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1
Section 1. Safety and General Information .............................................................................
2
Section 2. Tools and Aids .........................................................................................................
3
Section 3. Troubleshooting ......................................................................................................
4
Section 4. Air Cleaner and Air Intake System .........................................................................
5
Section 5. Fuel System and Governor.....................................................................................
6
Section 6. Lubrication System .................................................................................................
7
Section 7. Electrical System and Components ......................................................................
8
Section 8. Disassembly.............................................................................................................
9
Section 9. Inspection and Reconditioning ..............................................................................
10
Section 10. Reassembly............................................................................................................
Section 1
Safety and General Information
1
Section 1
Safety and General Information
Safety Precautions
To ensure safe operation please read the following statements and understand their meaning. Also
refer to your equipment manufacturer's manual for other important safety information. This manual
contains safety precautions which are explained below. Please read carefully.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
Accidental Starts can cause Rotating Parts can cause severe Hot Parts can cause severe burns.
severe injury or death. injury.
Do not touch engine while operating
Disconnect and ground spark plug Stay away while engine is in ȱȱĞȱǯ
leads before servicing. operation.
1.1
Section 1
Safety and General Information
WARNING
Flammable Solvents!
Carburetor cleaners and solvents are
¡¢ȱĚǯȱ
ȱǰȱ
Ěǰȱȱȱȱȱȱ
away from the area. Follow the
cleaner manufacturer’s warnings and
instructions on its proper and safe use.
Never use gasoline as a cleaning agent.
1.2
Section 1
Safety and General Information
(QJLQH,GHQWL¿FDWLRQ1XPEHUV
When ordering parts, or in any communication
involving an engine, always give the Model, 1
ęǰȱȱȱ of the engine.
ȱęȱȱȱȱȱȱ
Ĝ¡ȱȱȱȱǯȱȱȱŗȬŗǯȱȱ
¡ȱȱȱȱȱ ȱȱȱŗȬŘǯ
,GHQWL¿FDWLRQ/DEHO
)LJXUH,GHQWL¿FDWLRQ/DEHO
A. Model No. XT 7
Courage Vertical Shaft Engine
Numerical Designation
)LJXUH([SODQDWLRQRI,GHQWL¿FDWLRQ1XPEHUV
1.3
Section 1
Safety and General Information
10W-30
Gasoline/Alcohol Blends
ȱǻȱȱŗŖƖȱ¢ȱǰȱşŖƖȱȱ
gasoline by volume) is approved as a fuel for Kohler
ǯȱȱȦȱȱȱŘŖȱ
and E85 are not to be used and are not approved. Any
Figure 1-4. Oil Container Logo. failures resulting from use of these fuels will not be
warranted.
Refer to Section 6, Lubrication System, for detailed oil
check and oil change procedures. Gasoline/Ether Blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
ȱȱǻȱȱ¡ȱȱŗśƖȱȱ¢ȱ
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
1.4
Section 1
Safety and General Information
Periodic Maintenance
WARNING: Accidental Starts!
1
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment,
disable the engine by disconnecting the spark plug lead.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table. They should
also be included as part of any seasonal tune-up.
1.5
Section 1
Safety and General Information
(IF EQUIPPED)
(IF EQUIPPED)
1.6
Section 1
Safety and General Information
*HQHUDO6SHFL¿FDWLRQVï
ȱ ȱǻȓȱřŜŖŖȱǼ 1
XT-6 ................................................................................................................. ŘǯŜȱȱǻřǯśȱ
Ǽ
XT-7 ................................................................................................................. řǯŚȱȱǻŚǯśȱ
Ǽ
ȱȱȱǻȓȱŘŜŖŖȱǼ
XT-6 ................................................................................................................. ŞȱȉȱǻśǯşȱĞǯȱǯǼ
XT-7 ................................................................................................................. şǯśȱȉȱǻŝȱĞǯȱǯǼ
Bore
XT-6 .................................................................................................................. ŜśȱȱǻŘǯśŜȱǯǼ
XT-7 .................................................................................................................. ŝŖȱȱǻŘǯŝśȱǯǼȱ
Stroke
XT-6 .................................................................................................................. ŚśȱȱǻŗǯŞȱǯǼ
XT-7 .................................................................................................................. ŚśȱȱǻŗǯŞȱǯǼ
Displacement
XT-6 .................................................................................................................. ŗŚşȱȱǻşǯŗȱǯȱǯǼ
XT-7 .................................................................................................................. ŗŝřȱȱǻŗŖǯŜȱǯȱǯǼ
Compression Ratio
XT-6 .................................................................................................................. ŞǯřDZŗ
XT-7 .................................................................................................................. ŞǯśDZŗ
Dry Weight
XT-6 .................................................................................................................. ŗŖǯŞȱȱǻŘŚȱǯǼ
XT-7 .................................................................................................................. ŗřǯŗȱȱǻŘşȱǯǼ
ȱ¢ȱǻęǼ
XT-6 ................................................................................................................. ŖǯŜŖȱȱǻŘŖȱ£ǯǼ
XT-7 ................................................................................................................. ŖǯŜŖȬŖǯŜśȱȱǻŘŖȬŘŘȱ£ǯǼ
Blower Housing
ȱ
ȱȱ........................................................................... ŗŖȱȉȱǻŞŞȱǯȱǯǼ
Brake
ȱȱȱ .................................................................... şǯśȱȉȱǻŞŚȱǯȱǯǼ
Breather Cover
ȱȱȱ ..................................................................... ŗŖȱȉȱǻŞŞȱǯȱǯǼ
Camshaft
End Play.................................................................................................................. ŖǯŘȬŖǯŞȱȱǻŖǯŖŖŝŞȬŖǯŖřŗŚȱǯǼ
Running Side Clearance ....................................................................................... ŖǯŗśȬŖǯśŗȱȱǻŖǯŖŖśşȬŖǯŖŘȱǯǼ
Carburetor
ȱȱȱ .................................................................... 9.0 N·m (80 in. lb.)
