SERVICE MANUAL

COURAGE XT-6, XT-7

VERTICAL CRANKSHAFT
 Contents

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.

For Your Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in injury to
yourself and others.

WARNING WARNING WARNING

Accidental Starts can cause
severe injury or death.
Disconnect and ground spark plug
leads before servicing.
Rotating Parts can cause severe Hot Parts can cause severe burns.
injury.
Do not touch engine while operating
Stay away while engine is in ˜›ȱ“žœȱŠĞŽ›ȱœ˜™™’—ǯ
operation.

Accidental Starts! Rotating Parts! Hot Parts!

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.
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never operate
the engine with covers, shrouds, or
guards removed.
Engine components can get extremely
hot from operation. To prevent severe
burns, do not touch these areas while
the engine is running, or immediately
ŠĞŽ›ȱ’ȱ’œȱž›—Žȱ˜ěǯȱŽŸŽ›ȱ˜™Ž›ŠŽȱ
the engine with heat shields or guards
removed.

1.1
Section 1
Safety and General Information

WARNING WARNING CAUTION

([SORVLYH)XHOFDQFDXVH¿UHVDQG Carbon Monoxide can cause

severe burns.
˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ
engine is hot or running.
Explosive Fuel!
Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ
its vapors can explode if ignited. Store
gasoline only in approved containers,
in well ventilated, unoccupied
‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ̊–Žœǯȱ
˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ
engine is hot or running, since spilled
fuel could ignite if it comes in contact
with hot parts or sparks from ignition.
Do not start the engine near spilled
fuel. Never use gasoline as a cleaning
agent.
Electrical Shock can cause injury.
severe nausea, fainting or death.
Do not touch wires while engine is
Avoid inhaling exhaust fumes, and
running.
never run the engine in a closed
‹ž’•’—ȱ˜›ȱŒ˜—ę—ŽȱŠ›ŽŠǯ
Electrical Shock!
Never touch electrical wires or
Lethal Exhaust Gases! components while the engine is
Engine exhaust gases contain running. They can be sources of
poisonous carbon monoxide. Carbon electrical shock.
monoxide is odorless, colorless, and can
cause death if inhaled. Avoid inhaling
exhaust fumes, and never run the
Ž—’—Žȱ’—ȱŠȱŒ•˜œŽȱ‹ž’•’—ȱ˜›ȱŒ˜—ę—Žȱ
area.

WARNING

Cleaning Solvents can cause

severe injury or death.

Use only in well ventilated areas

away from ignition sources.

Flammable Solvents!
Carburetor cleaners and solvents are
Ž¡›Ž–Ž•¢ȱ̊––Š‹•Žǯȱ ŽŽ™ȱœ™Š›”œǰȱ
̊–ŽœǰȱŠ—ȱ˜‘Ž›ȱœ˜ž›ŒŽœȱ˜ȱ’—’’˜—ȱ
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
™ŽŒ’ęŒŠ’˜—ǰȱŠ—ȱŽ›’Š•ȱž–‹Ž› of the engine.

—’—Žȱ’Ž—’ęŒŠ’˜—ȱ—ž–‹Ž›œȱŠ™™ŽŠ›ȱ˜—ȱŠȱŽŒŠ•ȱ
ŠĜ¡Žȱ˜ȱ‘ŽȱŽ—’—Žȱœ‘›˜ž’—ǯȱŽŽȱ’ž›ŽȱŗȬŗǯȱ—ȱ
Ž¡™•Š—Š’˜—ȱ˜ȱ‘ŽœŽȱ—ž–‹Ž›œȱ’œȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŗȬŘǯ

,GHQWL¿FDWLRQ/DEHO
)LJXUH,GHQWL¿FDWLRQ/DEHO

A. Model No. XT 7
Courage Vertical Shaft Engine

Numerical Designation

B. Spec. No. XT173-0001

Engine Model )LUVWVSHFL¿FDWLRQ
Model written in this
XT-6 model series
XT-7

C. Serial No. 3723500328

Year Manufactured Code Factory Code
Code Year
37 2007
38 2008

)LJXUH([SODQDWLRQRI,GHQWL¿FDWLRQ1XPEHUV

1.3
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the engine
is extremely important, as is daily checking of oil level
Š—ȱŒ‘Š—’—ȱ˜’•ȱ›Žž•Š›•¢ǯȱŠ’•ž›Žȱ˜ȱžœŽȱ‘ŽȱŒ˜››ŽŒȱ
oil, or using dirty oil, will cause premature engine
wear and failure.
Oil Type
Use high quality detergent oil of ȱǻ–Ž›’ŒŠ—ȱ
Fuel Recommendations
WARNING: Explosive Fuel!
Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ
if ignited. Store gasoline only in approved containers, in
well ventilated, unoccupied buildings, away from sparks or
̊–Žœǯȱ˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱ‘˜ȱ˜›ȱ
running, since spilled fuel could ignite if it comes in contact
with hot parts or sparks from ignition. Do not start the
Ž›˜•Žž–ȱ—œ’žŽǼȱœŽ›Ÿ’ŒŽȱŒ•Šœœȱȱ˜›ȱ‘’‘Ž›. Select engine near spilled fuel. Never use gasoline as a cleaning
the viscosity based on the air temperature at the time agent.
˜ȱ˜™Ž›Š’˜—ȱŠœȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŗȬřǯ
General Recommendations
RECOMMENDED SAE VISCOSITY GRADES Purchase gasoline in small quantities and store
in clean, approved containers. A container with a
ŒŠ™ŠŒ’¢ȱ˜ȱŘȱŠ••˜—œȱ˜›ȱ•Žœœȱ ’‘ȱŠȱ™˜ž›’—ȱœ™˜žȱ’œȱ
10W-30, SAE 30 recommended. Such a container is easier to handle
10W-30 and helps eliminate spillage during refueling.

To ensure easy starting and minimize gum deposits in

°F -20 0 20 32 40 60 80 100
°C -30 -20 -10 0 10 20 30 40
‘ŽȱžŽ•ȱœ¢œŽ–ǰȱ˜ȱ—˜ȱžœŽȱŠœ˜•’—Žȱ•ŽĞȱ˜ŸŽ›ȱ›˜–ȱ‘Žȱ
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE previous season. Do not add oil to the gasoline. Do not
˜ŸŽ›ę••ȱ‘ŽȱžŽ•ȱŠ—”Dzȱ•ŽŠŸŽȱ›˜˜–ȱ˜›ȱŽ¡™Š—œ’˜—ǯ
Figure 1-3. Viscosity Grades Table.
Fuel Type
NOTE: Using other than service class SJ or higher oil ˜›ȱ‹Žœȱ›Žœž•œǰȱžœŽȱ˜—•¢ȱŒ•ŽŠ—ǰȱ›Žœ‘ǰȱž—•ŽŠŽȱ
or extending oil change intervals longer than gasoline with a pump sticker octane rating of 86 or
recommended can cause engine damage. ‘’‘Ž›ǯȱ—ȱŒ˜ž—›’Žœȱžœ’—ȱ‘Žȱ›ŽœŽŠ›Œ‘ȱ–Ž‘˜ǰȱ’ȱ
should be 90 octane minimum.
ȱ•˜˜ȱ˜›ȱœ¢–‹˜•ȱ˜—ȱ˜’•ȱŒ˜—Š’—Ž›œȱ’Ž—’ęŽœȱ‘Žȱȱ
œŽ›Ÿ’ŒŽȱŒ•ŠœœȱŠ—ȱȱŸ’œŒ˜œ’¢ȱ›ŠŽǯȱŽŽȱ’ž›ŽȱŗȬŚǯȱ Unleaded gasoline is recommended, as it leaves less
combustion chamber deposits. Leaded gasoline may
be used in areas where unleaded is not available
and exhaust emissions are not regulated. Be aware
RVIC
SE however, using unleaded gasoline will require more
E
API

frequent cylinder head servicing.

SJ

10W-30
Gasoline/Alcohol Blends
Šœ˜‘˜•ȱǻž™ȱ˜ȱŗŖƖȱŽ‘¢•ȱŠ•Œ˜‘˜•ǰȱşŖƖȱž—•ŽŠŽȱ
gasoline by volume) is approved as a fuel for Kohler
Ž—’—Žœǯȱ‘Ž›ȱŠœ˜•’—ŽȦŠ•Œ˜‘˜•ȱ‹•Ž—œȱ’—Œ•ž’—ȱŘŖȱ
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
Šœ˜•’—Žȱ‹•Ž—œȱǻž™ȱ˜ȱ–Š¡’–ž–ȱ˜ȱŗśƖȱȱ‹¢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.

Frequency Maintenance Required

’••ȱžŽ•ȱŠ—”ǯ
Š’•¢ȱ˜›ȱŽ˜›ŽȱŠ›’—ȱ
Check oil level.
—’—Ž
‘ŽŒ”ȱŠ’›ȱ’—Š”ŽȱŠ—ȱŒ˜˜•’—ȱŠ›ŽŠœDzȱŒ•ŽŠ—ȱŠœȱ—ŽŒŽœœŠ›¢ǯŵ
Ž›Ÿ’ŒŽȱ˜›ȱ›Ž™•ŠŒŽȱ™›ŽŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ȱǻ’ȱŽšž’™™ŽǼǯŵ
Yearly or Every 25 Hours
‘ŽŒ”ȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ȱ˜›ȱ’›¢ǰȱ•˜˜œŽȱ˜›ȱŠ–ŠŽȱ™Š›œǯŵ
Ž™•ŠŒŽȱžŽ•ȱꕝŽ›ǰȱ’ȱŽšž’™™Žǯ
Yearly or Every 50 Hours
Change oil.
Replace spark plug and set gap.
ŽŠ›•¢ȱ˜›ȱŸŽ›¢ȱŗŖŖȱ‘˜ž›œ
Ž™•ŠŒŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ǯŵ
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.

Storage ȱ Śǯȱ Remove the spark plug. Add one tablespoon of

ȱ‘ŽȱŽ—’—Žȱ ’••ȱ‹Žȱ˜žȱ˜ȱœŽ›Ÿ’ŒŽȱ˜›ȱ ˜ȱ–˜—‘œȱ˜›ȱ
more, use the following storage procedure:
ȱ ŗǯȱ •ŽŠ—ȱ‘ŽȱŽ¡Ž›’˜›ȱœž›ŠŒŽœȱ˜ȱ‘ŽȱŽ—’—Žǯ
ȱ Řǯȱ ‘Š—Žȱ‘Žȱ˜’•ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱœ’••ȱ Š›–ȱ
›˜–ȱ˜™Ž›Š’˜—ǯȱ˜›ȱž›‘Ž›ȱ’—˜›–Š’˜—ǰȱœŽŽȱ
Section 6, Lubrication System.
ȱ řǯȱ ‘ŽȱŽ—’—Žȱ–žœȱ‹Žȱ›ž—ȱž—’•ȱ‘ŽȱžŽ•ȱŠ—”ȱ’œȱ
completely emptied, or the gasoline must be
treated with a stabilizer to prevent deterioration.
ȱ¢˜žȱŒ‘˜˜œŽȱ˜ȱžœŽȱŠȱœŠ‹’•’£Ž›ǰȱ˜••˜ ȱ‘Žȱ
–Š—žŠŒž›Ž›ȇœȱ›ŽŒ˜––Ž—Š’˜—œǯȱ’••ȱ‘ŽȱžŽ•ȱ
tank with clean, fresh gasoline, and run the
Ž—’—Žȱ˜›ȱŘȬřȱ–’—žŽœȱ˜ȱŽȱœŠ‹’•’£ŽȱžŽ•ȱ’—˜ȱ
the carburetor.
engine oil into the spark plug hole. Reinstall the
plug, but do not connect the plug lead. Crank the
engine two or three revolutions.
5. Remove the spark plug. Cover the spark plug
hole with your thumb and turn the engine over
until the piston is at the top of its stroke (pressure
against the thumb is greatest). Reinstall the spark
plug, but do not connect the plug lead.
6. Store the engine in a clean, dry place. Never store
the machine or fuel container where there is an
˜™Ž—ȱ̊–Žǰȱœ™Š›”ǰȱ˜›ȱ™’•˜ȱ•’‘ȱœžŒ‘ȱŠœȱ˜—ȱŠȱ
water heater or on other appliances.

1.5
Section 1
Safety and General Information

(IF EQUIPPED)

(IF EQUIPPED)

Dimensions in millimeters. Inch equivalents shown in parentheses.

Figure 1-5. Typical Engine Dimensions.

