up to top of indicator
mark.
5. Reinstall and secure dipstick.
20 690 01 Rev. I
D
C
Oil Drain Plug
Oil Sentry
CHANGE OIL AND FILTER

Change oil while engine is warm.
1. Clean area around oil fill cap/dipstick. Remove drain
plug and oil fill cap/dipstick. Allow oil to drain
completely.
2. Clean area around oil filter. Place a container under
filter to catch any oil and remove filter. Wipe off
mounting surface. Reinstall drain plug. Torque to
14.0 Nm (125 in. lb.).
3. Place new filter in shallow pan with open end up. Fill
with new oil until oil reaches bottom of threads. Allow
2 minutes for oil to be absorbed by filter material.
4. Apply a thin film of clean oil to rubber gasket on new
filter.
5. Refer to instructions on oil filter for proper
installation.
6. Fill crankcase with new oil. Level should be at top of
indicator on dipstick.
7. Reinstall oil fill cap/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.
KohlerEngines.com
33
Lubrication System
OIL SENTRY (if equipped)
This switch is designed to prevent engine from starting
in a low oil or no oil condition. Oil Sentry may not shut
down a running engine before damage occurs. In some
applications this switch may activate a warning signal.
Read your equipment manuals for more information.
Oil Sentry pressure switch is installed into center oil
galley of filter adapter casting or into closure plate.
Based on application an elbow adapter may also be
used. On engines not equipped with Oil Sentry, oil
galley is sealed with a 1/8" pipe plug or completely
sealed.
OIL PRESSURE
Testing
On some models engine oil pressure can be tested
using an oil pressure tester. Follow instructions included
with tester. Pressure can be tested by removing oil filter
and installing tester adapter on mounting pad, or by
removing Oil Sentry pressure switch (or pipe plug) and
threading tester hose directly into mounting hole.
Installation
External Switch
1. Remove and discard pipe plug from center passage
of oil filter mounting pad.
2. Apply pipe sealant with Teflon (Loctite PST 592TM
Thread Sealant or equivalent) to threads of 90
adapter (if used), and Oil Sentry switch. Install
adapter (if used), and carefully tighten it to intended
position. Do not over tighten or damage adapter.
3. Install switch into adapter or center passage. Torque
switch to 4.5-5.0 Nm (40-45 in. lb.). Connect lead to
terminal on Oil Sentry switch.
Switch Behind Blower Housing
1. Remove blower housing. Remove and discard pipe
plug from closure plate.
2. Apply pipe sealant with Teflon (Loctite PST 592TM
Thread Sealant or equivalent) to threads of Oil
Sentry switch.
3. Install switch into closure plate. Torque switch to
4.5-5.0 Nm (40-45 in. lb.). Connect lead to terminal
on Oil Sentry switch.
4. Reinstall blower housing.
Testing
Compressed air, a pressure regulator, pressure gauge,
and a continuity tester are required to test switch.
1. Connect continuity tester across blade terminal and
metal case of switch. With 0 psi pressure applied to
switch, tester should indicate continuity (switch
closed).
2. Gradually increase pressure to switch. As pressure
increases through range of 2-5 psi tester should
indicate a change to no continuity (switch open).
Switch should remain open as pressure is increased
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.
34
KohlerEngines.com
20 690 01 Rev. I
Electrical System
SPARK PLUGS
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is running.
Spark Plug Component and Details
Inspection
Inspect each spark plug as it is removed from cylinder
head. Deposits on tip are an indication of general
condition of piston rings, valves, and carburetor.
Normal and fouled plugs are shown in following photos:
Normal
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
D
C
A
C
Wire Gauge
Ground Electrode
B
D
Spark Plug
Gap
NOTE: Do not clean spark plug in a machine using

abrasive grit. Some grit could remain in spark
plug and enter engine causing extensive wear
and damage.
Engine misfire or starting problems are often caused
by a spark plug that has improper gap or is in poor
condition.
Engine is equipped with following spark plugs:
On a worn plug, center electrode will be rounded and

gap will be greater than specified gap. Replace a worn
spark plug immediately.
Wet Fouled
Gap
0.76 mm (0.03 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 (0.03 in.).
2. Install plug into cylinder head.
3. Torque plug to 27 Nm (20 ft. lb.).
20 690 01 Rev. I
A wet plug is caused by excess fuel or oil in combustion

chamber. Excess fuel could be caused by a restricted air
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.
KohlerEngines.com
35
Electrical System
Carbon Fouled
ELECTRONIC IGNITION SYSTEM

Ignition System Components
H
E
F
B
Soft, sooty, black deposits indicate incomplete

combustion caused by a restricted air cleaner, over rich
carburetion, weak ignition, or poor compression.
Overheated
C
Position
A Kill Switch/Off
of Key Switch
C
Flywheel
E
Spark Plug
G
Kill Terminal
I Spark Plug Terminal
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 250 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.
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
If battery charge is insufficient to turn over engine,
recharge battery.
Battery Maintenance
Regular maintenance is necessary to prolong battery
life.
Battery Test
To test battery, follow manufacturer's instructions.
36
Air Gap
D
F
H
Magnet
Ignition Module
Spark Plug Boot
There is 1 type of ignition system used on these engines.

This system uses an ignition module which energizes
spark plug.
This ignition system is 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
occasionally fail or break down. Refer to Troubleshooting
to determine root of a reported problem.
Reported ignition problems are most often due to poor
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.
Fixed Ignition System
This system uses a capacitive discharge (CD) coil.
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. A
typical fixed ignition system consists of:
1 magnet assembly which is permanently affixed to
flywheel.
1 electronic capacitive-discharge ignition module
which mounts on engine crankcase.
1 kill switch (or key switch) which grounds module to
stop engine.
1 spark plug.
KohlerEngines.com
20 690 01 Rev. I
Electrical System
Electronic Ignition System 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 wont 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
Problem goes away.
Problem persists.
Possible Cause
Electrical System
Ignition or Electrical System
Conclusion
Check key switch, wires, connections,
safety interlocks, etc.
Leave kill lead isolated until all testing
is completed.
Test for Spark

NOTE: To maintain engine speeds normally obtained during cranking, do not remove engine spark plug.
1. Make sure spark plug lead is connected to spark plug.
2. Check condition of spark plug. Make sure gap is set to 0.76 mm (0.030 in.). If plug is in good condition, check/
adjust gap and reinstall.
3. a. Test for spark with ignition tester. Disconnect spark plug lead and connect it to post terminal of tester. Connect
clip to a good ground, not spark plug.
b. Make sure engine ignition switch, kill switch, or key switch is in RUN position.
4. Crank engine (minimum speed 500 RPM), and observe tester. Visible and audible sparks should be produced.
Condition
Audible and visible sparks are
produced.
Audible and visible sparks are not
produced.
Possible Cause
Ignition Module
Conclusion
Ignition module is OK.
Ignition Module or Electrical System Make sure engine ignition switch,

kill switch, or key switch is in RUN
position.
Check wires and terminals of ignition
module and other components for
accidental grounding and damaged
insulation.
If wires and terminals are OK, ignition
module is probably faulty and should
be replaced. Test module further using
an ohmmeter.
Test Ignition Module with Ohmmeter

NOTE: This test cannot be performed unless module has been fired at least once.
Measure resistance of module secondary using an ohmmeter.
1. Zero ohmmeter.
2. Connect one ohmmeter lead to laminations. Connect other lead to spark plug terminal of high-tension lead.
3. With ohmmeter leads connected in this manner, resistance of secondary should be 7,900 to 18,400 ohms. Refer
to Disassembly and Reassembly for complete ignition module removal and installation procedures.
Condition
Resistance is within specified range.
Resistance is low or 0 ohms.
Possible Cause
Module Secondary
Resistance is high or infinity ohms.

20 690 01 Rev. I
KohlerEngines.com
Conclusion
Module secondary is OK.
Module secondary is shorted.
Replace module.
Module secondary is open. Replace
module.
37
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 either a 9 or 15 amp, regulated battery charging system. Some have a 3 amp,
regulated system with a 70 watt lighting circuit.
Wiring Diagram-3 Amp Regulated Battery Charging System/70 Watt Lighting
D
U
AC
B+
T
M
T
S
AC
E
C
A
N
F
B
O
I
H
J
Red
Green
Violet
White
Bendix Starter
Spark Plug
Optional Fuel Solenoid
Optional Oil Sentry

Switch (Shutdown or
Indicator)
Engine Connector
Starter Solenoid
Optional Oil Sentry

Switch (Indicator Light)
Ground-To-Kill Lead
Key Switch
Optional Oil Sentry

Shutdown
Optional Fuse
Battery
Rectifier-Regulator
Flywheel
Stator
Ignition Module
Accessory
38
KohlerEngines.com
20 690 01 Rev. I
Electrical System
3 Amp/70 Watt Lighting Stator
NOTE: Zero ohmmeter on each scale to ensure accurate readings. Voltage tests should be made with engine running
at full throttle with no load. Battery must be fully charged.
To test charging system for no charge to battery:
1. With engine running in fast setting, measure voltage
across battery terminals using a DC voltmeter.
Condition
Voltage is more than 12.5
volts.
Voltage is 12.5 volts or
less.
Conclusion
Charging system is OK.
Stator or diode are
probably faulty. Continue
testing stator and diode.
2. Remove connector from rectifier-regulator. With

engine running in fast position, measure AC voltage
across stator leads using an AC voltmeter.
Condition
Voltage is 20 volts or
more.
Voltage is less than 20
volts.
Conclusion
Stator winding is OK.
Condition
Burned out lights.
Conclusion
Replace.
2. Disconnect lighting lead from wiring harness.

With engine running in fast setting, measure voltage
from lighting lead to ground using an AC voltmeter.
Condition
more.
volts.
Conclusion
Stator is OK. Check for
loose connections or
shorts in wiring harness.
Test stator using an
ohmmeter.
3. With engine stopped, measure resistance of stator

from lighting lead to ground using an ohmmeter.

ohmmeter.
3. With charging lead disconnected from battery and

engine stopped, measure resistance from charging
lead to ground using an ohmmeter. Note reading.
Reverse leads and measure resistance again.
In one direction, resistance should be infinity ohms
(open circuit). With leads reversed, some resistance
should be measured (about midscale on Rx1 range).
Condition
Resistance is low in both
directions.
Resistance is high in both
directions.
To test charging system for no lights:

1. Make sure lights are not burned out.
Condition
Resistance is
approximately 0.2 ohms.
Resistance is 0 ohms.
Resistance is infinity
ohms.
Conclusion
Stator is OK.
Stator is shorted. Replace
stator.
Stator or lighting lead is
open. Replace stator.
Conclusion
Diode is shorted. Replace
diode.
Diode or stator winding is
open. Continue testing.
4. Cut sleeving on charging lead to expose diode

connections.
Measure resistance from stator side of diode to
ground using an ohmmeter.
Condition
Resistance is
ohms.
20 690 01 Rev. I
Conclusion
Stator winding is OK,
diode is open. Replace
diode.
Stator winding is shorted.
Replace stator.
Stator winding or lead is
KohlerEngines.com
39
Electrical System
3 Amp/70 Watt Braking Stator
NOTE: Zero ohmmeter on each scale to ensure accurate readings. Voltage tests should be made with engine
running at full throttle with no load. Battery must be fully charged.
1. With engine running in fast setting, measure voltage
across battery terminals using a DC voltmeter.
Condition
volts.
less.
Conclusion
Stator or diode are
probably faulty. Continue
testing stator and diode.