1.7
Section 1
Safety and General Information
Connecting Rod
ȱȱȱŶ .................................................................. ŗŘǯśȱȉȱǻŗŗŖȱǯȱǯǼ
ȱȱȱǯǯ
New............................................................................................................... ŗŞǯŖŖŜȬŗŞǯŖŗŝȱȱǻŖǯŝŖŞŞȬŖǯŝŖşřȱǯǼ
ȱȱĞȱȱǯǯȱ
New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱȱǻŖǯŘřŜŘȬŖǯŘřŜşȱǯǼȱ
Crankshaft
End Play (free) .................................................................................................... ŖǯŘŘśȬŗǯŗŚśȱȱǻŖǯŖŖŞŞȬŖǯŖŚśŖŝȱǯǼ
Ğȱȱȱȱǯǯ
New.............................................................................................................. ŘŚǯşşŚȬŘśǯŖŖŖȱȱǻŖǯşŞŚŖȬŖǯşŞŚŘȱǯǼȱ
Ğȱȱȱȱȱǯǯ
New.............................................................................................................. ŘśǯŚŖŖȬŘśǯŚŘŗȱȱǻŖǯşşşşȬŗǯŖŖŖŞȱǯǼȱ
¢ ȱȱȱȱȱǯǯ
O.D. – Max. Wear Limit ............................................................................ ŘŚǯşŝśȬŘŚǯşŞşȱȱǻŖǯşŞřŘȬŖǯşŞřŞȱǯǼȱ
Max. Taper .................................................................................................. ŖǯŖŘśȱȱǻŖǯŖŖŖşȱǯǼ
Max. Out of Round .................................................................................... ŖǯŖŘśȱȱǻŖǯŖŖŖşȱǯǼ
Ğȱȱȱȱȱȱȱ
New.............................................................................................................. ŖǯŖŗśȬŖǯŖśŗȱȱǻŖǯŖŖŖśȬŖǯŖŖŘȱǯǼ
Crankcase
ȱȱĞȱȱǯǯȱ
New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱȱǻŖǯŘřŜŘȬŖǯŘřŜşȱǯǼ
Ğȱȱȱȱȱȱ
New.............................................................................................................. ŖǯŖŖśȬŖǯŖŘśȱȱǻŖǯŖŖŖŘȬŖǯŖŖŖşȱǯǼ
1.8
Section 1
Safety and General Information
Cylinder Bore
¢ȱȱǯǯ
New.............................................................................................................. ŝŖǯŖŖŖȬŝŖǯŖŗśȱȱǻŘǯŝśśŞȬŘǯŝśŜŚȱǯǼ 1
Max. Taper .................................................................................................. ŗŘǯŝȱȱǻŖǯŖŖŖśȱǯǼ
Max. Out of Round .................................................................................... ŗŘǯŝȱȱǻŖǯŖŖŖśȱǯǼ
Cylinder Head
¢ȱ
ȱȱŶ .................................................................... ŘŝǯŞ ȉȱǻŘŚŜȱǯȱǯǼȱ
Engine Cover
ȱȱȱȱȱȱ............................................. ŘǯŞȱȉȱǻŘśȱǯȱǯǼ
ȱȱȱȱȱȱȱ ............................... ŘǯřȱȉȱǻŘŖȱǯȱǯǼ
Fan/Flywheel
¢ ȱȱ........................................................................................ śŗǯśȱȉȱǻŚśŜȱǯȱǯǼ
Fuel Tank
Tank Bracket to Crankcase Stud Torque ........................................................ ŞȱȉȱǻŝŗȱǯȱǯǼ
ȱȱȱȱȱ ........................................................... ŚǯśȱȉȱǻŚŖȱǯȱǯǼ
Governor
ȱȱĞȬȬȱȱ ............................ ŖǯŖŘŖȬŖǯŖśŞȱȱǻŖǯŖŖŖŝȬŖǯŖŖŘŘȱǯǼ
ȱȱȱ .................................................................... şǯśȱȉȱǻŞŚȱǯȱǯǼ
ȱ ȱȱ...................................................................... şǯśȱȉȱǻŞŚȱǯȱǯǼ
ȱȱĞȱǯǯ
New.............................................................................................................. śǯşŜȬśǯşŞȱȱǻŖǯŘřŚŜȬŖǯŘřśŚȱǯǼ
ȱ ȱĞȱǯǯ
New ............................................................................................................. ŜǯŖŗȬŜǯŖřȱȱǻŖǯŘřŜŜȬŖǯŘřŝŚȱǯǼ
Ignition
Spark Plug Type (Champion® or equivalent)................................................ ŗŘȱǻ®)
1.9
Section 1
Safety and General Information
0XIÀHU
Exhaust Stud Torque ........................................................................................ 9.0 N·m (80 in. lb.)
¡ȱȱȱȱ........................................................................ ȱşǯśȱȉȱǻŞŚȱǯȱǯǼ
Oil
ȱȱ ȱŶ ...................................................................................... ȱŗŘǯřȱȉȱǻŗŖşȱǯȱǯǼ
ȱȱȱǯǯ
New ............................................................................................................ ŜşǯşŜȬŜşǯşŞȱȱǻŘǯŝśŚřȬŘǯŝśśŗȱǯǼ
ȱȱȬȬ¢ȱȱȱ
New.............................................................................................................. ŖǯŖŘŖȬŖǯŖśśȱȱǻŖǯŖŖŖŝȬŖǯŖŖŘŗȱǯǼ
Recoil
ȱȱȱ .................................................................. ŞȱȉȱǻŝŗȱǯȱǯǼ
Speed Control
ȱȱȱ¢ȱȱ ......................................ŞȱȉȱǻŝŗȱǯȱǯǼȱ
Valve Cover
ȱȱȱ........................................................................... ŞȱȉȱǻŝŗȱǯȱǯǼ
ȱȱȱĞȱǻȱȱǼ............................................... śǯŘŖŖȱȱǻŖǯŘŖŚŝȱǯǼ
¡ȱȱȱĞȱǻȱȱǼ............................................ śǯŘŚŝȱȱǻŖǯŘŖŜśȱǯǼ
1.10
Section 1
Safety and General Information
ȱȱȱȱ
New.............................................................................................................. śǯŚŜśȬśǯŚŞŖȱȱǻŖǯŘŗśŗȬŖǯŘŗśŝȱǯǼ
ŗ
Values are in metric units. English equivalents are shown in parentheses. Do not lubricate threads unless otherwise
indicated.
Ŷ¢ȱȱȱȱȱȱ¢ǯȱȱȱDZȱŗŖȬřŖȱȱǰȱȱ¢ȱȱ
ǻǛȱŚśŖřŖŚǼǰȱȱȬŗŖȱǻǛȱŖřŖŗřŗŖŚǼǰȱȱȬŚŖ®.
³Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of joint.
ȱ ȱȬȱȱȱȱȱȱȱȱȱǯȱȱȱȱȬȱ
ȱŗśŖǰȱ
ȬȱȱŗŗśǰȱȬȱ
ȱŗŘŖǰȱȬȱ
ȱŗŘŜǯ
Ś
ȱȱȱ¢ȱŘŖŖȱDzȱȱȱǯ
1.11
Section 1
Safety and General Information
Noncritical
4.8 5.8 8.8 10.9 12.9 Fasteners
Into Aluminum
Size
M10 ŘŗǯŝȱǻŗŜǼȱ ŘŝǯŗȱǻŘŖǼȱ ŚŝǯśȱǻřśǼȱ ŜŜǯŚȱǻŚşǼȱ ŞŗǯŚȱǻŜŖǼȱ řřǯşȱǻŘśǼ
M12 řŜǯŜȱǻŘŝǼȱ ŚŝǯśȱǻřśǼȱ ŞŘǯŝȱǻŜŗǼȱ ŗŗŜǯŜȱǻŞŜǼȱ ŗřşǯŝȱǻŗŖřǼȱ ŜŗǯŖȱǻŚśǼ
M14 śŞǯřȱǻŚřǼȱ ŝŜǯŚȱǻśśǼȱ ŗřŗǯśȱǻşŝǼȱ ŗŞŚǯŚȱǻŗřŜǼȱ ŘŗşǯŝȱǻŗŜŘǼȱ şŚǯşȱǻŝŖǼ
1.12
Section 2
Tools & Aids
Section 2
Tools & Aids
2
ȱ¢ȱȱȱȱȱȱȱęȱ¢ǰȱǰȱȱ¢ȱǯȱ¢ȱ
ȱȱȱȱȱǰȱȱȱȱȱȱǰȱǰȱȱǯȱȱǰȱȱ
ȱȱȱȱ ȱȱȱ¢ȱȱȱ ǯ
Tools
Description Source/Part No.