1.6
 Section 1
Safety and General Information

*HQHUDO6SHFL¿FDWLRQVï

Žȱ˜ Ž›ȱǻȓȱřŜŖŖȱǼ 1
XT-6 ................................................................................................................. ŘǯŜȱ”ȱǻřǯśȱ
Ǽ
XT-7 ................................................................................................................. řǯŚȱ”ȱǻŚǯśȱ
Ǽ

ŽȱŽŠ”ȱ˜›šžŽȱǻȓȱŘŜŖŖȱǼ
XT-6 ................................................................................................................. Şȱȉ–ȱǻśǯşȱĞǯȱ•‹ǯǼ
XT-7 ................................................................................................................. şǯśȱȉ–ȱǻŝȱĞǯȱ•‹ǯǼ

Bore
XT-6 .................................................................................................................. Ŝśȱ––ȱǻŘǯśŜȱ’—ǯǼ
XT-7 .................................................................................................................. ŝŖȱ––ȱǻŘǯŝśȱ’—ǯǼȱ

Stroke
XT-6 .................................................................................................................. Śśȱ––ȱǻŗǯŞȱ’—ǯǼ
XT-7 .................................................................................................................. Śśȱ––ȱǻŗǯŞȱ’—ǯǼ

Displacement
XT-6 .................................................................................................................. ŗŚşȱŒŒȱǻşǯŗȱŒžǯȱ’—ǯǼ
XT-7 .................................................................................................................. ŗŝřȱŒŒȱǻŗŖǯŜȱŒžǯȱ’—ǯǼ

Compression Ratio
XT-6 .................................................................................................................. ŞǯřDZŗ
XT-7 .................................................................................................................. ŞǯśDZŗ

Dry Weight
XT-6 .................................................................................................................. ŗŖǯŞȱ”ȱǻŘŚȱ•‹ǯǼ
XT-7 .................................................................................................................. ŗřǯŗȱ”ȱǻŘşȱ•‹ǯǼ

’•ȱŠ™ŠŒ’¢ȱǻ›Žę••Ǽ
XT-6 ................................................................................................................. ŖǯŜŖȱȱǻŘŖȱ˜£ǯǼ
XT-7 ................................................................................................................. ŖǯŜŖȬŖǯŜśȱȱǻŘŖȬŘŘȱ˜£ǯǼ

—•Žȱ˜ȱ™Ž›Š’˜—ȱȬȱŠ¡’–ž–ȱǻŠȱž••ȱ’•ȱŽŸŽ•Ǽȱ••ȱ’›ŽŒ’˜—œ................ Řśǚȱ—Ž›–’ĴŽ—

Air Cleaner Base

’›ȱ•ŽŠ—Ž›ȱŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ ...................................................................... Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ
’›ȱ•ŽŠ—Ž›ȱŠœŽȱ˜ȱ›Š—”ŒŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ............................................... Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ

Blower Housing
•˜ Ž›ȱ
˜žœ’—ȱžȱ˜›šžŽ........................................................................... ŗŖȱȉ–ȱǻŞŞȱ’—ǯȱ•‹ǯǼ

Brake
›Š”Žȱ˜ž—’—ȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................... şǯśȱȉ–ȱǻŞŚȱ’—ǯȱ•‹ǯǼ

Breather Cover
›ŽŠ‘Ž›ȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ ..................................................................... ŗŖȱȉ–ȱǻŞŞȱ’—ǯȱ•‹ǯǼ

Camshaft
End Play.................................................................................................................. ŖǯŘȬŖǯŞȱ––ȱǻŖǯŖŖŝŞȬŖǯŖřŗŚȱ’—ǯǼ
Running Side Clearance ....................................................................................... ŖǯŗśȬŖǯśŗȱ––ȱǻŖǯŖŖśşȬŖǯŖŘȱ’—ǯǼ

Carburetor
Š›‹ž›Ž˜›ȱžȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................... 9.0 N·m (80 in. lb.)

1.7
Section 1
Safety and General Information

Connecting Rod
˜——ŽŒ’—ȱ˜ȱŠœŽ—Ž›ȱ˜›šžŽŶ .................................................................. ŗŘǯśȱȉ–ȱǻŗŗŖȱ’—ǯȱ•‹ǯǼ

Connecting Rod-to-Crankpin Running Clearance

New............................................................................................................... ŖǯŖŘśȬŖǯŖŚśȱ––ȱǻŖǯŖŖŖşȬŖǯŖŖŗŝȱ’—ǯǼ

Connecting Rod-to-Crankpin Side Clearance................................................ ŖǯŗřȬŖǯřŝȱ––ȱǻŖǯŖŖśŗȬŖǯŖŗŚśȱ’—ǯǼ

Connecting Rod-to-Piston Pin Running Clearance....................................... ŖǯŖŖŞȬŖǯŖŘśȱ––ȱǻŖǯŖŖŖřȬŖǯŖŖŖşȱ’—ǯǼ

’œ˜—ȱ’—ȱ—ȱǯǯ
New............................................................................................................... ŗŞǯŖŖŜȬŗŞǯŖŗŝȱ––ȱǻŖǯŝŖŞŞȬŖǯŝŖşřȱ’—ǯǼ

˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱ˜›Žȱǯǯȱ
New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱ––ȱǻŖǯŘřŜŘȬŖǯŘřŜşȱ’—ǯǼȱ

˜—›˜•ȱ›ŠŒ”Žȱ˜ȱ›Š—”ŒŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ ............................................. 8 N·m (70 in. lb.)

Crankshaft
End Play (free) .................................................................................................... ŖǯŘŘśȬŗǯŗŚśȱ––ȱǻŖǯŖŖŞŞȬŖǯŖŚśŖŝȱ’—ǯǼ

›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ›Š—”ŒŠœŽȱǯǯ
New.............................................................................................................. ŘŚǯşşŚȬŘśǯŖŖŖȱ––ȱǻŖǯşŞŚŖȬŖǯşŞŚŘȱ’—ǯǼȱ

›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ•˜œž›Žȱ•ŠŽȱǯǯ
New.............................................................................................................. ŘśǯŚŖŖȬŘśǯŚŘŗȱ––ȱǻŖǯşşşşȬŗǯŖŖŖŞȱ’—ǯǼȱ

•¢ ‘ŽŽ•ȱ—ȱŠ’—ȱŽŠ›’—ȱ˜ž›—Š•ȱǯǯ
O.D. – Max. Wear Limit ............................................................................ ŘŚǯşŝśȬŘŚǯşŞşȱ––ȱǻŖǯşŞřŘȬŖǯşŞřŞȱ’—ǯǼȱ
Max. Taper .................................................................................................. ŖǯŖŘśȱ––ȱǻŖǯŖŖŖşȱ’—ǯǼ
Max. Out of Round .................................................................................... ŖǯŖŘśȱ––ȱǻŖǯŖŖŖşȱ’—ǯǼ

PTO End Main Bearing Journal O.D.

New ............................................................................................................. ŘśǯřŝŖȬŘśǯřŞśȱ––ȱǻŖǯşşŞŞȬŖǯşşşŚȱ’—ǯǼ
Max. Taper .................................................................................................. ŖǯŖŘśȱ––ȱǻŖǯŖŖŖşȱ’—ǯǼ
Max. Out of Round .................................................................................... ŖǯŖŘśȱ––ȱǻŖǯŖŖŖşȱ’—ǯǼ

›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ•˜œž›Žȱ•ŠŽȱž——’—ȱ•ŽŠ›Š—ŒŽȱ
New.............................................................................................................. ŖǯŖŗśȬŖǯŖśŗȱ––ȱǻŖǯŖŖŖśȬŖǯŖŖŘȱ’—ǯǼ

Crankcase
˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱ˜›Žȱǯǯȱ
New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱ––ȱǻŖǯŘřŜŘȬŖǯŘřŜşȱ’—ǯǼ

›Š—”œ‘ŠĞȱ˜ž›—Š•ȱ’—ȱ›Š—”ŒŠœŽȱž——’—ȱ•ŽŠ›Š—ŒŽȱ
New.............................................................................................................. ŖǯŖŖśȬŖǯŖŘśȱ––ȱǻŖǯŖŖŖŘȬŖǯŖŖŖşȱ’—ǯǼ

Connecting Rod Journal O.D.

New.............................................................................................................. ŘşǯşŞśȬŘşǯşşśȱ––ȱǻŗǯŗŞŖśȬŗǯŗŞŖşȱ’—ǯǼ
Max. Taper .................................................................................................. ŖǯŖŗŖȱ––ȱǻŖǯŖŖŖŚȱ’—ǯǼ
Max. Out of Round .................................................................................... ŖǯŖŗŖȱ––ȱǻŖǯŖŖŖŚȱ’—ǯǼ

1.8
 Section 1
Safety and General Information
Cylinder Bore
¢•’—Ž›ȱ˜›Žȱǯǯ
New.............................................................................................................. ŝŖǯŖŖŖȬŝŖǯŖŗśȱ––ȱǻŘǯŝśśŞȬŘǯŝśŜŚȱ’—ǯǼ 1
Max. Taper .................................................................................................. ŗŘǯŝȱ–’Œ›˜—œȱǻŖǯŖŖŖśȱ’—ǯǼ
Max. Out of Round .................................................................................... ŗŘǯŝȱ–’Œ›˜—œȱǻŖǯŖŖŖśȱ’—ǯǼ

Cylinder Head
¢•’—Ž›ȱ
ŽŠȱŠœŽ—Ž›ȱ˜›šžŽŶ .................................................................... ŘŝǯŞ ȉ–ȱǻŘŚŜȱ’—ǯȱ•‹ǯǼȱ

Š¡ǯȱžȬ˜Ȭ•Š—Žœœ ........................................................................................ ŖǯŖŞȱ––ȱǻŖǯŖŖřŗȱ’—ǯǼ

˜Œ”Ž›ȱ’Ÿ˜ȱŠ–ȱžȱ˜›šžŽŶ ........................................................................ şǯśȱȉ–ȱǻŞŚȱ’—ǯȱ•‹ǯǼ

˜Œ”Ž›ȱ›–ȱžȱ˜›šžŽŶ ................................................................................ ŗřǯŜȱȉ–ȱǻŗŘŖȱ’—ǯȱ•‹ǯǼ

Dipstick Tube Fastener

’™œ’Œ”ȱž‹ŽȱŠœŽ—Ž›ȱ˜›šžŽȱ....................................................................... Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ

Engine Cover
—’—Žȱ˜ŸŽ›ȱ˜ȱŠ•ŸŽȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ............................................. ŘǯŞȱȉ–ȱǻŘśȱ’—ǯȱ•‹ǯǼ
—’—Žȱ˜ŸŽ›ȱ—œŽ›ȱ˜ȱ—’—Žȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ ............................... Řǯřȱȉ–ȱǻŘŖȱ’—ǯȱ•‹ǯǼ

Fan/Flywheel
•¢ ‘ŽŽ•ȱžȱ˜›šžŽ........................................................................................ śŗǯśȱȉ–ȱǻŚśŜȱ’—ǯȱ•‹ǯǼ

Fuel Tank
Tank Bracket to Crankcase Stud Torque ........................................................ Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ
Š—”ȱ›ŠŒ”Žȱ˜ȱŠ—”ȱŠœŽ—Ž›ȱ˜›šžŽ ........................................................... Śǯśȱȉ–ȱǻŚŖȱ’—ǯȱ•‹ǯǼ

Governor
˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȬ˜Ȭ›Š—”ŒŠœŽȱž——’—ȱ•ŽŠ›Š—ŒŽ ............................ ŖǯŖŘŖȬŖǯŖśŞȱ––ȱǻŖǯŖŖŖŝȬŖǯŖŖŘŘȱ’—ǯǼ
˜ŸŽ›—˜›ȱŽŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................... şǯśȱȉ–ȱǻŞŚȱ’—ǯȱ•‹ǯǼ
˜ŸŽ›—˜›ȱ ŽŠ›ȱŠœŽ—Ž›ȱ˜›šžŽ...................................................................... şǯśȱȉ–ȱǻŞŚȱ’—ǯȱ•‹ǯǼ

˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱǯǯ
New.............................................................................................................. śǯşŜȬśǯşŞȱ––ȱǻŖǯŘřŚŜȬŖǯŘřśŚȱ’—ǯǼ

˜ŸŽ›—˜›ȱ ŽŠ›ȱ‘ŠĞȬ˜Ȭ ˜ŸŽ›—˜›ȱ ŽŠ›ȱž——’—ȱ•ŽŠ›Š—ŒŽ ..................... ŖǯŖşȬŖǯŗşȱ––ȱǻŖǯŖŖřśȬŖǯŖŖŝŚȱ’—ǯǼ

˜ŸŽ›—˜›ȱ ŽŠ›ȱ‘ŠĞȱǯǯ
New ............................................................................................................. ŜǯŖŗȬŜǯŖřȱ––ȱǻŖǯŘřŜŜȬŖǯŘřŝŚȱ’—ǯǼ

Ignition
Spark Plug Type (Champion® or equivalent)................................................ ŗŘȱǻ‘Š–™’˜—®)

Spark Plug Gap ................................................................................................. ŖǯŝŜŘȱ––ȱǻŖǯŖřŖȱ’—ǯǼ

Spark Plug Torque ............................................................................................ ŘŚǯśȱȉ–ȱǻŘŗŝȱ’—ǯȱ•‹ǯǼ

—’’˜—ȱ˜ž•Žȱ’›ȱ Š™ ................................................................................. ŖǯŘśŚȱ––ȱǻŖǯŖŗŖȱ’—ǯǼ

—’’˜—ȱ˜ž•ŽȱŠœŽ—Ž›ȱ˜›šžŽ ................................................................... ŗŖȱȉ–ȱǻŞŞȱ’—ǯȱ•‹ǯǼȱ

1.9
Section 1
Safety and General Information
0XIÀHU
Exhaust Stud Torque ........................................................................................ 9.0 N·m (80 in. lb.)
¡‘ŠžœȱžȱŠœŽ—Ž›ȱ˜›šžŽȱ........................................................................ ȱşǯśȱȉ–ȱǻŞŚȱ’—ǯȱ•‹ǯǼ

Oil
’•ȱŠ—ȱŒ›Ž ȱ˜›šžŽŶ ...................................................................................... ȱŗŘǯřȱȉ–ȱǻŗŖşȱ’—ǯȱ•‹ǯǼ

Oil Drain Plug Torque³...................................................................................... ŗřǯśȱȉ–ȱǻŗŘŖȱ’—ǯȱ•‹ǯǼ

Piston, Piston Rings, and Piston Pin

’œ˜—ȱ’—ȱ˜›Žȱǯǯ
New.............................................................................................................. ŗŞǯŖŖŖȬŗŞǯŖŖŞȱ––ȱǻŖǯŝŖŞŜȬŖǯŝŖŞşȱ’—ǯǼ

Piston Pin O.D.

