Kohler 5400 Manual

KS530-KS595
Service Manual
IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.
2 Safety
3 Maintenance
5 Specifications
18 Tools and Aids
21 Troubleshooting
25 Air Cleaner/Intake
26 Fuel System
38 Governor System
40 Lubrication System
42 Electrical System
55 Starter System
57 Emission Compliant Systems
60 Disassembly/Inspection and Service
76 Reassembly
22 690 01 Rev. -- KohlerEngines.com 1

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

Explosive Fuel can cause Accidental Starts can Electrical Shock can
fires and severe burns. cause severe injury or cause injury.
Do not fill fuel tank while death. Do not touch wires while
engine is hot or running. Disconnect and ground engine is running.
Gasoline is extremely flammable spark plug lead(s) before
and its vapors can explode if servicing. CAUTION
ignited. Store gasoline only in
approved containers, in well Before working on engine or Damaging Crankshaft
ventilated, unoccupied buildings, equipment, disable engine as and Flywheel can cause
away from sparks or flames. follows: 1) Disconnect spark plug personal injury.
Spilled fuel could ignite if it comes lead(s). 2) Disconnect negative (–)
in contact with hot parts or sparks battery cable from battery.
from ignition. Never use gasoline
as a cleaning agent. WARNING Using improper procedures can
lead to broken fragments. Broken
Hot Parts can cause fragments could be thrown from
WARNING severe burns. engine. Always observe and use
Rotating Parts can cause Do not touch engine precautions and procedures when
severe injury. while operating or just installing flywheel.
Stay away while engine after stopping.
is in operation. Never operate engine with heat
Keep hands, feet, hair, and shields or guards removed.
clothing away from all moving
parts to prevent injury. Never WARNING
operate engine with covers,
shrouds, or guards removed. Cleaning Solvents can
cause severe injury or
death.
WARNING
Use only in well
Carbon Monoxide can ventilated areas away
cause severe nausea, from ignition sources.
fainting or death.
Carburetor cleaners and solvents
Avoid inhaling exhaust are extremely flammable. Follow
fumes. cleaner manufacturer’s warnings
Engine exhaust gases contain and instructions on its proper and
poisonous carbon monoxide. safe use. Never use gasoline as a
Carbon monoxide is odorless, cleaning agent.
colorless, and can cause death if
inhaled.
2 KohlerEngines.com 22 690 01 Rev. --

Maintenance
MAINTENANCE INSTRUCTIONS
WARNING
Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as
death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect
Disconnect and ground spark plug lead(s) negative (–) battery cable from battery.
before servicing.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.
MAINTENANCE SCHEDULE
Every 25 Hours or Annually¹ (whichever comes first)
● Service/replace precleaner (if equipped). Air Cleaner/Intake
● Replace air cleaner element (if not equipped with precleaner). Air Cleaner/Intake
Every 100 Hours or Annually¹ (whichever comes first)

● Replace air cleaner element (if equipped with precleaner). Air Cleaner/Intake
● Change oil and filter. Lubrication System
● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake
Every 100 Hours

● Replace fuel filter.
● Check that all fasteners are in place and components are properly secured. Reassembly
Every 200 Hours²

● Have valve lash checked/adjusted. Reassembly
Every 500 Hours

● Replace spark plug and set gap. Electrical System
1
Perform these procedures more frequently under severe, dusty, dirty conditions.
2
Have a Kohler authorized dealer perform this service.
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).

Maintenance
OIL RECOMMENDATIONS STORAGE

We recommend use of Kohler oils for best performance. If engine will be out of service for 2 months or more
Other high-quality detergent oils (including synthetic) follow procedure below.
of API (American Petroleum Institute) service class SJ 1. Add Kohler PRO Series fuel treatment or equivalent
or higher are acceptable. Select viscosity based on to fuel tank. Run engine 2-3 minutes to get stabilized
air temperature at time of operation as shown in table fuel into carburetor (failures due to untreated fuel are
below. 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.

Specifications
Engine Dimensions-Flywheel Side

B
A C
D E
S I
H
J
R
K
Q
P N
M
L
164.8 mm (6.49 in.) 201.3 mm (7.92 in.)

A B 212.4 mm (8.36 in.) C D 100.0 mm (3.94 in.)
to Starter to Oil Filter
Ø 10.0 mm (0.39 in.)
E Oil Fill and Dipstick F G Throttle Cable Clip H 109.0 mm (4.29 in.)
Lifting Point
Connection for
I 46.5 mm (1.83 in.) J 85.1 mm (3.35 in.) K Evaporative Hose L 228.9 mm (9.01 in.)
(7/32" I.D.)
13.9 mm (0.55 in.) to
M 205.8 mm (8.10 in.) N 182.5 mm (7.19 in.) O P 148.1 mm (5.83 in.)
Center of Gravity
41.2 mm (1.62 in.) to
Q 317.8 mm (12.51 in.) R S 139.0 mm (5.47 in.)
Center of Gravity

Specifications
Engine Dimensions-Starter Side
V B
T C
S R D
E
Q
P
O
G F
N
L I
H
K
M
2 X Cored for M6
Self Tapping
Screw 17.7 mm 179.0 mm (7.05 in.)
(0.70 in.) Min. 326.5 mm
A B Exhaust Port Axis C D to Center of
Depth (12.85 in.) Gravity
(Accessory
Mounting
Location)
7/16-20 UNF-2B IN.
145.2 mm (5.72 in.) 64.0 mm (2.52 in.)
E F 81.3 mm (3.20 in.) G H 38.1 mm (1.50
to Exhaust Port Keyway Length in.) Depth
21.6-21.8 mm (0.85-
250.3 mm (9.86 in.)
I J 2 X 30.0 mm (1.18 in.) K 0.86 in.) Keyway L 95.0 mm (3.74 in.)
to Exhaust Port Depth
Cored for M8 Self
Tapping Screw
Engine Mounting 20.0 mm (0.79 in.) 61.9 mm (2.44 in.) to
M N O P 55.0 mm (2.17 in.)
Surface Min. Depth Starter Stud
(Ground Lug
Location)
195.0 mm (7.68 in.)
Q 95.0 mm (3.74 in.) R 171.5 mm (6.75 in.) S T 332.3 mm (13.08 in.)
Lifting Point
Optional Rectifier-
U V Starter Motor W Oil Fill and Dipstick
Regulator

Specifications
Engine Dimensions-PTO Side
A
B
O
D
N C
E
J
F
L
J F
I
G
Accessory Mounting
A 116.0 mm (4.57 in.) B 55.0 mm (2.17 in.) C 150° D Surface
2 X 288.8 mm Ø 254.0 mm
E F 35° G Rotation Direction H
(11.37 in.) (10.00 in.)
I 150.2 mm (5.91 in.) J 45° K 36.6 mm (1.44 in.) L 105.2 mm (4.14 in.)
Ø 9.7 mm (0.38 in.) Exhaust Flange
M N Exhaust Port Axis O
Lifting Point Mounting Surface

Specifications
Engine Dimensions-Oil Filter Side
A B
T E
F
S
J G
I H
L
R Q P M
O N
A 317.1 mm (12.49 in.) B 45.2 mm (1.78 in.) C 34.3 mm (1.35 in.) D 75.5° Speed Control
Lever Travel
324.9 mm 226.7 mm (8.93 in.)
E Optional Fuel Pump F Throttle Cable Clip G H
(12.79 in.) Lifting Point
14.5 mm (0.57 in.) Oil 113.6 mm (4.47 in.) to
I 215.7 mm (8.49 in.) J K L Oil Filter
Filter Removal Oil Filter
Engine Mounting Oil Drain Plug 3/8 6.5° Choke Lever
M N O P 17.0 mm (0.67 in.)
Surface N.P.T. IN. Travel
39.4 mm (1.55 in.) to
Optional 127.1 mm (5.01 in.) 33.8 mm (1.33 in.) Air
Q Carburetor R Connection for S Air Filter and Cover T Cleaner Cover
Shutdown Evaporative Hose Removal
Solenoid

Specifications
Engine Dimensions-Valve Cover Side
A
B
P D
N E
O
F
M
G
L H
K
I
Cored for M6 Self

Tapping Screw
16.5 mm (0.65
24.3 mm (0.96 in.)
A 64.2 mm (2.53 in.) B 16.0 mm (0.63 in.) C D in.) Min. Depth
to Spark Plug (Accessory
Mounting
Location)
E 93.2 mm (3.67 in.) F Carburetor G Oil Drain Plug H 122.7 mm (4.83 in.)
6.32-6.36 mm 85.5 mm (3.37 in.)
Ø 25.37-25.40 mm
I (0.249-0.250 in.) J K 100.0 mm (3.94 in.) L Ground Lug
(0.999-1.0 in.)
Keyway Width Mounting Boss
Cored for M6 Self
2 X Accessory Tapping Screw
112.6 mm (4.43 in.) to
M Mounting N O 88.0 mm (3.47 in.) P Thru (Accessory
Spark Plug
Surface Mounting
Location)

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 . . . . . . . . . . . . . . . . . . . . . KS530
5400 Series Engine
Numerical Designation
Specification . . . . . . . . . . . . . . . KS530-3002
Serial . . . . . . . . . . . . . . . . . . . . . 4723500328
Year Manufactured Code Factory Code
Code Year
47 2017
48 2018
49 2019
GENERAL SPECIFICATIONS3,4 KS530 KS540 KS590 KS595

Bore 94 mm (3.70 in.)
Stroke 78 mm (3.1 in.)
Displacement 541 cc (33.0 cu. in.)
Oil Capacity (refill) 1.4 L (1.5 U.S. qt.)
Maximum Angle of Operation (@ full oil level)5 25°
TORQUE SEQUENCES KS530 KS540 KS590 KS595

(Refer to Torque Specifications for torque values).
Connecting Rod Fasteners
3
Values are in Metric units. Values in parentheses are English equivalents.
4
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.
5
Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.

Specifications
TORQUE SEQUENCES KS530 KS540 KS590 KS595

(Refer to Torque Specifications for torque values).
Closure Plate Fasteners
6 4 2
11
9
10
1 3 5
Cylinder Head Fasteners
3
1
4 2
Oil Passage Cover Fasteners

1
3
5
4
2
Valve Cover Fasteners

3
1
2
4

Specifications
TORQUE SPECIFICATIONS3,6 KS530 KS540 KS590 KS595
Auto Choke
Smart-Choke™ Diaphragm Assembly Fastener 1 N·m (9 in. lb.)
Barrel Baffle
Fastener 9.3 N·m (82 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
Blower Housing to Adapter

4.8 Hi-Lo Fastener 1 N·m (9 in. lb.)
Blower Housing to Closure Plate

Breather
Cover Fastener 6.5 N·m (58 in. lb.)
Reed/Retainer Fastener 6.5 N·m (58 in. lb.)
Cam Levers
Fastener 12.5 N·m (110 in. lb.)
Carburetor
Stud 4.3 N·m (38 in. lb.)
M6 Nut 9 N·m (80 in. lb.)
Fuel Bowl Retaining Screws 4.0 N·m (35 in. lb.)
Choke Wire Hold Down Clamp (if equipped)

Closure Plate (torque sequence on page 11)

Fastener 24 N·m (212 in. lb.)
Connecting Rod (torque sequence on page 10)

Cap Fastener (torque in 2 increments) 5.5, 11.8 N·m (50, 105 in. lb.)
Crankcase
Oil Drain Plug 14.0 N·m (125 in. lb.)
Cylinder Head (torque sequence on page 11)

Fastener (torque in 2 increments) 24.4, 42.7 N·m (216, 378 in. lb.)
Rocker Arm Pivot Stud 13.5 N·m (120 in. lb.)
Rocker Arm Adjustment Nut Set Screw 5.5 N·m (50 in. lb.)
Dipstick Tube
3
6
Lubricate threads with engine oil prior to assembly.
Specifications
Electric Starter
10/24 Mounting Nut 3.8 N·m (34 in. lb.)
1/4-20 Nut 7.9 N·m (70 in. lb.)
Fixed Guard (if equipped)

Flywheel
M12 Retaining Screw 115 N·m (85 ft. lb.)
Fuel Line J-Clip

Fuel Pump Bracket

4.8 Hi-Lo Fastener 1 N·m (9 in. lb.)
Governor
Lever Nut 7.7 N·m (68 in. lb.)
Ignition
Spark Plug 27 N·m (20 ft. lb.)
Module Fastener 8.8 N·m (78 in. lb.) into new hole
Rectifier-Regulator Fastener 8.8 N·m (78 in. lb.)
Intake Manifold to Cylinder Head

Nuts 10.2 N·m (90 in. lb.)
Muffler
Retaining Nuts 27.8 N·m (246 in. lb.)
Bracket Fastener 11.3 N·m (100 in. lb.)
Oil Filter Pad Pipe Plug

1/8” N.P.T.F. 8.5 N·m (75 in. lb.)
Oil Baffle
Oil Passage Cover (torque sequence on page 11)

Oil Pump Housing

Oil Sentry™
Pressure Switch 6.2 N·m (55 in. lb.)
3
6
Specifications
Speed Control Bracket Assembly

Stator
Mounting Screw 8.8 N·m (78 in. lb.)
Stator Wire Clip Fastener 6.5 N·m (58 in. lb.)
Valve Cover
CLEARANCE SPECIFICATIONS3 KS530 KS540 KS590 KS595
Camshaft
End Play 0.317/1.187 mm (0.0125/0.0467 in.)
Running Clearance 0.025/0.126 mm (0.0009/0.0049 in.)
Bore I.D.
New 14.389/14.414 mm (0.5665/0.5675 in.)
Max. Wear Limit 14.427 mm (0.5680 in.)
Bearing Surface O.D.
New 14.288/14.364 mm (0.5625/0.5655 in.)
Connecting Rod
Connecting Rod-to-Crankpin Running Clearance
New 0.040/0.081 mm (0.0016/0.0032 in.)
Connecting Rod-to-Crankpin Side Clearance 0.400/0.630 mm (0.0157/0.0248 in.)
Connecting Rod-to-Piston Pin Running Clearance 0.012/0.034 mm (0.0005/0.0013 in.)
Piston Pin End I.D.
New 20.012/20.029 mm (0.7879/0.7885 in.)
Crankcase
Governor Cross Shaft Bore I.D.
New 6.026/6.05 mm (0.2372/0.2382 in.)
Crankshaft
End Play (free) 0.225/0.875 mm (0.0089/0.0344 in.)
Bore in Crankcase I.D.
New 41.003/41.027 mm (1.6143/1.6152 in.)
Bore in Closure Plate I.D.
New 40.9875/41.0125 mm (1.6137/1.6147 in.)
Crankshaft Bore (PTO)-to-Crankshaft Running
Clearance
New 0.068/0.114 mm (0.0027/0.0045 in.)
3
6
Specifications
Crankshaft (continued)
Flywheel End Main Bearing Journal O.D.
New 40.913/40.935 mm (1.6107/1.6116 in.)
Max. Taper 0.0220 mm (0.0009 in.)
Max. Out of Round 0.0250 mm (0.0010 in.)
PTO End Main Bearing Journal O.D.
New 40.913/40.935 mm (1.6107/1.6116 in.)
Max. Taper 0.0200 mm (0.0008 in.)
Connecting Rod Journal O.D.
New 40.982/41.000 mm (1.6135/1.6142 in.)
Max. Taper 0.0120 mm (0.0005 in.)
T.I.R.
PTO End, Crankshaft in Engine 0.150 mm (0.0059 in.)
Entire Crankshaft , in V-Blocks 0.100 mm (0.0039 in.)
Cylinder Bore
Bore I.D.
New 94.010/94.035 mm (3.7011/3.7021 in.)
Max. Taper 0.050 mm (0.0020 in.)
Cylinder Head
Max. Out-of-Flatness 0.076 mm (0.003 in.)
Governor
Governor Cross Shaft -to-Crankcase Running
Clearance 0.014/0.075 mm (0.0006/0.0030 in.)
Cross Shaft O.D.
New 5.975/6.012 mm (0.2352/0.2367 in.)
Governor Gear Shaft -to-Governor Gear Running
Clearance 0.070/0.160 mm (0.0028/0.0063 in.)
Gear Shaft O.D.
New 5.990/6.000 mm (0.2358/0.2362 in.)
Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Module Air Gap 0.203/0.305 mm (0.008/0.012 in.)
3

Specifications
Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.007/0.017 mm (0.0003/0.0007 in.)
Pin Bore I.D.
New 20.007/20.012 mm (0.7877/0.7879 in.)
Pin O.D.
New 19.995/20.000 mm (0.7872/0.7874 in.)
Top Compression Ring-to-Groove Side Clearance 0.025/0.065 mm (0.0010/0.0026 in.)
Middle Compression Ring-to-Groove Side
Clearance 0.040/0.080 mm (0.0016/0.0032 in.)
Oil Control Ring-to-Groove Side Clearance 0.090/0.210 mm (0.0035/0.0083 in.)
Top Compression Ring End Gap New Bore
New Bore 0.150/0.400 mm (0.0059/0.0157 in.)
Used Bore (max.) 0.770 mm (0.0300 in.)
Middle Compression Ring End Gap New Bore
New Bore 1.000/1.250 mm (0.0394/0.0492 in.)
Used Bore (max.) 1.504 mm (0.0592 in.)
Thrust Face O.D.7
New 93.975/93.989 mm (3.6998/3.7003 in.)
Piston Thrust Face-to-Cylinder Bore7 Running
Clearance 0.034/0.073 mm (0.0013/0.0029 in.)
Valves and Valve Tappets

Valve Lash8 0.101/0.152 mm (0.004/0.006 in.)
Intake Valve Stem-to-Valve Guide Running 0.038/0.076 mm (0.0015/0.0030 in.)
Clearance
Exhaust Valve Stem-to-Valve Guide Running 0.050/0.088 mm (0.0020/0.0035 in.)
Clearance
Intake Valve Guide I.D.
New 6.038/6.058 mm (0.2377/0.2385 in.)
Exhaust Valve Guide I.D.
New 6.038/6.058 mm (0.2377/0.2385 in.)
Intake Valve Minimum Lift 9.4 mm (0.370 in.)
Exhaust Valve Minimum Lift 9.3 mm (0.366 in.)
Nominal Valve Seat Angle 45°
3
7
Measure 7.5 mm (0.2953 in.) above bottom of piston skirt at right angles to piston pin.
8
Check valve lash every 200 hours, adjust as required.