Cylinder Leakdown Tester
ȱȱȱȱȱȱ¢ǰȱǰȱǰȱȱȱȱ ǯ
ȱŘśȱŝŜŗȱŖśȬ
Flywheel Strap Wrench
ȱȱĚ¢ ȱȱǯ ȱȱ
ȬŞŘŚŖş
Ignition System Tester
ȱȱȱȱȱ¢ǰȱ¡ȱǯ
ȱŘśȱŚśśȱŖŗȬ
ȱȱȱȱȱȱǻǼȱȱ¢ǯ
ȱŘŚȱŚśśȱŖŘȬ
Tachometer (Digital Inductive) Design Technology Inc.
For checking operating speed (RPM) of an engine. DTI-110
Vacuum/Pressure Tester
Alternative to a water manometer. Kohler 25 761 22-S
Aids
Description Source/Part No.
ĞȱȱǻȱŜŗřǼ
ȱŘśȱřśŝȱŗŚȬ
Dielectric Greaseȱǻ Ȧȱ ŜŜŗǼ
ȱŘśȱřśŝȱŗŗȬ
ȱŗŘŖ
Ȭȱ
ȱŗŘŜǯ
2.1
Section 2
Tools & Aids
2.2
Section 3
Troubleshooting
Section 3
Troubleshooting
3
Troubleshooting Guide Engine Will Not Crank
When troubles occur, be sure to check the simple ȱ ŗǯȱ ȱȱ¢ȱ ȱȱǯ
ǰȱ ȱȱęȱ¢ȱȱȱȱȱȱ ȱ Řǯȱ ¢ȱ¢ȱ ȱȱȱ ǯ
considered. For example, a starting problem could 3. Seized internal engine components.
ȱȱ¢ȱȱ¢ȱȱǯ
Engine Runs But Misses
ȱȱ¢ȱȱȱȱȱȱ ŗǯȱ ȱȱ ȱȱȱ¢ǯ
below. Use these to help locate the possible cause(s). Řǯȱ ȱȱ¢ȱȱǯ
ȱřǯȱ ȱ¢ȱȱǯ
Engine Cranks But Will Not Start 4. Spark plug lead boot loose on plug.
ȱ ŗǯȱ ¢ȱȱǯ ȱ śǯȱ ȱ ȱȱȱĴ¢ȱȱ
ȱ Řǯȱ ȱǰȱȱȱ ȱȱȱ¢ǯ the ignition module's kill terminal to ground.
ȱ řǯȱ ȱȱǯ ȱ Ŝǯȱ ȱǯ
4. Spark plug lead disconnected. ȱ ŝǯȱ ¢ȱȱȱȱ¢ȱǯ
ȱ śǯȱ
ȱ ȱȱěȱǯ ȱ Şǯȱ ȱȱ¢ǯ
ȱ Ŝǯȱ ¢ȱȱǯ
ȱ ŝǯȱ ¢ȱȱǯ Engine Will Not Idle
ȱ Şǯȱ ȱȱȱǻȱǼǯ ȱ ŗǯȱ ȱȱ ȱȱȱ¢ǯ
ȱ şǯȱ ȱȱȱǻȱǼǯ ȱ Řǯȱ ȱȱȦȱȱȱǯ
ȱ řǯȱ ¢ȱȱǯ
Engine Starts But Does Not Keep Running ȱ Śǯȱ ȱ¢ȱǯ
ȱ ŗǯȱ ȱȱȱȱǯ ȱ śǯȱ ȱȱȱȱ¢ȱǯ
ȱ Řǯȱ ȱǰȱȱȱ ȱȱȱ¢ǯ ȱ Ŝǯȱ ȱȱȱ ȱ¢ȱǯ
ȱ řǯȱ ¢ȱȱ¢ȱȱȱȱĴȱ 7. Low compression.
ǰȱǻȱǼǯ ȱ Şǯȱ ȱȱȱȱǯ
4. Loose wires or connections short ignition ȱ şǯȱ ȱDzȱȱ¢Ȧȱȱ
module's kill terminal to ground. problem.
ȱ śǯȱ ¢ȱ¢ȱȱǯ
ȱ Ŝǯȱ ¢ȱǯ Engine Overheats
ȱ ŝǯȱ ȱ¢ȱǯ ȱ ŗǯȱ ȱǰȱȱǰȱȱęǰȱȱȱ
shroud clogged.
Engine Starts Hard ȱ Řǯȱ ¡ȱȱǯ
ȱ ŗǯȱ ȱǰȱȱȱ ȱȱȱ¢ǯ ȱ řǯȱ ȱȱȱǯ
ȱ Řǯȱ ȱȱǯ ȱ Śǯȱ
ȱȱȱǯ
ȱ řǯȱ ȱȱ¢ȱ ȱȱǯ ȱ śǯȱ ¢ȱǯ
ȱ Śǯȱ ¢ȱȱ¢ȱȱȱȱĴȱ ȱ Ŝǯȱ ȱȱ¡ǯ
ȱǻȱǼǯ
ȱ śǯȱ ¢ȱȱǯ
6. Low compression.
7. Weak spark.
ȱ Şǯȱ ȱDzȱȱȱǯ
ȱ şǯȱ ¢ ȱ¢ȱǯ
ȱŗŖǯȱ ȱ¢ȱǯ
3.1
Section 3
Troubleshooting
3.2
Section 3
Troubleshooting
ȱ Śǯȱ ȱȱȱȱĝȦ¡ȱ
¢ǯ
3.3
Section 3
Troubleshooting
ȱȱȱȱ ................................................ȱȱȱ ȱ¢ȱ ǯ
ȱȱȱ¡ȱ¢ ......................................................ȱ¡ȱǯ
ȱȱȱ ...............................................................ȱȱǯ
3.4
Section 4
Air Cleaner and Air Intake System
Section 4
Air Cleaner and Air Intake System
4.1
Section 4
Air Cleaner and Air Intake System
Service Paper Element
Check the paper element for dirty, loose or damaged
parts every 25 hoursȱȱDzȱȱĞȱȱ
extremely dusty or dirty conditions. Yearly or every
100 hours of operation replace the paper element.
Follow these instructions to service:
Disassembly
Figure 4-3. Primer Bulb Hose.
The following procedure outlines complete
disassembly of the air cleaner assembly. Since removal Inspect Air Cleaner Components
ȱȱȱȱȱȱěȱȱȱ Whenever the air cleaner cover is removed, or the
and governor adjustment, Step 4 should only be paper element or precleaner are serviced, inspect the
performed if required. For further information see the following areas:
Dissassembly and Reassembly sections of this manual.
Outer Air Cleaner Cover - Make sure the air cleaner
1. Loosen the air cleaner cover retaining knob and cover is in good condition, not cracked, damaged,
remove the air cleaner cover. ȱȱȱȱǰȱ ȱȱěȱȱ
sealing ability of the air cleaner element.