New.............................................................................................................. ŗŝǯşşŖȬŗŝǯşşŜȱ––ȱǻŖǯŝŖŞŘȬŖǯŝŖŞśȱ’—ǯǼ

Top Compression Ring-to-Groove Side Clearance ...................................... ŖǯŖŘȬŖǯŖŜȱ––ȱǻŖǯŖŖŖŝȬŖǯŖŖŘřȱ’—ǯǼ

Middle Compression Ring-to-Groove Side Clearance ................................ ŖǯŖŘȬŖǯŖŜȱ––ȱǻŖǯŖŖŖŝȬŖǯŖŖŘřȱ’—ǯǼ

Top and Middle Compression Ring End Gap

New Bore..................................................................................................... ŖǯŖŘśȬŖǯŖŚŖȱ––ȱǻŖǯŖŖŖşȬŖǯŖŖŗśȱ’—ǯǼ

’œ˜—ȱ‘›žœȱŠŒŽȱǯǯ
New ............................................................................................................ ŜşǯşŜȬŜşǯşŞȱ––ȱǻŘǯŝśŚřȬŘǯŝśśŗȱ’—ǯǼ

’œ˜—ȱ‘›žœȱŠŒŽȬ˜Ȭ¢•’—Ž›ȱ˜›Žȱž——’—ȱ•ŽŠ›Š—ŒŽ
New.............................................................................................................. ŖǯŖŘŖȬŖǯŖśśȱ––ȱǻŖǯŖŖŖŝȬŖǯŖŖŘŗȱ’—ǯǼ

Recoil
ŽŒ˜’•ȱ˜ž—’—ȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................. Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ

Speed Control
™ŽŽȱ˜—›˜•ȱ›ŠŒ”ŽȱœœŽ–‹•¢ȱŠœŽ—Ž›ȱ˜›šžŽ ......................................Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼȱ

Valve Cover
Š•ŸŽȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ........................................................................... Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ

Valves and Valve Lifters

—Š”ŽȱŠ•ŸŽȱŠœ‘Ś ............................................................................................. ŖǯŖŝŜŘȬŖǯŗŘŝȱ––ȱǻŖǯŖŖřȬǯŖŖśȱ’—ǯǼ

Exhaust Valve LashŚ .......................................................................................... ŖǯŖŝŜŘȬŖǯŗŘŝȱ––ȱǻŖǯŖŖřȬǯŖŖśȱ’—ǯǼ

—Š”ŽȱŠ•ŸŽȱ’—’–ž–ȱ’Ğȱǻ˜ŸŽ›ȱ‹ŠœŽȱŒ’›Œ•ŽǼ............................................... śǯŘŖŖȱ––ȱǻŖǯŘŖŚŝȱ’—ǯǼ

¡‘ŠžœȱŠ•ŸŽȱ’—’–ž–ȱ’Ğȱǻ˜ŸŽ›ȱ‹ŠœŽȱŒ’›Œ•ŽǼ............................................ śǯŘŚŝȱ––ȱǻŖǯŘŖŜśȱ’—ǯǼ

Nominal Valve Seat Angle ............................................................................... ŘśǚǰȱŚśǚǰȱŜŖǚȱǻřȱŠ—•ŽœǼ

1.10
 Section 1
Safety and General Information

Valves and Valve Lifters (continued)

—Š”ŽȱŠ•ŸŽȱŽ–Ȭ˜ȬŠ•ŸŽȱ ž’Žȱž——’—ȱ•ŽŠ›Š—ŒŽ ............................... ŖǯŖŘŖȬŖǯŖŚŝȱ––ȱǻŖǯŖŖŖŝȬŖǯŖŖŗŞȱ’—ǯǼ 1

Exhaust Valve Stem-to-Valve Guide Running Clearance ............................ ŖǯŖśśȬŖǯŖŞŘȱ––ȱǻŖǯŖŖŘŗȬŖǯŖŖřŘȱ’—ǯǼ

—Š”ŽȱŠ•ŸŽȱ ž’Žȱǯǯ

New.............................................................................................................. śǯśŖŖȬśǯśŗŘȱ––ȱǻŖǯŘŗŜśȬŖǯŘŗŝŖȱ’—ǯǼ

ȱ—Š”ŽȱŠ•ŸŽȱŽ–ȱ’Š–ŽŽ›
New.............................................................................................................. śǯŚŜśȬśǯŚŞŖȱ––ȱǻŖǯŘŗśŗȬŖǯŘŗśŝȱ’—ǯǼ

¡‘ŠžœȱŠ•ŸŽȱ ž’Žȱǯǯ

New.............................................................................................................. śǯśŖŖȬśǯśŗŘȱ––ȱǻŖǯŘŗŜśȬŖǯŘŗŝŖȱ’—ǯǼ

Exhaust Valve Stem Diameter

New.............................................................................................................. śǯŚřŖȬśǯŚŚśȱ––ȱǻŖǯŘŗřŝȬŖǯŘŗŚřȱ’—ǯǼ

ŗ
Values are in metric units. English equivalents are shown in parentheses. Do not lubricate threads unless otherwise
indicated.

Ŷ™™•¢ȱ•ž‹›’ŒŠ—ȱ˜ȱŠœŽ—Ž›ȱ‘›ŽŠœȱ‹Ž˜›ŽȱŠœœŽ–‹•¢ǯȱŒŒŽ™Š‹•Žȱ•ž‹›’ŒŠ—œȱ’—Œ•žŽDZȱŗŖȬřŖȱŽ—’—Žȱ˜’•ǰȱ˜‹’•ȱœœŽ–‹•¢ȱ’•ȱ
ǻǛȱŚśŖřŖŚǼǰȱž‹˜’œȱȬŗŖȱǻǛȱŖřŖŗřŗŖŚǼǰȱŠ—ȱȬŚŖ®.

³Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of joint.
‘›ŽŠœȱ ’‘ȱ™›ŽȬŠ™™•’ŽȱœŽŠ•Š—ȱ˜ȱ—˜ȱ›Žšž’›Žȱ‘ŽȱžœŽȱ˜ȱŠ’’˜—Š•ȱœŽŠ•Š—ǯȱ™™›˜ŸŽȱœŽŠ•Š—œȱ’—Œ•žŽȱŽ›–ŠȬ˜Œȱ
ȱŗśŖǰȱ
Ž›–ŠȬ˜ŒȱȱŗŗśǰȱŽ›–ŠȬ˜Œȱ

ȱŗŘŖǰȱŽ›–ŠȬ˜Œȱ
ȱŗŘŜǯ

Ś
‘ŽŒ”ȱŸŠ•ŸŽȱ•Šœ‘ȱŽŸŽ›¢ȱŘŖŖȱ‘˜ž›œDzȱŠ“žœȱŠœȱ›Žšž’›Žǯ

1.11
Section 1
Safety and General Information

General Torque Values

Metric Fastener Torque Recommendations for Standard Applications

Tightening Torque: N·m (in. lb.) + or - 10%

Property Class
Noncritical
4.8 5.8 8.8 10.9 12.9 Fasteners
Into Aluminum
Size
M4ȱ ŗǯŘȱǻŗŗǼȱ ŗǯŝȱǻŗśǼȱ ŘǯşȱǻŘŜǼȱ ŚǯŗȱǻřŜǼȱ śǯŖȱǻŚŚǼȱ ŘǯŖȱǻŗŞǼ
M5ȱ ŘǯśȱǻŘŘǼȱ řǯŘȱǻŘŞǼȱ śǯŞȱǻśŗǼȱ ŞǯŗȱǻŝŘǼȱ şǯŝȱǻŞŜǼȱ ŚǯŖȱǻřśǼ
M6ȱ ŚǯřȱǻřŞǼȱ śǯŝȱǻśŖǼȱ şǯşȱǻŞŞǼȱ ŗŚǯŖȱǻŗŘŚǼȱ ŗŜǯśȱǻŗŚŜǼȱ ŜǯŞȱǻŜŖǼ
M8ȱ ŗŖǯśȱǻşřǼȱ ŗřǯŜȱǻŗŘŖǼȱ ŘŚǯŚȱǻŘŗŜǼȱ řřǯşȱǻřŖŖǼȱ ŚŖǯŝȱǻřŜŖǼȱ ŗŝǯŖȱǻŗśŖǼ

Tightening Torque: N·m (ft. lb.) + or - 10%

Property Class

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

Oil Drain Plug Tightening Torque: N·m (English Equiv.) Torque

Size Into Cast Iron Into Aluminum Conversions
1/8" NPT – ŚǯśȱǻŚŖȱ’—ǯȱ•‹ǯǼ
ȉ–ȱƽȱ’—ǯȱ•‹ǯȱ¡ȱŖǯŗŗř
1/4" ŗŝǯŖȱǻŗśŖȱ’—ǯȱ•‹ǯǼ ŗŗǯřȱǻŗŖŖȱ’—ǯȱ•‹ǯǼ
ȉ–ȱƽȱĞǯȱ•‹ǯȱ¡ȱŗǯřśŜ
3/8" ŘŖǯřȱǻŗŞŖȱ’—ǯȱ•‹ǯǼ ŗřǯŜȱǻŗŘŖȱ’—ǯȱ•‹ǯǼ
in. lb. = N·m x 8.85
1/2" ŘŝǯŗȱǻŘŖȱĞǯȱ•‹ǯǼ ŗŝǯŜȱǻŗřȱĞǯȱ•‹ǯǼ
Ğǯȱ•‹ǯȱƽȱȉ–ȱ¡ȱŖǯŝřŝ
3/4" řřǯşȱǻŘśȱĞǯȱ•‹ǯǼ ŘŗǯŝȱǻŗŜȱĞǯȱ•‹ǯǼ
X-708-1 ŘŝǯŗȦřřǯşȱǻŘŖȦŘśȱĞǯȱ•‹ǯǼ ŘŝǯŗȦřřǯşȱǻŘŖȦŘśȱĞǯȱ•‹ǯǼ

1.12
 Section 2
Tools & Aids

Section 2
Tools & Aids
2

Ž›Š’—ȱšžŠ•’¢ȱ˜˜•œȱŠ›ŽȱŽœ’—Žȱ˜ȱ‘Ž•™ȱ™Ž›˜›–ȱœ™ŽŒ’ęŒȱ’œŠœœŽ–‹•¢ǰȱ›Ž™Š’›ǰȱŠ—ȱ›ŽŠœœŽ–‹•¢ȱ™›˜ŒŽž›Žœǯȱ¢ȱ
žœ’—ȱ˜˜•œȱŽœ’—Žȱ˜›ȱ‘Žȱ“˜‹ǰȱ™›˜™Ž›ȱœŽ›Ÿ’Œ’—ȱ˜ȱŽ—’—Žœȱ’œȱŽŠœ’Ž›ǰȱŠœŽ›ǰȱŠ—ȱœŠŽ›ǯȱ—ȱŠ’’˜—ǰȱŒžœ˜–Ž›ȱ
œŠ’œŠŒ’˜—ȱŠ—ȱœŽ›Ÿ’ŒŽȱŒŠ™Š‹’•’’Žœȱ ’••ȱ‹Žȱ’—Œ›ŽŠœŽȱ‹¢ȱœ‘˜›Ž—’—ȱŽ—’—Žȱ˜ —’–Žǯ

Here is the list of tools and their sources:

Separate Tool Suppliers:

Kohler Tools SE Tools Žœ’—ȱŽŒ‘—˜•˜¢ȱ—Œǯ
Contact your local Kohler Śŗśȱ
˜ Š›ȱǯ ŝŜŞȱž››ȱŠ”ȱ›’ŸŽ
œ˜ž›ŒŽȱ˜ȱœž™™•¢ǯȱ Š™ŽŽ›ǰȱȱȱŚŞŚŚŜ Žœ–˜—ǰȱȱȱŜŖśśş
‘˜—ŽDZȱŞŗŖȬŜŜŚȬŘşŞŗȱȱ ‘˜—ŽDZȱŜřŖȬşŘŖȬŗřŖŖ
˜••ȱ›ŽŽDZȱŞŖŖȬŜŜŚȬŘşŞŗȱ
Š¡DZȱŞŗŖȬŜŜŚȬŞŗŞŗ

Tools
Description Source/Part No.
Cylinder Leakdown Tester
˜›ȱŒ‘ŽŒ”’—ȱŒ˜–‹žœ’˜—ȱ›ŽŽ—’˜—ȱŠ—ȱ’ȱŒ¢•’—Ž›ǰȱ™’œ˜—ǰȱ›’—œǰȱ˜›ȱŸŠ•ŸŽœȱŠ›Žȱ ˜›—ǯ ˜‘•Ž›ȱŘśȱŝŜŗȱŖśȬ
Flywheel Strap Wrench
˜ȱ‘˜•ȱĚ¢ ‘ŽŽ•ȱž›’—ȱ›Ž–˜ŸŠ•ǯ ȱ˜˜•œȱ ȬŞŘŚŖş
Ignition System Tester
˜›ȱŽœ’—ȱ˜ž™žȱ˜—ȱŠ••ȱœ¢œŽ–œǰȱŽ¡ŒŽ™ȱǯ ˜‘•Ž›ȱŘśȱŚśśȱŖŗȬ
˜›ȱŽœ’—ȱ˜ž™žȱ˜—ȱŒŠ™ŠŒ’’ŸŽȱ’œŒ‘Š›ŽȱǻǼȱ’—’’˜—ȱœ¢œŽ–ǯ ˜‘•Ž›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.
Š–œ‘ŠĞȱž‹›’ŒŠ—ȱǻŠ•œ™Š›ȱŜŗřǼ ˜‘•Ž›ȱŘśȱřśŝȱŗŚȬ
Dielectric Greaseȱǻ Ȧ˜ŸŠžŠ›ȱ ŜŜŗǼ ˜‘•Ž›ȱŘśȱřśŝȱŗŗȬ