Specifications
GENERAL TORQUE VALUES
English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel
Grade 2 or 5 Fasteners
Into Aluminum
Size Grade 2 Grade 5 Grade 8

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

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

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

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
Torque Conversions
N·m = in. lb. x 0.113 in. lb. = N·m x 8.85
N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

Tools and Aids
Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. By
using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service
capabilities and customer satisfaction by decreasing engine downtime.
Here is a list of tools and their source.
NOTE: Not all tools listed are required to service this engine.
SEPARATE TOOL SUPPLIERS
Kohler Tools SE Tools Design Technology Inc.
Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive
supply. Lapeer, MI 48446 Westmont, IL 60559
Phone 810-664-2981 Phone 630-920-1300
Toll Free 800-664-2981 Fax 630-920-0011
Fax 810-664-8181
TOOLS
Description Source/Part No.
Alcohol Content Tester Kohler 25 455 11-S
For testing alcohol content (%) in reformulated/oxygenated fuels.
Camshaft Endplay Plate SE Tools KLR-82405
For checking camshaft endplay.
Camshaft Seal Protector (Aegis) SE Tools KLR-82417
For protecting seal during camshaft installation.
Cylinder Leakdown Tester Kohler 25 761 05-S
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available: Design Technology Inc.
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines) DTI-731-03
Dealer Tool Kit (Domestic) Kohler 25 761 39-S
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester Kohler 25 455 01-S
Oil Pressure Test Kit Kohler 25 761 06-S
Rectifier-Regulator Tester (120 V AC/60Hz) Kohler 25 761 20-S
Dealer Tool Kit (International) Kohler 25 761 42-S
Complete kit of Kohler required tools.
Components of 25 761 42-S
Rectifier-Regulator Tester (240 V AC/50Hz) Kohler 25 761 41-S
Digital Vacuum/Pressure Tester Design Technology Inc.
For checking crankcase vacuum. DTI-721-01
Individual component available: Design Technology Inc.
Rubber Adapter Plug DTI-721-10
Electronic Fuel Injection (EFI) Diagnostic Software Kohler 25 761 23-S
For Laptop or Desktop PC.
EFI Service Kit Kohler 24 761 01-S
For troubleshooting and setting up an EFI engine.
Components of 24 761 01-S Design Technology Inc.
Fuel Pressure Tester DTI-019
Noid Light DTI-021
90° Adapter DTI-023
Code Plug, Red Wire DTI-027
Code Plug, Blue Wire DTI-029
Shrader Valve Adapter Hose DTI-037
Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031
Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033
K-Line Adapter Jumper Lead Wiring Harness Kohler 25 176 23-S
Kohler Wireless Diagnostic System Module (Bluetooth®) Kohler 25 761 45-S
For wireless Android EFI diagnostics.
Individual component available:
Wireless Diagnostic System Interface Cable Kohler 25 761 44-S

Tools and Aids
TOOLS
Flywheel Puller SE Tools KLR-82408
For properly removing flywheel from engine.
Flywheel Anchor Bolts, Washers, Nuts Tool Kohler 25 086 753-S
Used with Flywheel Puller to properly removing flywheel from 5400 Series engine.
Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Kohler 25 455 20-S
Used to properly remove fuel hose from engine components.
Hydraulic Valve Lifter Tool Kohler 25 761 38-S
For removing and installing hydraulic lifters.
For testing output on all systems, including CD.
Inductive Tachometer (Digital) Design Technology Inc.
For checking operating speed (RPM) of an engine. DTI-110
Offset Wrench (K and M Series) Kohler 52 455 04-S
For removing and reinstalling cylinder barrel retaining nuts.
For testing/verifying oil pressure on pressure lubricated engines.
Rectifier-Regulator Tester (120 volt current) Kohler 25 761 20-S
Rectifier-Regulator Tester (240 volt current) Kohler 25 761 41-S
For testing rectifier-regulators.
Components of 25 761 20-S and 25 761 41-S Design Technology Inc.
CS-PRO Regulator Test Harness DTI-031R
Special Regulator Test Harness with Diode DTI-033R
Spark Advance Module (SAM) Tester Kohler 25 761 40-S
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Starter Servicing Kit (All Starters) SE Tools KLR-82411
For removing and reinstalling drive retaining rings and brushes.
Individual component available:
Starter Brush Holding Tool (Solenoid Shift) SE Tools KLR-82416
Stepper Motor Controller Tool Kohler 25 455 21-S
For testing operation of stepper motor/Digital Linear Actuator (DLA).
Jumper Lead Tool Kohler 25 518 43-S
For use with Stepper Motor Controller Tool to test rotary stepper motor.
Triad/OHC Timing Tool Set Kohler 28 761 01-S
For holding cam gears and crankshaft in timed position while installing timing belt.
Valve Guide Reamer (K and M Series) Design Technology Inc.
For properly sizing valve guides after installation. DTI-K828
Valve Guide Reamer O.S. (Command Series) Kohler 25 455 12-S
For reaming worn valve guides to accept replacement oversize valves. Can be used
in low-speed drill press or with handle below for hand reaming.
Reamer Handle Design Technology Inc.
For hand reaming using Kohler 25 455 12-S reamer. DTI-K830

Tools and Aids
AIDS
Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S
Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S
Dielectric Grease Loctite® 51360
Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S
RTV Silicone Sealant
Loctite® 5900® Heavy Body in 4 oz. aerosol dispenser. Kohler 25 597 07-S
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved Loctite® 5910®
for use. Permatex® the Right Stuff® 1 Minute Gasket™ or Loctite® Nos. 5900® or Loctite® Ultra Black 598™
5910® are recommended for best sealing characteristics. Loctite® Ultra Blue 587™
Loctite® Ultra Copper 5920™
Permatex® the Right Stuff® 1
Minute Gasket™
Spline Drive Lubricant Kohler 25 357 12-S
FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL
A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft
flywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
1. Using an abrasive cut-off wheel, cut out a six tooth 1. Find a used connecting rod from a 10 HP or larger
segment of ring gear as shown. engine. Remove and discard rod cap.
2. Grind off any burrs or sharp edges. 2. Remove studs of a Posi-Lock rod or grind off
3. Invert segment and place it between ignition bosses aligning steps of a Command rod, so joint surface is
on crankcase so tool teeth engage flywheel ring flat.
gear teeth. Bosses will lock tool and flywheel in 3. Find a 1 in. long capscrew with correct thread size to
position for loosening, tightening, or removing with a match threads in connecting rod.
puller. 4. Use a flat washer with correct I.D. to slip on
capscrew and approximately 1 in. O.D. Assemble
capscrew and washer to joint surface of rod.

Troubleshooting
TROUBLESHOOTING GUIDE
When troubles occur, be sure to check simple causes which, at first, may seem too obvious to be considered. For
example, a starting problem could be caused by an empty fuel tank.
Some general common causes of engine troubles are listed below and vary by engine specification. Use these to
locate causing factors.
Engine Cranks But Will Not Start Engine Will Not Crank
● Battery connected backwards. ● Battery is discharged.
● Blown fuse. ● Faulty electric starter or solenoid.
● Carburetor solenoid malfunction. ● Faulty key switch or ignition switch.
● Choke not closing. ● Interlock switch is engaged or faulty.
● Clogged fuel line or fuel filter. ● Loose wires or connections that intermittently ground
● Diode in wiring harness failed in open circuit mode. ignition kill circuit.
● Empty fuel tank. ● Seized internal engine components.
● Faulty spark plug.
● Fuel pump malfunction-vacuum hose clogged or Engine Runs But Misses
leaking. ● Carburetor malfunction.
● Fuel shut-off valve closed. ● Engine overheated.
● Ignition module faulty or improperly gapped. ● Faulty spark plug.
● Interlock switch is engaged or faulty. ● Ignition module faulty or improperly gapped.
● Key switch or kill switch in OFF position. ● Interlock switch is engaged or faulty.
● Low oil level. ● Loose wires or connections that intermittently ground
● Quality of fuel (dirt, water, stale, mixture). ignition kill circuit.
● Spark plug lead disconnected. ● Quality of fuel (dirt, water, stale, mixture).
● Spark plug lead boot loose on plug.
Engine Starts But Does Not Keep Running ● Spark plug lead loose.
● Faulty carburetor.
● Faulty cylinder head gasket. Engine Will Not Idle
● Faulty or misadjusted choke or throttle controls. ● Engine overheated.
● Fuel pump malfunction-vacuum hose clogged or ● Faulty spark plug.
leaking. ● Idle fuel circuit in carburetor plugged/restricted.
● Intake system leak. ● Idle speed adjusting screw improperly set.
● Loose wires or connections that intermittently ground ● Inadequate fuel supply.
ignition kill circuit. ● Low compression.
● Quality of fuel (dirt, water, stale, mixture). ● Quality of fuel (dirt, water, stale, mixture).
● Restricted fuel tank cap vent. ● Restricted fuel tank cap vent.
Engine Starts Hard Engine Overheats
● Clogged fuel line or fuel filter. ● Cooling fan broken.
● Engine overheated. ● Excessive engine load.
● Faulty ACR mechanism. ● High crankcase oil level.
● Faulty or misadjusted choke or throttle controls. ● Lean fuel mixture.
● Faulty spark plug. ● Low crankcase oil level.
● Flywheel key sheared. ● Cooling system components clogged or restricted.
● Fuel pump malfunction-vacuum hose clogged or
leaking. Engine Knocks
● Interlock switch is engaged or faulty. ● Excessive engine load.
● Loose wires or connections that intermittently ground ● Incorrect oil viscosity/type.
ignition kill circuit. ● Internal wear or damage.
● Low compression. ● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture). ● Quality of fuel (dirt, water, stale, mixture).
● Weak spark.

Troubleshooting
Engine Loses Power Sludge is a natural by-product of combustion; a small

accumulation is normal. Excessive sludge formation
● Dirty air cleaner element. could indicate over rich fuel settings, weak ignition,
● Engine overheated. overextended oil change interval or wrong weight or
● Excessive engine load. type of oil was used.
● Restricted exhaust.
● Faulty spark plug. CLEANING ENGINE
● High crankcase oil level.
● Incorrect governor setting. WARNING
● Low battery. Cleaning Solvents can cause severe injury or
● Low compression. death.
● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture). Use only in well ventilated areas away from
ignition sources.
Engine Uses Excessive Amount of Oil
● Loose or improperly torqued fasteners. Carburetor cleaners and solvents are extremely
● Blown head gasket/overheated. flammable. Follow cleaner manufacturer’s warnings
● Breather reed broken. and instructions on its proper and safe use. Never use
● Clogged, broken, or inoperative crankcase breather. gasoline as a cleaning agent.
● Crankcase overfilled.
● Incorrect oil viscosity/type. After inspecting external condition of engine, clean
● Worn cylinder bore. engine thoroughly before disassembly. Clean individual
● Worn or broken piston rings. components as engine is disassembled. Only clean
● Worn valve stems/valve guides. parts can be accurately inspected and gauged for wear
or damage. There are many commercially available
Oil Leaks from Oil Seals, Gaskets cleaners that will quickly remove grease, oil, and grime
● Breather reed broken. from engine parts. When such a cleaner is used, follow
● Clogged, broken, or inoperative crankcase breather. manufacturer’s instructions and safety precautions
● Loose or improperly torqued fasteners. carefully.
● Piston blow by, or leaky valves. Make sure all traces of cleaner are removed before
● Restricted exhaust. engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down
EXTERNAL ENGINE INSPECTION lubricating properties of engine oil.
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 components 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.

Troubleshooting
CRANKCASE VACUUM TEST

WARNING WARNING
Carbon Monoxide can cause severe nausea,
fainting or death. Rotating Parts can cause severe injury.
Avoid inhaling exhaust fumes. Stay away while engine is in operation.
Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all
monoxide. Carbon monoxide is odorless, colorless, moving parts to prevent injury. Never operate engine
and can cause death if inhaled. with covers, shrouds, or guards removed.
A partial vacuum should be present in crankcase when engine is operating. Pressure in crankcase (normally caused
by a clogged or improperly assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available
spots.
Crankcase vacuum is best measured with either a water manometer or a vacuum gauge (inches of water gauge only).
Complete instructions are provided in kits.
To test crankcase vacuum with manometer: To test crankcase vacuum with vacuum/pressure gauge
1. Insert rubber stopper into oil fill hole. Be sure pinch (inches of water gauge only):
clamp is installed on hose and use tapered adapters 1. Remove dipstick or oil fill plug/cap.
to connect hose between stopper and one 2. Install adapter into oil fill/dipstick tube opening,
manometer tube. Leave other tube open to upside down over end of a small diameter dipstick
atmosphere. Check that water level in manometer is tube, or directly into engine if a tube is not used.
at 0 line. Make sure pinch clamp is closed. Insert barbed gauge fitting into hole in stopper.
2. Start engine and run no-load high speed. 3. Run engine and observe gauge reading.
3. Open clamp and note water level in tube. Analog tester–needle movement to left of 0 is a
Level in engine side should be a minimum of vacuum, and movement to right indicates a
10.2 cm (4 in.) above level in open side. pressure.
If level in engine side is less than specified (low/no Digital tester–depress test button on top of tester.
vacuum), or level in engine side is lower than level in Crankcase vacuum should be a minimum of 10.2 cm
open side (pressure), check for conditions in table (4 in.) of water. If reading is below specification, or if
below. pressure is present, check table below for possible
4. Close pinch clamp before stopping engine. causes and conclusions.
Condition Conclusion
Crankcase breather clogged or inoperative. 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.

Troubleshooting
COMPRESSION TEST
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.
Air escaping from crankcase breather. Ring or cylinder worn.
Air escaping from exhaust system. Defective exhaust valve/improper seating.
Air escaping from intake. Defective intake valve/improper seating.
Gauge reading in low (green) zone. Piston rings and cylinder in good condition.
Gauge reading in moderate (yellow) zone. Engine is still usable, but there is some wear present.
Customer should start planning for overhaul or
replacement.
Gauge reading in high (red) zone. Rings and/or cylinder have considerable wear. Engine
should be reconditioned or replaced.

Air Cleaner/Intake
AIR CLEANER Paper Element

These systems are CARB/EPA certified and components 1. Remove element from air cleaner adapter; service
should not be altered or modified in any way. precleaner. Discard element.
Air Cleaner Components 2. Install precleaner over new paper element and install
on air cleaner adapter. Secure element behind
retainer in housing.
A Position air cleaner cover on housing and line up knobs
with unlock symbol. Turn knobs toward lock symbol to
B secure.
A BREATHER TUBE
C Ensure both ends of breather tube are properly
connected.
B C
AIR COOLING
WARNING
D Hot Parts can cause severe burns.
E Do not touch engine while operating or just
F after stopping.
G H 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
I
E F
G H
A Cover Knob B Lock Symbol

Standard Air Cleaner
C Unlock Symbol D Cover
E Precleaner F Paper Element
G Retainer H Air Cleaner Adapter
PRO Air Cleaner
I 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.
Turn knobs toward unlock symbol and remove air
cleaner cover.
Precleaner (if equipped)
1. Remove precleaner from paper element.
2. Replace or wash precleaner in warm water with
detergent. Rinse and allow to air dry.
3. Lightly oil precleaner with new engine oil; squeeze
out excess oil.
4. Reinstall precleaner over paper element.