2. Remove the foam precleaner (if equipped), and
the paper air cleaner with the formed rubber seal. Air Cleaner Base - Make sure the base is properly
secured and not cracked or damaged. It is extremely
3. Disconnect the breather hose from the crankcase. important that the fasteners securing this component
See Figure 4-2. are tight at all times.
4.2
Section 4
Air Cleaner and Air Intake System
NOTE: Before reinstalling an air cleaner base that has Air Intake/Cooling System
been removed, make sure the metal bushings
in the base mounting holes are present. The Clean Air Intake/Cooling Areas
bushings prevent damage to the base and To ensure proper cooling, make sure the grass screen,
help maintain the proper mounting torque. ȱęǰȱ ȱǰȱȱȱ¡ȱ
surfaces of the engine are kept clean at all times.
Reassembly Under extremely dusty or dirty conditions, pay extra
The following procedure outlines complete Ĵȱȱȱǯ
reassembly of all air cleaner components.
NOTE: Operating the engine with a blocked grass
1. Reconnect the primer bulb hose (if equipped). See ǰȱ¢ȱȱȱȱęǰȱȦȱ
Figure 4-3. cooling shrouds removed, will cause engine
damage due to overheating.
2. Install the air cleaner base onto the mounting
studs.
4
ȱ řǯȱ ȱȱȱȱȱ ȱȱ ȱ¡ȱĚȱ
nuts and the hex screw. Torque all three to 8.1
N·m (72 in. lb.).
4.3
Section 4
Air Cleaner and Air Intake System
4.4
Section 5
Fuel System and Governor
Section 5
Fuel System and Governor
5.1
Section 5
Fuel System and Governor
ȱ ǯȱ
ȱȱȱ ȱȱȱȱȱĚ ǯ ȱ ȱ ȱȱȱȱĚ ȱȱȱǰȱȱȱ
ȱȱȱȱȱȱǯ
Śǯȱȱ ȱȱȱĚ ȱȱǯ Śǯȱȱ ȱȱȱĚ ȱȱȱǰȱȱȱ¢ȱ
a. Remove fuel line from carburetor. carburetor or clogged fuel line. If the fuel line is
ȱ ǯȱ ȱȱęȱȱȱȱȱȱȱ ǰȱȱȱȱȱ¢ȱȱȱȱ
spraying fuel into carburetor. replaced. If no fuel spray is entering carburetor,
ȱ ǯȱ ȱȱȱȱȱȱȱǯ replace primer bulb or primer hose.
Carburetor
ȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱȱśȬŘȱȱśȬřǯȱ
Figure 5-2. Carburetor With Primer. Figure 5-3. Carburetor With Choke.
5.2
Section 5
Fuel System and Governor
1. Engine starts hard, runs rough or stalls at idle. 1. Engine is out of fuel.
ȱ ȱ ȱęȱȱDzȱȱȱǯ
ȱ ȱ ȱȱȱ¢Dzȱȱȱȱȱǯ
Řǯȱȱ ȱȱȱǻȱ¢ȱȱ¢ȱ Řǯȱȱ ȱęȱȱDzȱȱȱǯ
ǰȱęǰȱȱȱȱȱ ǰȱȱ ȱ ȱ ȱȱ¢Dzȱȱȱǯ
governor hunting).
řǯȱȱ ȱȱȱǻȱ¢ȱęǰȱȱȱ řǯȱȱ ȱȱ¢Dzȱȱȱǯ
speed and power, governor hunting). ȱ ȱ ȱȱDzȱȱȱǯ
Śǯȱȱ ȱȱȱǯ 4. Dirt or debris in carb. Disassemble and clean.
Loose fuel bowl or drain screw. Disassemble and
ȱ ȱ ȱȱǯ
DZȱ ȱȱĞȱȱȱ ȱǯ
5.3
Section 5
Fuel System and Governor
Carburetor Removal
NOTE:ȱȱȱȱȱ¢ȱȱȱȱǯȱ
ȱ ŗǯȱ ȱȱȱȱȱȱǯȱ
2. Remove foam precleaner (if equipped) and paper element.
ȱ řǯȱ ȱ ȱ¡ȱĚȱȱȱ¡ȱĚȱ ȱȱȱȱǯ
ȱ Śǯȱ ȱȱǰȱȱǰȱȱȱǯ
ȱ śǯȱ ȱǰȱȱȱǯȱȱȱśȬŝǯȱ
+HDW'HÀHFWRU*DVNHW
Carburetor
Square Gasket
Notched Gasket
ȱ Řǯȱ ȱȱȬȱȱȱȱȱȱ
ȱĚǯȱȱȱśȬŞǯȱ
Emmulsion Tube
Tower
Fuel-Inlet
Needle
5.4
Section 5
Fuel System and Governor
ȱ Śǯȱ ȱȱĴȬȱ ǰȱȱĴȱ ȱ śǯȱ ȱȱȱ¢ǰȱȱȱȱ
ǰȱȱȱȱȱĴȱĞǰȱȱ plate and the carburetor body with a waterproof
ĴȱȱǯȱȱȱśȬŗŖȱȱśȬŗŘǯ ǯȱȱȱśȬŗŗǯȱ
Choke Lever
Throttle Shaft
Choke Spring
Choke Shaft
Choke Plate
DZȱ ĴȱĞȱ ȱȱ¢ȱȱ
Figure 5-11. Mark Choke Plate and Carburetor. 5
by corresponding wear to the carburetor
¢ǰȱȱȱǯȱȱȱ
ȱȱȱȱĴȱĞȱȱ ǯ
Throttle Choke
Lever Pilot Jet Lever
Throttle Plate
Choke
Plate
Throttle Plate Tower
Fuel Inlet Needle
Tower Fuel Inlet Needle
Emmulsion Tube
Float Pin
Main Jet
Float
Float Pin
O-Ring
Drain Screw
Fuel Bowl Screw
5.5
Section 5
Fuel System and Governor
ȱ Ŝǯȱȱ ȱȱȱȱ ȱȱȱȱȱȱ ȱ Ȋȱ ȱȱǰȱȱȱȱȱȱ¢ǰȱȱ
ȱȱȬȱĞǯȱȱȱśȬŗřǯ inlet needle and seat.
• ǰȱĚȱȱȱȱ ǯ
Choke Plate
DZȱ ȱȱȱȱȱȱȱȱ
ȱ ȱǰȱęǰȱǰȱȱȱ
ȱȱȱǯȱȱȱ
may damage these components.
Carburetor Inspection
Complete carburetor inspection should include the
DZȱ
ȱ Ȋȱ ȱȱ¢ȱȱǰȱǰȱȱ
other wear or damage.
Figure 5-13. Choke Plate Removal.
ȱ ŝǯȱȱ ȱȱȱĞȱȱȱȱȱ ȱ Ȋȱ ȱĚȱȱȱȱǯȱȱĚȱ
return spring, noting their positions for accurate hinge and pin for wear or damage.
¢ǯȱȱȱśȬŗŚǯ
• Inspect fuel inlet needle and seat for wear or
damage.
ȱ Ȋȱ ȱȱȱ ȱǰȱȬȱȱȱ
Choke Return wear or grooves.