engine running in fast position, measure AC voltage
Condition
Voltage is 5 volts or more.
volts.
Conclusion
Stator winding is OK.
ohmmeter.
3. With charging lead disconnected from battery and

engine stopped, measure resistance from charging
lead to ground using an ohmmeter. Note reading.
Reverse leads and measure resistance again.
In one direction, resistance should be infinity ohms
(open circuit). With leads reversed, some resistance
should be measured (about midscale on Rx1 range).
Condition
Resistance is low in both
directions.
Resistance is high in both
directions.
Conclusion
Diode is shorted. Replace
diode.
Diode or stator winding is
open. Continue testing.
4. Disconnect lighting lead (yellow) from wiring

harness.
Measure resistance from lighting lead to ground
using an ohmmeter.
Condition
Resistance is
ohms.
Conclusion
Stator winding is OK,
diode is open. Replace
diode.
Stator winding is shorted.
Replace stator.
Stator winding or lead is
To test charging system for no lights and battery

charging (braking system):
1. Make sure lights are not burned out.
To test battery charging system go to step 4,
otherwise perform steps 2 and 3 only.
Condition
Burned out lights.
2. Disconnect lighting lead (yellow) from wiring

harness.
from lighting lead to ground using an AC voltmeter.
Condition
more.
volts.
Conclusion
Stator is OK. Check for
loose connections or
shorts in wiring harness.
ohmmeter.
3. With engine stopped, measure resistance of stator

from lighting lead to ground using an ohmmeter.
Condition
Resistance is
ohms.
Conclusion
Stator is OK.
stator.
4. Disconnect braking lead (green) from wiring

harness.
from braking lead to ground using an AC voltmeter.
Condition
more.
volts.
Conclusion
Stator is OK. Circuitry on
unit that grounds braking
lead is shorted.
ohmmeter.
5. With engine stopped, measure resistance from

braking lead to ground using an ohmmeter.
Condition
Resistance is 0.2-0.4
ohms.
ohms.
40
Conclusion
Replace.
KohlerEngines.com
Conclusion
Stator is OK.
stator.
20 690 01 Rev. I
Electrical System
Wiring Diagram-9 or 15 Amp Regulated Battery Charging System
Q
D
AC
B+
P
AC
E
Q
F
B
I
O
Red
Green
Violet
White
Spark Plug
Optional Fuel Solenoid
Optional Oil Sentry

Switch (Shutdown)
Bendix Starter
Engine Connector
Starter Solenoid
Optional Oil Sentry

Switch (Indicator Light)
Ground-To-Kill Lead
Key Switch
Optional Oil Sentry

Shutdown
Optional Fuse
Battery
Rectifier-Regulator
Flywheel
Stator
Ignition Module
Accessory
Optional Oil Sentry

Switch (Indicator)
20 690 01 Rev. I
KohlerEngines.com
41
Electrical System
9/15 Amp Regulated Battery Charging System
NOTE: Zero ohmmeter on each scale before testing to
ensure accurate readings. Voltage tests should
be made with engine running at full throttle with
no load. Battery must be fully charged.
1. Insert an ammeter in B+ lead from rectifier-regulator.
With engine running at 3600 RPM and B+ (at
terminal on rectifier-regulator) to ground using a DC
voltmeter.
If voltage is 13.8 volts or more, place a minimum
load of 5 amps (turn on lights if 60 watts or more, or
place a 2.5 ohm, 100 watt resistor across battery
terminals) on battery to reduce voltage. Observe
ammeter.
Condition
Charge rate increases
when load is applied.
Charge rate does not
increase when load is
applied.
Condition
less.
volts.
BLADE STOP STATOR BRAKE CIRCUIT

Wiring Diagram-Blade Stop Stator Brake Circuit
A
B
Conclusion
Charging system is OK
and battery was fully
charged.
Test stator and rectifierregulator (steps 2 and 3).
3. With engine stopped, measure resistance across

stator leads using an ohmmeter.
Condition
Resistance is 0.1/0.2
ohms.
ohms.
Conclusion
Stator is OK.
Stator is open; replace.
4. With engine stopped, measure resistance from each

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

at high rate:
1. With engine running at 3600 RPM, measure voltage
from B+ lead to ground using a DC voltmeter.
42

engine running at 3600 RPM, measure AC voltage
Conclusion
Stator is OK. Rectifierregulator is faulty; replace.
Stator is faulty; replace.
Test stator further using an
ohmmeter (steps 3 and 4).
Condition
more.
volts.
Conclusion
Battery is unable to hold
charge; service or replace.
Faulty rectifier-regulator;
replace.
J
N
12V Switched Power
Stator Brake
Relay Coil
90
680
Engine
Kill
CDI Ignition
Reverse Mow Module

(OEM Supplied)
TRIAC
NO
NC
PTO
Brake
Seat
Key Switch
Blade stop stator brake circuit is provided as a safety

feature to ensure application can meet ANSI (American
National Standards Institute) application blade stop
requirements.
Circuit is activated if operator gets off of seat of
application while mower blade system is activated or in
certain reverse mow conditions.
Circuit is activated by taking ignition shutdown (kill) lead
to ground. This action turns on stator-brake relay which
shorts charging AC stator leads to produce a magnetic
field that will counter or resist rotation of flywheel. This
added resistance to rotation decreases amount of time it
takes for application deck blades to come to a full stop.
KohlerEngines.com
20 690 01 Rev. I
Electrical System
As Kohler blade stop stator brake circuit often is
operated in conjunction with other application circuits,
relay in Kohler circuit is specially configured with a 680
ohm resistor in parallel with relay coil. This is done to
negate transient voltage signals that would be normally
created by interrupting relay current once relay has been
activated. Therefore, relay replacement must only be
made with properly identified relay.
Troubleshooting-Stator Brake System
Stator Brake and Relay Harness Connections
Condition
Conclusion
Voltage does not increase. Shut down engine, remove
relay from its socket
and re-test at full engine
speed.
If battery voltage does
not increase with engine
operating, problem is likely
not with stator brake relay.
Continue testing stator and
rectifier-regulator.
Problems that could occur with Kohler portion circuit

generally could be caused by two component failures
or an incorrect relay replacement, which will create
following conditions.
To test for dead battery:
Brake relay has failed and is keeping stator shorted, so
no charge current can be passed from rectifier-regulator
to battery, eventually allowing battery to discharge.
1. Check battery voltage using a test meter with
application off.
2. Check battery voltage using a test meter with
application operating at maximum speed.
Battery voltage should increase from engine off condition
to engine full speed condition.
To test engine that will crank but will not start:

Brake stator relay is interacting with application safeties
or reverse mow electronics, preventing normal engine
start up.
1. Remove brake relay from its socket and attempt to
restart engine.
Condition
Engine starts.
F
E
Engine does not start.
Stator Assembly
Wiring Harness
Stator Leads to
Rectifier-Regulator
Stator Leads
Wire Tie (Black)
Push Wing Mount

(Black)
20 690 01 Rev. I
Conclusion
Relay is not correct for this
application or transient
protection resistor has
failed. Replace relay with
correct component.
Problem may exist with
application reverse mow
circuit, application safeties,
or with key switch keeping
ignition shutdown line tied
to engine ground.
2. Remove engine shutdown (kill) lead from application

wire harness and attempt to start engine again.
Condition
Engine does not start.
KohlerEngines.com
Conclusion
Fuel or ignition problem.
43
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 starters.
Troubleshooting-Starting Difficulties
Condition
Starter does not energize.
Possible Cause
Battery
Wiring
Starter energizes but turns

slowly.
Starter Switch
or Solenoid
Battery
Brushes
Transmission
or
Engine
44
Conclusion
Check specific gravity of battery. If low, recharge or replace
battery as necessary.
Clean corroded connections and tighten loose connections.
Replace wires in poor condition and with frayed or broken
insulation.
By-pass switch or solenoid with a jumper wire. If starter cranks
normally, replace faulty components.
Check specific gravity of battery. If low, recharge or replace
battery as necessary. Battery too small, must be at least 250
cold-cranking amps.
Check for excessively dirty or worn brushes and commutator.
Clean using a coarse cloth (not emery cloth).
Replace brushes if excessively or unevenly worn.
Make sure clutch or transmission is disengaged or placed
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.
KohlerEngines.com
20 690 01 Rev. I
Starter System
INERTIA DRIVE ELECTRIC STARTERS
Inertia Drive Electric Starter
When power is applied to starter, armature rotates. As

armature rotates, drive pinion moves out on splined
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, 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.
P
O
N
M
L
K
Starter Drive Service

It is not necessary to completely disassemble starter to
service drive components.
1. Disassemble retaining ring, use tool.
2 Grasp spring retainer and push it toward starter,
compressing anti-drift spring and exposing retaining
ring.
3. Holding spring retainer in retracted position,
assemble inner halves of removal tool around
armature shaft with retaining ring in inner groove.
Slide collar over inner halves to hold them in
position.
4. Thread center screw into removal tool until you feel
resistance. Use a wrench (1 1/8" or adjustable) to
hold base of removal tool. Use another wrench or
socket (1/2" or 13 mm) to turn center screw
clockwise. Resistance against center screw will tell
you when retaining ring has popped out of groove in
armature shaft.
5. Remove drive components, and drive nut (collar)
from armature shaft, paying attention to sequence. If
splines are dirty, clean them with solvent.
6. Splines should have a light film of lubricant.
Relubricate as necessary with Kohler bendix starter
lubricant. Reinstall or replace drive components,
assembling them in same sequence as they were
removed.
J
I
H
D
C
B
A
A
E
C
G
I
K
M
O
Thru Bolts
Brush Carrier
Assembly
Insulating Washer
Armature
Thrust Washer
Hex Flange Nut
Pinion
Retainer
20 690 01 Rev. I
Hex Flange Nut
Frame Assembly
D
H
J
L
N
P
Commutator End Cap

Wave Washer
Drive End Cap
Drive Nut (Collar)
Anti-Drift Spring
Retaining Ring
Retaining Ring Installation

1. Position retaining ring in groove in one of inner
halves. Assemble other half over top and slide on
outer collar.
2. Be certain drive components are installed in correct
sequence onto armature shaft.
3. Slip tool over end of armature shaft, so retaining ring
inside is resting on end of shaft. Hold tool with one
hand, exerting slight pressure toward starter. Tap top
of tool with a hammer until you feel retaining ring
snap into groove. Disassemble and remove tool.
4. Squeeze retaining ring with pliers to compress it into
groove.
5. Assemble inner halves with larger cavity around
spring retainer. Slide collar over them and thread
center screw in until resistance is felt.
6. Hold base of tool with a 1 1/8" wrench and turn
center screw clockwise with a 1/2" or 13 mm wrench
to draw spring retainer up around retaining ring. Stop
turning when resistance increases. Disassemble and
remove tool.
KohlerEngines.com
45
Starter System
Starter Disassembly
1. Remove drive components following instructions for
servicing drive.
2. Remove nut and insulating washer from positive (+)
brush lead stud.
3. Remove thru bolts and recessed nuts.
4. Remove commutator end cap and lift out brush
carrier assembly with brushes and springs.
5. Remove drive end cap, then pull armature with
thrust washer and wave washer (if equipped) out of
starter frame.
Brush Replacement
1. Remove nut and insulating washer from positive (+)
brush lead stud.
2. Remove thru bolts and captured hex nuts.
3. Remove commutator end cap, then pull brush carrier
assembly out of frame.
Commutator Service
Clean commutator with a coarse, lint free cloth. Do not
use emery cloth.
If commutator is badly worn or grooved, turn it down on
a lathe or replace armature.
Starter Reassembly
1. Place wave washer, followed by thrust washer onto
drive shaft of armature.
2. Insert armature into starter frame. Magnets will hold
it in place.
3. Align holes with spaces between magnets and install
drive end cap onto front of frame.
4. If brush assembly is not being replaced, position
springs and brushes within their pockets in carrier;
move them to retracted position, and install carton
staples to retain them. Replacement brushes come
pre-assembled in carrier housing, retained with two
carton staples.
5. Hold brush holder assembly with positive brush lead
stud up. Align molded sections with corresponding
cutouts in starter frame and slide brush carrier
assembly into place. Commutator will push carton
staples out as brush assembly is inserted.
6. Position commutator end cap over brush assembly,
aligning holes for stud terminal and thru bolts.
7. Install thru bolts and hex nuts. Torque to 3.3-3.9 Nm
(30-35 in. lb.).
8. Install insulating washer and hex flange nut onto
positive (+) brush lead stud. Make sure stud is
centered and does not touch metal end cap. Torque
hex flange nut to 2.2-4.5 Nm (20-40 in. lb.).
After installation and connection of starter lead,
torque outer nut to 1.6-2.8 Nm (12-25 in. lb.), do not
over torque.
9. Lubricate drive shaft with Kohler bendix starter drive
lubricant. Install drive components following
instructions for servicing drive.
46
KohlerEngines.com
20 690 01 Rev. I