Fuel System
Typical carbureted fuel system and related components Repair

include:
Pulse fuel pumps are not serviceable and must be
● Fuel tank. replaced when faulty.
● Fuel lines.
● In-line fuel filter. Removal
● Fuel pump.
● Carburetor. 1. Turn knobs toward unlock symbol and remove air
cleaner cover.
Fuel from tank is moved through in-line filter and fuel 2. Disconnect inlet, outlet, and pulse lines from fuel
lines by fuel pump. On engines not equipped with a fuel pump. Mark lines for proper reassembly.
pump, fuel tank outlet is located above carburetor inlet 3. Remove fuel pump from bracket.
and gravity moves fuel. Fuel then enters carburetor
float bowl and is drawn into carburetor body and mixed Installation
with air. This fuel-air mixture is then burned in engine
combustion chamber. 1. Install new fuel pump, pressing fuel pump onto
bracket past locking tabs.
FUEL RECOMMENDATIONS
NOTE: If necessary, carefully rebend locking tabs to
Refer to Maintenance. ensure fuel pump is secured.
FUEL LINE 2. Connect inlet, outlet, and pulse lines to their
Low permeation fuel line must be installed on carbureted respective fittings on pump. Secure with clamps.
Kohler Co. engines to maintain EPA and CARB 3. Position air cleaner cover on housing and line up
regulatory compliance. knobs with unlock symbol. Turn knobs toward lock
FUEL PUMP symbol to secure.
Some engines are equipped with an optional pulse fuel
pump secured on a bracket installed on blower housing. AUTO CHOKE (IF EQUIPPED)
Fuel pump has two internal chambers separated by If engine is equipped with Smart-ChokeTM, follow
a diaphragm. Air chamber is connected to engine troubleshooting procedures starting on page 32 of this
crankcase by a rubber hose. Fuel chamber has an inlet manual.
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.

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

Fuel System
CARBURETOR Shut-off Solenoid

K Gasket L Assembly
WARNING M Fuel Bowl Screw N Float Pin
Explosive Fuel can cause fires and severe Idle Speed Screw
burns. O Float P and Spring
Do not fill fuel tank while engine is hot or Q Throttle Plate Screw R Throttle Plate
running. Throttle Lever and
S Filter T
Gasoline is extremely flammable and its vapors can Shaft Assembly
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Spilled fuel could ignite These engines are equipped with a fixed main jet
if it comes in contact with hot parts or sparks from carburetor. Carburetors will have a low idle speed
ignition. Never use gasoline as a cleaning agent. adjustment screw.
Troubleshooting Checklist
Typical One-Barrel Carburetor Components When engine starts hard, runs rough, or stalls at low
idle speed, check these areas before adjusting or
T disassembling carburetor.
1. Make sure fuel tank is filled with clean, fresh
A gasoline.
2. Make sure fuel tank cap vent is not blocked and is
operating properly.
S
3. Make sure fuel is reaching carburetor. This includes
checking fuel shut-off valve, fuel tank filter screen,
R B in-line fuel filter, fuel lines and fuel pump for
restrictions or faulty components as necessary.
4. Make sure blower housing and carburetor are
Q C securely fastened to engine using gaskets in good
P condition.
5. Make sure air cleaner element (including precleaner
if equipped) is clean and all air cleaner components
are fastened securely.
D 6. Make sure ignition system, governor system,
E exhaust system, and throttle and choke controls are
F operating properly.
G
H
O
J
N
M
K
Choke Lever and

A B Choke Return Spring
Shaft Assembly
C Choke Plate D O-Ring
E Main Jet F O-Ring
G O-Ring H Carb Spacer
I Fuel Inlet Needle J Fuel Bowl

Fuel System
Troubleshooting-Carburetor Related Causes

Condition Possible Cause Conclusion
Engine starts hard, runs rough, or Low idle fuel mixture/speed Adjust low idle speed screw, then
stalls at idle speed. improperly adjusted. adjust low idle fuel needle.
Improper choke adjustment. Correct choke adjustment.
Engine runs rich (indicated by black, Choke partially closed during Check choke lever/linkage to ensure
sooty exhaust smoke, misfiring, loss operation. choke is operating properly.
of speed and power, governor
hunting, or excessive throttle Dirt under fuel inlet needle. Remove needle; clean needle and
opening). seat and blow with compressed air.
Bowl vent or air bleeds plugged. Remove fuel bowl. Clean vent, ports,
and air bleeds. Blow out all passages
with compressed air.
Fuel bowl O-ring leaks. Remove fuel bowl and replace
O-ring.
Leaky, cracked, or damaged float. Submerge float to check for leaks.
Engine runs lean (indicated by Idle holes plugged; dirt in fuel Remove fuel bowl. Clean main fuel
misfiring, loss of speed and power, delivery channels. jet and all passages; blow out with
governor hunting, or excessive compressed air.
throttle opening).
Fuel leaks from carburetor. Dirt under fuel inlet needle. Remove fuel bowl. Clean vent, ports,
and air bleeds. Blow out all passages
with compressed air.
Float is cracked or damaged. Replace float.
Carburetor solenoid gasket Replace gasket.
damaged.
Bowl retaining screws loose. Torque screws to 4.0 N·m (35 in. lb.).
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 either terminal of solenoid and
negative lead to other terminal of solenoid.
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.

Fuel System
Carburetor Circuits Carburetor Servicing

Float NOTE: Main and slow jets are fixed and size specific.
Fuel level in bowl is maintained by float and fuel inlet Fixed jets for high altitudes are available.
needle. Buoyant force of float stops fuel flow when ● Inspect carburetor body for cracks, holes, and other
engine is at rest. When fuel is being consumed, float will wear or damage.
drop and fuel pressure will push inlet needle away from ● Inspect float for cracks, holes, and missing or
seat, allowing more fuel to enter bowl. When demand damaged float tabs. Check float hinge and shaft for
ceases, buoyant force of float will again overcome fuel wear or damage.
pressure, rising to predetermined setting and stop flow. ● Inspect fuel inlet needle and seat for wear or damage.
Slow and Mid-Range ● Inspect spring loaded choke plate to make sure it
At low speeds engine operates only on slow circuit. As moves freely on shaft.
a metered amount of air is drawn through slow air bleed
jets, fuel is drawn through main jet and further metered 1. Perform removal procedures for appropriate air
through slow jet. Air and fuel are mixed in body of slow cleaner and carburetor outlined in Disassembly.
jet and exit to idle progression (transfer port) chamber. 2. Clean exterior surfaces of dirt or foreign material
From idle progression chamber, air fuel mixture is before disassembling carburetor. Remove bowl
metered through idle port passage. At low idle air/fuel retaining screws and carefully separate fuel bowl
mixture is preset and not adjustable. This mixture is then from carburetor body. Do not damage fuel bowl
mixed with main body of air and delivered to engine. O-rings. Transfer any remaining fuel into an
As throttle plate opening increases, greater amounts of approved container. Save all parts.
air/fuel mixture are drawn in through fixed and metered
idle progression holes. As throttle plate opens further, 3. Remove float pin, float, and inlet needle. Seat for
vacuum signal becomes great enough at venturi so main inlet needle is serviceable by replacing carb spacer
circuit begins to work. (inlet seat assembly). Remove carb spacer by
carefully lifting up and off carburetor body.
Main (high-speed)
At high speeds/loads engine operates on main circuit. NOTE: Lift straight up and not sideways to ensure main
As a metered amount of air is drawn through air jet, tube isn't damaged.
fuel is drawn through main jet. Air and fuel are mixed 4. Main jet can be removed from carb spacer by using
in main nozzle then enters main body of airflow where a blunt tool and gently pushing jet out of center
further mixing of fuel and air occurs. This mixture is then stem. Main jet is retained in carb spacer by O-ring.
delivered to combustion chamber. Carburetor has a fixed Inspect O-ring during disassembly and replace if
main circuit; no adjustment is possible. damaged. Repair kits are available for both gravity
and fuel pump equipped engines.
Carburetor Adjustments
5. Clean carburetor bowl and assembly as required.
NOTE: Carburetor adjustments should be made only
after engine has warmed up. 6. See illustration for carburetor components on page
28. Note O-ring on carb spacer to carburetor body
Carburetor is designed to deliver correct fuel-to-air and fuel bowl, inlet seat/spacer well and main jet.
mixture to engine under all operating conditions. Main Cleaning of passages and orifices can be done
fuel jet is calibrated at factory and is not adjustable. Idle using compressed air. Do not use wire or carburetor
fuel is also set at factory and is not adjustable. cleaner.
Low Idle Speed (RPM) Adjustment 7. After cleaning, inspect choke shaft and choke valve
NOTE: Actual low idle speed depends on application. assembly for wear. Replace as required with choke
Refer to equipment manufacturer’s shaft kit. To install kit go to step 8, otherwise go to
recommendations. step 10. Inspect throttle shaft and throttle valve
1. Low idle speed (without governor) for basic engines assembly. If wear is found on throttle shaft, install
is 1200 RPM (± 75 RPM). This can be adjusted by throttle shaft kit. To install kit go to step 10, otherwise
holding throttle lever against stop and turning low go to step 12. If wear is noted within choke and/or
idle speed screw in or out. throttle shaft bores of carburetor body, a complete
carburetor replacement is recommended.
2. These engines have governed idle. To set to
manufacturer's recommendation, turn adjustment
screw on speed control bracket in (clockwise) to
increase or out (counterclockwise)to decrease RPM
speed.
High Speed (RPM) Adjustment
1. With engine running, move throttle control to fast
and pin.
2. Loosen speed control bracket mounting screws,
slide bracket to adjust high speed setting, then
tighten screws.

Fuel System
8. Inspect and note choke valve position, placement, 13. Install new small O-ring over inlet seat boss of carb
and mating of valve plate to choke bore for proper spacer. Position new O-ring into molded grooves of
reassembly. While holding choke shaft in full open carb spacer.
position, pull choke valve straight out of bore and 14. Holding both carburetor pieces in upright position,
choke shaft using a pliers. Lift choke shaft and gently push to seat carb spacer into carburetor body.
spring out of carburetor body. Inspect choke shaft
bores for wear or dirt. If wear is noted within choke 15. Place inlet needle on float and lower into position on
shaft bore of carburetor body, a complete carburetor carb spacer; install float pin to secure.
replacement is recommended. 16. Reinstall carburetor bowl and secure to body with
9. Install new choke shaft and spring into carburetor two screws. Torque screws to 4.0 N·m (35 in. lb.).
choke shaft bore in same position as noted in 17. Install new gasket on solenoid assembly. Install
previous step. Position spring tab in proper position. solenoid assembly in fuel bowl and tighten securely.
While holding choke in full open position, carefully
slide new choke valve through center slot of choke 18. Reinstall carburetor using appropriate new
shaft, paying attention to proper orientation of valve. carburetor gaskets.
Push valve plate into shaft until plate parks in detent.
Rotate choke shaft assembly from full open to full High Altitude Operation
closed position. No interference should be noted. If this engine is operated at an altitude of 4000 ft.
10. Inspect and note throttle valve and lever position. (1219 meters) or above, a high altitude carburetor
Turn idle speed screw out (counterclockwise) two full kit is required. To obtain high altitude carburetor kit
turns to allow throttle valve to seat in a fully closed information or to find a Kohler authorized dealer, visit
position with throttle bore. While holding throttle in KohlerEngines.com or call 1-800-544-2444 (U.S. and
closed position, remove two screws from throttle Canada).
shaft/valve plate. Remove throttle plate from throttle This engine should be operated in its original
shaft. Lift throttle shaft and shaft filter out of configuration below 4000 ft. (1219 meters).
carburetor body. Inspect throttle shaft bores for wear
or dirt. If wear is noted within throttle shaft bore of Operating this engine with the wrong engine
carburetor body, a complete carburetor replacement configuration at a given altitude may increase its
is recommended. emissions, decrease fuel efficiency and performance,
and result in damage to the engine.
11. Install new shaft filter over throttle shaft and position
at top of shaft against lever. Install new throttle shaft
into carburetor throttle shaft bore in same position as
noted in previous step. Ensure that throttle lever will
contact idle speed screw when moved to closed
position. Inspect edge of new throttle plate. Note that
edge is chamfered to seal against throttle bore of
carburetor when closed. Installing throttle plate
incorrectly may allow throttle to pinch tight. Place a
drop of Loctite® on threads of each new screw.
While holding slight pressure on throttle lever to
closed position, align and start two plate screws.
Rotate throttle shaft assembly from completely
closed to full open position. Ensure there is no
binding or restriction, then tighten screws securely.
Do not overtighten.
12. Install new O-ring on main jet. Put a light film of oil
on O-ring. Place jet with O-ring into center stem of
carb spacer. Use a blunt tool to gently push and seat
jet/O-ring.

Fuel System
Smart-Choke™
Diaphragm assembly consists of a spring controlled diaphragm for initial choke pull-off and a thermostat to completely
open choke while engine warms up. A vacuum signal from intake manifold is routed through a check valve to
diaphragm and partially opens choke once engine starts. To complete choke opening, a bimetallic spring in diaphragm
assembly heats up over a preset time once this thermostat sees 12V as activated by oil pressure switch. When
engine is cold, a spring on diaphragm, in conjunction with a bimetallic spring, will hold choke closed for starting. When
engine is warm, bimetallic spring holds choke completely open while engine is running. Choke will be 2/3 closed when
warm and not running, allowing for partial choke on a hot restart. These two elements work together to operate a
smooth choke system that facilitates easy reliable starting in all conditions.
Smart-Choke™ Components
L
K
K
C C
E
A
D
B
J
B I
H
G
F
Check Valve
A B Vacuum Hose C K40 x 1.79 Screw D Diaphragm Assembly
Assembly
Intake Manifold Carburetor Gasket
E Choke Linkage F Intake Manifold G H
Gasket (Throttle)
I Carburetor Assembly J Carburetor Gasket K Carburetor Nut L Intake Adapter

Fuel System
Troubleshooting Smart-Choke™ Related Causes

Engine starts hard, runs rough, or Choke not closing. Check choke lever/linkage to ensure
stalls at idle speed. choke is operating properly.
Check that bimetallic spring actuates
freely.
Engine runs rich (indicated by black, Choke partially closed during Check choke lever/linkage to ensure
sooty exhaust smoke, misfiring, loss operation. choke is operating properly.
of speed and power, governor
hunting, or excessive throttle Check that bimetallic spring actuates
opening). freely.
Check choke diaphragm assembly
mounting.
Confirm 12V to thermostat on top of
diaphragm assembly.
Confirm check valve routing from
intake manifold to diaphragm
assembly is clear. Confirm initial
pull-off of choke during cranking.
Smart-Choke™ System Troubleshooting 8. Attach one wire of meter to red wire w/yellow tracer
terminal of assembly, and other wire to ground of
These procedures are to be performed on a cold engine. bracket or to ground strip of assembly body.
NOTE: Bimetallic spring assembly is pre-set at factory Thermostat resistance should read 15 ohms (+/- 10
and riveted shut. DO NOT attempt to adjust/ ohms). If assembly is warm, allow unit to cool to
change its settings. room temperature (68°F/20°C) for accurate testing.
NOTE: Do not remove or loosen diaphragm screws on If an infinite (open) reading is found, replace
diaphragm assembly. Position and torque is diaphragm assembly. Diaphragm vacuum signal will
pre-set at factory. not open choke plate fully when cold and will not
close choke plate fully when engine is warm.
NOTE: Thermostat temperature must be at room
temperature before testing. 9. Unplug check valve assembly from diaphragm and
draw a vacuum of -5 psig and confirm that it holds
1. Turn knobs toward unlock symbol and remove air for at least 30 seconds. If it does not, replace
cleaner cover. Lift and remove precleaner (if diaphragm assembly.
equipped) and air cleaner element from air cleaner
adapter. 10. Confirm check valve assembly is oriented correctly
and that it flows easily in one direction – toward
2. Remove blower housing. manifold.
3. Choke plate should be fully closed when engine is 11. Reinstall blower housing.
cold.
12. Start engine. Upon start up, choke plate should be
4. There should be light spring tension holding choke 1/3 closed. Choke plate should gradually change to
closed. full open position after 2 to 2-1/2 minutes of running.
5. There should not be any binding when choke shaft This action is performed by bimetallic spring
assembly is rotated, which could cause choke to assembly being heated. If choke plate fails to open,
remain partially open. recheck linkage for binding.
6. Check choke linkage for binding or debris build up. 13. With engine running, check voltage at bimetallic
Gently actuate linkage and observe that choke plate spring choke bracket assembly. Using a DVOM,
has full range of movement (open and close). attach black lead of meter to ground screw on
7. Unplug red wire with black tracer power lead of assembly bracket, and red lead of meter to red wire
bimetallic spring assembly. Measure heat circuit w/black tracer.
resistance of choke thermostat assembly, with a volt
ohm meter at room temperature (68°F/20°C).