Spring
ȱ Ȋȱ ȱĴȱȱȱĞȱȱȱ
assemblies for wear or excess play.
Gasket Replacement
¢ȱȱ ȱȱ ȱȱȱȱ
ǯȱȱȱȱȱ ȱȱ
ȱȱȱȱǯȱ ¢ȱȱȱ
the Kohler Parts Manual for the engine being serviced
ȱȱȱȱȱȱȱǯ
Figure 5-14. Choke Return Spring Removal.
Carburetor Reassembly
Carburetor Cleaning ȱ ŗǯȱ ȱȱĴȱĞȱȱȱȱ¢ǯ
WARNING: Flammable Solvents! 2. Apply thread sealant around three full threads
ȱȱȱȱȱ¡¢ȱĚǯȱ ȱȱĴȱȱ ȱȱĴȱȱ
ȱǰȱĚǰȱȱȱȱȱȱ ¢ȱȱ ȱȱȱĴȱĞǯȱȱ ¢ȱ¢ȱ¡ȱ
ȱǯȱ ȱȱȱȂȱ ȱȱ sealant.
ȱȱȱȱȱȱǯȱȱȱȱ
ȱȱȱǯ ȱ řǯȱ ĴȱȱȱȱȱȱȱȱĞȱ
(if equipped).
All carburetor parts should be cleaned thoroughly
ȱȱȱȱǯȱȱȱȱ ȱ Śǯȱ ȱȱȱĞȱȱȱȱ¢ǯ
ȱȱȱȱȱȱ ȱDZ
ȱ śǯȱ ȱȱȱȱȱȱȱȱȱ
• Carburetor body and bore, especially areas where ȱȱǰȱȱȱȱȱȱ
ĴȱȱȱĞȱȱǯ ȱȱȱȱȱĞǯȱȱȱśȬŗŗǯȱȱ
ȱȱȱȱȱĞȱ¢ȱȱȱȱȇȱ
surface.
5.6
Section 5
Fuel System and Governor
ȱ Ŝǯȱ Ĵȱȱȱȱȱȱȱȱ ȱ Řǯȱ ȱȱȇȱȱȱȱȱȱ
¢ǰȱȱȱȱȱĞǯȱ proper start position.
Engine Starting
ȱ Řǯȱ ȱȱȱȱȱȱȱȱ
engine powers to the OPEN or OFF position.
ȱ řǯȱ ȱȱȱ ȱȱȱȱȱ
ȱǯȱȱȱśȬŗŜǯ
5.7
Section 5
Fuel System and Governor
Control Arm
Bowden Cable
Governor
Gear
Sheath Flyweights
Governor Shaft
Cable Clamp
Figure 5-18. Governor Assembly.
Figure 5-17. Bowden Cable Connection.
Operation
ȱ Řǯȱ ȱȱ ȱȱȱȱȱȱ As the governor gear rotates, centrifugal force causes
ȱȱȬȱǯȱȱȱȱ ȱĚ¢ ȱȱȱ ȱȱȱǯȱ
selection, refer to the operating instructions of ȱȱĚ¢ ȱǰȱ¢ȱȱȱȱȱ
the equipment this engine powers. See Figure to protrude out. The regulating pin contacts the tab
śȬŗśǯ ȱȱȱĞǰȱȱȱĞȱȱǯȱȱ
ȱȱȱȱĞȱȱȱȱȱ
ȱ řǯȱ ȱȱĴȱȱȱȱȱȱ ȱȱǯȱȱȱȱȱȱȱ
ȱȱȱȱȬȱǯȱ ȱȱȱȱȱĞȱȱȱ ȱ
ȱȱȱĴȱȱȱȱǰȱȱ¢ȱ
DZȱ ȱȱȱȱȱ¢ȱȱȱ ȱȱȱĞȱȱȱȱ
Ĵȱȱ¢ȱȱȱȱ ȱȱĴȱǯ
ǯȱȱȱĴȱȱȱȱȱ
a designated CHOKE position, be sure to ȱȱȱȱȱȱȱȱĴȱȱȱ
ȱĜȱĴȱȱȱȱȱ ȯȱȱ ȱȱę¡ȬȱȱǻȱǼȱȯȱȱȱ
ȱǯȱȱ ȱȱȱȱȱ ȱȱȱȯȱȱ ȱȱȬȱȱ
be placed ON. ȯȱȱȱȱȱȱȱȱȱĴȱ
plate open. When the engine is operating, and the
ȱ Śǯȱ ¢ȱȱȱȱȱȱ ȱȱ governor gear assembly is rotating, the force applied
ȱȱȱȬȱ ǯ ¢ȱȱȱȱȱȱȱĞȱȱȱ
ȱȱĴȱǯȱȱȱȱ
ȱ śǯȱ ȱȱȱȱȱȱȱĴȱȱ tension and the force applied by the regulating pin are
ȱȱȱ¢ȱǯȱ in equilibrium during operation, holding the engine
speed constant. When load is applied, and the engine/
ȱ Ŝǯȱ ȱȱȱȱ¢ǯ governor gear speed decreases, the governor spring
ȱȱȱȱȱȱȱȱĴȱ
plate wider. This allows more fuel into the engine,
ȱȱǯȱȱȱȱȱ¢ȱ
5.8
Section 5
Fuel System and Governor
rapidly, so a reduction in speed is hardly noticed. As 2. Move the governor lever away from the
ȱȱȱȱȱĴǰȱȱȱ ȱǻ ȱȱĴǼǯȱȱȱśȬŗşǯȱ
spring tension and the force applied by the regulating Do notȱ¢ȱ¡ȱȱȱ¢ȱĚ¡ȱȱȱ
pin will again be in equilibrium. This maintains ȱĴȱǯ
the engine speed at a relatively constant level. The
ȱȱĴȱȱȱ¢ȱȱȱ ȱ řǯȱ ȱȱȱĞȱ ȱȱȱȱȱȱ
ȱȱĴȱǯȱȱȱȱȱȱǰȱ Ğȱclockwise as far as it will go. Then torque
depending on the application. the hex nut to 9.5 N·m (84 in. lb.)ǯȱȱȱśȬ
20.
Initial Governor Adjustment
ȱȱȱȱ ȱȱȱ
ȱȱȱȱȱȱȱȱĞǯȱȱ
ȱȱǰȱȱȱȱĴȱ
ȱȱȱȱȱȱȱȱȱȱ
Ĵȱȱȱȱǯȱ
ȱ ŗǯȱ ȱȱȱȱȱ ǯȱȱ
ȱśȬŗşǯȱ 5
5.9
Section 5
Fuel System and Governor
5.10
Section 6
Lubrication System
Section 6
Lubrication System
10W-30, SAE 30
10W-30
°F -20 0 20 32 40 60 80 100
°C -30 -20 -10 0 10 20 30 40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
6.1
Section 6
Lubrication System
ȱ řǯȱ Ğȱȱȱȱ¢ȱǰȱȱȱ
engine back to level.
Full Mark
4. Fill the crankcase with new oil of the proper type
to the FULL mark on the dipstick. See Figure
6-4. Always check the oil level with the dipstick
Operating ȱȱȱǯȱȱȱ ȱȱȱ
Range in when checking oil level.