EVAPORATIVE EMISSION COMPLIANT SYSTEM
Carbon Canister System
D
A
B
E
F
Fuel Tank Cap
Fuel Tank
Canister Breather
Filter
To Carburetor
Roll Over Valve

(ROV)
Carbon Canister
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
Fuel vapors travel from fuel tank through tubing to
carbon canister. On intake stroke of engine fuel vapors
are drawn in through a port in carburetor and burned
with fuel charge.
20 690 01 Rev. I
Maintenance
On Kohler-supplied canisters, breather filter can be
removed and cleaned with hot soapy water, dried and
reinstalled. Do not oil breather screen. This is done
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.
KohlerEngines.com
47

SECONDARY EMISSION COMPLIANT SYSTEM
Twin Secondary Air Induction System
E
A
C
B
D
C
A
Hose To Exhaust
Manifold
Hose To Exhaust
Manifold
Inlet Screen
Secondary Air
Valve Assembly
Hose To Carburetor
Inlet Screen
Single Secondary Air Induction System

F
I
H
G
F
Secondary Air
Valve Assembly
Hose To Exhaust
Manifold
Hose To Carburetor
For engine to be Tier III compliant, it may be fitted with a secondary air induction system (SAI).
Operation
Intake pulse of engine activates secondary air valve.
Air is drawn through an inlet screen of secondary air
valve. Air is then drawn into exhaust manifold and
muffler where it mixes with any unburned hydrocarbons,
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.
48
Maintenance
Air inlet screen in secondary air valve can be removed,
cleaned, and reinstalled. If inspection of system reveals
any damage or decomposition of hoses, secondary air
valve, or exhaust system, parts should be replaced.
KohlerEngines.com
20 690 01 Rev. I

Remove Inlet Screen
Inlet Components
Secondary Air Valve Assembly
Barb
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.
20 690 01 Rev. I
KohlerEngines.com
49

WARNING
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark plug lead(s)
before servicing.
Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative () battery cable from battery.
External Engine Components

A
W
B
O
N
C
M
K
I
L
U
P
N
M
K
Q
R
H
G
Oil Fill/Dipstick
Debris Screen
Blower Housing
Fuel Pump
Cylinder Head Baffle
Rectifier-Regulator
Electric Starter
Oil Filter
Fuel Filter
Oil Sentry
Air Cleaner Cover
Precleaner
Air Cleaner Element
Air Cleaner Base
Gasket
Carburetor
Ground Wire
Oil Drain Plug
Nikki Fuel Solenoid
Walbro Fuel Solenoid
Heat Deflector
Heat Shield
Carburetor Spacer
50
KohlerEngines.com
20 690 01 Rev. I

Clean all parts thoroughly as engine is disassembled.
Only clean parts can be accurately inspected
and gauged for wear or damage. There are many
commercially available cleaners that will quickly remove
grease, oil, and grime from engine parts. When such a
cleaner is used, follow manufacturers instructions and
safety precautions carefully.
Make sure all traces of cleaner are removed before
engine is reassembled and placed into operation. Even
3. Remove precleaner (if equipped), and air cleaner

element with formed rubber seal.
4. Remove nut(s) and long mounting screw securing air
cleaner base.
5. Disconnect breather hose from valve cover and
remove air cleaner base and gasket (with fuel pump
attached, if equipped).
Remove External Governor Components,
Carburetor, and Fuel Pump
Drain Oil from Crankcase and Remove Oil Filter

1. Remove oil drain plug and oil fill cap/dipstick.
2. Allow ample time for oil to drain from crankcase.
3. Remove and discard oil filter.
Remove Blower Housing
1. Remove screws securing blower housing to closure
plate.
2. Lift blower housing and separate spark plug lead
from corresponding slot.
Remove Oil Sentry Pressure Switch (if equipped)
NOTE: Pressure switch is installed into center oil galley
of filter adapter casting or into closure plate.
1. Disconnect lead from Oil Sentry pressure switch.
2. Remove pressure switch from center oil galley or
adapter elbow of filter adapter casting or from
closure plate.
Disconnect Spark Plug Lead
Carefully pull on boot section and disconnect spark plug
lead.
Remove Muffler
1. Remove nuts or 5/16-18 cap screws attaching
muffler or exhaust system to engine. Remove any
attached brackets.
2. Remove muffler and gasket from exhaust port.
Remove Cylinder Head Baffle
Remove screws attaching cylinder head baffle to cylinder
head and remove cylinder head baffle.
Remove Rectifier-Regulator
1. Unplug connector from rectifier-regulator.
2. Remove screws securing rectifier-regulator to
crankcase. Remove rectifier-regulator.
Remove Electric Starter
1. Disconnect starter lead from terminal stud.
2. Remove nuts securing starter to closure plate.
Remove starter.
Remove Air Cleaner
pump if fuel pump is secured to air cleaner base.
Mark lines for proper reassembly.
2. Loosen knobs and remove air cleaner cover.
20 690 01 Rev. I
WARNING
burns.
running.
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: It is recommended that a new governor lever be
installed whenever removal is performed.
1. Shut off fuel supply. Disconnect fuel line from
carburetor inlet fitting. If a fuel pump is used,
disconnect pulse line from fitting on closure plate.
2. Remove heat deflector or carburetor spacer/heat
shield (if equipped) mounting screw and special
washer, which also secures ground lead for fuel
shut-off solenoid, if so equipped.
3. If carburetor uses a fuel solenoid, carefully cut
plastic tie strap and disconnect fuel solenoid lead
from wiring harness.
4. Slide carburetor outward and disconnect throttle and
choke linkages.
5. Mark mounted position of speed control bracket in
slotted holes and remove screws securing speed
control bracket to closure plate. Note or mark
governor spring hole for correct installation later.
Unhook governor spring, then remove control
bracket (with fuel pump attached, if equipped) and
linkages from engine.
6. Loosen nut and remove governor lever from
governor cross shaft.
7. Remove carburetor gasket, then carefully remove
heat deflector or carburetor spacer/heat shield (if
equipped) and gaskets from intake stud. Heat
deflector is made from a plastic that is quite brittle.
Do not pry on corners, or you risk cracking/breaking
deflector. If prying is necessary to loosen deflector,
carefully pry near intake stud only. Remove
mounting stud from cylinder only if required.
8. Remove insert from intake port (some models), if
separate from heat deflector.
KohlerEngines.com
51

Flywheel/Ignition Components
Remove Ignition Module

1. Disconnect kill lead from ignition module.
2. Rotate flywheel magnet away from module.
3. Remove RFI sheathed spark plug lead from
retaining clip, if so equipped.
4. Remove screws and ignition module.
A
B
C
Flywheel Screw
Washer
Fan Mounting Plate
Fan
Magnet
Flywheel
Ignition Module
Stator
Flywheel Key
52
Remove Debris Screen, Fan, and Flywheel

NOTE: Always use a flywheel strap wrench or flywheel
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
or wedge between fins of cooling fan, as fins
could become cracked or damaged.
NOTE: Always use a puller to remove flywheel from
crankshaft. Do not strike crankshaft or flywheel,
as they could be cracked or damaged.
1. Unsnap debris screen from cooling fan.
2. Remove retaining screw, washer and fan mounting
plate, securing fan and flywheel to crankshaft.
3. Carefully lift cooling fan to disengage two drive pins
and remove it from flywheel.
Flywheel with Puller Holes
1. Remove flywheel from crankshaft using a puller.
2. Remove flywheel key from crankshaft.
Flywheel without Puller Holes
1. Remove flywheel from crankshaft by pulling from
under ring gear with large gear puller.
2. Remove flywheel key from crankshaft.
Flywheel Inspection
Inspect flywheel for cracks and check keyway for wear
or damage. Replace flywheel if cracked. If flywheel key
is sheared or keyway is damaged, replace crankshaft,
flywheel, and key.
Inspect ring gear for cracks or damage. Ring gears are
not available separately. Replace flywheel if ring gear is
damaged.
Remove Stator
NOTE: To disconnect B+ or stator leads from wiring
harness connector, insert a small screwdriver, or
similar narrow flat blade, and bend down locking
tang of terminal(s). Gently pull lead(s) out of
connector.
Remove screws securing stator to closure plate bosses.
KohlerEngines.com
20 690 01 Rev. I

Cylinder Head Components
D
A
B
F
E
H
C
G
M
L
Q
P
N
A
Gasket
Cylinder Head Screw
Valve Spring
M
Q
Valve
Cylinder Head
Spark Plug
Push Rod
Valve Spring Retainer
Valve Stem Seal
Valve Spring Cap
Rocker Arm
Set Screw
Valve Cover Gasket
Valve Cover
Screw
Rocker Arm Pivot
Rocker Arm Stud
Push Rod Guide Plate
Remove Valve Cover

Valve Cover with Gasket
1. Remove screws securing valve cover and any
attached brackets.
2. Remove valve cover and gasket from cylinder head.
Valve Cover with RTV Sealant
NOTE: Valve cover is sealed to cylinder head using
RTV silicone sealant. When removing valve
cover, use care not to damage gasket surfaces
of cover and cylinder head. To break RTV seal,
hold a block of wood against 1 flat face of valve
cover. Strike wood firmly with a mallet. If seal
doesn't break loose after 1 or 2 attempts, repeat
procedure on other side.
1. Remove screws securing valve cover and any
attached brackets.
2. Using a brass wire brush and gasket remover or
similar solvent, clean old RTV from surface of
cylinder head and valve cover.
Remove Cylinder Head
1. Loosen inner set screws (T15 TORX) and back off
rocker arm adjusting nuts. Remove push rods and
mark them, so they can be reinstalled in same
location.
20 690 01 Rev. I
2. Remove screws securing cylinder head. Note thick

washer used on screw closest to exhaust port.
3. Remove cylinder head and head gasket.
4. Remove drain back check ball (some models) from
keyhole slot in crankcase. Models without a check
ball have an internal drain back tube in crankcase.
Disassemble Cylinder Head
NOTE: Before disassembly, mark all valve train
components that will be reused, to assure they
are reassembled on same side.
1. Remove spark plug.
2. Remove adjustment nuts, pivots and rocker arms
from pivot studs.
3. Remove rocker arm pivot studs and push rod guide
plates.
4. Remove valves.
a. Compress valve springs using a valve spring
compressor and remove keepers.
b. Remove compressor; then remove valve spring
caps, valve springs, and valves.
KohlerEngines.com
53