Fuel System
14. Select DC VOLTS on your meter. You should see a CONTROLS

minimum of 12 volts DC. Some engines are equipped with single wire controls.
If no voltage is present, test for voltage at oil Refer to Unitized Throttle and Choke Control for details.
pressure switch. Some engines are equipped with separate throttle and
choke controls. Refer to Separate Throttle and Choke
Oil Pressure Switch Control for details. Some engines are equipped with a
Smart-Choke™ assembly and a separate throttle control.
A
Unitized Throttle and Choke Control
Some engines are equipped with a unitized throttle and
B choke control. This assembly controls choke and engine
speed with a single lever.
Throttle Cable Adjustment
Throttle/Choke Controls Details
A Power In Terminal
B Power Out Terminal
If voltage is present at power in terminal but not at A B
power out terminal when engine is running, pressure
switch is potentially faulty. Remove switch and install
a pressure test gauge and start engine. Consult A Cold Engine B Warm Engine
troubleshooting section of this manual for oil
pressure testing instructions. If adequate pressure is Speed Control Bracket Alignment Hole
found, replace pressure switch and confirm
operation/voltage readings. E
15. If linkage is free and choke plate fails to open fully
after 2 minutes, check spring tension of bimetallic
assembly. If necessary, replace diaphragm D A
assembly.
16. Reinstall air cleaner element (with precleaner if
equipped) on air cleaner adapter. Secure element
behind retainer in housing. Position air cleaner cover
on housing and line up knobs with unlock symbol.
Turn knobs toward lock symbol to secure. B
Starting an Engine Equipped with Smart-Choke™

1. Smart-Choke™ system will automatically control C
choke plate position for starting.
2. Make sure equipment is in neutral.
3. Activate starter switch. Release switch as soon as A Throttle Cable Clamp B Alignment Hole
engine starts.
C Choke Linkage D Throttle Linkage
If starter does not turn engine over, shut starter off
immediately. Do not make further attempts to start E Throttle Control Lever
engine until condition is corrected. Do not jump start NOTE: Choke is placed ON by moving throttle control
using another battery. See your Kohler authorized slightly past fast position. If throttle control does
dealer for trouble analysis. not have a designated choke ON position, be
4. For operation, after engine starts, move throttle and sure to leave sufficient throttle control travel past
set desired engine operating speed. fast position. This will enable choke to be placed
ON.

Fuel System
1. Loosen control cable clamp. High Speed (RPM) Adjustment

2. Place throttle control lever of equipment into fast or
high speed position. Speed Control Bracket Details
3. Align hole in throttle lever with hole in speed control
bracket by inserting a pencil or 6.35 mm (1/4 in.) drill
bit.
4. Pull on outer shield of throttle control cable to
remove any slack. Tighten cable clamp securely.
Starting an Engine Equipped with Unitized Throttle
and Choke Control
Starting Throttle Control Details

A A
A 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
manufacturer’s instructions for specific information.
A NOTE: If engine is equipped with a fuel pump, carefully
remove fuel lines from housing and remove
pump from bracket.
A Cold Engine or Warm Engine
1. Make sure throttle cable is adjusted properly (see
NOTE: Do not crank engine continuously for more than Throttle Cable Adjustment).
10 seconds at a time. If engine does not start,
allow a 60 second cool down period between 2. Start engine and allow it to warm up. Place throttle
starting attempts. Failure to follow these control lever into fast or high speed position. Turn
guidelines can burn out starter motor. governed idle adjusting screw out/counterclockwise,
so there is clearance from control lever, and that
NOTE: If engine develops sufficient speed to disengage contact cannot occur during Step 4.
starter but does not keep running (a false start),
engine rotation must be allowed to come to a 3. Align hole in throttle lever with hole in speed control
complete stop before attempting to restart bracket by inserting a pencil or 6.35 mm (1/4 in.) drill
engine. If starter is engaged while flywheel is bit.
rotating, starter pinion and flywheel ring gear 4. Loosen speed control bracket mounting screws.
may clash, resulting in damage to starter. Slide bracket forward or backward, until desired high
If starter does not turn engine over, shut starter off speed (RPM) is reached. Check speed with a
immediately. Do not make further attempts to start tachometer.
engine until condition is corrected. Do not jump start To increase high speed (RPM), move bracket toward
using another battery. See your Kohler authorized dealer carburetor.
for trouble analysis. To decrease high speed (RPM), move bracket away
1. For a Cold or Warm Engine – Place throttle/choke from carburetor.
control into fast/choke ON position. This will also 5. Tighten speed control bracket mounting screws.
place choke into ON position. Recheck speed with a tachometer and readjust if
2. Make sure equipment is in neutral. necessary.
3. Activate starter switch. Release switch as soon as Torque mounting screws as follows:
engine starts. Into new hole – 11.3 N·m (100 in. lb.).
4. For Operation – After engine starts, move throttle/ Into used hole – 7.5 N·m (65 in. lb.).
choke control from fast/choke ON position and set 6. Adjust governed idle (see Governed Idle Adjustment
desired engine operating speed (between slow and which follows).
fast position).

Fuel System
Governed Idle Adjustment SEPARATE THROTTLE AND CHOKE CONTROL

Some engines are equipped with separate throttle and
This procedure must follow High Speed Adjustment choke controls. This allows you to adjust choke and
just described. If not already completed, perform that throttle controls individually.
operation first.
Install Separate Control Cables
Speed Control Bracket Alignment Hole Details
D
A
C A
A Governed Idle Screw

B
1. Turn governed idle adjusting screw out
(counterclockwise), until it no longer contacts control
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 A Throttle Cable Clamp B Alignment Hole
throttle (fast). Choke link should not move as throttle
moves through normal range. If it does, back C Throttle Linkage D Throttle Control Lever
adjusting screw out until it no longer moves.
4. Move throttle control lever to choke position. Check Throttle Control Installation
if choke has fully closed by placing your finger on 1. Loosen cable clamp screw on speed control bracket
right side of lower end of choke lever/choke link and assembly.
applying gentle pressure towards carburetor. If
controls have been properly set, link should not 2. Move application throttle control lever to maximum
move. 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.
4. Align hole in throttle lever with hole in speed control
bracket by inserting a pencil or 6.35 mm (1/4 in.) drill
bit.
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.

Fuel System
Choke Control Installation Changing High Speed (RPM) on Engines with

In this engine series, choke cable connects to carburetor Separate Controls (Increase or Decrease RPM)
choke lever and is secured to air cleaner adapter with a Speed Control Bracket Details
cable clamp.
B A A
C
A Cable Clamp B Air Intake Adapter

A Speed Control Bracket Mounting Screw
C Choke Lever
NOTE: If engine is equipped with a fuel pump, carefully
1. Connect choke cable boden wire to carburetor choke remove fuel lines from housing and remove
lever. pump from bracket.
2. Position choke cable under cable clamp and secure 1. Check that governor spring and installation matches
to air intake adapter. intended high speed RPM operating range.
3. Push/move choke control to off position in 2. Start engine, move application throttle lever to full
application panel until it bottoms, then pull it back throttle/fast, and loosen mounting screws of main
approximately 1/16 in. speed control bracket to allow repositioning.
4. Push on choke cable, ahead of clamp on air cleaner 3. To increase RPM: Move speed control bracket,
adapter, until choke lever stops. Do not force. Then towards carburetor. To decrease RPM: Move speed
tighten cable clamp screw. control bracket, away from carburetor. Check RPM
with a tachometer and tighten screws when correct
Starting an Engine Equipped with Separate Control setting has been obtained.
Cables
4. To ensure that RPM has been obtained, move
1. Place throttle control midway between slow and fast throttle lever to low idle/slow then back to full throttle/
positions. Place choke control into on position. fast position and check RPM with a tachometer.
2. Start engine.
3. For a Cold Engine – Gradually return choke control Setting Low Idle RPM
to off position after engine starts and warms up. 1. Move application control to slow position.
Engine/equipment may be operated during warm up 2. Using a tachometer, check RPM. Then, using a
period, but it may be necessary to leave choke screwdriver, turn low idle speed screw inward
partially on until engine warms up. (clockwise) to increase RPM, and outward
4. For a Warm Engine – Return choke to off position as (counterclockwise) to lower RPM.
soon as engine starts.

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
K G
L
J
O
H
I
K
M M
Inside Engine
A B
C
Round Head Square
A Governor Cross Shaft B C Lock Washer D Nut
Neck Bolt
E Governor Lever F Governor Spring G Speed Control Bracket H Control Lever
Throttle Linkage and Linkage Retainer

I Choke Linkage J K L Linkage Spring
Spring Bushing
M Flyweight N Regulating Pin O Governor Gear

Governor System
This governor design works as follows: Governor Adjustments

● Centrifugal force acting on rotating governor gear NOTE: Do not tamper with governor setting. Overspeed
assembly causes flyweights to move outward as is hazardous and could cause personal injury.
speed increases. Governor spring tension moves
them inward as speed decreases. Initial Adjustment Procedure
● As flyweights move outward, they cause regulating pin Make this adjustment whenever governor arm is
to move outward. loosened or removed from cross shaft. Adjust as follows:
● Regulating pin contacts tab on cross shaft causing 1. Make sure throttle linkage is connected to governor
shaft to rotate. arm and throttle lever on carburetor.
● One end of cross shaft protrudes through crankcase.
Rotating action of cross shaft is transmitted to throttle 2. Loosen nut holding governor lever to cross shaft.
lever of carburetor through external throttle linkage. 3. Move governor lever toward carburetor as far as it
● When engine is at rest, and throttle is in fast position, will go (wide open throttle) and hold in this position.
tension of governor spring holds throttle plate open.
When engine is operating, governor gear assembly is 4. Grasp cross shaft with a pliers, and turn shaft
rotating. Force applied by regulating pin against cross counterclockwise as far as it will go. Torque nut to
shaft tends to close throttle plate. Governor spring 7.7 N·m (68 in. lb.).
tension and force applied by regulating pin balance
each other during operation, to maintain engine Governor Sensitivity Adjustment
speed. Governor sensitivity is adjusted by repositioning
● When load is applied and engine speed and governor governor spring in holes in governor lever. If speed
gear speed decreases, governor spring tension moves surging occurs with a change in load, governor is set too
governor arm to open throttle plate wider. This allows sensitive. If a big drop in speed occurs when a normal
more fuel into engine, increasing engine speed. As load is applied, governor should be set for greater
speed reaches governed setting, governor spring sensitivity.
tension and force applied by regulating pin will again Desired high speed setting (RPM) will determine
offset each other to hold a steady engine speed. governor spring used.

Lubrication System
This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft, and
connecting rod bearing surfaces. Other component areas are splash lubricated.
A high-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating
temperatures. A pressure relief valve limits maximum pressure of system. Closure plate must be removed to service
oil pickup, pressure relief valve, and oil pump.
Lubrication Components
A Oil Fill/Dipstick B Oil Sentry™ C Oil Filter D Oil Drain Plug
OIL RECOMMENDATIONS 4. Apply a thin film of clean oil to rubber gasket on new
Refer to Maintenance. filter.
CHECK OIL LEVEL 5. Refer to instructions on oil filter for proper
installation.
NOTE: To prevent extensive engine wear or damage,
never run engine with oil level below or above 6. Fill crankcase with new oil. Level should be at top of
operating range indicator on dipstick. indicator on dipstick.
Ensure engine is cool and level. Clean oil fill/dipstick 7. Reinstall oil fill cap/dipstick and tighten securely.
areas of any debris. 8. Start engine; check for oil leaks. Stop engine; correct
1. Remove dipstick; wipe oil off. leaks. Recheck oil level.
2. Reinsert dipstick into tube; press completely down. 9. Dispose of used oil and filter in accordance with
local ordinances.
3. Remove dipstick; check oil level. Level should be at
top of indicator on dipstick. OIL SENTRY™ (if equipped)
4. If oil is low on indicator, add oil up to top of indicator This switch is designed to prevent engine from starting
mark. in a low oil or no oil condition. Oil Sentry™ may not shut
down a running engine before damage occurs. In some
5. Reinstall and secure dipstick. applications this switch may activate a warning signal.
CHANGE OIL AND FILTER Read your equipment manuals for more information.
Change oil while engine is warm. Oil Sentry™ pressure switch is installed in closure plate
pressure port. On engines not equipped with Oil Sentry™,
1. Clean area around oil fill cap/dipstick. Remove drain installation hole is sealed with a 1/8" pipe plug.
plug and oil fill cap/dipstick. Allow oil to drain
completely. Installation
2. Clean area around oil filter. Place a container under 1. Apply pipe sealant with Teflon® (Loctite® PST® 592TM
filter to catch any oil and remove filter. Wipe off Thread Sealant or equivalent) to threads of switch.
mounting surface. Reinstall drain plug. Torque to 2. Install switch into closure plate.
14.0 N·m (125 in. lb.).
3. Torque switch to 6.2 N·m (55 in. lb.). Connect lead to
3. Place new filter in shallow pan with open end up. Fill terminal or connector plug to terminals on Oil
with new oil until oil reaches bottom of threads. Allow Sentry™ switch.
2 minutes for oil to be absorbed by filter material.

Lubrication System
Testing 2. Gradually increase pressure to switch. As pressure

increases through range of 2-5 PSI, tester should
Compressed air, a pressure regulator, pressure gauge, indicated a change to continuity (contacts closed)
and a continuity tester are required to test switch. between terminal #1 and terminal #3 on switch.
Identify switch used and follow appropriate testing Continuity condition between #1 and #3 terminals
procedure. should remain closed while pressure is further
increased to 90 PSI.
3-Terminal Switch
3. Gradually decrease pressure through range of 2-5
E PSI. Tester should indicate a change in continuity
between terminals #1 and #3 (contacts open) down
D to 0 PSI.
Replace switch if it does not operate as expected for
F either test 1 or 2 as detailed above.
Single-Terminal Switch
B
A
C
A Single Terminal Oil Pressure

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).
A Terminal 1 Power In 2. Gradually increase pressure to switch. As pressure
increases through range of 2-5 psi tester should
B Terminal 2 Oil Pressure indicate a change to no continuity (switch open).
Switch should remain open as pressure is increased
C Terminal 3 Power Out to 90 psi maximum.
D Red Wire Power In 3. Gradually decrease pressure through range of 2-5
E Green Wire Oil Pressure psi. Tester should indicate a change to continuity
(switch closed) down to 0 psi.
F Red Wire Power Out to Choke Thermostat
4. Replace switch if it does not operate as specified.
Test 1
1. Connect continuity tester across blade terminal #2
and metal case of switch. With 0 PSI applied to OIL PRESSURE
switch, tester should indicate continuity (contacts
closed). Testing
2. Gradually increase pressure to switch. As pressure Engine oil pressure can be tested using an oil pressure
increases through range of 2-5 PSI, tester should tester. Follow instructions included with tester. Pressure
indicated a change to no continuity (contacts open). can be tested by removing oil filter and installing tester
Switch contacts should remain open as pressure is adapter on mounting pad, or by removing Oil Sentry™
further increased to 90 PSI. pressure switch (or pipe plug) and threading tester hose
directly into mounting hole.
3. Gradually decrease pressure through range of 2-5
PSI. Tester should indicate a change in continuity at
terminal (Switch closed) down to 0 PSI.
Test 2
1. Connect continuity tester leads at terminal #1 and
terminal #3 of switch. With 0 PSI applied to switch,
tester should indicate no continuity (contacts open)
between terminals #1 and #3.

Electrical System
BATTERY CHARGING SYSTEM Fixed Ignition System

CAUTION This system uses an inductive discharge (ID) coil.
Ignition timing and spark remains constant regardless of
Electrical Shock can cause injury. engine speed. Timing of spark is controlled by location of
Do not touch wires while engine is running. flywheel magnet group as referenced to engine TDC. A
typical fixed ignition system consists of:
● 1 magnet assembly which is permanently affixed to
flywheel.
NOTE: Observe following guidelines to avoid damage to ● 1 electronic inductive-discharge ignition module which
electrical system and components: mounts on engine crankcase.
● Make sure battery polarity is correct. A negative (-) ● 1 kill switch (or key switch) which grounds module to
ground system is used. stop engine.
● 1 spark plug.
● Disconnect rectifier-regulator plug and/or wiring
harness plug before doing any electric welding on
equipment powered by engine. Disconnect all other BATTERY
electrical accessories in common ground with engine. A 12-volt battery with 250 cold cranking amps (cca) is
generally recommended for starting in all conditions.
● Prevent stator (AC) leads from touching or shorting A smaller capacity battery is often sufficient if an
while engine is running. This could damage stator. application is started only in warmer temperatures.
These engines are equipped with either a 12 or 15 amp, Actual cold cranking requirement depends on engine
regulated battery charging system. size, application, and starting temperatures. Cranking
requirements increase as temperatures decrease and
Ignition System Components battery capacity shrinks. Refer to equipment's operating
instructions for specific battery requirements.
Battery Size Recommendations
A E H If battery charge is insufficient to turn over engine,
recharge battery.
F
Battery Maintenance
D B Regular maintenance is necessary to prolong battery
F life.
Battery Test
G To test battery, follow manufacturer's instructions.
C
A Kill Switch/Off Position B Air Gap

of Key Switch
C Flywheel D Magnet
E Spark Plug F Ignition Module
G Kill Terminal H 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.