RTV Silicone Sealant

Ž›–ŠȬ˜”ȱ
ȱŗśŖ
Ž›–ŠȬ˜”ȱȱŗŗś
Ž›–ŠȬ˜”ȱ

ȱŗŘŖ
Ž›–ŠȬ˜”ȱ
ȱŗŘŜǯ

2.1
Section 2
Tools & Aids

2.2

Section 3
Troubleshooting
Troubleshooting Guide
When troubles occur, be sure to check the simple
ŒŠžœŽœǰȱ ‘’Œ‘ȱŠȱꛜȱ–Š¢ȱœŽŽ–ȱ˜˜ȱ˜‹Ÿ’˜žœȱ˜ȱ‹Žȱ
considered. For example, a starting problem could
‹ŽȱŒŠžœŽȱ‹¢ȱŠ—ȱŽ–™¢ȱžŽ•ȱŠ—”ǯ
˜–ŽȱŒ˜––˜—ȱ¢™Žœȱ˜ȱŽ—’—Žȱ›˜ž‹•ŽœȱŠ›Žȱ•’œŽȱ
below. Use these to help locate the possible cause(s).
Engine Cranks But Will Not Start
ȱ ŗǯȱ –™¢ȱžŽ•ȱŠ—”ǯ
ȱ Řǯȱ ˜˜›ȱžŽ•ǰȱ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱžŽ•ȱœ¢œŽ–ǯ
ȱ řǯȱ •˜ŽȱžŽ•ȱ•’—Žǯ
4. Spark plug lead disconnected.
ȱ śǯȱ
’••ȱœ ’Œ‘ȱ’—ȱ˜ěȱ™˜œ’’˜—ǯ ȱ Şǯȱ Š›‹ž›Ž˜›ȱŠ“žœŽȱ’—Œ˜››ŽŒ•¢ǯ
ȱ Ŝǯȱ Šž•¢ȱœ™Š›”ȱ™•žǯ
ȱ ŝǯȱ Šž•¢ȱ’—’’˜—ȱ–˜ž•Žǯ
ȱ Şǯȱ ‘˜”Žȱ—˜ȱŒ•˜œ’—ȱǻ’ȱŽšž’™™ŽǼǯ
ȱ şǯȱ —’—Žȱ—˜ȱ™›’–Žȱǻ’ȱŽšž’™™ŽǼǯ
Engine Starts But Does Not Keep Running
ȱ ŗǯȱ Žœ›’ŒŽȱžŽ•ȱŠ—”ȱŒŠ™ȱŸŽ—ǯ
ȱ Řǯȱ ˜˜›ȱžŽ•ǰȱ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱžŽ•ȱœ¢œŽ–ǯ
ȱ řǯȱ Šž•¢ȱ˜›ȱ’—Œ˜››ŽŒ•¢ȱŠ“žœŽȱŒ‘˜”Žȱ˜›ȱ‘›˜Ĵ•Žȱ
Œ˜—›˜•œǰȱǻ’ȱŽšž’™™ŽǼǯ
4. Loose wires or connections short ignition
module's kill terminal to ground.
ȱ śǯȱ Šž•¢ȱŒ¢•’—Ž›ȱ‘ŽŠȱŠœ”Žǯ
ȱ Ŝǯȱ Šž•¢ȱŒŠ›‹ž›Ž˜›ǯ
ȱ ŝǯȱ —Š”Žȱœ¢œŽ–ȱ•ŽŠ”ǯ
Engine Starts Hard
ȱ ŗǯȱ ˜˜›ȱžŽ•ǰȱ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱžŽ•ȱœ¢œŽ–ǯ
ȱ Řǯȱ •˜ŽȱžŽ•ȱ•’—Žǯ
’‘ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ
ȱ řǯȱ ˜˜œŽȱ˜›ȱŠž•¢ȱ ’›Žœȱ˜›ȱŒ˜——ŽŒ’˜—œǯ
ȱ Śǯȱ Šž•¢ȱ˜›ȱ’—Œ˜››ŽŒ•¢ȱŠ“žœŽȱŒ‘˜”Žȱ˜›ȱ‘›˜Ĵ•Žȱ
Œ˜—›˜•œȱǻ’ȱŽšž’™™ŽǼǯ
ȱ śǯȱ Šž•¢ȱœ™Š›”ȱ™•žǯ
6. Low compression.
7. Weak spark.
ȱ Şǯȱ —’—Žȱ˜ŸŽ›‘ŽŠŽDzȱŠ’›ȱŒ’›Œž•Š’˜—ȱ›Žœ›’ŒŽǯ
ȱ şǯȱ •¢ ‘ŽŽ•ȱ”Ž¢ȱœ‘ŽŠ›Žǯ
ȱŗŖǯȱ —Š”Žȱœ¢œŽ–ȱ•ŽŠ”ǯ
Section 3
Troubleshooting
3
Engine Will Not Crank
ȱ ŗǯȱ ˜˜œŽȱ˜›ȱŠž•¢ȱ ’›Žœȱ˜›ȱŒ˜——ŽŒ’˜—œǯ
ȱ Řǯȱ Šž•¢ȱ”Ž¢ȱœ ’Œ‘ȱ˜›ȱ’—’’˜—ȱœ ’Œ‘ǯ
3. Seized internal engine components.
Engine Runs But Misses
ŗǯȱ ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱžŽ•ȱœ¢œŽ–ǯ
Řǯȱ ™Š›”ȱ™•žȱŠž•¢ȱ˜›ȱ˜ž•Žǯ
ȱřǯȱ ˜˜›ȱšžŠ•’¢ȱ˜ȱžŽ•ǯ
4. Spark plug lead boot loose on plug.
ȱ śǯȱ ˜˜œŽȱ ’›Žœȱ˜›ȱŒ˜——ŽŒ’˜—œȱ’—Ž›–’ĴŽ—•¢ȱœ‘˜›ȱ
the ignition module's kill terminal to ground.
ȱ Ŝǯȱ —’—Žȱ˜ŸŽ›‘ŽŠŽǯ
ȱ ŝǯȱ Šž•¢ȱ’—’’˜—ȱ–˜ž•Žȱ˜›ȱ’–™›˜™Ž›•¢ȱŠ™™Žǯ
Engine Will Not Idle
ȱ ŗǯȱ ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱžŽ•ȱœ¢œŽ–ǯ
ȱ Řǯȱ Š•ŽȱžŽ•ȱŠ—Ȧ˜›ȱž–ȱ’—ȱŒŠ›‹ž›Ž˜›ǯ
ȱ řǯȱ Šž•¢ȱœ™Š›”ȱ™•žǯ
ȱ Śǯȱ žŽ•ȱœž™™•¢ȱ’—ŠŽšžŠŽǯ
ȱ śǯȱ •ŽȱžŽ•ȱŠ“žœ’—ȱ—ŽŽ•Žȱ’–™›˜™Ž›•¢ȱœŽǯ
ȱ Ŝǯȱ •Žȱœ™ŽŽȱŠ“žœ’—ȱœŒ›Ž ȱ’–™›˜™Ž›•¢ȱœŽǯ
7. Low compression.
ȱ Şǯȱ Žœ›’ŒŽȱžŽ•ȱŠ—”ȱŒŠ™ȱŸŽ—ǯ
ȱ şǯȱ —’—Žȱ˜ŸŽ›‘ŽŠŽDzȱŒ˜˜•’—ȱœ¢œŽ–ȦŠ’›ȱŒ’›Œž•Š’˜—ȱ
problem.
Engine Overheats
ȱ ŗǯȱ ’›ȱ’—Š”Žǰȱ›ŠœœȱœŒ›ŽŽ—ǰȱŒ˜˜•’—ȱꗜǰȱ˜›ȱŒ˜˜•’—ȱ
shroud clogged.
ȱ Řǯȱ ¡ŒŽœœ’ŸŽȱŽ—’—Žȱ•˜Šǯ
ȱ řǯȱ ˜ ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ
ȱ Śǯȱ
ȱ śǯȱ Šž•¢ȱŒŠ›‹ž›Ž˜›ǯ
ȱ Ŝǯȱ ŽŠ—ȱžŽ•ȱ–’¡ž›Žǯ
3.1
Section 3
Troubleshooting
Engine Knocks
ȱ ŗǯȱ ¡ŒŽœœ’ŸŽȱŽ—’—Žȱ•˜Šǯ
ȱ Řǯȱ ˜ ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ
ȱ řǯȱ •ȱ˜›ȱ’–™›˜™Ž›ȱžŽ•ȱ¢™Žǯ
4. Internal wear or damage.
ȱ śǯȱ žŠ•’¢ȱ˜ȱžŽ•ǯ
ȱ Ŝǯȱ —Œ˜››ŽŒȱ›ŠŽȱ˜ȱ˜’•ǯ
Engine Loses Power
ȱ ŗǯȱ ˜ ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ
ȱ Řǯȱ
’‘ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ ȱ Ȋȱ ‘ŽŒ”ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‘›˜Šȱ˜›ȱ’›ǯȱ’›ȱ’—ȱ‘Žȱ
ȱ řǯȱ ’›¢ȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ǯ
ȱ Śǯȱ ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱžŽ•ȱœ¢œŽ–ǯ
ȱ śǯȱ ¡ŒŽœœ’ŸŽȱŽ—’—Žȱ•˜Šǯ
ȱ Ŝǯȱ —’—Žȱ˜ŸŽ›‘ŽŠŽǯ
ȱ ŝǯȱ Šž•¢ȱœ™Š›”ȱ™•žǯ
8. Low compression.
9. Exhaust restriction.
ŗŖǯȱ —Œ˜››ŽŒȱ˜ŸŽ›—˜›ȱœŽĴ’—ǯ
Engine Uses Excessive Amount of Oil
ȱ ŗǯȱ —Œ˜››ŽŒȱ˜’•ȱŸ’œŒ˜œ’¢ȱ˜›ȱ¢™Žǯ
ȱ Řǯȱ •˜Žǰȱ‹›˜”Ž—ȱ˜›ȱ’—˜™Ž›Š’ŸŽȱ‹›ŽŠ‘Ž›ǯ
3. Worn or broken piston rings.
ȱ Śǯȱ ˜›—ȱŒ¢•’—Ž›ȱ‹˜›Žǯ
ȱ śǯȱ ˜›—ȱŸŠ•ŸŽȱœŽ–œȱ˜›ȱŸŠ•ŸŽȱž’Žœǯ
ȱ Ŝǯȱ ›Š—”ŒŠœŽȱ˜ŸŽ›ę••Žǯ
ȱ ŝǯȱ •˜ —ȱ‘ŽŠȱŠœ”ŽDzȱ˜ŸŽ›‘ŽŠŽǯ
Oil Leaks from Oil Seals, Gaskets
ȱ ŗǯȱ •˜Žǰȱ‹›˜”Ž—ȱ˜›ȱ’—˜™Ž›Š’ŸŽȱ‹›ŽŠ‘Ž›ǯ
2. Worn or broken piston rings.
ȱ řǯȱ ’œ˜—ȱ‹•˜ ‹¢ǰȱ˜›ȱ•ŽŠ”¢ȱŸŠ•ŸŽœǯ
4. Restricted exhaust.
External Engine Inspection
Ž˜›ŽȱŒ•ŽŠ—’—ȱ˜›ȱ’œŠœœŽ–‹•’—ȱ‘ŽȱŽ—’—Žǰȱ–Š”ŽȱŠȱ
‘˜›˜ž‘ȱ’—œ™ŽŒ’˜—ȱ˜ȱ’œȱŽ¡Ž›—Š•ȱŠ™™ŽŠ›Š—ŒŽȱŠ—ȱ
Œ˜—’’˜—ǯȱ‘’œȱ’—œ™ŽŒ’˜—ȱŒŠ—ȱ’ŸŽȱŒ•žŽœȱ˜ȱ ‘Šȱ
–’‘ȱ‹Žȱ˜ž—ȱ’—œ’Žȱ‘ŽȱŽ—’—ŽȱǻŠ—ȱ‘ŽȱŒŠžœŽǼȱ
when it is disassembled.
ȱ Ȋȱ ‘ŽŒ”ȱ˜›ȱ‹ž’•ž™ȱ˜ȱ’›ȱŠ—ȱŽ‹›’œȱ˜—ȱ‘Žȱ
Œ›Š—”ŒŠœŽǰȱŒ˜˜•’—ȱꗜǰȱ›ŠœœȱœŒ›ŽŽ—ǰȱŠ—ȱ˜‘Ž›ȱ
Ž¡Ž›—Š•ȱœž›ŠŒŽœǯȱ’›ȱ˜›ȱŽ‹›’œȱ˜—ȱ‘ŽœŽȱŠ›ŽŠœȱ
ŒŠ—ȱŒŠžœŽȱ˜ŸŽ›‘ŽŠ’—ǯ
ȱ Ȋȱ ‘ŽŒ”ȱ˜›ȱ˜‹Ÿ’˜žœȱ˜’•ȱ•ŽŠ”œȱŠ—ȱŠ–ŠŽȱ
Œ˜–™˜—Ž—œǯȱ¡ŒŽœœ’ŸŽȱ˜’•ȱ•ŽŠ”ŠŽȱŒŠ—ȱ’—’ŒŠŽȱ
ŠȱŒ•˜Žȱ˜›ȱ’—˜™Ž›Š’ŸŽȱ‹›ŽŠ‘Ž›ǰȱ ˜›—ȱ˜›ȱ
Š–ŠŽȱœŽŠ•œȱ˜›ȱŠœ”Žœǰȱ˜›ȱ•˜˜œŽȱŠœŽ—Ž›œǯ
3.2
ȱ Ȋȱ ‘ŽŒ”ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŒ˜ŸŽ›ȱŠ—ȱ‹ŠœŽȱ˜›ȱŠ–ŠŽǰȱ
˜›ȱ’—’ŒŠ’˜—œȱ˜ȱ’–™›˜™Ž›ȱęȱŠ—ȱœŽŠ•ǯ
ȱ Ȋȱ ‘ŽŒ”ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ǯȱ˜˜”ȱ˜›ȱ‘˜•Žœǰȱ
ŽŠ›œǰȱŒ›ŠŒ”Žȱ˜›ȱŠ–ŠŽȱœŽŠ•’—ȱœž›ŠŒŽœǰȱ
˜›ȱ˜‘Ž›ȱŠ–ŠŽȱ‘ŠȱŒ˜ž•ȱŠ••˜ ȱž—ę•Ž›Žȱ
Š’›ȱ’—˜ȱ‘ŽȱŽ—’—Žǯȱ•œ˜ȱ—˜Žȱ’ȱ‘ŽȱŽ•Ž–Ž—ȱ’œȱ
’›¢ȱ˜›ȱŒ•˜Žǯȱ‘ŽœŽȱŒ˜ž•ȱ’—’ŒŠŽȱ’–™›˜™Ž›ȱ
maintenance.
‘›˜Šȱ’œȱž›‘Ž›ȱ’—’ŒŠ’˜—ȱ‘Šȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱ
 Šœȱ—˜ȱž—Œ’˜—’—ȱ™›˜™Ž›•¢ǯ
ȱ Ȋȱ ‘ŽŒ”ȱ’ȱ‘Žȱ˜’•ȱ•ŽŸŽ•ȱ’œȱ ’‘’—ȱ‘Žȱ˜™Ž›Š’—ȱ
›Š—Žȱ˜—ȱ‘Žȱ’™œ’Œ”ǯȱȱ’ȱ’œȱŠ‹˜ŸŽǰȱœ—’ěȱ˜›ȱ
gasoline odor.
ȱ Ȋȱ ‘ŽŒ”ȱ‘ŽȱŒ˜—’’˜—ȱ˜ȱ‘Žȱ˜’•ǯȱ›Š’—ȱ‘Žȱ˜’•ȱ’—˜ȱ
ŠȱŒ˜—Š’—Ž›Dzȱ’ȱœ‘˜ž•ȱ̘ ȱ›ŽŽ•¢ǯȱ‘ŽŒ”ȱ˜›ȱ–ŽŠ•ȱ
Œ‘’™œȱŠ—ȱ˜‘Ž›ȱ˜›Ž’—ȱ™Š›’Œ•Žœǯ
•žŽȱ’œȱŠȱ—Šž›Š•ȱ‹¢Ȭ™›˜žŒȱ˜ȱŒ˜–‹žœ’˜—ǰȱŠ—ȱ
œ–Š••ȱŠ–˜ž—œȱ˜ȱŠŒŒž–ž•Š’˜—ȱŠ›Žȱ—˜›–Š•ǯȱ¡ŒŽœœ’ŸŽȱ
œ•žŽȱ˜›–Š’˜—ȱŒ˜ž•ȱ’—’ŒŠŽȱœŽŸŽ›Š•ȱ™›˜‹•Ž–œDZȱ
‘Žȱ ›˜—ȱ¢™Žȱ˜›ȱ Ž’‘ȱ˜ȱ˜’•ȱ ŠœȱžœŽǰȱ‘Žȱ˜’•ȱ Šœȱ
—˜ȱŒ‘Š—ŽȱŠȱ‘Žȱ›ŽŒ˜––Ž—Žȱ’—Ž›ŸŠ•œǰȱŠ—ȱ˜ŸŽ›Ȭ
›’Œ‘ȱžŽ•ȱ–’¡ž›Žǰȱ˜›ȱŠȱ ŽŠ”ȱ’—’’˜—ǰȱ˜ȱ—Š–ŽȱŠȱŽ ȱ
possible causes.
NOTEDZȱ ȱ’œȱ˜˜ȱ™›ŠŒ’ŒŽȱ˜ȱ›Š’—ȱ˜’•ȱŠȱŠȱ•˜ŒŠ’˜—ȱ
Š Š¢ȱ›˜–ȱ‘Žȱ ˜›”‹Ž—Œ‘ǯȱŽȱœž›Žȱ˜ȱŠ••˜ ȱ
Š–™•Žȱ’–Žȱ˜›ȱŒ˜–™•ŽŽȱ›Š’—ŠŽǯ
Cleaning Engine
Ў›ȱ’—œ™ŽŒ’—ȱ‘ŽȱŽ¡Ž›—Š•ȱŒ˜—’’˜—ȱ˜ȱ‘ŽȱŽ—’—Žǰȱ
Œ•ŽŠ—ȱ‘Žȱž—’ȱ‘˜›˜ž‘•¢ȱ‹Ž˜›Žȱ’œŠœœŽ–‹•’—ȱ’ǯȱ
•œ˜ȱŒ•ŽŠ—ȱ’—’Ÿ’žŠ•ȱŒ˜–™˜—Ž—œȱŠœȱ‘ŽȱŽ—’—Žȱ’œȱ
’œŠœœŽ–‹•Žǯȱ—•¢ȱŒ•ŽŠ—ȱ™Š›œȱŒŠ—ȱ‹ŽȱŠŒŒž›ŠŽ•¢ȱ
’—œ™ŽŒŽȱŠ—ȱŠžŽȱ˜›ȱ ŽŠ›ȱ˜›ȱŠ–ŠŽǯȱ‘Ž›Žȱ
Š›Žȱ–Š—¢ȱŒ˜––Ž›Œ’Š••¢ȱŠŸŠ’•Š‹•ŽȱŒ•ŽŠ—Ž›œȱ‘Šȱ ’••ȱ
šž’Œ”•¢ȱ›Ž–˜ŸŽȱ›ŽŠœŽǰȱ˜’•ǰȱŠ—ȱ›’–Žȱ›˜–ȱŽ—’—Žȱ
parts. When such a cleaner is used, follow the
manufacturer’s instructions and safety precautions
carefully.
Š”Žȱœž›ŽȱŠ••ȱ›ŠŒŽœȱ˜ȱ‘ŽȱŒ•ŽŠ—Ž›ȱŠ›Žȱ›Ž–˜ŸŽȱ‹Ž˜›Žȱ
the engine is reassembled and placed into operation.
ŸŽ—ȱœ–Š••ȱŠ–˜ž—œȱ˜ȱ‘ŽœŽȱŒ•ŽŠ—Ž›œȱŒŠ—ȱšž’Œ”•¢ȱ
‹›ŽŠ”ȱ˜ —ȱ‘Žȱ•ž‹›’ŒŠ’—ȱ™›˜™Ž›’Žœȱ˜ȱŽ—’—Žȱ˜’•ǯ