Change the oil while the engine is still warm. The oil
ȱĚ ȱȱ¢ȱȱ¢ȱ ¢ȱȱǯȱ
ȱŗŘŖǰȱȬȱ
ȱŗŘŜǯȱ
6.2
Section 6
Lubrication System
6. Fill the crankcase with the recommended oil Splash Lubrication System
to the FULL mark on the dipstick. See Figure
6-4. Always check the oil level with the dipstick Operation
ȱȱȱǯȱȱȱ ȱȱȱ This engine uses splash lubrication to deliver oil for
when checking oil level. internal lubrication. The governor gear, located near
ȱĴȱȱȱȱǰȱȱȱȱȱȱȱȱ
ȱ ŝǯȱ ȱȱȱęȱȦȱȱȱ that dip into crankcase oil and splash it onto internal
securely. engine parts.
6.3
Section 6
Lubrication System
6.4
Section 7
Electrical System and Components
Section 7
Electrical System and Components
This section covers the operation, service, and repair of the electrical system and electrical system components.
Spark Plug
Feeler Gauge
ȱęȱȱȱȱȱĞȱȱ
¢ȱȱȱȱȱȱȱȱȱȱȱȱ
ȱȱĴǯ Spark Plug
ȱȱȱȱ ȱȱ ȱȱDZ
ȱ řǯȱ ȱȱȱȱȱȱȱǯȱȱ
ȱŝȬŗǯȱȱȱȱ¢ȱ¢ȱȱ
ȱȱǯȱ ȱȱȱȱȱ0.762
mm (0.030 in.).
7.1
Section 7
Electrical System and Components
7.2
Section 7
Electrical System and Components
Spark Plug
Terminal (C)
Air Gap
0.254 mm Ignition Module
(0.010 in.)
Spark Plug
Kill Terminal
Magnets Lamination (A)
Flywheel 7
Ignition Module
(Enlarged View)
Kill Switch or Off
Position of Key Switch
7.3
Section 7
Electrical System and Components
Air Gap
0.254 mm Ignition
(0.010 in.) Module
Spark Plug
Spark Plug
Terminal (C)
Lamination (A)
Magnets
Flywheel
Ignition Module
(Enlarged View)
ȱ Ȋȱ ǰȱȱȱȱȱ ȱ¢ȱȱ¢ȱȱȱȱ
ȱȱȱǯȱ ǰȱ ǰȱȱȱ ȱȱ
information is provided to help systematically
ȱȱȱȱȱȱǯ
7.4
Section 7
Electrical System and Components
c. ȱ ȱȱȱȱ
ǰȱȱ
ȱȱ¢ȱ¢ȱȱȱȱ
ǯȱ ȱȱȱ ȱȱ ǯȱȱȱȱȱȱ
ȱȱȱȱǯ ohmmeter (Test 4).
7.5
Section 7
Electrical System and Components
Figure 7-4. CDI and IDI Ignition Module Tester. Figure 7-5. Testing CDI or IDI Ignition Modules.
7.6
Section 8
Disassembly
Section 8
Disassembly
8.1
Section 8
Disassembly
Drain Oil
NOTE: There are two ways to drain oil from this
engine: by inverting the dipstick tube, and by Crankcase Plug
removing the crankcase drain plug.
Figure 8-2. Crankcase Plug.
Drain Oil from Dipstick Tube
3. Drain the oil into an approved container.
1. To keep dirt, grass clippings, and other debris out
ȱȱǰȱȱȱȱȱȱȱęȱ
cap/dipstick.
Remove Engine Cover Insert and Cover
1. Remove the four Torx screws securing the engine
ȱ Řǯȱ ȱȱȱęȱȦǯ
cover insert. See Figure 8-3.
3. Tilt the engine on its side with the air cleaner
facing up. See Figure 8-1. Drain the oil into an
approved container. Cover Insert
Air Cleaner
Up
Oil Flow
Figure 8-1. Draining Oil from Dipstick Tube.
8.2
Section 8
Disassembly
5HPRYH0XIÀHU$VVHPEO\
Remove Recoil Starter ȱ ŗǯȱ ȱ ȱ¡ȱĚȱȱȱȱȱ
ȱ ŗǯȱ ĞȱěȱȱȱǯȱȱȱŞȬśǯ guard to the cylinder head. See Figure 8-7.
8.3
Section 8
Disassembly
ȱ Řǯȱ ȱȱȱĝȱěȱȱǯȱȱȱŞȬŞǯ
Hex Nuts
Hex Flange Screw
ȱ řǯȱ ȱȱȱĚȱȱȱȱ
exhaust studs, noting orientation.
Air Cleaner
Base Gasket
Figure 8-9. Removing Air Cleaner Cover.
Primer
2. Remove the paper element and the foam
Hose
ȱǻȱǼǯ
ȱ řǯȱ ȱȱ ȱ¡ȱȱȱȱ¡ȱĚȱ
screw securing the air cleaner base to the cylinder
head and the crankcase. See Figure 8-10.
8.4
Section 8
Disassembly
Throttle Lever
Figure 8-15. Disconnecting Carburetor Linkage.
ȱ Śǯȱ ȱěȱȱȇȱȱǰȱȱǰȱ
and spacer gasket, noting the sequence. See
Figure 8-16.
Hose Clamp
ȱ řǯȱ ȱȱĴȱȱ ȱȱȱǯ
Gently push the rod and spring linkages up
ȱȱȱȱȱĴȱǯȱȱ
Figure 8-15.
8.5
Section 8
Disassembly
2. Slide carburetor to the end of the intake studs. Remove Governor Spring
See Figure 8-14. 1. Disconnect the governor spring from the speed
control bracket. See Figure 8-20.
ȱ řǯȱ ȱȱĴȱȱ ȱȱȱǯ
Gently push the rod and spring linkages up
ȱȱȱȱȱĴȱǯȱȱ
Figure 8-15.
ȱ śǯȱ ȱěȱȱȇȱȱǰȱȱǰȱ
and spacer gasket, noting the sequence. See
Figure 8-19.
8.6
Section 8
Disassembly
8
Bracket Screws Figure 8-25. Disconnecting Kill Lead.
ȱ Řǯȱ ȱȱ¡ȱĚȱ ȱȱȱȱ
securing the ignition module. Mark the stud for
Hex Nut Bracket ęȱȱ¢ǯȱȱȱŞȬŘŜǯ
8.7
Section 8
Disassembly
ȱ Śǯȱ ȱȱĚ¢ ȱ¢ȱȱȱĞǯȱ
See Figure 8-30.
Breather
Cover
ȱ Řǯȱ ȱȱȱȱȱĞȱěȱȱǰȱȱ
ȱȱȱĚ¢ ȱȱ¢ǯ
ȱ řǯȱ ȱĚ¢ ȱȱȱȱȱȱĞǯȱȱ
ȱǰȱȱȱȱȱȱȱȱęȱ ǰȱ
¢ȱěȱȱȱȱĚ¢ ǯȱȱȱŞȬ
29.
8.8
Section 8
Disassembly
8.9
Section 8
Disassembly
Figure 8-37. Removing Push Rods. Figure 8-39. Removing Guide Plate.