Electrical System
Wiring Diagram-12/15 Amp Regulated Battery Charging System
P
K T
U
J D S
S
AC
O B+ R
AC
E
L P
C Q
A
M
B G
N I
_ + J
O
A Red B Green C Violet D White

Optional Fuel Shut-off Optional Oil Sentry™
E Spark Plug F G H Bendix Starter
Solenoid Switch (Indicator)
I Engine Connector J Starter Solenoid K Ground-To-Kill Lead L Key Switch
M Optional Oil Sentry™ N Optional Fuse O Battery P Rectifier-Regulator
Q Flywheel R Stator S Ignition Module T Accessory
Equipment Safety
U Circuit

Electrical System
Wiring Diagram-12/15 Amp Regulated Battery Charging System with Smart-ChokeTM
P
K T
U
J D T
S
AC
O B+ S
AC
E
L Q
C R
A
M
A
F
A
B
N I
V
H
G
_ + J
O

3-Terminal Oil
E Spark Plug F Fuel Shut-off Solenoid G Sentry™ H Bendix Starter
Switch (Indicator)
Equipment Safety Smart-Choke™
U V
Circuit Diaphragm Assembly
NOTE: Refer to Smart-ChokeTM in Fuel System section for troubleshooting.

Electrical System
Wiring Diagram-12/15 Amp Regulated Battery Charging System with Fuel Relay
Q
K T
X
D
J S
S AC
O B+ R
AC E
L P D
C Q
M V
G W
B
I V
N
H A
F V
_ + J
O

Optional Oil Sentry™
E Spark Plug F Fuel Shut-off Solenoid G H Bendix Starter
Switch (Indicator)
Equipment Safety
U Fuel Shut-off Relay V Orange W Yellow X Circuit

Electrical System
Wiring Diagram-12/15 Amp Regulated Battery Charging System with Fuel Relay and Stator Brake Relay
P Z
T Z
X K D
D
J T
S AC
O P S
B+ Y
AC E B
L A
AA
M C R
V A
G
B
W
N I
H A U
_ +
J F
O

Optional Oil Sentry™
E Spark Plug F Fuel Shut-off Solenoid G H Bendix Starter
Switch (Indicator)
Equipment Safety
U Fuel Shut-off Relay V Orange W Yellow X Circuit
Y Stator Brake Relay Z Brown AA Stator Connector

Electrical System
12/15 Amp Battery Charging Systems

NOTE: Always zero digital volt-ohm meter (DVOM) on each scale before testing to ensure accurate readings. Voltage
test should be made with engine running at specific test condition noted. Battery should be checked for state
of charge (non-operating voltage 12.5 VDC or lower, battery should be charged or replaced).
When problems occur in keeping a battery fully charged or a battery charges at a high rate, battery or charging
system may be cause of fault. Before performing any testing, battery must be fully charged.
To test charging system: 6. With engine off and stator unplugged from rectifier-
1. Visually inspect system components and wiring. regulator, check for resistance/continuity between
Look for damaged or loose wire connections, across stator leads (white wires).
including battery cables.
2. Set DVOM to DC volts, place one lead of tester on
rectifier-regulator body and other lead to battery Resistance is 0.1/0.2 Stator coil is OK.
negative (-) terminal. Run engine and observe volt ohms.
reading on meter. If voltage is 0.5 VDC or less Resistance is 0 ohms. Stator is shorted; replace.
continue with testing. If voltage is higher than 0.5 Resistance is infinity Stator is open; replace.
VDC, inspect and repair wiring/connections as ohms/no continuity.
needed (insufficient ground). NOTE: If engine is equipped with stator brake, retest at
3. Perform these output tests for charging system using white 2 wire stator connector if results are found
DVOM set to DC volts. to be unacceptable for confirmation.
a. With engine off and key switch in OFF position, 7. With engine off and stator unplugged from rectifier-
measure voltage at battery. If less than 12.4 VDC, regulator, check for resistance/continuity from stator
recharge battery and retest. If 12.5 VDC continue leads (white wires) to ground.
with tests.
b. Run engine at high speed no load (greater than Condition Conclusion
3000 RPM). After running 1 minute, measure Resistance is infinity ohms Stator is OK (not shorted
voltage at battery. (no continuity). to ground).
i. If voltage increases to between 13-15 VDC, Resistance (or continuity) Stator leads are shorted to
system is working correctly. measured. ground; replace.
ii. If voltage increases to 15.5 VDC or higher,
system is overcharging. Replace rectifier- 8. If stator tests good (steps 4-7), but system was
regulator. identified in step 3 as not working, failure is likely
iii. If voltage stays at 12.5 VDC or decreases, with rectifier-regulator. Replace rectifier-regulator,
charging system is NOT operating, proceed to retest system to confirm repairs (step 3).
step 4.
4. With engine off, unplug rectifier-regulator connector
and inspect connector terminals within connector
body and rectifier-regulator terminals for corrosion/
arching/damage. Repair/replace as needed. If OK,
proceed to next test.
NOTE: If engine is equipped with stator brake, inspect
white 2 wire stator connector in addition to 3
terminal rectifier-regulator connector.
5. Set DVOM to AC volts, place test leads to each
white stator wire. Run engine at 1200 RPM or
greater and monitor voltage.
Voltage is 13 volts AC or Stator is OK.
more.
Voltage is less than 13 Stator is faulty. Continue
volts AC. with steps 6 and 7).

Electrical System
IGNITION SYSTEM Normal

Spark Plug
Component and Details
A
B
Plug taken from an engine operating under normal

conditions will have light tan or gray colored deposits. If
center electrode is not worn, plug can be set to proper
gap and reused.
Worn
C D
A Wire Gauge B Spark Plug

C Ground Electrode D Gap
NOTE: Do not clean spark plug in a machine using
abrasive grit. Some grit could remain in spark
plug and enter engine causing extensive wear
and damage.
Engine misfire or starting problems are often caused On a worn plug, center electrode will be rounded and
by a spark plug that has improper gap or is in poor gap will be greater than specified gap. Replace a worn
condition. spark plug immediately.
Engine is equipped with following spark plugs: Wet Fouled
Standard Plug RFI Plug

Gap 0.76 mm (0.030 in.) 0.76 mm (0.030 in.)
Thread Size 12 mm 12 mm
Reach 19.1 mm (3/4 in.) 19.1 mm (3/4 in.)
Hex Size 15.9 mm (5/8 in.) 17.5 mm (11/16 in.)
Refer to Maintenance for Repairs/Service Parts.
Service
Clean out spark plug recess. Remove plug and replace.
1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.030 in.). A wet plug is caused by excess fuel or oil in combustion
chamber. Excess fuel could be caused by a restricted air
2. Install plug into cylinder head. cleaner, a carburetor problem, or operating engine with
3. Torque plug to 27 N·m (20 ft. lb.). too much choke. Oil in combustion chamber is usually
caused by a restricted air cleaner, a breather problem,
Inspection worn piston rings, or valve guides.
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:

Electrical System
Carbon Fouled Overheated
Soft, sooty, black deposits indicate incomplete Chalky, white deposits indicate very high combustion
combustion caused by a restricted air cleaner, over rich temperatures. This condition is usually accompanied
carburetion, weak ignition, or poor compression. by excessive gap erosion. Lean carburetor settings,
an intake air leak, or incorrect spark timing are normal
causes for high combustion temperatures.
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 won’t have spark). Be certain drive is in neutral and
all external loads are disconnected.
Test Ignition Systems
NOTE: If engine starts or runs during testing, you may need to ground kill lead to shut it down. Because you have
interrupted kill circuit, it may not stop using switch.
Isolate and verify trouble is within engine.
1. Locate connectors where wiring harnesses from engine and equipment are joined. Separate connectors and
remove white kill lead from engine connector. Rejoin connectors and position or insulate kill lead terminal so it
cannot touch ground. Try to start engine to verify whether reported problem is still present.
Problem goes away. Electrical System Check key switch, wires,
connections, safety interlocks, etc.
Problem persists. Ignition or Electrical System Leave kill lead isolated until all
testing is completed.

Electrical System
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.
Audible and visible sparks are Ignition Module Ignition module is OK.
produced.
Audible and visible sparks are not Ignition Module or Electrical System Make sure engine ignition switch,
produced. 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 8,200 to 23,000 ohms. Refer
to Disassembly and Reassembly for complete ignition module removal and installation procedures.
Resistance is within specified range. Module Secondary Module secondary is OK.
Resistance is low or 0 ohms. Module secondary is shorted.
Replace module.
Resistance is high or infinity ohms. Module secondary is open. Replace
module.

Electrical System
FUEL SHUT-OFF RELAY CIRCUIT Troubleshooting-Fuel Shut-Off Relay System

Some engines are equipped with a fuel shut-off relay. NOTE: Refer to Fuel Shut-Off Solenoid in Fuel System
This relay is part of wiring harness and is activated with section for individual testing of solenoid valve.
voltage supplied by equipment. Power is supplied to Review Fuel System section for more
fuel shut-off solenoid through a relay. By design, power information.
to solenoid can be interrupted by application safety
interlock circuit (seat switch/brake switch/operator If engine cranks but does not start, restricted fuel
present). delivery could be a possible cause. Confirm fuel delivery
to carburetor.
If relay needs replacement, wiring harness must be
replaced. To test fuel shut-off circuit/relay, confirm all equipment
safety switches are in starting mode (refer to equipment
Fuel Shut-off Relay Harness Connections manual for detailed safety operation procedures).
I 1. Locate engine to equipment 6 pin connector. With
equipment switch in ON/RUN position, use
appropriate size meter probe and measure voltage
E at yellow wire of 6 pin connector using a volt/ohm
meter.
F
B
C
H D
Zero (0) voltage should be seen at yellow wire.
2. Remove 2 pin connector from fuel shut-off solenoid
E and probe red wire terminal. Battery voltage should
be present.
F
G
A Stator Assembly B Wiring Harness

Stator Leads to
C D Rectifier-Regulator
Rectifier-Regulator
E Ignition Kill Wire F Fuel Shut-Off Relay
Harness Routed Engine to Equipment
G Between Starter and H 6 Pin Connector
Crankcase If voltage is present at yellow wire of 6 pin connector,
Fuel Shut-off Solenoid this is an indication that engine kill wire is grounded/
I equipment safety circuit has been activated through
Connector
a seat switch/PTO switch/operator present switch (if
equipped). Refer to equipment manual to identify and
determine fault. If relay of circuit is found to be at fault,
replace wiring harness (relay is not serviced separately).

Electrical System
Condition Engine operates as designed.

Key Switch Safety Circuit Yellow Wire (Volts) Solenoid (Volts)
OFF Operate 0 0
ON Operate 0 12
START Operate 0 12
Possible Cause None, system OK.
Conclusion None, system OK.
Condition Engine cranks but will not start (voltage at yellow wire).
OFF Activated 0 0
ON Activated 12 0
START Activated 12 0
Possible Cause Equipment safety system activated or white kill wire shorted to ground.
Conclusion Refer to equipment manual for inspection/repair procedures or repair white kill wire short.
Condition Engine cranks but will not start.

OFF Operate 0 0
ON Operate 0 0
START Operate 0 0
Possible Cause No voltage at yellow wire, no voltage at fuel shut-off solenoid.
Conclusion Bad connection, broken wire, bad fuel shut-off relay.
Condition Engine cranks but will not start.

OFF Operate 0 0
ON Operate 0 12
START Operate 0 12
Possible Cause Defective fuel shut-off solenoid or bad/open ground wire at solenoid connector.
Conclusion Replace fuel shut-off solenoid or repair/replace wiring harness.

Electrical System
BLADE STOP STATOR BRAKE AND FUEL SHUT-OFF Stator Brake and Fuel Shut-off Relay Harness
CIRCUIT Connections
Some engines are equipped with a fuel shut-off relay K
and a stator brake relay. These relays are part of wiring
harness. Refer to FUEL SHUT-OFF RELAY CIRCUIT
(on previous pages) for troubleshooting fuel relay part of G
circuit. F
H
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. A
Circuit is activated if operator gets off of seat of
application while mower blade system is activated or in B
certain reverse mow conditions.
Circuit is activated by taking ignition shutdown (kill) lead
to ground. This action turns on stator-brake relay which C
shorts charging AC stator leads to produce a magnetic E
field that will counter or resist rotation of flywheel, along
with removing power from fuel solenoid. This added J
resistance to rotation decreases amount of time it takes D
for application deck blades to come to a full stop.
If relay needs replacement, wiring harness must be
replaced. F
E
G
I
D
A Stator Assembly B Wiring Harness

Stator Leads to
C D Rectifier-Regulator
Rectifier-Regulator
2 Wire Stator
E F Ignition Kill Wire
Connector
G Fuel Shut-Off Relay H Stator Brake Relay
Harness Routed Engine to Equipment
I Between Starter and J 6 Pin Connector
Crankcase
Fuel Shut-off Solenoid
K Connector

Electrical System
Troubleshooting-Stator Brake System To test engine that will crank but will not start:
NOTE: If removing stator brake relay for testing, Stator brake relay is interacting with application safeties
carefully remove sealing tape from around that or reverse mow electronics, preventing normal engine
relay only. Ensure this area is then resealed with start up.
electrical tape if relay is reinstalled after testing, 1. Remove brake relay from its socket and attempt to
to protect relay from debris, etc. restart engine.
Engine starts. Relay has failed. Replace
wiring harness.
Engine does not start. Problem may exist with
application reverse
mow circuit, application
A safeties, or with key
switch keeping ignition
shutdown line tied to
engine ground. Refer to
equipment manual.
A Stator Brake Relay

2. Remove engine shutdown (kill) white lead from
application wire harness and attempt to start engine
Problems that could occur with Kohler portion of circuit again.
generally could be caused by component failures, which
will create following conditions. Condition Conclusion
1. Dead battery Engine does not start. Fuel or ignition problem.
2. Engine cranks but will not start
Engine starts. White kill wire circuit/
To test for dead battery: application safety circuit
issue. Refer to equipment
Stator brake relay may have failed and is keeping stator manual.
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.
Voltage does not increase. Shut down engine,
remove stator brake relay
from its socket and retest
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. Refer to page
Battery Charging System
earlier in this section.

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.
NOTE: Battery must be tested and confirmed acceptable prior to troubleshooting starter system. Follow battery or
OEM battery testing procedures.
Engines in this series use inertia drive starters. Inertia drive starters are not serviceable.
Troubleshooting-Starting Difficulties
Starter does not energize. Battery Check specific gravity of battery and battery state of charge. If
low, recharge or replace battery as necessary.
Wiring Clean corroded connections and tighten loose connections.
Replace wires in poor condition and with frayed or broken
insulation.
Starter Switch By-pass switch or solenoid with a jumper wire. If starter
or Solenoid cranks normally, replace faulty components. Consult with
OEM electrical system service procedures for OEM related
component diagnostics. Perform solenoid test procedure.
Starter energizes but turns Battery Check specific gravity of battery and battery state of charge. If
slowly. low, recharge or replace battery as necessary.
Transmission Make sure clutch or transmission is disengaged or placed
or Engine in neutral. This is especially important on equipment with
hydrostatic drive. Transmission must be exactly in neutral to
prevent resistance which could keep engine from starting.
Check for seized engine components such as bearings,
connecting rod, and piston.
INERTIA DRIVE ELECTRIC STARTERS When power is applied to starter, armature rotates. As
armature rotates, drive pinion moves out on drive shaft
splines and into mesh with flywheel ring gear. When
pinion reaches end of drive shaft, it rotates flywheel and
cranks engine.
When engine starts, flywheel rotates faster than starter
armature and drive pinion. This moves drive pinion out
of mesh with ring gear and into retracted position. When
power is removed from starter, armature stops rotating
and drive pinion is held in retracted position by anti-drift
spring.

Starter System
Inertia Drive Starter Tests

NOTE: Please perform following testing as near to conditions during failure.
Before Starting
● Disable ignition system: disconnect spark plug lead from spark plug, then ground spark plug lead to engine block
using mechanical means.
● Battery voltage should be tested and must be at 12.4 VDC or higher. Do not proceed if battery voltage is less than
12.4 VDC as battery should be charged.
● Test meter leads before use. (Set meter to Ohms and check for resistance reading of less than 0.5 Ohm.)
● If available, use clamping meter leads to assist with testing.
● Set meter to next highest voltage scale that includes 12 VDC.
● When taking readings, allow meter to stabilize before recording. Reading should stabilize after 3 to 5 seconds. If
reading continues to drop while cranking, stop test and perform a battery load test.
A B C
D D D
+ - + - + -
G H
+ - + - +
E E - F
I J K
Test #1 Test #2 Test #3

A Battery Voltage Test B Voltage Drop Across C Voltage Drop Across D DVOM
(Static) Battery (Cranking) Starter (Cranking)
Touch meter leads
Use starter end plate
E Battery F Starter G to actual battery H as test point.
terminals.
I Test #1 Results J Test #2 Results K Test #3 Results
Test 1 Conclusions
• If battery voltage is above 12.4 VDC continue to Test 2.
• If voltage is below 12.4 VDC, charge battery and retest.
• If battery will not hold a charge it should be replaced before continuing test or replacing starter.
Test 2 Conclusions
• If battery cranking voltage is above 9.0 VDC continue to Test 3.
• If battery cranking voltage is below 9.0 VDC you should check battery by using a load tester. Also check for external
engine load.
Test 3 Conclusions
• If difference between test 2 and test 3 is greater than 1 VDC check all positive and negative electrical connections
for corrosion and/or loose fasteners in starter circuit.