Model SV470/480/530/540/590/600/610 Valve Details
E
E
A
G
INTAKE VALVE
EXHAUST VALVE
A
B
C
D
E
F
G
Dimension
Seat Angle
Guide Depth
Guide I.D.
Valve Head Diameter
Valve Face Angle
Valve Margin (Min.)
Valve Stem Diameter
Intake
89
10.20 mm
6.038/6.058 mm
37.625/37.375 mm
45
1.5 mm
5.982/6.00 mm
Exhaust
89
6.2 mm
6.038/6.058 mm
32.125/32.375 mm
45
1.5 mm
5.90/5.988 mm
Model SV620 Valve Details

H
A
B
A
B
F
C
C
K
EXHAUST VALVE
A
B
C
D
E
F
G
H
I
J
K
54
Dimension
Seat Angle
Seat Angle
Seat Angle
Guide Depth
Guide I.D.
Valve Head Diameter
Valve Face Angle
Valve Face Angle
Valve Face Angle
Valve Margin (Min.)
Valve Stem Diameter
INTAKE VALVE
D
E
Intake
89
111/109
61/59
10.20 mm
6.038/6.058 mm
37.625/37.375 mm
45
39.275/39.525
60
1.7 mm
5.982/6.000 mm
KohlerEngines.com
Exhaust
89
131/129
51/49
6.2 mm
6.038/6.058 mm
32.125/32.375 mm
45
33.675/33.925
60
1.7 mm
5.90/5.988 mm
20 690 01 Rev. I

Inspection and Service
Carefully inspect valve mechanism parts. Inspect valve
springs and related hardware for excessive wear or
distortion. Check valves and valve seats for evidence
of deep pitting, cracks, or distortion. Check running
clearance between valve stems and guides.
Hard starting, or loss of power accompanied by high
fuel consumption, may be symptoms of faulty valves.
Although these symptoms could also be attributed to
worn rings, remove and check valves first. After removal,
clean valve heads, faces, and stems with a power wire
brush. Then, carefully inspect each valve for defects
such as warped head, excessive corrosion, or worn stem
end. Replace valves found to be in bad condition.
Valve Guides
If a valve guide is worn beyond specifications, it will not
guide valve in a straight line. This may result in burned
valve faces or seats, loss of compression, and excessive
oil consumption.
To check valve guide-to-valve stem clearance,
thoroughly clean valve guide and, using a split-ball
gauge, measure inside diameter. Then, using an outside
micrometer, measure diameter of valve stem at several
points on stem where it moves in valve guide. Use
largest stem diameter to calculate clearance. If intake
clearance exceeds 0.038/0.076 mm (0.0015/0.0030
in.) or exhaust clearance exceeds 0.050/0.088 mm
(0.0020/0.0035 in.), determine whether valve stem or
guide is responsible for excessive clearance.
Maximum (I.D.) wear on intake valve guide is 6.135 mm
(0.2415 in.) while 6.160 mm (0.2425 in.) is maximum
allowed on exhaust guide. Guides are not removable. If
guides are within limits but valve stems are worn beyond
limits, replace valves.
Valve Seat Inserts
Hardened steel alloy intake and exhaust valve seat
inserts are press fitted into cylinder head. Inserts are
not replaceable, but they can be reconditioned if not too
badly pitted or distorted. If seats are cracked or badly
warped, cylinder head should be replaced.
Recondition valve seat inserts following instructions
provided with valve seat cutter being used. Final cut
should be made with an 89 cutter as specified for valve
seat angle. With proper 45 valve face angle, and valve
seat cut properly (44.5 as measured from center line
when cut 89) this would result in desired 0.5 (1.0 full
cut) interference angle where maximum pressure occurs
on valve face and seat.
Lapping Valves
Reground or new valves must be lapped in, to provide
a good seal. Use a hand valve grinder with suction
cup for final lapping. Lightly coat valve face with fine
grade of grinding compound, then rotate valve on seat
with grinder. Continue grinding until smooth surface is
obtained on seat and on valve face. Thoroughly clean
cylinder head in soap and hot water to remove all traces
of grinding compound. After drying cylinder head, apply
a light coating of engine oil to prevent rusting.
20 690 01 Rev. I
Cam/Closure Plate Components

A
C
B
C
D
E
D
P
O
M
L
K
J
I
Oil Seal
Closure Plate
Gasket
Oil Passage Cover
Cam Gears
Thrust Washer
Cam Levers
Cam Shaft (Exhaust)
Closure Plate Gasket
Gerotor Gears
Oil Pump
Cam Shaft Pin
Cam Shaft (Intake)
Regulating Pin
Governor Gear
Governor Gear Shaft
Remove Closure Plate

1. Remove screws securing closure plate to crankcase.
Note location and position of any attached clips or
clamps.
2. A gasket is used between closure plate and
crankcase. If necessary, carefully tap on bosses for
starter or oil filter with a soft-faced mallet to loosen.
Do not pry on gasket surfaces of crankcase or oil
pan, as this can cause damage resulting in leaks.
3. Remove closure plate assembly and gasket.
KohlerEngines.com
55

4. If wiring harness needs to be separated from closure
plate, pry open clamps and pull out through slot.
Disassemble Closure Plate
NOTE: Governor gear is held onto shaft by small
molded tabs in gear. When gear is removed
these tabs are destroyed and gear must be
replaced. Governor gear removal is required for
closure plate disassembly and cleaning of oil
passages.
1. Remove governor gear and regulating pin assembly.
Gently pry upward using blades of two small
screwdrivers.
2. Remove screws securing oil passage cover to
closure plate. Remove cover and gasket.
Governor Gear and Shaft Inspection
Inspect governor gear teeth. Look for any evidence of
worn, chipped, or cracked teeth. If one or more of these
problems is noted, replace governor gear.
Gear is held onto governor shaft by molded tabs, which
are damaged when gear is removed. Never reuse gear
once it has been pulled from shaft. Replace governor
shaft only if it is damaged or worn.
Remove Governor Shaft
1. Remove blower housing, flywheel, and cooling fan.
2. Remove stator and crankshaft key.
3. Remove closure plate screws and closure plate.
4. Rotate engine to top dead center aligning timing
marks on crankshaft and cam gears.
5. Remove governor gear assembly and regulating pin
from closure plate with two small screwdrivers.
6. Locate governor pin from flywheel side. With a small
punch, drive pin out of closure plate. This could also
be done with a press. Do not remove governor pin
with a vise grip or pliers, you may damage closure
plate.
7. Remove any old gasket material from mating
surfaces of crankcase and closure plate. Use an
aerosol gasket remover to help loosen any old
gasket material. Do not scrape surfaces, as any
scratches, nicks, or burrs can result in leaks.
Install Governor Shaft
Governor Shaft Components and Details
B
A
44.50 mm (1.750 in.) To Gasket Surface - Before

Oil Passage Cover Plate and Gasket are
Assembled
Governor Gear Shaft
56
1. Install new pin by pressing or lightly tapping it into

closure plate. It must be installed so that it protrudes
44.50 mm (1.750 in.), plus or minus 0.101 mm
(0.004 in.) above crankcase boss.
2. Install new governor regulating pin and governor
gear assembly.
3. Make sure governor gear assembly rotates freely.
4. Check that timing marks are still aligned.
5. Install a new closure plate gasket and install closure
plate. Torque fasteners to 24.5 Nm (216 in. lb.).
6. Complete engine reassembly following Reassembly
procedures.
7. When engine reassembly is completed, reset initial
governor adjustment according to procedure in
Governor System.
Closure Plate and Passage Cover Inspection and
Service
Passage Cover Torque Sequence
NOTE: Passage cover with 3 fasteners does not require

a torque sequence.
If disassembly was performed, inspect and ensure
oil passages in closure plate and passage cover are
completely clean and not obstructed in any way. Check
straightness of passage cover if required, against a flat
surface.
Use a new passage cover gasket and install passage
cover onto closure plate. Reinstall mounting screws
and torque to 4.0 Nm (35 in. lb.), following sequence.
Passage cover with 3 fasteners does not require a
torque sequence.
Remove Cam Gears, Cam Shafts, and Oil Pump
NOTE: ACR weight and spring normally captured by
thrust washer and installation of closure plate,
will fall out if exhaust cam gear is turned upside
down.
NOTE: Cam gear assemblies may contain either two or
four rivets.
KohlerEngines.com
20 690 01 Rev. I

NOTE: Engine Serial No. 332740003 and lower, use a
rubber outlet between oil pump outlet and lower
bearing area. Some models use an open seal
with an internal passage to feed oil to lower
bearing. Some models use a closed or solid
seal, and crankshaft is crossed-drilled to feed oil
to lower bearing.
Engine Serial No. 332740003 and higher, outlet
of oil pump is closed and no rubber seal is used.
1. Remove thrust washer(s) and cam gears from cam
shafts. Later models will have a thrust washer on
exhaust side only.
2. Remove screws securing cam levers to crankcase.
Mark cam levers for proper reassembly.
3. Pull exhaust side cam shaft and slotted thrust
washer, out of crankcase.
4. If engine contains an internal drain back tube,
unhook it from oil pump and pull it out of crankcase
passage. Check for cracks, brittleness or damage.
Replace if questionable in any way.
5. Remove screws securing oil pump and intake side
cam shaft to crankcase. If a drain back tube is used,
it may be unhooked and removed separately or
together with oil pump. Carefully pull upward on cam
shaft to remove assembly from crankcase cavity. A
small rubber oil pump outlet seal on outlet of oil
pump may become dislodged during removal. Do
not lose it.
6. If necessary, oil pump can be separated from intake
side cam shaft. Provide appropriate support for
shaft, and drive out lower pin. Oil pump assembly
can then be removed from cam shaft.
Oil Pump Assembly and Pressure Relief Valve
Outlet Seal Styles (Some Models)
A
A
Open Seal
B
B
Closed Seal
Pump Outlet Styles

A
Open Outlet Seal
20 690 01 Rev. I
Closed Outlet Seal
Closure plate must be removed to inspect and service

oil pump. Check oil pump and gears for cracks, damage,
wear, and smooth rotation. Replace pump if any binding
is noted or reuse is questionable in any way.
A pressure relief valve is built into oil pump to limit
maximum pressure. It is not serviceable. If a problem
exists with pressure relief valve, oil pump assembly
should be replaced.
Automatic Compression Release (ACR)
These engines are equipped with an ACR mechanism.
ACR lowers compression at cranking speeds to make
starting easier.
Operation
ACR mechanism consists of an actuating spring and
a pivoting flyweight/control pin assembly, located in
exhaust side cam gear. A thrust washer and mounting
closure plate hold ACR in position. At cranking speeds
(700 RPM or lower), spring holds flyweight in and
rounded surface of control pin protrudes above exhaust
cam lobe. This pushes exhaust valve off its seat during
first part of compression stroke. Compression is reduced
to an effective ratio of about 2:1 during cranking.
After starting, when engine speed exceeds 700 RPM,
centrifugal force overcomes force of the flyweight spring.
Flyweight moves outward, rotating control pin to expose
the flat surface, which is lower than cam lobe. Control
pin no longer has any effect on exhaust valve, and
engine operates at full power.
When engine is stopped, spring returns flyweight/control
pin assembly to compression release position, ready for
next start.
Benefits
As a result of reduced compression at cranking speeds,
several important benefits are obtained:
1. Manual (retractable) starting is much easier. Without
ACR, manual starting would be virtually impossible.
2. Electric start models can use a smaller starter and
battery which are more practical for application.
3. ACR eliminates need for a spark retard/advance
mechanism. A spark retard/advance mechanism
would be required on engines without ACR to
prevent kickback which would occur during starting.
ACR eliminates this kickback, making manual
starting safer.
4. Choke control setting is less critical with ACR. If
flooding occurs, excess fuel is blown out opened
exhaust valve and does not hamper starting.
5. Engines with ACR start much faster in cold weather
than engines without ACR.
6. Engines with ACR can be started with spark plugs
which are worn or fouled. Engines without ACR are
more difficult to start with those same spark plugs.
Cam Gears Inspection and Service
Inspect gear teeth and cam lobes of intake and exhaust
cam gears. If lobes exhibit excessive wear, or teeth are
worn, chipped or broken, replacement of cam gear(s) will
be necessary.
KohlerEngines.com
57