8.10
Section 8
Disassembly
ȱ řǯȱ ȱȱȱȱȱȱȱǻȱŞȬŚŘǼȱȱ
ȱȱȱȱǻȱŞȬŚřǼǰȱȱȱ
both valves from the opposite end of the head
Figure 8-40. Removing Cylinder Head. ǻȱŞȬŚŚǼǯȱȱȱȱ
ȱȱ
EXHAUST for reinstallation.
2. Remove the cylinder head, noting the positioning
of the dowels. See Figure 8-41.
DZȱ ¢ȱȱ¢ȇȱȱȱȱ
a seal. There is no valve seal on the
exhaust side.
Intake
Valve
End
Dowels Valve
8
Gasket Seal
Figure 8-41. Cylinder Head Dowels.
8.11
Section 8
Disassembly
8.12
Section 8
Disassembly
Gear
ȱ Řǯȱ ȱȱȱȱȱȱĞǯȱ
See Figure 8-50. Figure 8-52. Removing Connecting Rod Cap.
Remove Piston
Hitchpin ȱ ŗǯȱ ¢ȱȱȱȱȱȱĴȱ
connecting rod out of the cylinder bore. See
Figure 8-53.
Governor
Shaft
8.13
Section 8
Disassembly
8.14
Section 9
Inspection and Reconditioning
Section 9
Inspection and Reconditioning
This section covers the operation, inspection, and repair/reconditioning of major internal engine components.
The following components are not covered in this section. They are covered in sections of their own:
Clean all parts thoroughly. Only clean parts can be accurately inspected and gauged for wear or damage. There
are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts.
When such a cleaner is used, follow the manufacturer’s instructions and safety precautions carefully. Use gasket
remover to remove old material from the valve cover, cylinder head, crankcase, and oil pan. Do not scrape the
gasket surfaces, as this could cause damage resulting in leaks.
Make sure all traces of cleaning solvents are removed before the engine is reassembled and placed into
operation. Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil.
Crankcase
ȱȱ¢ȱ ȱȱǯȱȱȱǰȱȱȱȱȱȱȱěȱȱȱȱ
cylinder wall. Without lubrication, the piston rings would make metal to metal contact with the wall, causing
Ĝȱȱǯȱȱȱȱ¢ȱ ȱȱȱȱȱ¢ȱ£ȱȱȱȱȱȱ
ęȱȱȱȱȱȱǯ
9
Flywheel
Inspection
ȱȱĚ¢ ȱȱȱȱȱȱ¢ ¢ȱȱ ȱȱǯȱȱȱĚ¢ ȱȱǯȱȱȱ
Ě¢ ȱ¢ȱȱȱȱȱ¢ ¢ȱȱǰȱȱȱĞǰȱĚ¢ ǰȱȱ¢ǯ
ȱȱȱȱȱȱȱǯȱȱȱȱȱȱ¢ǯȱȱȱĚ¢ ȱȱȱ
ring gear is damaged.
9.1
Section 9
Inspection and Reconditioning
D E A E D
A
F F
B B
C C
9.2
Section 9
Inspection and Reconditioning
Hard starting, or loss of power accompanied by high fuel consumption, may be symptoms of faulty valves.
ȱȱ¢ȱȱȱȱĴȱȱ ȱǰȱȱȱȱȱȱęǯȱĞȱ
removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for
ȱȱȱ ȱǰȱ¡ȱǰȱȱ ȱȱǯȱȱȱȱȱȱȱȱǯȱ
ȱȱȱȱȱȱȱȱȱ ȱȱȱ¢ȱǯ
Normal:ȱȱĞȱȱȱȱȱȱȱ Leakage:ȱȱȱȱȱȱȱȱȱȱ ȱ
can be reconditioned and reused if the face and allow leakage, resulting in a valve burned on one side
margin are in good shape. If a valve is worn to where only.
the margin is less than 1/32" do not reuse it. The valve
shown was in operation for almost 1000 hours under
controlled test conditions.
Bad Condition: The valve depicted here should be Coking: Coking is normal on intake valves and is not
replaced. Note the warped head; margin damaged harmful. If the seat is good, the valve could be reused
ȱȱ ǯȱȱȱȱȱĴȱ Ğȱǯ
to excessive hours or a combination of poor operating
conditions.
9.3
Section 9
Inspection and Reconditioning
Excessive Combustion Temperatures: The white Stem Corrosion: Moisture in fuel or from
deposits seen here indicate very high combustion condensation are the most common causes of valve
temperatures, usually due to a lean fuel mixture. stem corrosion. Condensation occurs from improper
preservation during storage and when engine is
repeatedly stopped before it has a chance to reach
ȱȱǯȱȱȱ
valves.
9.4
Section 9
Inspection and Reconditioning
Valve Guides
ȱȱȱȱȱ ȱ¢ȱęǰȱȱ ȱ
not guide the valve in a straight line. This may result
in burned valve faces or seats, loss of compression,
and excessive oil consumption.
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ȱȱ ȱȱȱȱĴȱȱ
ǯȱȱ¢ȱĴȱȱ ȱȱȱşȬŘǯȱȱęȱ 9
ȱȱȱȱ ȱȱşŖǚȱĴȱȱęȱȱ
the valve seat angle in Figure 9-1. With the proper 45°
valve face angle, and the valve seat cut properly (44.5°
as measured from center line when cut 90°) this would
result in the desired 0.5° (1.0° full cut) interference
angle where the maximum pressure occurs on the
valve face and seat.
9.5
Section 9
Inspection and Reconditioning
9.6
Section 10
Reassembly
Section 10
Reassembly
10.1
Section 10
Reassembly
Install Crankshaft 3. Aim the triangle on top of the piston towards the
ȱ ŗǯȱ ¢ȱȱȱĞȱȱȱȱ push rod chamber. See Figure 10-3.
through the front seal, and fully seat into place.
ȱȱŗŖȬŗǯȱȱȱĞȱȱȱ
journal for the connecting rod is away from the
cylinder.
Triangle
2. Compress the piston rings using a piston ring Figure 10-4. Installing Piston.
compressor. See Figure 10-2.
ȱ śǯȱ ȱȱȱȱȱĞǰȱȬȱȱȱ
tap the piston into the bore. See Figure 10-5.
10.2
Section 10
Reassembly
ȱ Ŝǯȱ ȱȱĞȱȱȱ ȱȱȱ
rod. Align the rod cap and connecting rod to
match the marks. Torque the screws to 12.5 N·m
(110 in. lb.). See Figure 10-6. Timing Marks
Match
Marks
Retainer
Install Tappets
1. Install the INTAKE and the EXHAUST tappets
into their respective positions, as previously
marked. See Figure 10-7.
Governor
Gear
Figure 10-9. Installing Governor Gear.
ȱ Řǯȱ ȱȱȱȱĞȱȱȱȱ ȱ
the hitch pin. See Figure 10-10.
10
Figure 10-7. Installing Tappets.
Hitch Pin
Install Camshaft
ȱ ŗǯȱ ȱȱĞȱȱȱȱȱ Shaft
with light grease or oil.
ȱ Řǯȱ ȱȱĞȱȱȱȱȱǯȱ
See Figure 10-8.
10.3
Section 10
Reassembly
Dowels
5
4
2
Figure 10-13. Torque Sequence.