Emission Compliant Systems
EVAPORATIVE EMISSION COMPLIANT SYSTEM

Carbon Canister System
D
A
Roll Over Valve

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

SECONDARY EMISSION COMPLIANT SYSTEM

Secondary Air Induction System
B
A
Secondary Air Hose To Exhaust

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

Remove Inlet Screen

Inlet Components
A
B
A Secondary Air Valve Assembly B Barb C Inlet Screen

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

Disassembly/Inspection and Service
WARNING
Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as
death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Disconnect and ground spark plug lead(s)
before servicing.
External Engine Components
T
V
H T
T
T
W
J S
I
A
J B
I
O R
Q L
E
M C
P
O G D
F
A Oil Fill/Dipstick B Oil Fill/Dipstick Tube C Oil Filter D Oil Drain Plug
E Air Cleaner Adapter F Intake Manifold G Intake Manifold Nut H Cover
PRO Air Cleaner
I Precleaner J Paper Element K L Fuel Filter
Cover
Line Retained in
M Pulse Line N Outlet Fuel Line O P Fuel Pump
Housing
Blower Housing to
Q Fuel Pump Bracket R Inlet Fuel Line S Blower Housing T Closure Plate
Screw
Blower Housing to
U Fixed Guard Screw V Fixed Guard W Adapter Screw

Clean all parts thoroughly as engine is disassembled. Remove Blower Housing

Only clean parts can be accurately inspected
and gauged for wear or damage. There are many NOTE: Unless fuel pump bracket is damaged
commercially available cleaners that will quickly remove disassembly from blower housing is
grease, oil, and grime from engine parts. When such a unnecessary.
cleaner is used, follow manufacturer’s instructions and 1. Remove screws securing blower housing to closure
safety precautions carefully. plate.
Make sure all traces of cleaner are removed before 2. Remove screw securing blower housing to air
engine is reassembled and placed into operation. Even cleaner adapter and lift off blower housing.
lubricating properties of engine oil. Remove Intake Manifold, Carburetor, Air Cleaner
Adapter
Disconnect Spark Plug Lead
Carefully pull on boot section and disconnect spark plug
lead. Carefully remove spark plug lead wire tie from
valve cover. A B
Turn Off Fuel Supply
Shut off fuel supply.
Drain Oil from Crankcase and Remove Oil Filter
C
1. Remove oil drain plug and oil fill cap/dipstick.
2. Allow ample time for oil to drain from crankcase. F D
3. Remove and discard oil filter.
E
Remove Air Cleaner
1. Turn knobs toward unlock symbol and remove air A Diaphragm Assembly B Black Ground Wire
cleaner cover. C Red Wire D Breather Hose
2. Lift and remove precleaner (if equipped) and air
cleaner element from air cleaner adapter. E Hose Clamp F Air Cleaner Adapter
1. If carburetor uses a fuel solenoid, disconnect fuel
Remove Fuel Pump (if equipped) solenoid lead from carburetor solenoid.
NOTE: Inlet, outlet, and pulse lines can remain on fuel 2. If engine is equipped with Smart-ChokeTM, unplug
pump unless replacement is required. diaphragm assembly red wire from wiring harness.
NOTE: Unless fuel pump is being replaced, disassembly Unplug black ground wire from Smart-ChokeTM
from fuel pump bracket is unnecessary. diaphragm assembly.
1. Disconnect fuel pump outlet line from carburetor inlet
fitting. Line is retained in blower housing, pull to
remove.
2. Using hose removal tool (see Tools and Aids),
carefully remove pulse line from oil fill/dipstick tube.
3. Remove fuel pump from bracket.
Remove Fixed Guard (if equipped)
NOTE: Unless fixed guard is damaged, disassembly
from blower housing is unnecessary.
Remove screw securing fixed guard to blower housing.
Unsnap guard from housing.

3. Move hose clamp on breather hose away from air Standard Choke
intake elbow. Using Hose Removal Tool (see Tools
and Aids), carefully remove breather hose from air B
cleaner adapter. A
B C
G C
D
E
F
A Air Cleaner Adapter B Nut
C Gasket D Carburetor
E Stud F Gasket
G Intake Manifold
D
Smart-ChokeTM
A Retainer B Throttle Linkage
B
C Governor Lever D Choke Linkage L A
4. Unhook retainer from throttle linkage and remove K
linkage from governor lever. Snap retainer on end of K
linkage for reassembly.
I
5. Remove nuts securing intake manifold to cylinder
head. H J
Standard Choke Single Wire Controls
Slide assembly forward and off intake studs. Turn C
assembly 90° to remove choke linkage from speed
control bracket. Remove and discard intake manifold D
gasket. H E
Smart-ChokeTM F
G
Slide assembly forward and off intake studs.
Remove and discard intake manifold gasket. A Air Cleaner Adapter B Nut
Assembly includes plastic intake manifold, carburetor C Gasket D Carburetor
with solenoid and linkage(s), air intake adapter, and if
equipped Smart-Choke components. E Stud F Gasket
Separate parts only if additional service is required. G Intake Manifold H Vacuum Hose
Check Valve Diaphragm
I J
Assembly Assembly
Smart-ChokeTM
K K40 x 1.79 Screw L Linkage

Remove External Governor Components Remove Ignition Module
A
B
A B
C
B
Speed Control
A B Screw
Bracket
1. 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 and
unhook governor spring. Remove screws securing
speed control bracket to closure plate. Remove A Screw B Ignition Module
control bracket.
C Tab Terminal
2. Loosen nut and remove governor lever, bolt, lock
washer, and nut from governor cross shaft. 1. Disconnect white lead wire from ignition module tab
terminal.
Remove Oil Fill/Dipstick Tube 2. Rotate flywheel magnet away from module.
Remove screw securing tube to closure plate. Lift tube 3. Remove screws and ignition module.
from closure plate.
Remove Wiring Harness
Remove Oil Sentry™ Pressure Switch (if equipped)
1. Remove purple B+ wire from center of rectifier-
NOTE: Pressure switch is installed into closure plate. regulator connector.
1. Cut wire tie securing lead to switch. 2. Remove cylinder head baffle screw securing ground
2. Disconnect lead or remove connector from Oil wire of wiring harness.
Sentry™ pressure switch. 3. Carefully remove both wire ties securing harness to
3. Remove pressure switch from closure plate. closure plate. Starter side from below closure plate;
above closure plate by cylinder head.
Remove Rectifier-Regulator
A B
A Rectifier-Regulator B Connector
1. Remove screws securing rectifier-regulator to
crankcase. Remove rectifier-regulator.
2. Unplug connector from rectifier-regulator.

Remove Debris Screen, Fan, and Flywheel

A
A
B
B
C
D
A Anchor Bolt Assembly

F B Anchor Bolt Assembly in Opposite Direction
G 6. Position flywheel puller with center screw on

flywheel screw. Secure each anchor bolt evenly to
puller as shown.
H
A
B
C
A Debris Screen B Flywheel Screw

C Washer D Fan Mounting Plate D
E Fan F Flywheel Key
G Flywheel H Magnet
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, Flywheel Puller
A B Anchor Bolt
as they could be cracked or damaged. Center Screw
1. Unsnap debris screen from cooling fan. C Nut D Washer
2. Remove retaining screw, washer, and fan mounting
plate, securing fan and flywheel to crankshaft. 7. Turn center screw of puller to loosen and remove
3. Carefully lift cooling fan to disengage two drive pins flywheel. Use puller to lift flywheel from engine.
and remove it from flywheel. 8. Remove flywheel key from crankshaft.
4. Reinstall flywheel retaining screw.
Flywheel Inspection
5. Install an anchor bolt assembly (see Tools and Aids)
in each hole of flywheel. Be sure to install them in Inspect flywheel for cracks and check keyway for wear
opposite directions as shown. 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 Remove Cylinder Head Baffle
A
C
B D
A
A
B
A Stator Wire Clip B Screw A

C Screw D Stator
Cylinder Head
1. Remove screw securing stator wire clip; remove clip. A Screw B Baffle
2. Remove screws securing stator to closure plate Remove screws attaching cylinder head baffle to cylinder
bosses. head and remove cylinder head baffle.
Remove Electric Starter Remove Valve Cover
A
A
B
B
A Valve Cover B Screw

A Nut B Starter NOTE: Valve cover is sealed to cylinder head using
NOTE: Before removing, observe placement of starter RTV silicone sealant. When removing valve
in closure plate for reassembly. cover, use care not to damage sealing surfaces
of cover and cylinder head. To break RTV seal,
Remove nuts securing starter to closure plate. Remove hold a block of wood against 1 flat face of valve
starter. 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.
2. Remove valve cover from cylinder head.
3. 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
E
G
H
I
C
M J
K
F
P N D
N
M L
A Cylinder Head Gasket B Exhaust Valve C Intake Valve D Cylinder Head

E Spark Plug F Valve Stem Seal G Valve Spring H Valve Spring Cap
I Retainer Lock J Push Rod Guide Plate K Rocker Stud L Push Rod
Rocker Pivot
M Rocker Arm N O Set Screw P Cylinder Head Screw
Assembly
NOTE: Before disassembly, mark all valve train components that will be reused, to ensure they are reassembled on
same side.
1. Loosen inner set screws (T15 Torx Drive) and back off rocker arm adjusting nuts. Remove push rods and mark
them, so they can be reinstalled in same location.
2. Remove adjustment nuts, pivots and rocker arms from pivot studs.
3. Remove rocker arm pivot studs and push rod guide plate.
4. Remove spark plug.
5. Remove screws securing cylinder head.
6. Remove cylinder head and head gasket.
7. Remove valves.
a. Compress valve springs using a valve spring compressor and remove retainers.
b. Remove compressor; then remove valve spring caps, valve springs, and valves.

Inspection and Service

Valve Details
F F
E E
G G
A A A A
B B
H H
C C
INTAKE VALVE EXHAUST VALVE
D D
Dimension Intake Exhaust

A Seat Angle 44.5° 44.5°
B Insert O.D. 40.094/40.11 mm (1.578/1.579 in.) 35.094/35.11 mm (1.381/1.382 in.)
C Guide Depth 11.85/12.25 mm (0.466/0.482 in.) 10.80/11.20 mm (0.425/0.440 in.)
D Guide I.D. 6.038/6.058 mm (0.2377/0.2385 in.) 6.038/6.058 mm (0.2377/0.2385 in.)
E Valve Head Diameter 35.875/36.125 mm (1.412/1.422 in.) 32.875/33.125 mm (1.294/1.304 in.)
F Valve Face Angle 45° 45°
G Valve Margin (Min.) 0.5 mm (0.0196 in.) 1.0 mm (0.0393 in.)
H Valve Stem Diameter 5.982/6.000 mm (0.2355/0.2362 in.) 5.970/5.988 mm (0.2350/0.2357 in.)
After cleaning, check flatness of cylinder head and corresponding top surface of crankcase, using a surface plate or
precision straight edge and feeler gauge. Maximum allowable out of flatness is 0.076 mm (0.003 in.).
Carefully inspect valve mechanism parts. Inspect valve 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 Remove Closure Plate

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 A
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 a 44.5° cutter as specified for
valve seat angle. Cutting proper 45° valve face angle, B
as specified, and proper valve seat angle (44.5°,half of
full 89° angle) will achieve desired 0.5° (1.0° full cut)
interference angle where maximum pressure occurs on
valve face and seat.
Lapping Valves C
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 Closure Plate
A Closure Plate Screw B
with grinder. Continue grinding until smooth surface is Assembly
obtained on seat and on valve face. Thoroughly clean C Crankcase
cylinder head in soap and hot water to remove all traces
of grinding compound. After drying cylinder head, apply NOTE: Closure plate is sealed to crankcase using RTV
a light coating of engine oil to prevent rusting. silicone sealant. When removing closure plate,
use care not to damage sealing surface of
Intake Valve Stem Seal crankcase.
Always use a new seal when valves are removed
from cylinder head. Seals should also be replaced if 1. Remove screws securing closure plate to crankcase.
deteriorated or damaged in any way. Never reuse an old 2. To break RTV seal, use a prying device and apply
seal. pressure at corner of closure plate where breather is
located until RTV separates; then pull from corners
Remove Breather to remove closure plate assembly. Do not pry on
sealing surfaces of crankcase or closure plate, as
A this can cause damage resulting in leaks.
Disassemble Closure Plate Assembly
B
C
F D A
C
E
B
Breather Cover
A B Breather Cover
Screw
C Torx Screw D Reed Retainer
E Breather Reed F Breather Filter A Oil Passage Cover B Governor Gear
NOTE: Breather cover is sealed to closure plate using Oil Passage Cover
RTV silicone sealant. Once removed, cover C Screws
must be replaced. When removing breather
cover, use care not to damage sealing surface of NOTE: Governor gear is held onto shaft by small
closure plate. molded tabs in gear. When gear is removed
these tabs are destroyed and gear must be
1. Remove screw securing breather cover to closure replaced. Governor gear removal is required for
plate; remove cover. closure plate disassembly and cleaning of oil
2. Remove Torx screw, reed retainer, and breather passages. Unless bearings are being replaced,
reed. they can stay in closure plate.
3. Remove breather filter from closure plate.

Governor Gear Inspection Install Governor Shaft

Inspect governor gear teeth. Look for any evidence of
worn, chipped, or cracked teeth. If one or more of these Governor Shaft Components and Details
problems is noted, replace governor gear.
Gear is held onto governor shaft by molded tabs, which A B
are damaged when gear is removed. Never reuse gear
once it has been pulled from shaft.
Remove Governor Gear and Oil Passage Cover
A 40.0 mm (1.574 in.) To Gasket Surface - Before

A Oil Passage Cover Plate and Gasket are
Assembled
B B Governor Gear Shaft
Install new governor gear shaft by pressing or lightly
tapping it into closure plate. It must be installed so that
C it protrudes 40.0 mm (1.574 in.), plus or minus 0.2 mm
(0.0078 in.) above closure plate boss.
Closure Plate and Passage Cover Inspection and
Service
Passage Cover Torque Sequence
2
A Oil Passage Cover Screws
4
B Oil Passage Cover
C Oil Passage Cover Gasket 5
3
1. Remove governor gear and regulating pin assembly.
Gently pry upward using blades of two small 1
screwdrivers.
2. Remove screws securing oil passage cover to
closure plate. Remove cover and gasket.
Oil Seal Inspection
Inspect oil seal in closure plate and remove it if it is worn If disassembly was performed, inspect and ensure
or damaged. oil passages in closure plate and passage cover are
completely clean and not obstructed in any way. Check
Governor Shaft Inspection straightness of passage cover if required, against a flat
Replace governor shaft only if it is damaged or worn. surface.
Remove Governor Shaft Use a new passage cover gasket and install passage
1. Locate governor shaft from flywheel side. With a cover onto closure plate. Reinstall mounting screws and
small punch, drive shaft out of closure plate. This torque to 6.5 N·m (58 in. lb.), following sequence.
could also be done with a press. Do not remove
governor shaft with a vise grip or pliers, you may Install New Governor Gear Assembly
damage closure plate. 1. Install new governor regulating pin and governor
gear assembly.
2. Using a brass wire brush and gasket remover or
similar solvent, clean old RTV from surface of 2. Make sure governor gear assembly rotates freely.
closure plate and crankcase. Do not scrape
surfaces, as any scratches, nicks, or burrs can result
in leaks.

Remove Camshaft 4. Engines with ACR start much faster in cold weather
than engines without ACR.
5. Engines with ACR can be started with spark plugs
A which are worn or fouled. Engines without ACR are
more difficult to start with those same spark plugs.
Cam Gear Inspection and Service
Inspect gear teeth and cam lobes of camshaft. If lobes
exhibit excessive wear, or teeth are worn, chipped or
broken, replacement of camshaft will be necessary.
Remove Balance Shafts
B A
A Camshaft B Crankcase
Carefully pull upward on camshaft to remove assembly
from crankcase cavity.
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. 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 A Balance Shaft 1 B Balance Shaft 2
during first part of compression stroke. Compression 1. Rotate crankshaft clockwise to line up lower timing
is reduced to an effective ratio of about 2:1 during marks on crankshaft gear and balance shaft 1 gear.
cranking. 2. Lift balance shaft 1 from crankcase and mark BS1
After starting, when engine speed exceeds 700 RPM, for reassembly.
centrifugal force overcomes force of flyweight spring. 3. Rotate crankshaft clockwise to move crankshaft
Flyweight moves outward, rotating control pin to expose weights, then lift balance shaft 2 from crankcase and
flat surface, which is lower than cam lobe. Control pin mark BS2 for reassembly.
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. Electric start models can use a smaller starter and
battery which are more practical for application.
2. 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.
3. Choke control setting is less critical with ACR. If
flooding occurs, excess fuel is blown out opened
exhaust valve and does not hamper starting.