Balance Weight/Piston Assembly Components
A
K
L
M
N
I
J
Crankshaft Gear
Crankshaft
Crank Gear Key
Third Generation
Balance Weight
Washer
Hitch Pin
Oil Seal
End Cap
Connecting Rod
Wrist Pin Retainer
Wrist Pin
Piston
Piston Ring Set
First Generation
Balance Weight
Second Generation
Balance Weight
Remove Connecting Rod and Piston

NOTE: If a carbon ridge is present at top of bore, use a
ridge reamer to remove it before attempting to
remove piston.
1. Rotate crankshaft so rod journal is in 9 oclock
position.
2. Remove screws and connecting rod cap.
3. Carefully push connecting rod and piston away from
crankshaft and out of cylinder bore.
58

Check bearing area (big end) for score marks and
excessive wear. Service replacement connecting rods
are available in STD crankpin size.
Remove Piston from Connecting Rod
Remove wrist pin retainer and wrist pin. Separate piston
from connecting rod.
KohlerEngines.com
20 690 01 Rev. I

Scratches on rings and pistons are caused by abrasive
material such as carbon, dirt, or pieces of hard metal.
Detonation damage occurs when a portion of fuel charge
ignites spontaneously from heat and pressure shortly
after ignition. This creates two flame fronts that meet and
explode to create extreme hammering pressures on a
specific area of piston. Detonation generally occurs from
using low octane fuels.
Preignition or ignition of fuel charge before timed spark
can cause damage similar to detonation. Preignition
damage is often more severe than detonation damage.
Preignition is caused by a hot spot in combustion
chamber from sources such as glowing carbon deposits,
blocked fins, improperly seated valve, or wrong spark
plug.
Replacement pistons are available in STD and 0.08 mm
(0.003 in.) oversize, which include new rings and piston
pins. Service replacement piston ring sets are also
available separately. Always use new piston rings when
installing pistons. Never reuse old rings.
Piston and Rings

Inspection
Piston and Rings Components and Details
A
B
C
D
E
F
G
I
H
A
Piston Ring
End Gap
Identification Mark
Piston
Top Compression
Ring
Center
Compression Ring
Rails
Expander
Oil Control Ring

(3 Piece)
Scuffing and scoring of pistons and cylinder walls

occurs when internal temperatures approach welding
point of piston. Temperatures high enough to do this are
created by friction, which is usually attributed to improper
lubrication, and/or overheating of engine.
Normally, very little wear takes place in piston bosspiston pin area. If original piston and connecting rod
can be reused after new rings are installed, original pin
can also be reused, but new piston pin retainers are
required. Piston pin is part of piston assembly; if pin boss
or pin are worn or damaged, a new piston assembly is
required.
Ring failure is usually indicated by excessive oil
consumption and blue exhaust smoke. When rings fail,
oil is allowed to enter combustion chamber where it is
burned along with fuel. High oil consumption can also
occur when piston ring end gap is incorrect because
ring cannot properly conform to cylinder wall under this
condition. Oil control is also lost when ring gaps are not
staggered during installation.
When cylinder temperatures get too high, lacquer and
varnish collect on pistons causing rings to stick which
results in rapid wear. A worn ring usually takes on a
shiny or bright appearance.
20 690 01 Rev. I
Remove Piston Rings

1. Remove top and center compression rings using a
ring expander.
2. Remove oil control ring rails, then remove spacer.
Some important points to remember when servicing
piston rings:
1. Cylinder bore must be deglazed before service ring
sets are used.
2. If cylinder bore is within wear limits (refer to
Specifications) and old piston is within wear limits,
free of score or scuff marks, old piston may be
reused.
3. Remove old rings and clean up grooves. Never
reuse old rings.
4. Before installing rings on piston, place each of top
two rings in its running area in cylinder bore and
check end gap. Compare to listed specifications.
Clearance Specifications-Top and Middle
Compression Ring End Gap
New Bore
Top Ring
0.15/0.40 mm (0.006/0.016 in.)
Middle Ring
0.30/0.55 mm (0.012/0.022 in.)
Max. Used Bore
0.77 mm (0.030 in.)
5. After installing new compression (top and middle)
rings on piston, check piston-to-ring side clearance.
Maximum recommended side clearance for each
ring is 0.04 mm (0.0016 in.). If side clearance is
greater than specified, a new piston must be used.
Install Piston Rings
NOTE: Rings must be installed correctly. Ring
installation instructions are usually included with
new ring sets. Follow instructions carefully. Use
a piston ring expander to install rings. Install
bottom (oil control) ring first and top
compression ring last.
KohlerEngines.com
59

To install piston rings, proceed as follows:
1. Oil control ring (bottom groove): Install expander and
then rails. Make sure ends of expander are not
overlapped.
2. Compression ring (center groove): Install center ring
using a piston ring installation tool. Make sure
identification mark is up when ring is installed.
3. Compression ring (top groove): Install top ring using
a piston ring installation tool. Make sure identification
mark is up when ring is installed.
Remove Crankshaft and Balance Weight Assembly
Carefully remove crankshaft and balance weight
assembly from crankcase. On engines with Second
Generation Balance Weight, carefully lift lower control
link (for balance weight), off boss of crankcase as
crankshaft is removed. Models with Third Generation
Balance Weight have a balance weight guidance
shaft and link which can be removed before removing
crankshaft and balance weight assembly.
Crankshaft and Crank Gear Inspection and Service
Inspect teeth of crank gear. If teeth are badly worn,
chipped, or some are missing, replacement of crank
gear will be necessary. Remove gear by pulling it off key
and crankshaft.
Inspect crankshaft bearing journal surfaces for wear,
scoring, grooving, etc. If they show signs of damage or
are out of running clearance specifications, crankshaft
must be replaced.
Inspect crankshaft keyways. If worn or chipped,
replacement of crankshaft will be necessary.
Inspect crankpin for wear, score marks or aluminum
transfer. Slight score marks can be cleaned with crocus
cloth soaked in oil. If wear limits are exceeded, it will be
necessary to replace crankshaft.
Balance Weight Disassembly
If necessary, First and Second Generation Balance
Weight Assembly can be separated from crankshaft.
Disassemble only if required.
1. Remove crank gear from crankshaft and carefully
remove key from keyway.
2. For first generation balance weight assembly:
remove guide shoe from guide pin on flywheel side
of assembly.
For second generation balance weight assembly:
remove link from guide pin on PTO side of assembly.
3. Remove long hex flange screw securing two balance
weight halves together on crankshaft. Note
orientation of all parts. Guide pin is on flywheel side
for balance weight design with closure plate side
guide shoe. Guide pin is on PTO side for balance
weight design with lower control link. Hold guide pin
with wrench or torx bit socket as required. Do not
hold or damage outside diameter (O.D.) of guide pin.
4. Mark weights for proper reassembly and carefully
slide balance weights off crankshaft eccentrics.
60
Balance Weight Assembly

Measurement Locations
A
Guide Pin O.D.
Crankshaft
Eccentric
Balance Weight
Bearing Surface
Balance Weight
Guide Shoe
NOTE: These procedures apply only to First and

Second Generation Balance Weights. Third
Generation Balance Weight should not be
disassembled.
Balance weight assembly counterbalances crankshaft
weights and internal forces during operation to minimize
vibration. Several key areas of balance weight must
be checked before installation and use. Additionally,
mating components (crankshaft eccentrics and closure
plate guide channel) must also be inspected for wear or
damage.
Use these procedures to check balance weight and
matching components.
Balance Weight-to-Eccentric Clearance
NOTE: Do not use a feeler gauge to measure balance
weight-to-eccentric clearance.
Before balance weight assembly is reassembled to
crankshaft, running clearance to crankshaft eccentrics
must be accurately checked. Failure to maintain required
clearances will result in vibration or engine failure.
KohlerEngines.com
20 690 01 Rev. I

Measuring Balance Weight to Crankshaft Eccentric
Ring(s) Clearance
1. Use an inside micrometer, telescoping gauge, or
bore gauge and measure inside diameter of balance
weight bearing surface. Take two measurements 90
to each other on each weight.
2. Then use an outside micrometer and measure
across each eccentric on crankshaft. Again take two
measurements 90 to each other.
3. Running clearance is eccentric diameter subtracted
from balance weight bearing diameter (step 1 minus
step 2). If measurements are outside maximum wear
limits listed in Specifications, affected component(s)
must be replaced.
Measuring Balance Weight Guide Pin and Guide
Shoe-to-Closure Plate Guide Channel Running
Clearance
1. Use an outside micrometer and measure outside
width of balance weight guide shoe.
2. Use an inside micrometer, telescoping gauge or
similar tool and measure width of guide channel in
closure plate. Record these dimensions.
3. Use an outside micrometer again and measure O.D.
of balance weight guide pin.
4. Use a split ball gauge or dial calipers and measure
I.D. of corresponding hole in guide shoe. Record
these dimensions.
If any of measurements taken are outside maximum
wear limits listed in Specifications, affected
component(s) must be replaced.
Remove Governor Cross Shaft
1. Remove hitch pin and washer located on outside of
governor cross shaft.
2. Slide shaft inward and remove it through inside of
crankcase. Be careful not to lose small washer in
inside portion of shaft.
Remove PTO and Flywheel Side Oil Seals
Use a seal puller to remove PTO and flywheel side oil
seals.
Crankcase
Check all gasket surfaces to make sure they are free of
gasket fragments and deep scratches or nicks.
Check cylinder wall for scoring. In severe cases,
unburned fuel can wash necessary lubricating oil off
piston and cylinder wall. Piston rings make metal to
metal contact with wall, causing scuffing and scoring.
Scoring of cylinder wall can also be caused by localized
hot spots from blocked cooling fins or from inadequate or
contaminated lubrication.
If cylinder bore is scored, worn, tapered, or out-of-round,
resizing may be possible. Use an inside micrometer or
telescoping gauge to determine amount of wear (refer to
specifications). If wear exceeds published limits, a 0.08
mm (0.003 in.) oversize piston is available. If cylinder
will not clean up at 0.08 mm (0.003 in.) oversize, a short
block or replacement engine will need to be considered.
20 690 01 Rev. I
Honing
Detail
A
A
23-33 Crosshatch
While most commercially available cylinder hones can
be used with either portable drills or drill presses, use
of a low speed drill press is preferred as it facilitates
more accurate alignment of bore in relation to crankshaft
counter bore. Honing is best accomplished at a drill
speed of about 250 RPM and 60 strokes per minute.
After installing coarse stones in hone, proceed as
follows:
1. Lower hone into bore and, after centering, adjust it
so stones are in contact with cylinder wall. Use of a
commercial cutting-cooling agent is recommended.
2. With lower edge of each stone positioned even with
lowest edge of bore, start drill and honing process.
Move hone up and down while resizing to prevent
formation of cutting ridges. Check size frequently.
Make sure bore is cool when measuring.
3. When bore is within 0.064 mm (0.0025 in.) of
desired size, remove coarse stones and replace with
burnishing stones. Continue with burnishing stones
until within 0.013 mm (0.0005 in.) of desired size and
then use finish stones (220-280 grit) and polish to
final size. 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, too steep an angle will result in high oil
consumption.
4. After honing, check bore for roundness, taper, and
size. Use an inside micrometer, telescoping gauge,
or bore gauge to take measurements. These
measurements should be taken at three locations in
cylinder at top, middle, and bottom. Two
measurements should be taken (perpendicular to
each other) at 3 different locations.
KohlerEngines.com
61