Basic Engine Tests
Crankcase Vacuum Test
ȱ™Š›’Š•ȱŸŠŒžž–ȱœ‘˜ž•ȱ‹Žȱ™›ŽœŽ—ȱ’—ȱ‘Žȱ
crankcase when the engine is operating. Pressure
’—ȱ‘ŽȱŒ›Š—”ŒŠœŽȱǻ—˜›–Š••¢ȱŒŠžœŽȱ‹¢ȱŠȱŒ•˜Žȱ˜›ȱ
’–™›˜™Ž›•¢Ȭ˜™Ž›Š’—ȱ‹›ŽŠ‘Ž›ǼȱŒŠ—ȱŒŠžœŽȱ˜’•ȱ˜ȱ‹Žȱ
˜›ŒŽȱ˜žȱŠȱ˜’•ȱœŽŠ•œǰȱŠœ”Žœǰȱ˜›ȱ˜‘Ž›ȱŠŸŠ’•Š‹•Žȱœ™˜œǯ
›Š—”ŒŠœŽȱŸŠŒžž–ȱ’œȱ‹Žœȱ–ŽŠœž›Žȱ ’‘ȱŠȱ ŠŽ›ȱ
–Š—˜–ŽŽ›ȱ˜›ȱŸŠŒžž–Ȧ™›Žœœž›ŽȱŽœȱŠžŽǯȱŽŽȱ
Section 2, Tools and Aids. Complete instructions are
™›˜Ÿ’Žȱ ’‘ȱ‘ŽȱŽœŽ›œǯ
Žœȱ‘ŽȱŒ›Š—”ŒŠœŽȱŸŠŒžž–ȱ ’‘ȱŠȱ–Š—˜–ŽŽ›ȱŠœȱ
˜••˜ œDZ
ȱ ŗǯȱ —œŽ›ȱ‘Žȱ›ž‹‹Ž›ȱœ˜™™Ž›ȱ’—˜ȱ‘Žȱ˜’•ȱꕕȱ‘˜•Žǯȱ
Be sure the pinch clamp is installed on the
hose and use the tapered adapters to connect
‘Žȱ‘˜œŽȱ‹Ž ŽŽ—ȱ‘Žȱœ˜™™Ž›ȱŠ—ȱ˜—Žȱ˜ȱ‘Žȱ
–Š—˜–ŽŽ›ȱž‹ŽœǯȱŽŠŸŽȱ‘Žȱ˜‘Ž›ȱž‹Žȱ˜™Ž—ȱ˜ȱ
‘ŽȱŠ–˜œ™‘Ž›Žǯȱ‘ŽŒ”ȱ‘Šȱ‘Žȱ ŠŽ›ȱ•ŽŸŽ•ȱ’—ȱ‘Žȱ
manometer is at the “0” line. Make sure the pinch
clamp is closed.
ȱ Řǯȱ Š›ȱ‘ŽȱŽ—’—ŽȱŠ—ȱ›ž—ȱŠȱ—˜Ȭ•˜Šȱ‘’‘ȱ’•Žȱ
speed (2800 to 3750 RPM).
ȱ řǯȱ ™Ž—ȱ‘ŽȱŒ•Š–™ȱŠ—ȱ—˜Žȱ‘Žȱ ŠŽ›ȱ•ŽŸŽ•ȱ’—ȱ‘Ž
Incorrect Vacuum in Crankcase
Possible Cause
ȱ ŗǯȱ ›Š—”ŒŠœŽȱ‹›ŽŠ‘Ž›ȱŒ•˜Žȱ˜›ȱ’—˜™Ž›Š’ŸŽǯ
ȱ Řǯȱ ŽŠ•œȱŠ—Ȧ˜›ȱŠœ”Žœȱ•ŽŠ”’—ǯȱ˜˜œŽȱ˜›ȱ
’–™›˜™Ž›•¢ȱ˜›šžŽȱŠœŽ—Ž›œǯ
ȱ řǯȱ ’œ˜—ȱ‹•˜ ‹¢ȱ˜›ȱ•ŽŠ”¢ȱŸŠ•ŸŽœǯȱ˜—ę›–ȱ ’‘ȱ
Œ¢•’—Ž›ȱ•ŽŠ”˜ —ȱŽœǯ
4. Restricted exhaust.
Section 3
Troubleshooting
ȱ ȱ ž‹Žǯȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘ŽȱŽ—’—Žȱœ’Žȱœ‘˜ž•ȱ‹ŽȱŠȱ
ȱ ȱ –’—’–ž–ȱ˜ȱ10.2 cm (4 in.)ȱŠ‹˜ŸŽȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘Žȱ
˜™Ž—ȱœ’Žǯȱȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘ŽȱŽ—’—Žȱœ’Žȱ’œȱ‘Žȱ
œŠ–ŽȱŠœȱ‘Žȱ˜™Ž—ȱœ’Žȱǻ—˜ȱŸŠŒžž–Ǽǰȱ˜›ȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ
‘ŽȱŽ—’—Žȱœ’Žȱ’œȱ•˜ Ž›ȱ‘Š—ȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘Žȱ˜™Ž—ȱ
œ’Žȱǻ™›Žœœž›ŽǼǰȱŒ‘ŽŒ”ȱ˜›ȱ‘ŽȱŒ˜—’’˜—œȱ’—ȱ‘Žȱ
table below.
4. Close the pinch clamp before stopping the
engine. 3
ȱ˜ȱ™Ž›˜›–ȱ‘ŽȱŽœȱ ’‘ȱ‘ŽȱŸŠŒžž–Ȧ™›Žœœž›ŽȱŠžŽDZȱ
1. Insert the stopper as in Step 1.
ȱȱŘǯȱȱȱ—œŽ›ȱ‘Žȱ‹Š›‹ŽȱŠžŽȱęĴ’—ȱ’—˜ȱ‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ
stopper. Be sure the gauge needle is at “0.”
ȱȱřǯȱ ž—ȱ‘ŽȱŽ—’—ŽǰȱŠœȱ’—ȱŽ™ȱŘǰȱŠ—ȱ˜‹œŽ›ŸŽȱ‘Žȱ
ŠžŽȱ›ŽŠ’—ǯȱŽŽ•Žȱ–˜ŸŽ–Ž—ȱ˜ȱ‘Žȱ•ŽĞȱ
˜ȱȃŖȄȱ’œȱŠȱŸŠŒžž–ǰȱŠ—ȱ–˜ŸŽ–Ž—ȱ˜ȱ‘Žȱ›’‘ȱ
’—’ŒŠŽœȱŠȱ™›Žœœž›Žǯȱȱ–’—’–ž–ȱ˜ȱŗŖǯŘȱŒ–ȱ
ȱ ȱ ǻŚȱ’—ǯǼȱ˜ȱŸŠŒžž–ȱœ‘˜ž•ȱ‹Žȱ™›ŽœŽ—ǯ
Compression Test
‘ŽœŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠ—ȱŠž˜–Š’Œȱ
compression release (ACR) mechanism. Because
˜ȱ‘Žȱȱ–ŽŒ‘Š—’œ–ǰȱ’ȱ’œȱ’ĜŒž•ȱ˜ȱ˜‹Š’—ȱŠ—ȱ
accurate compression reading. As an alternate, use the
leakdown test described on Page 3.4.
Solution
ȱ ŗǯȱ ’œŠœœŽ–‹•Žȱ‹›ŽŠ‘Ž›ǰȱŒ•ŽŠ—ȱ™Š›œȱ‘˜›˜ž‘•¢ǰȱ
reassemble, and recheck pressure.
2. Replace all worn or damaged seals and gaskets.
Š”Žȱœž›ŽȱŠ••ȱŠœŽ—Ž›œȱŠ›Žȱ’‘Ž—ŽȱœŽŒž›Ž•¢ǯȱ
œŽȱŠ™™›˜™›’ŠŽȱ˜›šžŽȱŸŠ•žŽœȱŠ—ȱœŽšžŽ—ŒŽœȱ
 ‘Ž—ȱ—ŽŒŽœœŠ›¢ǯ
ȱ řǯȱ ŽŒ˜—’’˜—ȱ™’œ˜—ǰȱ›’—œǰȱŒ¢•’—Ž›ȱ‹˜›ŽǰȱŸŠ•ŸŽœǰȱ
Š—ȱŸŠ•ŸŽȱž’Žœǯ
ȱ Śǯȱ Ž™Š’›ȱ˜›ȱ›Ž™•ŠŒŽȱ›Žœ›’ŒŽȱ–žĝŽ›ȦŽ¡‘Šžœȱ
œ¢œŽ–ǯ
3.3
Section 3
Troubleshooting

Cylinder Leakdown Test ȱ ȱ ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŽ—ȱ’œȱ–˜›ŽȱŠŒŒŽœœ’‹•Žǰȱ¢˜žȱŒŠ—ȱžœŽȱ