Remove Connecting Rod and Piston Piston and Rings Inspection

Scuffing and scoring of pistons and cylinder walls occurs
B C when internal temperatures approach welding point
A 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 boss-
piston 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
D 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,
Connecting Rod oil is allowed to enter combustion chamber where it is
A B Rod Cap
Screw burned along with fuel. High oil consumption can also
C Piston Assembly D Connecting Rod occur when piston ring end gap is incorrect because
ring cannot properly conform to cylinder wall under this
NOTE: If a carbon ridge is present at top of bore, use a condition. Oil control is also lost when ring gaps are not
ridge reamer to remove it before attempting to staggered during installation.
remove piston.
When cylinder temperatures get too high, lacquer and
1. Rotate crankshaft so rod journal is in 8 o’clock varnish collect on pistons causing rings to stick which
position. results in rapid wear. A worn ring usually takes on a
2. Remove screws and connecting rod cap. shiny or bright appearance.
3. Carefully push connecting rod and piston away from Scratches on rings and pistons are caused by abrasive
crankshaft and out of cylinder bore. material such as carbon, dirt, or pieces of hard metal.
Inspection and Service Detonation damage occurs when a portion of fuel charge
Check bearing area (big end) for score marks and ignites spontaneously from heat and pressure shortly
excessive wear. Service replacement connecting rods after ignition. This creates two flame fronts that meet and
are available in STD crankpin size. explode to create extreme hammering pressures on a
specific area of piston. Detonation generally occurs from
Remove Piston from Connecting Rod using low octane fuels.
Preignition or ignition of fuel charge before timed spark
A can cause damage similar to detonation. Preignition
damage is often more severe than detonation damage.
B Preignition is caused by a hot spot in combustion
chamber from sources such as glowing carbon deposits,
C blocked fins, improperly seated valve, or wrong spark
plug.
Replacement pistons are available in STD bore size.
Replacement pistons include new piston ring sets and
new piston pins.
A Replacement ring sets are also available separately
D
for STD pistons. Always use new piston rings when
installing pistons. Never reuse old rings.
Remove Piston Rings
A Piston Pin Retainer B Piston Pin 1. Remove top and center compression rings using a
ring expander.
C Piston Assembly D Connecting Rod
2. Remove oil control ring rails, then remove spacer.
Remove piston pin retainers and piston pin. Separate
piston from connecting rod.

Some important points to remember when servicing Install New Piston Rings
piston rings: Piston Ring Orientation
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, C E
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 new rings on piston, place top 2
rings, each in turn, in its running area in cylinder
bore and check end gap. Top compression ring end B A
gap clearance is 0.150/0.400 mm (0.0059/0.0157
in.) for a new bore, or 0.770 mm (0.0300 in.) for a D
used bore. Middle compression ring end cap is
1.000/1.250 mm (0.0394/0.0492 in.) for a new bore,
or 1.504 mm (0.0592 in.) for a used bore. A Top Oil Rail Gap B Bottom Oil Rail Gap
5. After installing new compression (top and middle) Oil Ring Expander
C Middle Ring Gap D
rings on piston, make sure top compression ring-to- Gap
groove side clearance and is 0.025/0.065 mm E Top Ring Gap
(0.0010/0.0026 in.) and middle compression ring-to-
groove side clearance 0.040/0.080 mm NOTE: Rings must be installed correctly. Use a piston
(0.0016/0.032 in.). If side clearance is greater than ring expander to install rings. Install bottom (oil
specified, a new piston must be used. control) ring first and top compression ring last.
To install piston rings, proceed as follows:
Piston and Rings
1. Oil control ring (bottom groove): Install expander and
Piston and Rings Components and Details then rails. Make sure ends of expander are not
overlapped.
2. Middle Compression ring (center groove): Install
center ring using a piston ring installation tool. Make
A sure identification mark is up when ring is installed.
3. Top Compression ring (top groove): Install top ring
using a piston ring installation tool. Make sure
identification mark is up when ring is installed.
B
D
E C
F
Top Compression Middle Compression
A B
Ring Ring
C Oil Control Ring D Top Rail
E Expander Ring F Rail

Remove Crankshaft Remove Oil Pump Assembly
A
C
B
A
C B
A Crankshaft Gear B Crankshaft A Oil Pump Housing Assembly

C Key B Oil Pump Assembly
1. Carefully remove crankshaft from crankcase. C Oil Pump Housing Screws
2. Remove crankshaft gear from crankshaft and 1. Remove screws and lift oil pump housing assembly
carefully remove key from keyway. from crankcase.
Crankshaft and Crankshaft Gear Inspection and 2. Remove oil pump assembly gerotor gears from
Service crankcase.
Inspect teeth of crankshaft gear. If teeth are badly worn,
chipped, or some are missing, replacement of crankshaft Oil Pump Inspection
gear will be necessary. Remove gear by pulling it off key Check oil pump and gears for cracks, damage, wear,
and crankshaft. and smooth rotation. Replace pump if any binding is
noted or reuse is questionable in any way.
Inspect crankshaft bearing journal surfaces for wear,
scoring, grooving, etc. If they show signs of damage or A pressure relief valve is built into oil pump to limit
are out of running clearance specifications, crankshaft maximum pressure. It is not serviceable. If a problem
must be replaced. exists with pressure relief valve, oil pump assembly
should 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.

Remove Cam Levers Remove Oil Baffle
A A
B B
A Cam Lever Screw

B Cam Levers
NOTE: It is not necessary to remove cam levers unless
replacement is intended. If cam lever screw is
removed for any reason, discard screw, do not A Oil Baffle Screws
reuse/reinstall. A new screw must be used.
B Oil Baffle
Remove screw and cam levers from crankcase. Mark
cam levers (T top, B bottom) for proper reassembly. Remove screws securing oil baffle to bottom of
crankcase; remove oil baffle.
Remove Governor Cross Shaft
Remove PTO Side Oil Seal
B Use a seal puller to remove PTO side oil seal.
C Crankcase
A
Inspection and Service
Check all gasket surfaces to make sure they are free of
gasket fragments and deep scratches or nicks.
B
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, use an inside micrometer or telescoping gauge
to determine amount of wear (refer to Specifications).
If wear exceeds published limits, a short block or
replacement engine will need to be considered.
A Governor Cross Shaft
B Washer
C Hitch Pin
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 washer on inside
portion of shaft.

Honing Clean Cylinder Bore after Honing

Detail 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.
A 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
A 23°-33° Crosshatch
While most commercially available cylinder hones can A
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 A 7.5 mm (0.2953 in.)
follows:
1. Lower hone into bore and, after centering, adjust it
so stones are in contact with cylinder wall. Use of a NOTE: Do not use a feeler gauge to measure piston-to-
commercial cutting-cooling agent is recommended. bore clearance; it will yield inaccurate
measurements. Always use a micrometer.
2. With lower edge of each stone positioned even with
lowest edge of bore, start drill and honing process. Before installing piston into cylinder bore, it is necessary
Move hone up and down while resizing to prevent that clearance be accurately checked. This step is
formation of cutting ridges. Check size frequently. often overlooked, and if clearances are not within
Make sure bore is cool when measuring. specifications, engine failure will usually result.
3. When bore is within 0.064 mm (0.0025 in.) of Use following procedure to accurately measure piston-
desired size, remove coarse stones and replace with to-bore clearance:
burnishing stones. Continue with burnishing stones 1. Use a micrometer and measure diameter of piston
until within 0.013 mm (0.0005 in.) of desired size and 7.5 mm (0.2953 in.) above bottom of piston skirt and
then use finish stones (220-280 grit) and polish to perpendicular to piston pin.
final size. A crosshatch should be observed if honing
is done correctly. Crosshatch should intersect at 2. Use an inside micrometer, telescoping gauge, or
approximately 23°-33° off horizontal. Too flat an bore gauge and measure cylinder bore.
angle could cause rings to skip and wear Measurement approximately 63.5 mm (2.5 in.) below
excessively, too steep an angle will result in high oil top of bore and perpendicular to piston pin.
consumption. 3. Piston-to-bore clearance is difference between bore
4. After honing, check bore for roundness, taper, and diameter and piston diameter (step 2 minus step 1).
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.

Reassembly
NOTE: Make sure engine is assembled using all Install Oil Baffle
specified torque values, torque sequences, and
clearances. Failure to observe specifications A
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. B
Make sure all traces of any cleaner are removed before
engine is assembled and placed into operation. Even
lubricating properties of engine oil.
Check closure plate, crankcase, cylinder head, and
valve cover to be certain all old sealing 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.
Install PTO Side Oil Seal
PTO Seal Depth Details
A Oil Baffle Screws

B Oil Baffle
B
Install oil baffle in crankcase and secure with screws.
Torque screws to 7.9 N·m (70 in. lb.).
Install Governor Cross Shaft
B
A
C A
Seal Depth
A Oil Seal B 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 Governor Cross Shaft

B Washer
C Hitch Pin
1. Place first 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 second washer onto shaft from outside as far
as it will go. Secure by inserting hitch pin in
machined groove.

Reassembly
Install Cam Levers 3. Install camshaft into oil pump housing; turn to drop
into place. Turn camshaft to align timing mark to
center of crankshaft PTO bore.
A
4. Lift camshaft out.
B Install Crankshaft and Crankshaft Gear
B
A
C
A Cam Lever Screw
B Cam Levers
NOTE: Do not reinstall a cam lever screw that has been
removed. Discard removed screw and install
new screw with Loctite® Dri-Loc® patch.
Install cam levers on screw and secure to crankcase.
Torque screw to 12.5 N·m (110 in. lb.).
Install Oil Pump and Oil Pump Housing Assembly
A
A Crankshaft Gear
B Crankshaft
B C Key
1. Carefully install crank gear key in keyway and slide
crankshaft gear on crankshaft.
2. Carefully install crankshaft into crankcase, through
PTO seal, and seat fully into place.
A Oil Pump Housing Assembly

B Oil Pump Assembly
C Oil Pump Housing Screws
1. Lightly grease gerotor gears and set them into
crankcase.
2. Install oil pump housing and secure to crankcase
with screws; torque screws to 4.8 N·m (42 in. lb.).

Reassembly
Install Piston to Connecting Rod 4. Guide connecting rod down and rotate crankshaft to
mate journals. Install rod cap.
A 5. Install screws and torque in 2 increments, in
sequence shown, first to 5.5 N·m (50 in. lb.), finally
B to 11.8 N·m (105 in. lb.).
Install Balance Shafts
C
Balance Shaft 1 Timing Mark Detail
A
A A
D
B B
Crankshaft Timing Balance Shaft 1

A Piston Pin Retainer B Piston Pin A B
Hole Timing Hole
C Piston Assembly D Connecting Rod 1. Rotate crankshaft clockwise (to move weights) and
Assemble piston, connecting rod, piston pin, and piston install balance shaft 1 into crankcase aligning timing
pin retainers. hole in balance shaft 1 with timing hole on crank
gear.
Install Piston to Connecting Rod Balance Shaft 2 Timing Mark Detail
Connecting Rod Fastener Torque Sequence
B B
A A
Balance Shaft 2 Balance Shaft 1

A B
Timing Dots Timing Hole
2. Rotate crankshaft clockwise again (to move weights
toward oil pump) and install balance shaft 2 aligning
2 dots on balance shaft 2 with 1 hole in balance
1 shaft 1.
3. Rotate crankshaft to TDC.
NOTE: Proper orientation of piston/connecting rod

inside engine is extremely important. Improper
orientation can cause extensive wear or
damage.
1. If piston rings were removed, see Disassembly/
Inspection and Service procedure to install rings.
2. Lubricate cylinder bore, crankshaft journal,
connecting rod journal, piston, and rings with engine
oil.
3. 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.

Reassembly
Install Camshaft Install Closure Plate

Closure Plate Sealant Pattern on Crankcase
A
A Camshaft B Crankcase
1. Ensure cam levers are in proper position toward A Sealant Bead on Crankcase
cylinder.
2. Install camshaft aligning timing mark with crankshaft Closure Plate Fastener Torque Sequence
gear mark. Proper installation places cam gear
below crankcase surface. 6 4 2
Install Flywheel Side Oil Seal 11
Oil Seal Depth Details
8
B A 9
10
7
1 3 5
NOTE: Always use fresh sealant. Using outdated
sealant can result in leakage. Refer to Tools and
Seal Depth Aids for a listing of approved sealants.
A Oil Seal B 3 mm (0.12 in.) 1. Make sure sealing surfaces of crankcase and
Lubricate outside diameter and lip of flywheel end oil closure plate are clean, dry, and free of any nicks or
seal. Support closure plate and install oil seal. Using a burrs.
seal driver, drive seal to a depth of 3 mm (0.12 in.) in 2. Ensure oil passage cover gasket, oil passage cover,
seal bore. and governor gear assembly, have been properly
assembled to closure plate. As closure plate is
lowered into position, rotate crankshaft slightly to
help engage governor gear.
3. Install screws securing closure plate to crankcase.
4. Torque closure plate fasteners to 24.0 N·m
(212 in. lb.) using sequence shown.

Reassembly
Install Breather Breather Cover Sealant Pattern

Components
D
C
E
F
B G
A Sealant Bead on Closure Plate

H
A NOTE: Always use fresh sealant. Using outdated
Aids for a listing of approved sealants.
Breather Cover 1. Install breather filter into closure plate.
A B Breather Filter
Alignment Pin
2. Install breather reed and reed retainer; hold them in
C Breather Cover D Cover Screw alignment and secure with screw. Torque screw to
Breather Reed 6.5 N·m (58 in. lb.).
E F Reed Retainer
Screw 3. Make sure sealing surfaces are clean and free of
G Breather Reed H Sealant Bead nicks or damage.
4. Apply a 1.5 mm (1/16 in.) bead of RTV sealant to
breather cover sealing surface of closure plate as
shown. Bead must surround entire screw hole.
5. Position a new breather cover on alignment pin and
secure with screw. Torque screw to 6.5 N·m
(58 in. lb.).
6. Install breather hose into breather cover.

Reassembly
Install Cylinder Head
E
G Q
H
I
C
M J
K
F
P N D
N
M L
A Cylinder Head Gasket B Exhaust Valve C Intake Valve D Cylinder Head

E Spark Plug F Valve Stem Seal G Valve Spring H Valve Spring Cap
I Retainer Lock J Push Rod Guide Plate K Rocker Stud L Push Rod
Rocker Pivot
M Rocker Arm N O Set Screw P Cylinder Head Screw
Assembly
Q Tab
Assemble Cylinder Head NOTE: Do not reuse cylinder head screws or gasket,
always replace with new parts.
Prior to assembly, lubricate all components with engine
oil, including tips of valve stems and valve guides. Using NOTE: If crankshaft has not been turned since
a valve spring compressor, install following items in installation of crank gear, turn it one (1) complete
order listed. revolution. This will set piston at top dead center
(TDC) of compression stroke, for proper valve
● Valve spring seal (intake valve only). lash adjustment later.
● Intake and exhaust valves.
● Valve springs. 1. Check to make sure there are no nicks or burrs on
● Valve spring caps. sealing surfaces of cylinder head or crankcase.
● Valve spring retainer locks. 2. Install a new cylinder head gasket with tab on gasket
in 4 o'clock position.
Install Cylinder Head
3. Install cylinder head and start six screws.
Cylinder Head Torque Sequence
4. Using torque sequence shown, torque cylinder head
screws in two stages; initially to 24.4 N·m
1 3 (216 in. lb.), and finally to 42.7 N·m (378 in. lb.).
Install Rocker Arms and Push Rods
5 NOTE: Installation and seating of push rods into cam
lever recesses during this sequence is critical.
6 Position engine with cylinder head up if possible,
to aid with proper installation of push rods and
rocker arms, and adjusting valve lash.
4 2
NOTE: If being reused, push rods should always be
installed in their original position.