Clean Cylinder Bore after Honing
Proper cleaning of cylinder walls following honing is
critical. Grit left in cylinder bore can destroy an engine in
less than one hour of operation after a rebuild.
Final cleaning operation should always be a thorough
scrubbing with a brush and hot, soapy water. Use a
strong detergent capable of breaking down machining
oil while maintaining a good level of suds. If suds break
down during cleaning, discard dirty water and start again
with more hot water and detergent. Following scrubbing,
rinse cylinder with very hot, clear water, dry it completely,
and apply a light coating of engine oil to prevent rusting.
Measuring Piston-to-Bore Clearance
Piston Detail
8 mm (0.314 in.)
NOTE: Do not use a feeler gauge to measure piston-tobore clearance; it will yield inaccurate
measurements. Always use a micrometer.
Before installing piston into cylinder bore, it is necessary
that clearance be accurately checked. This step is
often overlooked, and if clearances are not within
specifications, engine failure will usually result.
Use following procedure to accurately measure pistonto-bore clearance:
1. Use a micrometer and measure diameter of piston 8
mm (0.314 in.) above bottom of piston skirt and
perpendicular to piston pin.
2. Use an inside micrometer, telescoping gauge, or
bore gauge and measure cylinder bore. Take
measurement approximately 63.5 mm (2.5 in.) below
top of bore and perpendicular to piston pin.
3. Piston-to-bore clearance is difference between bore
diameter and piston diameter (step 2 minus step 1).
62
KohlerEngines.com
20 690 01 Rev. I
Reassembly
Balance Weight/Piston Assembly Components
A
K
L
M
N
I
J
Crankshaft Gear
Crankshaft
Crank Gear Key
Third Generation
Balance Weight
Washer
Hitch Pin
Oil Seal
End Cap
Connecting Rod
Wrist Pin Retainer
Wrist Pin
Piston
Piston Ring Set
First Generation
Balance Weight
Second Generation
Balance Weight
NOTE: Make sure engine is assembled using all

specified torque values, torque sequences, and
clearances. Failure to observe specifications
could cause severe engine wear or damage.
Always use new gaskets. Apply a small amount
of oil to threads of critical fasteners before
assembly, unless a sealant or Loctite is
specified or preapplied.
20 690 01 Rev. I
Make sure all traces of any cleaner are removed before

engine is assembled and placed into operation. Even
Check closure plate, crankcase, cylinder heads, and
valve covers to be certain all old gasket material has
been removed. Use gasket remover, lacquer thinner, or
paint remover to remove any remaining traces. Clean
surfaces with isopropyl alcohol, acetone, lacquer thinner,
or electrical contact cleaner.
KohlerEngines.com
63
Reassembly
1. If oil pump assembly was removed from intake cam
shaft, reassemble it onto shaft. Press fit of drive pins
in holes may be one of two designs. One style of
tube has drive pin holes machined to be a clearance
(slip) fit on one side and a press fit on other
accepting smooth style drive pins. Later design
tubes have holes uniformly machined and use
knurled style drive pins. Support cam shaft
(clearance holes up, when applicable), and install
shorter 2.5 mm (0.098 in.) diameter pin in outer hole,
closest to bottom end. Center pin in shaft.
2. If it was removed, install and center longer, 3 mm
(0.118 in.) diameter drive pin into upper hole.
3. Lightly grease gerotor gears and install into oil
pump, with short drive pin fitted into slot of inner
gear.
Install PTO Side Oil Seal

PTO Seal Depth Details
Pump Outlet Seals
Seal Depth
5.5 mm (0.216 in.)
Use a seal driver and install to a depth of 5.5 mm (0.216
in.) into crankcase.
A
Oil Seal
Install Governor Cross Shaft

1. Place thin thrust washer onto governor cross shaft
as far as it will go.
2. Lightly lubricate shaft with oil, and install it from
inside crankcase.
3. Slide thick thrust washer onto shaft from outside as
far as it will go. Secure by inserting hitch pin in
machined groove.
A
A
A
E
A
B
C
Intake Cam Shaft
3 mm Diameter Pin
Oil Pump Assembly
Hole Location 2
Hole Location 1
2.5 mm Diameter
Pin
64
Open Seal
Closed Seal
Oil Pump Outlet Styles
Install Oil Pump Assembly and Intake Cam Shaft

Assembled Intake Cam Shaft Details
Open Outlet Style

(Requires Seal)
Closed Outlet Style
4. Determine if outlet of oil pump is open or closed.

Open style pumps require use of a rubber seal
between pump outlet and lower main bearing area.
Some models use an open style seal with an internal
passage to feed oil to lower bearing. Some models
use a closed seal without an oil passage, and
crankshaft is crossed-drilled for lower bearing
lubrication. Both styles of outlet seals are shown. If a
new seal is to be ordered, be sure it is same style as
what was removed. Lightly lubricate ends of oil
pump outlet seal with oil and install in into outlet of
oil pump.
KohlerEngines.com
20 690 01 Rev. I
Reassembly
5. Install intake cam shaft down into crankcase boss.
Seat rubber oil pump outlet seal into machined
pocket. If an open style outlet seal is used, check to
make sure small feed hole is open and aligned with
lower main bearing oil feed hole. Use a 3/32 allen
wrench, or a light with a mirror. Push steel sleeves in
pump housing down until bottomed against mounting
surface. Install two M5 mounting screws. Hold pump
outlet against main bearing area and torque screws
to 6.2 Nm (55 in. lb.) into new holes, or 4.0 Nm (35
in. lb.) into used holes.
6. If engine uses a drain back tube, insert round
flanged end into hole near base of cylinder and clip it
onto oil pump body.
Install Crankshaft and Balance Weight
NOTE: If installing a crankshaft with third generation
balance weight, steps 1 and 2 do not need to be
performed.
1. Assemble crankshaft balance weight if removed
from crankshaft.
a. Lubricate crankshaft eccentrics and balance
weight bearing surfaces with oil.
b. Install two balance weight halves onto crankshaft
eccentrics as marked or originally installed.
c. First generation balance weight assembly: Align
weights and install balance weight screw, through
mounting holes, from PTO side. Thread it into
guide pin outside weight on flywheel side. Hold
guide pin with a wrench or Torx bit, and torque
screw to 11.3 Nm (100 in. lb.). Do not hold, or
damage outside diameter (O.D.) of guide pin.
Second generation balance weight assembly:
Align weights and insert balance weight screw,
through mounting holes from flywheel side.
Thread it into guide pin outside weight on PTO
side. Hold guide pin with a wrench or Torx bit, and
torque screw to 11.3 Nm (100 in. lb.). Do not
hold, or damage outside diameter (O.D.) of guide
pin. Apply grease to inner diameter (I.D.) of each
hole in control link and install one end over guide
pin.
2. Carefully install crank gear key in keyway.
3. First generation balance weight assembly: Carefully
install crankshaft into crankcase, through PTO seal,
and seat fully into place. Rotate crankshaft so
journal for connecting rod is away from cylinder.
Second generation balance weight assembly: Make
sure pivot pin on boss in lower section of crankcase
is clean and free of any nicks, or surface
irregularities. Apply a small amount of grease to O.D.
Third generation balance weight assembly: Carefully
install crankshaft into crankcase, through PTO seal,
and seat fully into place.
20 690 01 Rev. I
4. First generation balance weight assembly: Install

balance weight guide shoe onto guide pin with solid
end toward crankshaft.
Second generation balance weight assembly: Apply
a small amount of grease to O.D. of guide pin on
PTO side of counterweight and install control link.
Carefully install crankshaft with link (hold in position
as required), through PTO seal. Slightly rotate
counterweight assembly and guide outer end of link
over stationary guide pin in crankcase. Seat link and
crankshaft fully into place, do not force either part
into position.
Third generation balance weight assembly: Apply a
small amount of engine oil to ends of guidance shaft.
Install guidance shaft through links into boss of
crankcase.
Install Piston Rings
NOTE: For detailed piston inspection procedures and
piston ring installation refer to Disassembly/
Inspection and Reconditioning.
Install Piston to Connecting Rod
Assemble piston, connecting rod, piston pin, and piston
pin retainers.
Install Piston and Connecting Rod
NOTE: Proper orientation of piston/connecting rod
inside engine is extremely important. Improper
orientation can cause extensive wear or
damage.
1. Stagger piston rings in grooves until end gaps are
120 apart. Lubricate cylinder bore, crankshaft
journal, connecting rod journal, piston, and rings with
engine oil.
2. Compress piston rings using a piston ring
compressor. Orient FLY mark on piston toward
flywheel side of crankcase. Place ring compressor
on top surface of crankcase and make certain it is
seated down around entire circumference. Use a
soft, rubber grip hammer handle and tap piston/
connecting rod into bore. First tap should be rather
firm, so oil ring moves from compressor into bore in
one smooth, quick motion. Otherwise oil ring rails
may spring out and jam between ring compressor
and top of bore.
3. Guide connecting rod down and rotate crankshaft to
mate journals. Install rod cap.
4. Install screws and torque in 2 increments, first to
5.5 Nm (50 in. lb.), finally to 11.5 Nm (100 in. lb.).
KohlerEngines.com
65
Reassembly
Cam/Closure Plate Components
Install Exhaust Cam Shaft and Cam Gear

A
Drive Pin Locations for Exhaust Cam Shaft

F
C
B
A
C
D
E
D
P
O
M
L
K
J
I
Oil Seal
Closure Plate
Gasket
Oil Passage Cover
Cam Gears
Thrust Washer
Cam Levers
Cam Shaft (Exhaust)
Closure Plate Gasket
Gerotor Gears
Oil Pump
Cam Shaft Pin
Cam Shaft (Intake)
Regulating Pin
Governor Gear
Governor Gear Shaft
Install Cam Levers