ȱŒ¢•’—Ž›ȱ•ŽŠ”˜ —ȱŽœȱŒŠ—ȱ‹ŽȱŠȱŸŠ•žŠ‹•ŽȱŠ•Ž›—Š’ŸŽȱ
˜ȱŠȱŒ˜–™›Žœœ’˜—ȱŽœǯȱ¢ȱ™›Žœœž›’£’—ȱ‘ŽȱŒ˜–‹žœ’˜—ȱ
Œ‘Š–‹Ž›ȱ›˜–ȱŠ—ȱŽ¡Ž›—Š•ȱŠ’›ȱœ˜ž›ŒŽǰȱ¢˜žȱŒŠ—ȱ
ŽŽ›–’—Žȱ’ȱ‘ŽȱŸŠ•ŸŽœȱ˜›ȱ›’—œȱŠ›Žȱ•ŽŠ”’—ǰȱŠ—ȱ‘˜ ȱ
‹Š•¢ǯ
Šȱ‹›ŽŠ”Ž›ȱ‹Š›ȱŠ—ȱœ˜Œ”Žȱ˜—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ—žȦ
screw to hold it in position.
ȱ ȱ ˜žȱ–Š¢ȱ—ŽŽȱŠ—ȱŠœœ’œŠ—ȱ˜ȱ‘˜•ȱ‘Žȱ‹›ŽŠ”Ž›ȱ
‹Š›ȱž›’—ȱŽœ’—ǯȱȱ‘ŽȱŽ—’—Žȱ’œȱ–˜ž—Žȱ’—ȱŠȱ
™’ŽŒŽȱ˜ȱŽšž’™–Ž—ǰȱ¢˜žȱ–Š¢ȱ‹ŽȱŠ‹•Žȱ˜ȱ‘˜•ȱ’ȱ‹¢ȱ
‘ŽȱŒ¢•’—Ž›ȱ•ŽŠ”˜ —ȱŽœŽ›ȱ’œȱŠȱ›Ž•Š’ŸŽ•¢ȱœ’–™•Žǰȱ Œ•Š–™’—ȱ˜›ȱ Ž’—ȱŠȱ›’ŸŽ—ȱŒ˜–™˜—Ž—ǯȱžœȱ‹Žȱ
’—Ž¡™Ž—œ’ŸŽȱ•ŽŠ”˜ —ȱŽœŽ›ȱ˜›ȱœ–Š••ȱŽ—’—Žœǯȱ ŒŽ›Š’—ȱ‘Šȱ‘ŽȱŽ—’—ŽȱŒŠ——˜ȱ›˜ŠŽȱ˜ěȱ˜ȱȱ’—ȱ
‘ŽȱŽœŽ›ȱ’—Œ•žŽœȱŠȱšž’Œ”ȱ’œŒ˜——ŽŒȱŒ˜ž™•’—ȱ˜›ȱ either direction.
ŠĴŠŒ‘’—ȱ‘ŽȱŠŠ™Ž›ȱ‘˜œŽȱŠ—ȱŠȱ‘˜•’—ȱ˜˜•ǯ
4. Install the adapter into the spark plug hole, but
Leakdown Test Instructions ˜ȱ—˜ȱŠĴŠŒ‘ȱ’ȱ˜ȱ‘ŽȱŽœŽ›ȱŠȱ‘’œȱ’–Žǯ
ȱ ŗǯȱ ž—ȱ‘ŽȱŽ—’—Žȱ˜›ȱřȬśȱ–’—žŽœȱ˜ȱ Š›–ȱ’ȱž™ǯ
ȱ śǯȱ ˜——ŽŒȱŠ—ȱŠŽšžŠŽȱŠ’›ȱœ˜ž›ŒŽȱǻŞŖȬŗŖŖȱ™œ’Ǽȱ˜ȱ‘Žȱ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱœ™Š›”ȱ™•žǯ tester.

ȱ řǯȱ ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱž—’•ȱ‘Žȱ™’œ˜—ȱ’œȱŠȱ˜™ȱ 6. Turn the regulator knob in the increase

ŽŠȱŒŽ—Ž›ȱǻǼȱ˜ȱ‘ŽȱŒ˜–™›Žœœ’˜—ȱœ›˜”Žǯȱ˜žȱ (clockwise) direction until the gauge needle is in
will need to hold the engine in this position while ‘Žȱ¢Ž••˜ ȱœŽȱŠ›ŽŠȱŠȱ‘Žȱ•˜ ȱǻ›’‘ǼȱŽ—ȱ˜ȱ‘Žȱ
testing. The holding tool supplied with the tester scale.
ŒŠ—ȱ‹ŽȱžœŽȱ’ȱ‘ŽȱȱŽ—ȱ˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ’œȱ
accessible. ȱ ŝǯȱ ˜——ŽŒȱ‘ŽȱŽœŽ›ȱšž’Œ”Ȭ’œŒ˜——ŽŒȱ˜ȱ‘Žȱ
ŠŠ™Ž›ǯȱ˜Žȱ‘ŽȱŠžŽȱ›ŽŠ’—ȱŠ—ȱ•’œŽ—ȱ˜›ȱ
ȱ ȱ •’Žȱ‘Žȱ‘˜•’—ȱ˜˜•ȱ˜—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞǰȱŠ•’—ȱ escaping air at the carburetor inlet, exhaust outlet,
‘Žȱœ•˜ȱ ’‘ȱ˜—Žȱ˜ȱ‘Žȱ–˜ž—’—ȱ‘˜•Žœȱ˜—ȱ‘Žȱ Š—Ȧ˜›ȱŒ›Š—”ŒŠœŽȱ‹›ŽŠ‘Ž›ǯ
ȱŠŒŽǰȱŠ—ȱ’‘Ž—ȱ’ȱ˜—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱ
—œŠ••ȱŠȱřȦŞȈȱ‹›ŽŠ”Ž›ȱ‹Š›ȱ’—˜ȱ‘Žȱœ•˜ȱ˜ȱ‘Žȱ ȱ Şǯȱ ‘ŽŒ”ȱ¢˜ž›ȱŽœȱ›Žœž•œȱŠŠ’—œȱ‘ŽȱŠ‹•Žȱ‹Ž•˜ DZ
holding tool, so it is perpendicular to both the
‘˜•’—ȱ˜˜•ȱŠ—ȱŒ›Š—”œ‘ŠĞǰȱ˜›ȱ’—œŽ›ȱŠȱœ‘˜ž•Ž›ȱ
bolt through the slot and thread it into the
mounting hole.

Leakdown Test Results

’›ȱŽœŒŠ™’—ȱ›˜–ȱŒ›Š—”ŒŠœŽȱ‹›ŽŠ‘Ž› ................................................ŽŽŒ’ŸŽȱ›’—œȱ˜›ȱ ˜›—ȱŒ¢•’—Ž›ȱ Š••œǯ

’›ȱŽœŒŠ™’—ȱ›˜–ȱŽ¡‘Šžœȱœ¢œŽ– ......................................................ŽŽŒ’ŸŽȱŽ¡‘ŠžœȱŸŠ•ŸŽǯ

’›ȱŽœŒŠ™’—ȱ›˜–ȱŒŠ›‹ž›Ž˜› ...............................................................ŽŽŒ’ŸŽȱ’—Š”ŽȱŸŠ•ŸŽǯ

Gauge reading in low (green) zone .....................................................’œ˜—ȱ›’—œȱŠ—ȱŒ¢•’—Ž›ȱ’—ȱ˜˜ȱŒ˜—’’˜—ǯ

ŠžŽȱ›ŽŠ’—ȱ’—ȱ–˜Ž›ŠŽȱǻ¢Ž••˜ Ǽȱ£˜—Ž.........................................Engine is still usable, but there is some wear

™›ŽœŽ—ǯȱžœ˜–Ž›ȱœ‘˜ž•ȱœŠ›ȱ™•Š——’—ȱ˜›ȱ
˜ŸŽ›‘Šž•ȱ˜›ȱ›Ž™•ŠŒŽ–Ž—ǯ
Gauge reading in high (red) zone........................................................’—œȱŠ—Ȧ˜›ȱŒ¢•’—Ž›ȱ‘ŠŸŽȱŒ˜—œ’Ž›Š‹•Žȱ ŽŠ›ǯȱ
Engine should be reconditioned or replaced.

3.4

Section 4
Air Cleaner and Air Intake System
Air Cleaner
This engine is equipped with a replaceable, high
density paper air cleaner. An optional foam precleaner
may also be included. See Figure 4-1. Intake air is
drawn in through the blower housing, and passes
through the precleaner (if equipped), the paper
element and then into the carburetor. The outer air
cleaner cover is secured by one knob, and removed by
turning the knob counterclockwise.
Air Cleaner Element
Air Cleaner Cover
Optional Foam Precleaner
Figure 4-1. Air Cleaner Assembly (Exploded View).
Service Precleaner
Wash or replace the optional precleaner yearly
or every 25 hoursȱ˜ȱ˜™Ž›Š’˜—Dzȱ–˜›Žȱ˜ĞŽ—ȱž—Ž›ȱ
extremely dusty or dirty conditions. Follow these
instructions to service:
1. Loosen the air cleaner cover knob and remove the
cover. See Figure 4-1.
2. Remove the precleaner and wash with detergent
in warm water.
Section 4
Air Cleaner and Air Intake System
Check the air cleaner assembly daily or before
starting the engine. Check for any buildup of dirt and
debris, as well as loose or damaged components. See
Figure 4-1. 4
NOTE: Operating the engine with loose or damaged
Š’›ȱŒ•ŽŠ—Ž›ȱŒ˜–™˜—Ž—œȱŒ˜ž•ȱŠ••˜ ȱž—ę•Ž›Žȱ
air in, resulting in premature wear and
failure.
Air Cleaner Base
3. Rinse the precleaner thoroughly until all traces
of detergent are eliminated. Squeeze out excess
water (do not wring), and allow the precleaner to
air dry.
4. Reinstall the precleaner.
5. Reinstall the air cleaner cover and tighten the
knob securely.
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 hoursȱ˜ȱ˜™Ž›Š’˜—Dzȱ–˜›Žȱ˜ĞŽ—ȱž—Ž›ȱ
extremely dusty or dirty conditions. Yearly or every
100 hours of operation replace the paper element.
Follow these instructions to service:

1. Loosen the air cleaner knob and remove the

cover. Remove the paper air cleaner element and
the precleaner (if equipped). See Figure 4-1.

2. Do not wash the paper element or use

pressurized air, as this will damage the element.
Replace a dirty, bent, or damaged element with a
genuine Kohler element.
3. When servicing the air cleaner, check the air
cleaner base. Make sure it is secured and not
damaged. Also, check the air cleaner cover for
Š–ŠŽȱ˜›ȱ’–™›˜™Ž›ȱęǯȱŽ™•ŠŒŽȱŠ••ȱŠ–ŠŽȱŠ’›ȱ
cleaner components.
4. If any loose dirt or debris fell into the air cleaner
when the element was removed, carefully remove
it and wipe the base clean.
Figure 4-2. Breather Hose.
ȱ Śǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—Žȱ—žœȱ›˜–ȱ‘Žȱ
mounting studs which secure the air cleaner base,
carburetor, and gaskets. Remove the third hex
œŒ›Ž ȱŠĴŠŒ‘’—ȱ‘Žȱ‹ŠœŽȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱ
5. Remove the air cleaner base by swinging it out
˜ȱ‘Žȱ•ŽĞȱŠ—ȱ’œŒ˜——ŽŒ’—ȱ‘Žȱ™›’–Ž›ȱ‘˜œŽȱǻ’ȱ
equipped) from the carburetor. See Figure 4-3.

5. Check the condition of the rubber seal on the

paper element. If the condition is questionable in
any way, replace the element.

6. Reinstall the paper element and the optional

™›ŽŒ•ŽŠ—Ž›ǰȱ’ȱŽšž’™™ŽǯȱŽŠĴŠŒ‘ȱ‘ŽȱŒ˜ŸŽ›ǯ

Disassembly
The following procedure outlines complete
disassembly of the air cleaner assembly. Since removal
˜ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽȱŠ•œ˜ȱŠěŽŒœȱŒŠ›‹ž›Ž˜›ȱ–˜ž—’—ȱ
and governor adjustment, Step 4 should only be
performed if required. For further information see the
Dissassembly and Reassembly sections of this manual.
1. Loosen the air cleaner cover retaining knob and
remove the air cleaner cover.
2. Remove the foam precleaner (if equipped), and
the paper air cleaner with the formed rubber seal.
3. Disconnect the breather hose from the crankcase.
See Figure 4-2.
Figure 4-3. Primer Bulb Hose.
Inspect Air Cleaner Components
Whenever the air cleaner cover is removed, or the
paper element or precleaner are serviced, inspect the
following areas:
Outer Air Cleaner Cover - Make sure the air cleaner
cover is in good condition, not cracked, damaged,
˜›ȱ–’œœ’—ȱ‘Žȱ›ŽŠ’—’—ȱ”—˜‹ǰȱ ‘’Œ‘ȱŒŠ—ȱŠěŽŒȱ‘Žȱ
sealing ability of the air cleaner element.
Air Cleaner Base - Make sure the base is properly
secured and not cracked or damaged. It is extremely
important that the fasteners securing this component
are tight at all times.

Primer Bulb Hose - Make sure the hose is not cracked

”’—”Žȱ˜›ȱŠ–ŠŽǰȱŠ—ȱŠĴŠŒ‘Žȱ˜ȱ‹˜‘ȱ‘ŽȱŠ’›ȱ
cleaner base and the carburetor. See Figure 4-3.

4.2

NOTE: Before reinstalling an air cleaner base that has
been removed, make sure the metal bushings
in the base mounting holes are present. The
bushings prevent damage to the base and
help maintain the proper mounting torque.
Reassembly
The following procedure outlines complete
reassembly of all air cleaner components.
1. Reconnect the primer bulb hose (if equipped). See
Figure 4-3.
2. Install the air cleaner base onto the mounting
studs.
ȱ řǯȱ —œŠ••ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽȱ ’‘ȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—Žȱ
nuts and the hex screw. Torque all three to 8.1
N·m (72 in. lb.).
Section 4
Air Cleaner and Air Intake System
Air Intake/Cooling System
Clean Air Intake/Cooling Areas
To ensure proper cooling, make sure the grass screen,
Œ˜˜•’—ȱꗜǰȱ‹•˜ Ž›ȱ‘˜žœ’—ǰȱŠ—ȱ˜‘Ž›ȱŽ¡Ž›—Š•ȱ
surfaces of the engine are kept clean at all times.
Under extremely dusty or dirty conditions, pay extra
ŠĴŽ—’˜—ȱ˜ȱ‘ŽœŽȱŠ›ŽŠœǯ
NOTE: Operating the engine with a blocked grass
œŒ›ŽŽ—ǰȱ’›¢ȱ˜›ȱ™•žŽȱŒ˜˜•’—ȱꗜǰȱŠ—Ȧ˜›ȱ
cooling shrouds removed, will cause engine
damage due to overheating.
4

4. Reconnect the breather hose. See Figure 4-2.

5. Install the air cleaner element with the pleated

side out.