Reassembly
1. Position push rod guide plate on cylinder head with 1. Make sure sealing surfaces of valve cover and
extruded edges down over push rod bores. Secure cylinder head are clean, and free of any nicks or
by installing rocker arm pivot studs. Torque studs to burrs.
13.5 N·m (120 in. lb.). 2. Apply a 1.5 mm (1/16 in.) bead of sealant to valve
2. Note mark or tag identifying push rod as either cover as shown. Position valve cover and start
intake or exhaust. Apply grease to ends of push mounting screws.
rods. Insert push rods into push rod bores and seat 3. Torque valve cover screws to 12.9 N·m (114 in. lb.)
lower end into dimpled recess of cam levers. It may into new holes, or 6.8 N·m (60 in. lb.) into used
be necessary to lift or shift lower end of push rod holes, using sequence shown.
slightly, and feel rod seats into recess.
3. Apply grease to contact surfaces of rocker arms and Install Spark Plug
adjusting nuts and install them onto pivot studs. 1. Check gap using wire feeler gauge. Adjust gap to
4. With engine at TDC of compression stroke, insert a 0.76 mm (0.030 in.).
0.127 mm (0.005 in.) flat feeler gauge between end 2. Install plug into cylinder head.
of 1 valve and rocker arm. Turn adjustment nut with
a wrench until a slight drag is felt on feeler gauge. 3. Torque plug to 27 N·m (20 ft. lb.).
Hold nut in position and torque set screw (T15 Torx
drive) to 5.5 N·m (50 in. lb.). To prevent damage to Install Cylinder Head Baffle
nut, torque Torx screw only. Perform adjustment
procedure on other valve. After tightening, recheck A
adjustment. Proper valve clearance is 0.101/0.152
mm (0.004/0.006 in.).
Install Valve Cover
Valve Cover Sealant Pattern
A
B
A Screw B Cylinder Head Baffle

Install screws securing baffle to cylinder head. Leave
screw securing baffle to crankcase loose. Torque
screws to 9.3 N·m (82 in. lb.) into new holes, or 4.0 N·m
(35 in. lb.) into used holes.
Valve Cover Torque Sequence Install Electric Starter

Install electric starter to closure plate and secure with
nuts. Torque nuts to 3.8 N·m (34 in. lb.).
1 3
NOTE: Always use fresh sealant. Using outdated

Aids for a listing of approved sealants.

Reassembly
Install Stator CAUTION

Damaging Crankshaft and Flywheel can
C cause personal injury.
B D
A
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.
NOTE: Before installing flywheel make sure crankshaft
taper and flywheel hub are clean, dry and
completely free of lubricants. Presence of
A Stator Wire Clip B Screw lubricants can cause flywheel to be over
C Screw D Stator stressed and damaged when mounting screw is
torqued to specification.
1. Position stator onto mounting bosses so leads lay in
channel and recess of closure plate. NOTE: Make sure flywheel key is installed properly in
keyway. Flywheel can become cracked or
2. Install screws to secure stator. Torque to 8.8 N·m (78 damaged if key is not properly installed.
in. lb.).
NOTE: Always use a flywheel strap wrench or flywheel
3. Install stator wire clip and secure to closure plate. holding tool to hold flywheel when tightening
Torque screw to 6.5 N·m (58 in. lb.). flywheel fastener. Do not use any type of bar or
wedge between cooling fins or flywheel ring
Install Fan and Flywheel gear, as these parts could become cracked or
damaged.
1. Install flywheel onto crankshaft aligning keyway with
A key. Be careful not to shift or unseat key.
2. Install key into crankshaft keyway. Make sure key is
fully seated.
B
3. Position fan onto flywheel, so locating pins drop into
C corresponding recesses.
D 4. Install fan mounting plate onto fan, aligning four
cutouts, followed by heavy flat washer and screw.
5. Use a flywheel strap wrench or holding tool to hold
E flywheel and torque screw. Torque to 115 N·m
(85 ft. lb.).
6. Snap debris screen onto cooling fan.
F
Install Wiring Harness
1. On starter side of engine, secure wiring harness clip
G from below closure plate. On cylinder head side of
engine, secure wiring harness clip from above
closure plate.
H 2. Remove cylinder head baffle screw and secure
ground lead. Torque screw to 9.3 N·m (82 in. lb.) into
new hole, or 4.0 N·m (35 in. lb.) into used hole.
3. Check that locking tang on terminal of violet B+
wiring harness lead is angled upward. Insert terminal
into center location of rectifier-regulator plug
A Debris Screen B Flywheel Screw connector until it locks into place. If not already
C Washer D Fan Mounting Plate inserted, two AC leads from stator go in outer
locations.
E Fan F Flywheel Key
G Flywheel H Magnet

Reassembly
Install Ignition Module Install Oil Sentry™ or Pipe Plug

Apply pipe sealant with Teflon® (Loctite® PST® 592™
A Thread Sealant or equivalent), to threads of 1/8” pipe
plug. Install and tighten into port on closure plate. Torque
B pipe plug to 4.5-5.0 N·m (40-45 in. lb.). If a switch was
installed, apply sealant to threads of Oil Sentry™ switch
and install into port on closure plate. Torque switch to
6.2 N·m (55 in. lb.). Connect wiring harness lead or
C connector to switch. Wire tie leads to switch.
D Install Oil Fill Tube
Install tube into closure plate and secure with screw.
Torque screw to 6.5 N·m (58 in. lb.) into new holes, or
3.4 N·m (30 in. lb.) into used holes.
Install Governor Lever
A Screw B Ignition Module E F A

C Tab Terminal D Wire Tie
1. Rotate flywheel so magnet is away from ignition
module bosses. Using screws, install ignition module
to crankcase bosses. Move module as far away from D
flywheel as possible. Tighten screws sufficiently to B
keep module in position. C
2. Rotate flywheel to align magnet with ignition module.
3. Insert a 0.25 mm (0.010 in.) flat feeler gauge A Governor Lever B Nut
between magnet and ignition module. Loosen C Lock Washer D Round Head Bolt
screws so magnet pulls module against feeler
gauge. Governor Cross
E F Governor Spring
Shaft
4. Torque screws to 8.8 N·m (78 in. lb.) into new holes,
or 3.4 N·m (30 in. lb.) into used holes. NOTE: It is recommended a new governor lever be
installed whenever removal is performed.
5. Rotate flywheel back and forth checking for
clearance between magnet and ignition module. 1. Install governor lever onto governor shaft with lever
Make sure magnet does not strike module. Recheck section up.
air gap with a feeler gauge and readjust if necessary. 2. Insert lock washer into governor lever; secure lever
Final air gap: 0.203/0.305 mm (0.008/0.012 in.). with bolt and nut.
6. Connect kill lead to tab terminal on ignition module. 3. Install governor spring (long end loop) in governor
7. Secure spark plug lead wire tie into valve cover. lever.
Install Rectifier-Regulator
A B
A Rectifier-Regulator B Connector
1. Attach connector to rectifier-regulator terminals.
2. Using M6 screws, mount rectifier-regulator onto
crankcase bosses, with cooling fins out. Torque
screws to 8.8 N·m (78 in. lb.).

Reassembly
Install Intake Manifold Smart-ChokeTM

B
B M A
A L L
C
C J
I K
D
E
D
Intake Manifold
A Intake Port Stud B Gasket E
C Indicator Tab Down D Intake Manifold I F
E Nut H G
1. Install a new gasket on intake port studs with
Indicator tab on gasket pointing down. A Air Cleaner Adapter B Nut
2. Slide intake manifold onto intake port studs and start Carburetor Gasket Indicator Tab Up (on
C D
nuts on studs. Torque nuts to 10.2 N·m (90 in. lb.). (Choke) Fuel Inlet Side)
Install Carburetor E Carburetor F Stud
Standard Choke Carburetor Gasket
G H Intake Manifold
(Throttle)
A B Check Valve
I Vacuum Hose J Assembly
C Diaphragm
K L K40 x 1.79 Screw
Assembly
Smart-ChokeTM
M
Linkage
D 1. Install studs into intake manifold. Torque to 4.3 N·m
H (38 in. lb.).
E 2. Install carburetor gasket (throttle) on studs, followed
F by carburetor.
G 3. Install carburetor gasket (choke) with indicator tab
up (on fuel inlet side) on studs, follow by air cleaner
A Air Cleaner Adapter B Nut adapter. Secure with nuts. Torque to 9 N·m (80 in.
Carburetor Gasket Indicator Tab Up (on lb.).
C D
(Choke) Fuel Inlet Side) 4. Install Smart-ChokeTM linkage to choke lever on
E Carburetor F Stud carburetor.
Carburetor Gasket 5. Assemble vacuum hoses to check valve, then
G H Intake Manifold assemble to Smart-ChokeTM assembly.
(Throttle)
1. Install studs into intake manifold. Torque to 4.3 N·m 6. Install other end of Smart-ChokeTM linkage into lever
(38 in. lb.). of Smart-ChokeTM assembly.
2. Install carburetor gasket (throttle) on studs, followed 7. Attach vacuum hose to intake manifold and secure
by carburetor. Smart-ChokeTM assembly to manifold. Torque screws
to 1 N·m (9 in. lb.).
3. Install carburetor gasket (choke) with indicator tab
up (on fuel inlet side) on studs, follow by air cleaner 8. Install bushing into throttle lever on carburetor. Install
adapter. Secure with nuts. Torque to 9 N·m (80 in. throttle linkage and linkage spring into throttle lever.
lb.).
4. Install choke linkage into choke lever on carburetor.
5. Install bushing into throttle lever on carburetor. Install
throttle linkage and linkage spring into throttle lever.

Reassembly
Connect Wire Controls 2. Attach speed control bracket to mounting locations

on engine with M6 screws. Position bracket as
marked during disassembly. Torque screws to
11.3 N·m (100 in. lb.) into new holes, or 7.5 N·m
(65 in. lb.) into used holes.
D Governor Spring Detail
A KS530
C Governor Spring
RPM Throttle Stop
B Color
3600 Yes Brown
Control Bracket 3450 Yes Brown
A Choke Linkage B Lower Hole 3400 Yes Yellow
Governor Spring 3300 Yes Yellow
C Control Bracket Slot D Location in
Control Bracket 3200 Yes Yellow
1. If engine has Standard Choke Single Wire Controls, 2800 Yes Yellow
position choke linkage from carburetor into lower
hole in speed control bracket and out lower slot.
KS540
A B Governor Spring
RPM Throttle Stop
C Color
3600 Yes Yellow
3450 Yes Yellow
3400 Yes Yellow
Throttle Linkage 3300 Yes Brown
A B Governor Lever
Bushing 3200 Yes Yellow
C Throttle Linkage 2800 Yes Blue
2. Insert throttle linkage bushing into governor lever;
insert throttle linkage into governor lever and secure
with bushing. KS590
3. Move governor lever toward carburetor, to limit of its Governor Spring
travel (wide-open throttle) and hold in this position. RPM Throttle Stop Color
Do not apply excessive pressure, flexing or distorting
linkage. Grasp cross shaft with a pliers, and turn 3600 Yes Red
shaft counterclockwise as far as it will go. Torque nut 3450 Yes Red
to 7.7 N·m (68 in. lb.).
3400 Yes Yellow
Mounting Speed Control Bracket 3300 Yes Yellow
3200 Yes Yellow
B
A 2800 Yes Blue
KS595
Governor Spring
B RPM Throttle Stop Color
3600 No Red
3450 No Red
Speed Control
A Bracket B Screw 3400 No Brown
1. Attach governor spring to throttle lever of speed 3300 No Brown
control bracket. 3200 No Brown
2800 No Blue

Reassembly
External Engine Components
T
V
H T
T
T
W
J S
I
A
J B
I
O R
Q L
E
M C
P
O G D
F
A Oil Fill/Dipstick B Oil Fill/Dipstick Tube C Oil Filter D Oil Drain Plug
E Air Cleaner Adapter F Intake Manifold G Intake Manifold Nut H Cover
PRO Air Cleaner
I Precleaner J Paper Element K L Fuel Filter
Cover
Line Retained in
M Pulse Line N Outlet Fuel Line O P Fuel Pump
Housing
Blower Housing to
Q Fuel Pump Bracket R Inlet Fuel Line S Blower Housing T Closure Plate
Screw
Blower Housing to
U Fixed Guard Screw V Fixed Guard W Adapter Screw

Reassembly
Install Blower Housing Prepare Engine for Operation

1. Position blower housing on engine. Engine is now completely reassembled. Before starting
2. Align mounting locations, then install M6 shouldered or operating engine, be sure following have been done.
mounting screws. 1. All hardware is tightened securely.
Torque screws to 11.3 N·m (100 in. lb.) into new 2. Oil drain plug, Oil Sentry™ pressure switch (if
holes, or 6.8 N·m (60 in. lb.) into used holes. equipped), and a new oil filter are installed.
3. Install T15 screw securing blower housing to air 3. Crankcase is filled with correct amount, weight, and
cleaner adapter. Torque screw to 1 N·m (9 in. lb.). type of oil.
Install Fixed Guard (if equipped) Connect Spark Plug Lead
Install fixed guard. Torque screw to 0.8 N·m (7 in. lb.). Connect lead to spark plug.
Install Fuel Pump (if equipped) Testing Engine
1. Attach fuel pump mounting bracket to blower It is recommended engine be operated on a test stand or
housing with screw. Torque screw to 1 N·m (9 in. bench prior to installation in piece of equipment.
lb.). 1. Set engine up on a test stand. Install an oil pressure
2. Install fuel pump so pulse fitting is oriented in three gauge. Start engine and check to be certain oil
o’clock position, pressing fuel pump onto bracket pressure (5 psi or more) is present.
past locking tabs. 2. Run engine for 5-10 minutes between idle and
NOTE: If necessary, carefully rebend locking tabs to mid-range. Adjust throttle and choke controls and
ensure fuel pump is secured. high-speed setting as necessary. Make sure
3. Connect pulse line to dipstick tube and fuel line to maximum engine speed does not exceed equipment
carburetor inlet fitting and secure with clamps. manufacturer's recommended RPM. Adjust
carburetor idle speed screw as necessary. Refer to
4. Route fuel lines into retaining cutouts in blower Fuel System and Governor System.
housing.
Install Air Cleaner Element, Precleaner, and Air
Cleaner Cover
1. Install precleaner (if equipped) over new paper
element and install on air cleaner adapter. Secure
element behind retainer in housing.
2. Position air cleaner cover on housing and line up
knobs with unlock symbol. Turn knobs toward lock
symbol to secure.
Install Drain Plug, Oil Filter, and Oil
1. Install oil drain plug. Torque plug to 14 N·m
(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 and secure oil fill cap/dipstick.

1P22 690 01
© 2018 by Kohler Co. All rights reserved. 8 85612 70213 5

Kohler 5400 Manual

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KS530-KS595

22 690 01 Rev. -- KohlerEngines.com 1

WARNING WARNING CAUTION

2 KohlerEngines.com 22 690 01 Rev. --

Every 100 Hours or Annually¹ (whichever comes ﬁrst)

Every 100 Hours

Every 200 Hours²

Every 500 Hours

22 690 01 Rev. -- KohlerEngines.com 3

OIL RECOMMENDATIONS STORAGE

4 KohlerEngines.com 22 690 01 Rev. --

Engine Dimensions-Flywheel Side

164.8 mm (6.49 in.) 201.3 mm (7.92 in.)

22 690 01 Rev. -- KohlerEngines.com 5

Engine Dimensions-Starter Side

6 KohlerEngines.com 22 690 01 Rev. --

Engine Dimensions-PTO Side

22 690 01 Rev. -- KohlerEngines.com 7

Engine Dimensions-Oil Filter Side

8 KohlerEngines.com 22 690 01 Rev. --

Engine Dimensions-Valve Cover Side

Cored for M6 Self

22 690 01 Rev. -- KohlerEngines.com 9

ENGINE IDENTIFICATION NUMBERS

GENERAL SPECIFICATIONS3,4 KS530 KS540 KS590 KS595

TORQUE SEQUENCES KS530 KS540 KS590 KS595

10 KohlerEngines.com 22 690 01 Rev. --

TORQUE SEQUENCES KS530 KS540 KS590 KS595

Cylinder Head Fasteners

Oil Passage Cover Fasteners

Valve Cover Fasteners

22 690 01 Rev. -- KohlerEngines.com 11

TORQUE SPECIFICATIONS3,6 KS530 KS540 KS590 KS595

Blower Housing to Adapter

Blower Housing to Closure Plate

Choke Wire Hold Down Clamp (if equipped)

Closure Plate (torque sequence on page 11)

Connecting Rod (torque sequence on page 10)

Cylinder Head (torque sequence on page 11)

TORQUE SPECIFICATIONS3,6 KS530 KS540 KS590 KS595

Fixed Guard (if equipped)

Fuel Line J-Clip

Fuel Pump Bracket

Intake Manifold to Cylinder Head

Oil Filter Pad Pipe Plug

Oil Passage Cover (torque sequence on page 11)

Oil Pump Housing

TORQUE SPECIFICATIONS3,6 KS530 KS540 KS590 KS595

Speed Control Bracket Assembly

CLEARANCE SPECIFICATIONS3 KS530 KS540 KS590 KS595

CLEARANCE SPECIFICATIONS3 KS530 KS540 KS590 KS595

22 690 01 Rev. -- KohlerEngines.com 15

CLEARANCE SPECIFICATIONS3 KS530 KS540 KS590 KS595

Piston, Piston Rings, and Piston Pin

Valves and Valve Tappets

16 KohlerEngines.com 22 690 01 Rev. --

GENERAL TORQUE VALUES

English Fastener Torque Recommendations for Standard Applications

Size Grade 2 Grade 5 Grade 8

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

Metric Fastener Torque Recommendations for Standard Applications

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