Install two cam levers as shown. Dimple for seating push
rod must face up. Secure each cam lever using an M6
screw. Torque screws to 7.5 Nm (65 in. lb.). Lubricate
dimple and bottom side of cam lever with light grease or
oil.
66
Exhaust Cam Shaft
3 mm Diameter Pin
2.5 mm Diameter Pin
1.86 mm
Hole Location 1
Hole Location 2
1. If drive pins were removed from exhaust cam shaft,

follow same procedure used earlier for intake cam
shaft and reinstall them.
2. Apply a dab of grease to formed groove in thrust
washer. Slide washer onto cam shaft so short drive
pin is seated in groove. Grease will hold washer in
position. Pivot exhaust cam lever toward push rod
bore, then insert cam shaft into counterbore of
crankcase. Make sure pin stays in groove of thrust
washer.
3. Lubricate cam surfaces of cam gears with light
grease or oil.
4. Assemble and install ACR (automatic compression
release) into exhaust cam gear if removed for
servicing.
a. Install spring onto ACR weight with loop around
post, and formed upper leg hooked behind upper
section.
b. Install ACR assembly into hole of exhaust cam
gear and hook long leg behind notched tab.
5. Lift exhaust cam lever and install exhaust cam gear
with assembled ACR onto cam shaft, engaging slot
with upper drive pin. Rotate gear and shaft so EX
timing mark on cam gear is in 8 oclock position.
Install thrust washer onto cam shaft.
Install Intake Cam on Cam Shaft
NOTE: Cam gear assemblies may contain either two or
four rivets.
Lift intake cam lever and install intake cam gear onto
intake cam shaft, engaging slot with upper drive pin.
Rotate gear and shaft so IN timing mark on cam gear
is in 4 oclock position. Early models only: install thrust
washer (if used originally), onto cam shaft.
Install Crank Gear
Orient crankshaft so key is in 12 oclock position. Hold
crank gear with timing marks visible and slide it onto
crankshaft and key, so timing marks on crank gear align
with timing marks on cam gears.
KohlerEngines.com
20 690 01 Rev. I
Reassembly
Install Flywheel Side Oil Seal
Lubricate outside diameter and lip of flywheel end oil
seal. Support closure plate and install oil seal. Using a
seal driver, drive seal to a depth of 5 mm (0.196 in.) in
seal bore.
Install Closure Plate Gasket, Closure Plate, and
Wiring Harness
Closure Plate Fastener Torque Sequence
14
12
10
9
11
20 690 01 Rev. I
13
NOTE: A special gasket used between closure plate

and crankcase controls crankshaft endplay, no
shimming is required. Do not use RTV sealant in
place of gasket.
NOTE: Engines with first generation balance weight:
Apply grease to outside flat surfaces of balance
weight guide shoe. Position guide shoe so solid
end is toward crankshaft. Make sure guide shoe
stays in this position during step 2.
1. Make sure sealing surfaces of crankcase and
closure plate are clean, dry, and free of any nicks or
burrs. Install a new closure plate gasket onto
crankcase.
2. Ensure gasket, cover plate, and governor gear
assembly, have been properly assembled to closure
plate. Start closure plate onto crankcase. Be sure
guide shoe (models with First Generation Balance
Weight), is aligned with guide channel in closure
plate, and cam shafts and governor gear shaft are
aligned with their mating bearing surfaces. As
closure plate is lowered into final position, rotate
crankshaft slightly to help engage governor gear.
3. Install screws securing closure plate to crankcase,
with any clamps for wiring harness and sheathed
RFI suppression spark plug lead (#5 location, if
equipped). If wiring harness was separated from
closure plate, route harness through clamps and slot
in closure plate. Close clamps to retain harness.
4. Torque closure plate fasteners to 24.5 Nm
(216 in. lb.) using sequence shown.
KohlerEngines.com
67
Reassembly
Cylinder Head Components
D
A
B
F
E
H
C
G
M
L
Q
P
N
A
Gasket
Cylinder Head Screw
Valve Spring
M
Q
Valve
Cylinder Head
Spark Plug
Push Rod
Valve Spring Retainer
Valve Stem Seal
Valve Spring Cap
Rocker Arm
Set Screw
Valve Cover Gasket
Valve Cover
Screw
Rocker Arm Pivot
Rocker Arm Stud
Push Rod Guide Plate
Assemble Cylinder Head

Prior to assembly, lubricate all components with engine
oil, including tips of valve stems and valve guides. Using
a valve spring compressor, install following items in
order listed.
Intake and exhaust valves.
Valve spring caps.
Valve springs.
Valve spring retainers.
Valve spring keepers.
Install Cylinder Head

Cylinder Head Torque Sequence
3
4
2
NOTE: Do not reuse cylinder head screws or gasket,

always replace with new parts.
NOTE: If crankshaft has not been turned since
installation of crank gear, turn it one (1) complete
revolution. This will set piston at top dead center
(TDC) of compression stroke, for proper valve
lash adjustment later.
68
KohlerEngines.com
20 690 01 Rev. I
Reassembly
1. Check to make sure there are no nicks or burrs on
sealing surfaces of cylinder head or crankcase.
2. If engine uses a drain back check ball, install it into
keyhole slot in top of crankcase.
3. Install a new cylinder head gasket.
4. Install cylinder head and start six screws. Install thick
washer on screw closest to exhaust port.
5. Using torque sequence shown, torque cylinder head
screws in two stages; initially to 20.5 Nm
(180 in. lb.), and finally to 41.0 Nm (360 in. lb.).
Install Rocker Arms and Push Rods
NOTE: Installation and seating of push rods into cam
lever recesses during this sequence is critical.
Position engine with cylinder head up if possible,
to aid with proper installation of push rods and
rocker arms, and adjusting valve lash.
NOTE: If being reused, push rods should always be
installed in their original position.
1. Position push rod guide plates on cylinder head with
extruded edges down over push rod bores. Secure
by installing rocker arm pivot studs. Torque studs to
13.5 Nm (120 in. lb.).
2. Apply grease to contact surfaces of rocker arms and
adjusting nuts and install them onto pivot studs.
3. Note mark or tag identifying push rod as either
intake or exhaust. Apply grease to ends of push
rods. Insert push rods into push rod bores and seat
lower end into dimpled recess of cam levers. It may
be necessary to lift or shift lower end of push rod
slightly, and feel rod seats into recess. Once seated,
hold it in place as you position rocker arm. Push rod
must stay in recess while rocker arms are positioned
and adjusted.
4. With engine at TDC of compression stroke, insert
correct size flat feeler gauge (see below) between
appropriate valve stem and rocker arm. Tighten
adjustment nut with a wrench until a slight drag is felt
on feeler gauge. Hold nut in position and torque set
screw (T15 Torx drive) to 5.5 Nm (50 in. lb.). To
prevent damage to nut, torque Torx screw only.
Perform adjustment procedure on other valve.
Intake Valve
0.127 mm (0.005 in.)
Exhaust Valve
0.178 mm (0.007 in.)
4
2
Valve Cover with Gasket

1. Make sure sealing surfaces of valve cover and
cylinder head are clean, and free of any nicks or
burrs.
2. Install a new valve cover gasket, followed by valve
cover. Position any brackets mounted on valve cover
and start seven mounting screws.
3. Torque valve cover screws to 11.0 Nm (95 in. lb.)
into new holes, or 7.5 Nm (65 in. lb.) into used
holes, using sequence shown.
Valve Cover with RTV
A
RTV Overlap Area
(1/2 way
between holes)
NOTE: Always use fresh sealant. Using outdated
sealant can result in leakage. Refer to Tools and
Aids for important 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.
1. Prepare sealing surface of cylinder head and valve
cover.
2. Apply a 1.6 mm (1/16 in.) bead of sealant to valve
cover as shown, noting RTV overlap area.
3. Position cover on cylinder head. Position any
brackets mounted on valve cover and start seven
mounting screws.
A
Clearance Specifications-Valve
20 690 01 Rev. I
Install Valve Cover

Valve Cover Torque Sequence
KohlerEngines.com
RTV Sealant
69
Reassembly
2. Install two screws to secure stator and torque to
6.0 Nm (55 in. lb.), into new holes, or 4.0 Nm
(35 in. lb.), into used holes.
Install Wiring Harness
Check locking tang on terminal of violet B+ wiring
harness lead is angled upward. Insert terminal into
center location of rectifier-regulator plug connector until
it locks into place. If not already inserted, two AC leads
from stator go in outer locations.
4. Torque valve cover screws to 11.0 Nm (95 in. lb.)

into new holes, or 7.5 Nm (65 in. lb.) into used
holes, using sequence shown.
Flywheel/Ignition Components
A
B
C
Install Pipe Plug or Fitting and Pulse Line for Fuel

Pump
1. Apply pipe sealant with Teflon (Loctite PST 592
Thread Sealant or equivalent), to 1/8 pipe plug or
90 fitting (as equipped). Install and tighten into
tapped vacuum port of closure plate. Torque plug to
4.5-5.0 Nm (40-45 in. lb.). Turn outlet of a fitting to
8 oclock position.
2. If a fitting is used, connect fuel pump pulse line and
secure with clamp. If fuel pump is attached to air
cleaner base, do not connect pulse line at this time.
Install Fan and Flywheel
CAUTION
Damaging Crankshaft and Flywheel can
cause personal injury.
H
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.
J
I
Flywheel Screw
Washer
Fan Mounting Plate
Fan
Magnet
Flywheel
Ignition Module
Stator
Flywheel Key
Pulse Line Fitting
Install Stator and Wiring Harness

Install Stator
1. Position stator onto mounting bosses so leads lay in
channel and recess of closure plate. They will
become captured when blower housing is installed.
If a clamp was used to retain leads, remove screw in
No. 13 location and install clamp. Hold clamp in
position and torque screw to 24.5 Nm (216 in. lb.)
70
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 over
stressed and damaged when mounting screw is
torqued to specification.
NOTE: Make sure flywheel key is installed properly in
keyway. Flywheel can become cracked or
damaged if key is not properly installed.
NOTE: Always use a flywheel strap wrench or flywheel
holding tool to hold flywheel when tightening
flywheel fastener. Do not use any type of bar or
wedge between cooling fins or flywheel ring
gear, as these parts could become cracked or
damaged.
1. Install appropriate key into crankshaft keyway.
Based on crankshaft keyway style, use either a
woodruff or straight key. Make sure key is fully
seated.
2. Install flywheel onto crankshaft aligning keyway with
key. Be careful not to shift or unseat key.
3. Position fan onto flywheel, so locating pins drop into
corresponding recesses.
4. Install fan mounting plate onto fan, aligning four
cutouts, followed by heavy flat washer and screw.
KohlerEngines.com
20 690 01 Rev. I
Reassembly
5. Use a flywheel strap wrench or holding tool to hold flywheel and torque screw. For an M10 screw, torque to 66.5
Nm (49 ft. lb.). For an M12 screw, torque to 88.0 Nm (65 ft. lb.).
External Engine Components
A
W
B
O
N
C
M
K
I
L
U
P
N
M
K
Q
R
H
G
Oil Fill/Dipstick
Debris Screen
Blower Housing
Fuel Pump
Cylinder Head Baffle
Rectifier-Regulator
Electric Starter
Oil Filter
Fuel Filter
Oil Sentry
Air Cleaner Cover
Precleaner
Air Cleaner Element
Air Cleaner Base
Gasket
Carburetor
Ground Wire
Oil Drain Plug
Nikki Fuel Solenoid
Walbro Fuel Solenoid
Heat Deflector
Heat Shield
Carburetor Spacer
Install Electric Starter