6. Install the precleaner (if equipped) into the air

cleaner cover.

7. Reinstall the air cleaner cover and secure with the

cover knob.

NOTE: Damaged, worn, or loose air cleaner

Œ˜–™˜—Ž—œȱŒŠ—ȱŠ••˜ ȱž—ę•Ž›ŽȱŠ’›ȱ’—˜ȱ
the engine causing premature wear and
failure. Tighten or replace all loose or
damaged components.

4.3
Section 4
Air Cleaner and Air Intake System

4.4
 Section 5
Fuel System and Governor

Section 5
Fuel System and Governor

Fuel Recommendations Gasoline/Ether Blends

WARNING: Explosive Fuel!
Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ
’ȱ’—’Žǯȱ˜›ŽȱŠœ˜•’—Žȱ˜—•¢ȱ’—ȱŠ™™›˜ŸŽȱŒ˜—Š’—Ž›œǰȱ’—ȱ
 Ž••ȬŸŽ—’•ŠŽǰȱž—˜ŒŒž™’Žȱ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ
˜›ȱ̊–Žœǯȱ˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱ‘˜ȱ
˜›ȱ›ž——’—ǰȱœ’—ŒŽȱœ™’••ŽȱžŽ•ȱŒ˜ž•ȱ’—’Žȱ’ȱ’ȱŒ˜–Žœȱ’—ȱ
Œ˜—ŠŒȱ ’‘ȱ‘˜ȱ™Š›œȱ˜›ȱœ™Š›”œȱ›˜–ȱ’—’’˜—ǯȱ˜ȱ—˜ȱ
œŠ›ȱ‘ŽȱŽ—’—Žȱ—ŽŠ›ȱœ™’••ŽȱžŽ•ǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—ŽȱŠœȱŠȱ
Œ•ŽŠ—’—ȱŠŽ—ǯ
General Recommendations
Purchase gasoline in small quantities and store
in clean, approved containers. A container with a
capacity of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling. To
minimize gum deposits in your fuel system and to
ensure easy starting, do notȱžœŽȱŠœ˜•’—Žȱ•ŽĞȱ˜ŸŽ›ȱ
from the previous season. Do not add oil to the
Šœ˜•’—Žȱ˜›ȱ˜ŸŽ›ę••ȱ‘ŽȱžŽ•ȱŠ—”ǯȱŽȱœž›Žȱ˜ȱ•ŽŠŸŽȱ›˜˜–ȱ
for the fuel to expand.
Fuel Type
For best results, use only clean, fresh, unleaded
Šœ˜•’—Žȱ ’‘ȱŠȱ™ž–™ȱœ’Œ”Ž›ȱ˜ŒŠ—Žȱ›Š’—ȱ˜ȱŞŝȱ˜›ȱ
higher. In countries using the Research method, it
should be 90 octane minimum.
Ž‘¢•ȱŽ›’Š›¢ȱž¢•ȱ‘Ž›ȱǻǼȱŠ—ȱž—•ŽŠŽȱ
Šœ˜•’—Žȱ‹•Ž—œȱǻž™ȱ˜ȱŠȱ–Š¡’–ž–ȱ˜ȱŗśƖȱȱ‹¢ȱ
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
Fuel System 5
The typical fuel system and related components
’—Œ•žŽȱ‘ŽȱžŽ•ȱŠ—”ǰȱ’—Ȭ•’—ŽȱžŽ•ȱꕝŽ›ȱǻ’ȱŽšž’™™ŽǼǰȱ
carburetor, and fuel lines.
Operation
‘ŽȱžŽ•ȱ›˜–ȱ‘ŽȱŠ—”ȱ’œȱ–˜ŸŽȱ‘›˜ž‘ȱ‘Žȱ’—Ȭ•’—Žȱ
ꕝŽ›ȱŠ—ȱžŽ•ȱ•’—Žœȱ‹¢ȱ›ŠŸ’¢ǯȱžŽ•ȱ‘Ž—ȱŽ—Ž›œȱ‘Žȱ
ŒŠ›‹ž›Ž˜›ȱ̘Šȱ‹˜ •ȱŠ—ȱ’œȱ–˜ŸŽȱ’—˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ
‹˜¢ǯȱ‘Ž›Žǰȱ‘ŽȱžŽ•ȱ’œȱ–’¡Žȱ ’‘ȱŠ’›ǯȱ‘’œȱžŽ•ȬŠ’›ȱ
mixture is then burned in the engine combustion
chamber.
Fuel Filter (Optional)
Ž™•ŠŒŽȱ‘ŽȱžŽ•ȱꕝŽ›ȱyearly or every 50 hours of
˜™Ž›Š’˜—ǯȱŽ–˜Ÿ’—ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱꛜȱ ’••ȱŠ••˜ ȱ
ŽŠœ¢ȱŠŒŒŽœœȱ˜ȱ‘ŽȱžŽ•ȱꕝŽ›ǯȱŽŽȱ’ž›ŽȱśȬŗǯ

Unleaded gasoline is recommended, as it leaves less

combustion chamber deposits. Leaded gasoline may
be used in areas where unleaded is not available
Š—ȱŽ¡‘ŠžœȱŽ–’œœ’˜—œȱŠ›Žȱ—˜ȱ›Žž•ŠŽǯȱŽȱŠ Š›Žȱ
however, using unleaded gasoline will require more
frequent cylinder head servicing. Fuel Filter
Gasoline/Alcohol blends Figure 5-1. Replacing Fuel Filter (Air Cleaner Off).
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends including E20 Troubleshooting
Š—ȱŞśȱŠ›Žȱ—˜ȱ˜ȱ‹ŽȱžœŽȱŠ—ȱŠ›Žȱ—˜ȱŠ™™›˜ŸŽǯȱ—¢ȱ Use the guide on the following page to determine if
failures resulting from use of these fuels will not be fuel is reaching the combustion chamber.
warranted.

5.1
Section 5
Fuel System and Governor

Fuel System Test Guide

Test Conclusion
ŗǯȱȱ ‘ŽŒ”ȱ˜›ȱ‘Žȱ˜••˜ ’—DZ 1. Gasoline components oxidize over time resulting
ȱ Šǯȱ ‘ŽȱžŽ•ȱŠ—”ȱ‘Šœȱ›Žœ‘ǰȱŒ•ŽŠ—ȱŠœȱ’—ȱ’ǯ ’—ȱ•˜œȱŸ˜•’’•’¢ǰȱ–Š”’—ȱœŠ›’—ȱ–˜›Žȱ’ĜŒž•ǯȱ
ȱ ‹ǯȱ Š”Žȱœž›ŽȱžŽ•ȱŒŠ™ȱŸŽ—ȱ’œȱ˜™Ž—ǯ Replace old gas with fresh gas.
Řǯȱȱ ‘ŽŒ”ȱ˜›ȱžŽ•ȱ’—ȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ǯ Řǯȱȱ ȱ‘Ž›Žȱ’œȱžŽ•ȱŠȱ’™ȱ˜ȱœ™Š›”ȱ™•žǰȱžŽ•ȱ’œȱ›ŽŠŒ‘’—ȱ
ȱ Šǯȱ ’œŒ˜——ŽŒȱŠ—ȱ›˜ž—ȱœ™Š›”ȱ™•žȱ•ŽŠǯ the combustion chamber.
ȱ ‹ǯȱ •˜œŽȱŒŠ›‹ž›Ž˜›ȱŒ‘˜”Žȱǻ’ȱŽšž’™™ŽǼǯ
c. Turn engine over several times. ȱ ȱ ȱ‘Ž›Žȱ’œȱ—˜ȱžŽ•ȱŠȱ’™ȱ˜ȱœ™Š›”ǰȱŒ‘ŽŒ”ȱ˜›ȱžŽ•ȱ
ȱ ǯȱ Ž–˜ŸŽȱœ™Š›”ȱ™•žȱŠ—ȱŒ‘ŽŒ”ȱ˜›ȱžŽ•ȱŠȱ’™ǯ ̘ ȱ›˜–ȱžŽ•ȱŠ—”ȱǻŽœȱřǼǯ

řǯȱȱ ‘ŽŒ”ȱžŽ•ȱ̘ ȱ›˜–ȱŠ—”ȱ˜ȱ˜™’˜—Š•ȱžŽ•ȱꕝŽ›ǯ řǯȱȱ ȱžŽ•ȱ˜Žœȱ̘ ȱ›˜–ȱžŽ•ȱ•’—Žǰȱ›ŽŒ˜——ŽŒȱ•’—ŽȱŠ—ȱ

ȱ Šǯȱ ’œŒ˜——ŽŒȱžŽ•ȱ‘˜œŽȱ›˜–ȱꕝŽ›ȱǻ’ȱŽšž’™™ŽǼǯ Œ‘ŽŒ”ȱ˜›ȱŠž•¢ȱžŽ•ȱꕝŽ›ȱǻŽœȱřǼǯ

ȱ ‹ǯȱ
˜•ȱžŽ•ȱ•’—Žȱ‹Ž•˜ ȱŠ—”ȱŠ—ȱ˜‹œŽ›ŸŽȱžŽ•ȱ̘ ǯ
Śǯȱȱ ‘ŽŒ”ȱ˜›ȱžŽ•ȱ̘ ȱ˜ȱŒŠ›‹ž›Ž˜›ǯ
a. Remove fuel line from carburetor.
ȱ ‹ǯȱ Ž–˜ŸŽȱŠ’›ȱꕝŽ›ȱŠ—ȱŽœȱ’ȱ™›’–Ž›ȱ‹ž•‹ȱ’œȱ
spraying fuel into carburetor.
ȱ Œǯȱ ‘ŽŒ”ȱ˜›ȱ”’—”œȱ˜›ȱ•ŽŠ”œȱ’—ȱ™›’–Ž›ȱ‘˜œŽǯ
ȱ ȱ ȱžŽ•ȱ˜Žœȱ—˜ȱ̘ ȱ›˜–ȱžŽ•ȱ•’—ŽǰȱŒ‘ŽŒ”ȱ˜›ȱ
Œ•˜ŽȱžŽ•ȱŠ—”ȱŸŽ—ȱ˜›ȱžŽ•ȱ•’—Žǯ
Śǯȱȱ ȱžŽ•ȱ˜Žœȱ̘ ȱ›˜–ȱ‘Žȱ•’—ŽǰȱŒ‘ŽŒ”ȱ˜›ȱŠž•¢ȱ
carburetor or clogged fuel line. If the fuel line is
ž—˜‹œ›žŒŽǰȱ‘ŽȱžŽ•ȱŠ—”ȱ’œȱŠž•¢ȱŠ—ȱ–žœȱ‹Žȱ
replaced. If no fuel spray is entering carburetor,
replace primer bulb or primer hose.

Carburetor
˜ž›ŠŽȱȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŽ’‘Ž›ȱŠȱ™›’–Ž›ȱ˜›ȱŒ‘˜”ŽȱŒŠ›‹ž›Ž˜›ǯȱŽŽȱ’ž›ŽœȱśȬŘȱŠ—ȱśȬřǯȱ

WARNING: Explosive Fuel!

Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ’ȱ’—’Žǯȱ˜›ŽȱŠœ˜•’—Žȱ˜—•¢ȱ’—ȱŠ™™›˜ŸŽȱŒ˜—Š’—Ž›œǰȱ’—ȱ Ž••ȱ
ŸŽ—’•ŠŽǰȱž—˜ŒŒž™’Žȱ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ̊–ŽœǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—ŽȱŠœȱŠȱŒ•ŽŠ—’—ȱŠŽ—ǯ

Figure 5-2. Carburetor With Primer. Figure 5-3. Carburetor With Choke.