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screws, securing the oil pan to the crankcase. See
Figure 10-12. Figure 10-14. Torquing Oil Pan Screws.
10.4
Section 10
Reassembly
Gasket
Dowels
Figure 10-17. Installing Cylinder Dowels.
Figure 10-15. Installing Valves.
3. Match the two sides of the head together and
2. Install the intake valve seal onto the intake valve. ęȱȱȱȱ¡ȱ ǯȱȱȱ
Next, slide the valve springs onto both valves 10-18.
and lock them in place with the valve spring
keepers. See Figure 10-16.
3
Keeper Spring 2
Intake
Seal
10
1 4
10.5
Section 10
Reassembly
10.6
Section 10
Reassembly
8. Tighten the rocker pivot with a wrench until a Install Flywheel Brake Assembly
slight drag is felt on the feeler gauge. See Figure 1. Install the two spacers onto the two brake
10-23. Hold the nut in that position and torque assembly screws.
the jam nut to 9.5 N·m (84 in. lb.). Perform the
same adjustment procedure on the opposite 2. Torque them to 9.5 N·m (84 in. lb.). See Figure
valve. 10-25.
ȱŗŖǯȱ ȱȱȱȱȱęȱȱȱȱ
screws.
2
3
Figure 10-25. Installing Flywheel Brake Assembly.
10.7
Section 10
Reassembly
ȱ ŗǯȱ ȱȱ¢ȱȱȱĞȱ¢ ¢ǯȱȱ
sure key is fully seated. See Figures 10-27 and
Flywheel Key 10-28.
ȱ Řǯȱ ȱȱĚ¢ ȱȱȱĞȱȱ
Breather the keyway with the key. See Figure 10-28.
Cover
Keyway
Teardrop
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Flywheel can Cause Personal Injury!
ȱȱȱȱȱȱĚ¢ ȱȱȱ Figure 10-28. Installing Flywheel.
ȱȱȱĞȱȦȱĚ¢ ǯȱȱȱ¢ȱ
causes extensive engine damage, but can also cause personal 3. Align the teardrop slot on the fan with the raised
¢ǰȱȱȱȱȱȱ ȱȱȱ ȱȱȱĚ¢ ǯȱȱȱȱȱȱ
ǯȱ ¢ȱȱȱȱȱ ȱȱ ȱĚ¢ ǰȱȱȱȱȱȱȱ
ȱȱ ȱȱȱĚ¢ ǯ nut.
DZȱ ȱȱȱĚ¢ ȱ¢ȱȱȱ
¢ȱȱȱ¢ ¢ǯȱȱĚ¢ ȱȱ
become cracked or damaged if the key is not
properly installed.
DZȱ ¢ȱȱȱĚ¢ ȱȱ ȱȱȱ
ȱĚ¢ ȱ ȱȱȱĚ¢ ȱ
fastener. Do not use any type of bar or
ȱȱȱȱĚ¢ ȱȱǰȱ
as these parts could become cracked or
damaged.
Figure 10-29. Torquing Flywheel Nut.
10.8
Section 10
Reassembly
Install Ignition Module 4. Set the air gap by placing a 0.254 mm (0.010 in.)
ȱ ŗǯȱ ȱȱĚ¢ ȱȱȱȱȱȱ plastic feeler gauge between the magnet and the
away from the ignition module legs. Position module. Loosen the stud and let the magnet draw
the ignition module on the legs with the kill tab the module against the feeler gauge. See Figure
down. See Figures 10-30 and 10-32. 10-32. Torque the fasteners to 10 N·m (88 in. lb.).
Magnets
Ignition
Module
Feeler
Gauge
Leg
Kill Tab
Figure 10-30. Positioning Ignition Module/Magnets Figure 10-32. Feeler Gauge.
Bracket Screws
10
Bracket
Bracket Nut
Figure 10-31. Tightening Ignition Module Stud. Figure 10-33. Attaching Fuel Tank Bracket.
3. Install the spacer onto the ignition module stud. ȱ Řǯȱ ¢ȱĴȱȱȱȱȱȱȱ
See Figure 10-31. ȱ ȱȱ¡ȱĚȱǯȱȱȱ
10-33.
10.9
Section 10
Reassembly
3. Secure the top of the fuel tank to the crankcase
by installing the two threaded studs. Torque the
studs to 10 N·m (88.5 in. lb.). See Figure 10-34.
Spacer Stud
Shaft
ȱ Řǯȱ ĴȱȱĴȱȱȱȱȱȱ
the top of the governor lever. See Figure 10-37.
Throttle Linkage
Hook
Spring
10.10
Section 10
Reassembly
DZȱȱ ȱȱȱěȱȱȱȱȱȱǯȱȱŗŖȬřşǰȱŗŖȬŚŖǰȱȱŗŖȬŚŗȱ¢ȱ
ȱěȱȱȱȱȱ ȱȱ ȱǯ
Throttle Linkage
Linkage Spring
Speed Control Bracket
Throttle
Lever
Governor Spring
Governor Lever
Throttle
Linkage Spring Throttle Linkage
Lever
Speed Control Bracket
Choke
Lever
Choke Linkage
Governor Lever
Governor Spring
Choke Linkage
Governor Lever
Speed Control Bracket
Governor Spring
Figure 10-41. Variable Speed with Choke.
10.11
Section 10
Reassembly
Spring
Linkage Throttle
Linkage
Throttle Lever
Figure 10-42. Installing Governor Spring. Figure 10-44. Installing Throttle Linkage.
Spacer Gasket
Head Spacer
Heat Shield
Figure 10-45. Installing Carburetor (Primer Model).
10.12
Section 10
Reassembly
ȱ Řǯȱ ȱȱĴȱȱȱȱȱ
ȱȱĴȱȱȱȱǯȱȱȱ
10-44. Figure 10-48. Connecting Fuel Hose.
10
Figure 10-49. Installing Primer Hose (If Equipped).
10.13
Section 10
Reassembly
3. Slide the air cleaner base onto the carburetor 6. Install the paper element and the foam precleaner
ǯȱĴȱȱȱ¢ȱ¢ȱ ȱȱ (if equipped) into the air cleaner body. See Figure
ȱ¡ȱȱȱȱǰȱȱȱ¡ȱĚȱ ŗŖȬśŘǯȱĴȱȱȱȱȱǯ
screw into the crankcase. See Figure 10-50.
Hex Nuts
Hex Flange
Screw
Figure 10-50. Installing Air Cleaner Base. Figure 10-52. Installing Air Cleaner.
ȱ Śǯȱ Ĵȱȱȱȱȱȱǯȱȱ
Figure 10-51.
Install Dipstick Tube
1. Install the dipstick tube to the crankcase. See
Figure 10-53.
10.14
Section 10
Reassembly
ȱ Řǯȱ ȱȱĝȱȱȱ¡ȱǯȱȱ
Install Recoil
Figure 10-55.
1. Place the recoil onto the studs protruding from
the blower housing. See Figure 10-58.
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10.15
Section 10
Reassembly
2. Torque the nuts to 2.8 N·m (25 in. lb.). See Figure
10-59.
10.16
FORM NO.: TP-2601
ISSUED: 3/08
REVISED:
LITHO IN U.S.A.
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