Install electric starter to closure plate and secure with
nuts. Make sure wires are clear of any moving parts and
torque nuts to 3.6 Nm (32 in. lb.).
Install Ignition Module
1. Rotate flywheel so magnet is away from ignition
module bosses. Using screws, install ignition module
to crankcase bosses with kill terminal up. Move
module as far away from flywheel as possible.
Tighten screws sufficiently to keep module in
position.
2. Rotate flywheel to align magnet with ignition module.
20 690 01 Rev. I
3. Insert a 0.25 mm (0.010 in.) flat feeler gauge

between magnet and ignition module. Loosen
screws so magnet pulls module against feeler
gauge.
4. Torque screws to 6.0 Nm (55 in. lb.) into new holes,
or 4.0 Nm (35 in. lb.) into used holes.
5. Rotate flywheel back and forth checking for
clearance between magnet and ignition module.
Make sure magnet does not strike module. Recheck
air gap with a feeler gauge and readjust if necessary.
Final air gap: 0.203/0.305 mm (0.008/0.012 in.).
6. Connect kill lead to tab terminal on ignition module.
KohlerEngines.com
71
Reassembly
7. If equipped with a sheathed RFI suppression spark
plug lead, place lead in retaining clip so braided
wires will be in direct contact with clip when closed.
Carefully close clip with a pliers until a 0.127 mm
(0.005 in.) gap exists between ends. Do not pinch or
flatten clip.
Install Spark Plug
1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.03 in.).
2. Install plug into cylinder head.
3. Torque plug to 27 Nm (20 ft. lb.).
Install Heat Deflector, Carburetor, Linkage and Air
Cleaner Base
1. If carburetor mounting stud was removed, reinstall it
in outer cylinder location (closest to head). Use an
E5 Torx socket or two nuts tightened together, and
turn stud in until tight.
2. Make sure all gasket surfaces are clean and free of
any nicks or damage.
3. Install a new intake gasket onto carburetor stud,
then install heat deflector or carburetor spacer.
Curved section of heat deflector should be down,
toward engine. If deflector contains a molded
protruding point, it should be towards back inserted
into intake port. Be sure protruding point goes
through large hole in gasket, to keep it aligned.
4. Models with one screw and one mounting stud only:
Insert a 3/16 diameter rod, approximately 4 long,
into open mounting hole in heat deflector/carburetor
spacer to serve as a temporary alignment pin. Be
careful not to force rod or damage threads.
5. Install heat shield (if equipped) with gasket or a new
carburetor gasket onto mounting stud(s) and/or
alignment pin.
6. Attach choke and throttle linkages to carburetor and
install carburetor assembly. If governor lever was not
disconnected, slide it onto governor shaft with lever
up.
7. If carburetor has a fuel solenoid, fasten ground lead
to crankcase boss, with toothed washer between
eyelet terminal and boss. Torque screw to 8.0 Nm
(70 in. lb.). Connect solenoid power lead to wiring
harness and secure with a tie strap.
8. Connect fuel line to carburetor and secure with a
hose clamp.
9. Install air cleaner base (with fuel pump attached, if
equipped).
a. Install a new air cleaner base gasket. Check two
metal spacers are in air cleaner base mounting
holes and install base onto stud(s), and or
alignment pin. Make sure upper mounting tab is
positioned above closure plate boss. Install nut(s)
and finger tighten.
b. Models with one screw and one mounting stud
only: Apply hand pressure to keep parts from
shifting, then carefully remove alignment pin and
install DRY long M6 thread forming screw. DO
NOT OIL. Check to make sure all gaskets are still
in proper position.
72
c. Torque nut(s) to 5.5 Nm (48 in. lb.). Torque screw

to 8.0 Nm (70 in. lb.) into a new hole, or 5.5 Nm
(48 in. lb.) into a used hole, do not over tighten.
An M6 screw for upper tab will be installed when
blower housing is mounted.
10. Attach breather hose to valve cover and air cleaner
base.
Install and Adjust Governor Lever
E
F
D
C
Governor Lever
Speed Control
Bracket
Choke Linkage
Throttle Linkage
Fuel Pump Bracket
Fuel Pump
NOTE: It is recommended a new governor lever be

installed whenever removal is performed.
1. Install governor lever onto governor shaft with lever
section up. Connect throttle linkage using black
linkage bushing.
2. Move governor lever toward carburetor, to limit of its
travel (wide-open throttle) and hold in this position.
Do not apply excessive pressure, flexing or distorting
linkage. Grasp cross shaft with a pliers, and turn
shaft counterclockwise as far as it will go. Torque nut
to 7.0-8.5 Nm (60-75 in. lb.).
Mounting Speed Control Bracket
1. Attach governor spring to governor lever and throttle
lever of speed control bracket, in original holes. If
holes were not marked during disassembly, refer to
Governor Spring Location charts. Connect choke
linkage from carburetor to actuating lever of speed
control bracket.
2. Attach speed control bracket to mounting locations
on engine with M6 screws. Position bracket as
marked during disassembly. Torque screws to
11.0 Nm (95 in. lb.) into new holes, or 7.5 Nm
(65 in. lb.) into used holes.
KohlerEngines.com
20 690 01 Rev. I
Reassembly
Early Style Governor Spring Location
A
High Speed
RPM
Governed Idle
RPM
Governor
Lever Hole
Throttle Lever White Spring Green Spring Black Spring

Hole
3201-3400
3201-3400
3201-3400
1601-1800
X
X
X
Later Style Governor Spring Location
A
Governor
Lever Hole
Throttle Lever
Hole
Red Spring
Alignment
Hole
Less than 3000 RPM
Less than 3000 RPM
High Speed RPM
Governed Idle
RPM
Current Style Governor Spring Location
D
C
A
High Speed
RPM
Governed Idle RPM

89mm Bore 94mm Bore
Governor
Lever Hole
Throttle Lever
Hole
Red Spring
Alignment
Hole
2400-2900
1500-2150
1750-2150
2901-3100
1500-2150
1750-2150
3101-3750
1500-2150
1750-2150
20 690 01 Rev. I
KohlerEngines.com
73
Reassembly
Install Fuel Pump (if equipped)
NOTE: If fuel pump is attached to air cleaner base, fuel
lines and pulse line should still be connected to
fuel pump. Connect pulse line to pulse fitting and
secure with clamp.
1. Attach fuel pump mounting bracket to speed control
bracket with two M5 screws. Torque screws to
6.5 Nm (55 in. lb.) into new holes, or 4.0 Nm
(35 in. lb.) into used holes.
2. Attach fuel pump to bracket so pulse fitting is
oriented in four oclock position. Secure with two M6
screws. Torque screws to 9.5 Nm (84 in. lb.) into
new holes, or 5.9 Nm (52 in. lb.) into used holes. Do
not over tighten.
3. Connect pulse and fuel lines to fuel pump and
secure with clamps.
Install Rectifier-Regulator
1. Using M6 screws, mount rectifier-regulator onto
crankcase bosses, with cooling fins out. Torque
screws to 6.0 Nm (55 in. lb.) into new holes, or
4.0 Nm (35 in. lb.) into used holes.
2. Attach connector to rectifier-regulator terminals.
Install Cylinder Head Baffle
Attach cylinder head baffle to cylinder head using
screws. Torque screws to 10.2-12.4 Nm (90-110 in. lb.)
into new holes, or 7.0-8.5 Nm (62-75 in. lb.) into used
holes.
Install Oil Sentry or Pipe Plug
Apply pipe sealant with Teflon (Loctite PST 592
Thread Sealant or equivalent), to threads of 1/8 pipe
plug or adapter. Install and tighten into port on closure
plate. Torque pipe plug to 4.5-5.0 Nm (40-45 in. lb.). If
a switch was installed, apply sealant to threads of Oil
Sentry switch and install into adapter, center passage
or closure plate behind blower housing. Torque switch
to 4.5-5.0 Nm (40-45 in. lb.). Connect green wiring
harness lead to terminal on switch.
Install Blower Housing and Debris Screen
1. Position blower housing on engine and route spark
plug lead through underside slot.
2. Check stator leads are within notch of blower
housing. Align mounting locations, then install four
M6 shouldered mounting screws. If a flat washer
was used under head on one screw, install screw in
location closest to oil fill/dipstick.
Torque screws to 11.6 Nm (99 in. lb.) into new
holes, or 7.7 Nm (68 in. lb.) into used holes.
3. Snap debris screen onto cooling fan.
74
Install Air Cleaner Element, Precleaner, and Air

Cleaner Cover
1. Install air cleaner element with pleated side out. Seat
rubber seal onto all edges of air cleaner base.
2. Install precleaner (if equipped), into upper section of
air cleaner cover.
3. Install air cleaner cover and secure with two
retaining knobs.
Install Muffler
1. Install gasket, muffler, and nuts on exhaust port
studs. Leave nuts slightly loose.
2. If an auxiliary muffler bracket is used, install M6
screw(s) into bracket.
3. Torque nuts to 24.4 Nm (216 in. lb.). Torque screws
to 7.5 Nm (65 in. lb.).
Install Drain Plug, Oil Filter, and Oil
1. Install oil drain plug. Torque plug to 14 Nm
(125 in. lb.).
2. Place new filter in shallow pan with open end up. Fill
with new oil until oil reaches bottom of threads. Allow
2 minutes for oil to be absorbed by filter material.
3. Apply a thin film of clean oil to rubber gasket on new
filter.
4. Refer to instructions on oil filter for proper
installation.
5. Fill crankcase with new oil. Level should be at top of
indicator on dipstick.
6. Reinstall oil fill cap/dipstick and tighten securely.
Prepare Engine for Operation
Engine is now completely reassembled. Before starting
or operating engine, be sure following have been done.
1. All hardware is tightened securely.
2. Oil drain plug, Oil Sentry pressure switch (if
equipped), and a new oil filter are installed.
3. Crankcase is filled with correct amount, weight, and
type of oil.
KohlerEngines.com
20 690 01 Rev. I
Reassembly
Testing Engine
It is recommended engine be operated on a test stand or
bench prior to installation in piece of equipment.
1. Set engine up on a test stand. Install an oil pressure
gauge. Start engine and check to be certain oil
pressure (5 psi or more) is present.
2. Run engine for 5-10 minutes between idle and
mid-range. Adjust throttle and choke controls and
high-speed setting as necessary. Make sure
maximum engine speed does not exceed 3300
RPM. Adjust carburetor idle fuel needle and/or idle
speed screw as necessary. Refer to Fuel System
and Governor System.
20 690 01 Rev. I
KohlerEngines.com
75
2014 by Kohler Co. All rights reserved.

76
KohlerEngines.com
20 690 01 Rev. I

Kohler Courage 20 Service Manual - 20 - 690 - 01 - EN

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SV470-SV620

Accidental Starts can

Electrical Shock can

Before working on engine or

Using improper procedures can

Never operate engine with heat

Before working on engine or equipment, disable engine as

Every 100 Hours

Every 200 Hours

Every 500 Hours

VALVE COVER VIEW

--Spec. 00XX: 477 cc (29.1 cu. in.)

Oil Capacity (refill)

Air Cleaner Base

5.5 Nm (48 in. lb.)

Values are in Metric units. Values in parentheses are English equivalents.

5.1-6.2 Nm (45-55 in. lb.)

24.5 Nm (216 in. lb.)

5.5, 11.5 Nm (50, 100 in. lb.)

14.0 Nm (125 in. lb.)

3.3-3.9 Nm (30-35 in. lb.)

88.0 Nm (65 ft. lb.)

7.0-8.5 Nm (60-75 in. lb.)

24.4 Nm (216 in. lb.)

Oil Filter Pad Pipe Plug

4.5-5.0 Nm (40-46 in. lb.)

Values are in Metric units. Values in parentheses are English equivalents.

4.5-5.0 Nm (40-45 in. lb.)

11.0 Nm (95 in. lb.) into new hole

6.0 Nm (55 in. lb.) into new hole

11.0 Nm (95 in. lb.) into new hole

67.011/67.086 mm (2.6382/2.6412 in.)

0.5/1.5 mm (0.019/0.059 in.)

17.95/18.05 mm (0.707/0.711 in.)

Values are in Metric units. Values in parentheses are English equivalents.

0.03/0.055 mm (0.0012/0.0022 in.)

6.025/6.05 mm (0.2372/0.2382 in.)

0.225/1.025 mm (0.0089/0.040 in.)

Values are in Metric units. Values in parentheses are English equivalents.

Max. Wear Limit

Spec. 00XX: 84.010/84.035 mm

0.8 mm (0.003 in.)

0.013/0.075 mm (0.0005/0.003 in.)

0.165/0.315 mm (0.0065/0.0124 in.)

Piston, Piston Rings, and Piston Pin

22.006/22.012 mm (0.8685/0.8666 in.)

Values are in Metric units. Values in parentheses are English equivalents.

Piston, Piston Rings, and Piston Pin (Continued)

0.127 mm (0.005 in.)

Values are in Metric units. Values in parentheses are English equivalents.

Tightening Torque: Nm (ft. lb.) 20%

Metric Fastener Torque Recommendations for Standard Applications

Tightening Torque: Nm (in. lb.) 10%

Tightening Torque: Nm (ft. lb.) 10%

Tools and Aids

Design Technology Inc.

Tools and Aids

Tools and Aids

ROCKER ARM/CRANKSHAFT TOOL