Troubleshooting — Fuel System

ȱžŽ•Ȭœ¢œŽ–ȱ›Ž•ŠŽȱ™›˜‹•Ž–œȱ˜ŒŒž›ǰȱŒ‘ŽŒ”ȱ‘Žȱ˜••˜ ’—ȱŠ›ŽŠœȱ‹Ž˜›ŽȱŠĴŽ–™’—ȱ˜ȱŠ“žœȱ˜›ȱ’œŠœœŽ–‹•Žȱ‘Žȱ
carburetor.
ȱ Ȋȱ žŽ•ȱŠ—”ȱ’œȱꕕŽȱ ’‘ȱŒ•ŽŠ—ǰȱ›Žœ‘ȱŠœ˜•’—Žǯ
ȱ Ȋȱ žŽ•ȱŒŠ™ȱŸŽ—ȱ’œȱ—˜ȱ‹•˜Œ”ŽȱŠ—ȱ˜™Ž›Š’—ȱ™›˜™Ž›•¢ǯ
ȱ Ȋȱ žŽ•ȱ’œȱ›ŽŠŒ‘’—ȱŒŠ›‹ž›Ž˜›ȱŸ’Šȱ’—Ȭ•’—ŽȱžŽ•ȱꕝŽ›ȱǻ’ȱŽšž’™™ŽǼȱŠ—ȱžŽ•ȱ•’—Žœǯ
ȱ Ȋȱ ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽǰȱŒŠ›‹ž›Ž˜›ǰȱŠ—ȱŠœ”ŽœȱŠ›ŽȱœŽŒž›Ž•¢ȱŠœŽ—ŽȱŠ—Ȧ˜›ȱ˜›šžŽȱ˜ȱŽ—’—Žǯ
• Air cleaner element is clean, and all air cleaner components are fastened securely.
ȱ Ȋȱ ˜ŸŽ›—˜›ȱœ¢œŽ–ǰȱŽ¡‘Šžœȱœ¢œŽ–ǰȱŠ—ȱ‘›˜Ĵ•ŽȦŒ‘˜”ŽȱŒ˜—›˜•œȱŠ›Žȱ˜™Ž›Š’—ȱ™›˜™Ž›•¢ǯ

5.2

Fuel System Troubleshooting Guide
1. Engine starts hard, runs rough or stalls at idle.
Řǯȱȱ —’—Žȱ›ž—œȱ›’Œ‘ȱǻ’—’ŒŠŽȱ‹¢ȱ‹•ŠŒ”ȱœ˜˜¢ȱ
œ–˜”Žǰȱ–’œę›’—ǰȱ•˜œœȱ˜ȱœ™ŽŽȱŠ—ȱ™˜ Ž›ǰȱŠ—ȱ
governor hunting).
řǯȱȱ —’—Žȱ›ž—œȱ•ŽŠ—ȱǻ’—’ŒŠŽȱ‹¢ȱ–’œę›’—ǰȱ•˜œœȱ˜ȱ
speed and power, governor hunting).
Śǯȱȱ žŽ•ȱ•ŽŠ”œȱ›˜–ȱŒŠ›‹ž›Ž˜›ǯ
Carburetor Adjustments
While this carburetor is designed to deliver the
Œ˜››ŽŒȱžŽ•Ȭ˜ȬŠ’›ȱ–’¡ž›Žǰȱœ˜–ŽȱŠ“žœ–Ž—œȱ–Š¢ȱ‹Žȱ
necessary.
DZȱ “žœȱŒŠ›‹ž›Ž˜›ȱŠĞŽ›ȱŽ—’—Žȱ’œȱ Š›–Žȱž™ǯ
Idle Adjustment Screw
Do not tampered with this screw on engines with
a primer bulb, since these models operate only
at full speed, and do not idle. On engines with a
Œ‘˜”Žȱ‘Žȱ’•ŽȱŠ“žœ–Ž—ȱœŒ›Ž ȱ’œȱžœŽȱ˜ȱꗎȱž—Žȱ
Ž—’—Žȱ’•Žǯȱ‘˜ž•ȱŠ—ȱŠ“žœ–Ž—ȱ‹Žȱ›Žšž’›Žǰȱž›—ȱ
‘ŽȱœŒ›Ž ȱŒ•˜Œ” ’œŽȱ˜ȱ’—Œ›ŽŠœŽȱ’•Žȱœ™ŽŽǰȱŠ—ȱ
Œ˜ž—Ž›Œ•˜Œ” ’œŽȱ˜ȱ•˜ Ž›ȱ’•Žȱœ™ŽŽǯȱŽŽȱ’ž›ŽȱśȬŚǯ
Idle Adjustment
Screw
Figure 5-4. Idle Adjustment Screw.
High-Speed (RPM) Adjustment
‘Žȱ›ŽŒ˜––Ž—Žȱ–Š¡’–ž–ȱ—˜Ȭ•˜Šȱ‘’‘ȱœ™ŽŽȱ
(RPM) for most engines is 3300 RPM. The actual
speed depends on the application.
WARNING: Overspeed is Hazardous!
ŸŽ›ȱœ™ŽŽȱ’œȱ‘Š£Š›˜žœȱŠ—ȱŒ˜ž•ȱŒŠžœŽȱ™Ž›œ˜—Š•ȱ’—“ž›¢ǯ
Section 5
Fuel System and Governor
1. Engine is out of fuel.
ȱ ȱ ’›ȱꕝŽ›ȱ’œȱŒ•˜ŽDzȱŒ•ŽŠ—ȱ˜›ȱ›Ž™•ŠŒŽǯ
ȱ ȱ ™Š›”ȱ™•žȱ’œȱŠž•¢Dzȱ›Ž™•ŠŒŽȱ˜›ȱŽœȱ˜›ȱœ™Š›”ǯ
Řǯȱȱ ’›ȱꕝŽ›ȱ’œȱŒ•˜ŽDzȱŒ•ŽŠ—ȱ˜›ȱ›Ž™•ŠŒŽǯ
ȱ ȱ Š›‹ž›Ž˜›ȱ’œȱ’›¢Dzȱ’œŠœœŽ–‹•ŽȱŠ—ȱŒ•ŽŠ—ǯ
řǯȱȱ ‹œ›žŒŽȱžŽ•ȱœž™™•¢DzȱŒ‘ŽŒ”ȱ˜›ȱŒ•˜œǯ
ȱ ȱ ’›ȱ’—Š”Žȱ•ŽŠ”DzȱŒ‘ŽŒ”ȱ˜›ȱ•ŽŠ”œǯ
4. Dirt or debris in carb. Disassemble and clean.
Loose fuel bowl or drain screw. Disassemble and
ȱ ȱ Œ‘ŽŒ”ȱ˜›ȱ•ŽŠ”œǯ
Engines with Primer Bulb 5
ȱ ŗǯȱ Ž—ȱ‘ŽȱŠ“žœ–Ž—ȱŠ‹ȱ˜—ȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ
‹›ŠŒ”Žȱž™ȱ˜ȱ’—Œ›ŽŠœŽȱŽ—’—Žȱœ™ŽŽǰȱŠ—ȱ˜ —ȱ˜ȱ
›ŽžŒŽȱœ™ŽŽǯȱŽŽȱ’ž›ŽȱśȬśǯ
Figure 5-5. Engine Speed Adjustment Tab.
Engines With Choke
ȱ ŗǯȱ ž›—ȱ‘Žȱ‘’‘Ȭœ™ŽŽȱŠ“žœ–Ž—ȱœŒ›Ž ȱŒ•˜Œ” ’œŽȱ
˜ȱŽŒ›ŽŠœŽȱŽ—’—Žȱœ™ŽŽȱŠ—ȱŒ˜ž—Ž›Œ•˜Œ” ’œŽȱ˜ȱ
’—Œ›ŽŠœŽȱœǯȱŽŽȱ’ž›ŽȱśȬŜǯȱ
Speed Control Screw
(Hidden From View)
Figure 5-6. Speed Control Screw.
5.3
Section 5
Fuel System and Governor

Carburetor Removal
NOTE:ȱ—œž›ŽȱžŽ•ȱŠ—”ȱ’œȱŽ–™¢ȱ™›’˜›ȱ˜ȱŒŠ›‹ž›Ž˜›ȱ›Ž–˜ŸŠ•ǯȱ

WARNING: Explosive Fuel!

Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ’ȱ’—’Žǯȱ˜›ŽȱŠœ˜•’—Žȱ˜—•¢ȱ’—ȱŠ™™›˜ŸŽȱŒ˜—Š’—Ž›œǰȱ’—ȱ Ž••ȱ
ŸŽ—’•ŠŽǰȱž—˜ŒŒž™’Žȱ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ̊–ŽœǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—ŽȱŠœȱŠȱŒ•ŽŠ—’—ȱŠŽ—ǯ

ȱ ŗǯȱ ˜˜œŽ—ȱŠ’›ȱŒ•ŽŠ—Ž›ȱ”—˜‹ȱŠ—ȱ›Ž–˜ŸŽȱŒ˜ŸŽ›ǯȱ
2. Remove foam precleaner (if equipped) and paper element.
ȱ řǯȱ Ž–˜ŸŽȱ ˜ȱ‘Ž¡ȱ̊—Žȱ—žœȱŠ—ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱœŽŒž›’—ȱŠ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽǯ
ȱ Śǯȱ ’œŒ˜——ŽŒȱ‹›ŽŠ‘Ž›ȱ‘˜œŽǰȱ™›’–Ž›ȱ‘˜œŽǰȱŠ—ȱŒŠ›‹ž›Ž˜›ȱ•’—”ŠŽǯ
ȱ śǯȱ Ž–˜ŸŽȱŒŠ›‹ž›Ž˜›ǰȱ—˜’—ȱŠœ”ŽȱœŽšžŽ—ŒŽǯȱŽŽȱ’ž›ŽȱśȬŝǯȱ

+HDW'HÀHFWRU*DVNHW
Carburetor
Square Gasket
Notched Gasket

Cylinder Head Spacer

Figure 5-7. Carburetor Gasket Sequence (Exploded View).

Carburetor Disassembly ȱ řǯȱ —œŒ›Ž ȱ‘Žȱ–Š’—ȱ“Žȱ›˜–ȱ’—œ’Žȱ‘Žȱ˜ Ž›ǯȱ

ȱ ŗǯȱ Ž–˜ŸŽȱ‘ŽȱžŽ•ȱ‹˜ •ȱœŒ›Ž ǰȱžŽ•ȱ‹˜ •ǰȱȬ›’—ȱ A light tap on the tower will dislodge the
Š—ȱ̘Šȱ™’—ǯȱŽŽȱ’ž›ŽȱśȬŗŘǯ Ž––ž•œ’˜—ȱž‹ŽǯȱŽŽȱ’ž›ŽȱśȬşǯ

ȱ Řǯȱ •’Žȱ‘Žȱœ™›’—Ȭ•˜ŠŽȱžŽ•ȱ’—•Žȱ—ŽŽ•Žȱ˜žȱ˜ȱ
‘Žȱ̘ŠǯȱŽŽȱ’ž›ŽȱśȬŞǯȱ
Emmulsion Tube
Tower

Fuel-Inlet
Needle

Figure 5-9. Emmulsion Tube Removal.

Figure 5-8. Fuel Inlet Needle Removal.

5.4
 Section 5
Fuel System and Governor
ȱ Śǯȱ Ž–˜ŸŽȱ‘Žȱ‘›˜Ĵ•ŽȬ™•ŠŽȱœŒ›Ž ǰȱ‘Žȱ‘›˜Ĵ•Žȱ ȱ śǯȱ ˜ȱŽ—œž›ŽȱŠŒŒž›ŠŽȱ›ŽŠœœŽ–‹•¢ǰȱ–Š›”ȱ‘ŽȱŒ‘˜”Žȱ
™•ŠŽǰȱŠ—ȱœ•’Žȱ˜žȱ‘Žȱ‘›˜Ĵ•Žȱœ‘ŠĞǰȱ—˜’—ȱ plate and the carburetor body with a waterproof
‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ™˜œ’’˜—ǯȱŽŽȱ’ž›ŽœȱśȬŗŖȱŠ—ȱśȬŗŘǯ ™Ž—ǯȱŽŽȱ’ž›ŽȱśȬŗŗǯȱ

Choke Lever
Throttle Shaft
Choke Spring
Choke Shaft
Choke Plate

Figure 5-10. Throttle Shaft Removal.

DZȱ ‘›˜Ĵ•Žȱœ‘ŠĞȱ ŽŠ›ȱ’œȱ—˜›–Š••¢ȱŠŒŒ˜–™Š—’Žȱ
Figure 5-11. Mark Choke Plate and Carburetor. 5
by corresponding wear to the carburetor
‹˜¢ǰȱ–Š”’—ȱ›Ž™Š’›ȱ’–™›ŠŒ’ŒŠ•ǯȱŽ™•ŠŒŽȱ‘Žȱ
Ž—’›ŽȱŒŠ›‹ž›Ž˜›ȱ’ȱ‘Žȱ‘›˜Ĵ•Žȱœ‘ŠĞȱ’œȱ ˜›—ǯ

Throttle Choke
Lever Pilot Jet Lever

Primer Vent Throttle Shaft Choke

Shaft

Throttle Adjustment Screw Choke

Throttle Plate Screw Spring
Throttle Plate Screw

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

Carburetor with Primer Carburetor with Choke

Figure 5-12. Carburetor (Exploded View).

5.5
Section 5
Fuel System and Governor
ȱ Ŝǯȱȱ ›Šœ™ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱ ’‘ȱŠȱ™•’Ž›œȱŠ—ȱ›Ž–˜ŸŽȱ’ȱ
›˜–ȱ‘ŽȱŒ‘˜”ŽȬ™•ŠŽȱœ‘ŠĞǯȱŽŽȱ’ž›ŽȱśȬŗřǯ
Choke Plate
Figure 5-13. Choke Plate Removal.
ȱ ŝǯȱȱ Ž–˜ŸŽȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞȱŠ—ȱ’œŒ˜——ŽŒȱ‘ŽȱŒ‘˜”Žȱ
return spring, noting their positions for accurate
›ŽŠœœŽ–‹•¢ǯȱŽŽȱ’ž›ŽȱśȬŗŚǯ
Choke Return
Spring
Figure 5-14. Choke Return Spring Removal.
Carburetor Cleaning
WARNING: Flammable Solvents!
Š›‹ž›Ž˜›ȱŒ•ŽŠ—Ž›œȱŠ—ȱœ˜•ŸŽ—œȱŠ›ŽȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•Žǯȱ
ŽŽ™ȱœ™Š›”œǰȱ̊–ŽœǰȱŠ—ȱ˜‘Ž›ȱœ˜ž›ŒŽœȱ˜ȱ’—’’˜—ȱŠ Š¢ȱ›˜–ȱ
‘ŽȱŠ›ŽŠǯȱ˜••˜ ȱ‘ŽȱŒ•ŽŠ—Ž›ȱ–Š—žŠŒž›Ž›Ȃœȱ Š›—’—œȱŠ—ȱ
’—œ›žŒ’˜—œȱ˜—ȱ’œȱ™›˜™Ž›ȱŠ—ȱœŠŽȱžœŽǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—Žȱ
ŠœȱŠȱŒ•ŽŠ—’—ȱŠŽ—ǯ
All carburetor parts should be cleaned thoroughly
žœ’—ȱŠȱŒ˜––Ž›Œ’Š•ȱŒŠ›‹ž›Ž˜›ȱŒ•ŽŠ—Ž›ǯȱŠ”Žȱœž›ŽȱŠ••ȱ
ž–ȱŽ™˜œ’œȱŠ›Žȱ›Ž–˜ŸŽȱ›˜–ȱ‘Žȱ˜••˜ ’—ȱŠ›ŽŠœDZ
• Carburetor body and bore, especially areas where
‘›˜Ĵ•Žȱ™•ŠŽȱŠ—ȱœ‘ŠĞȱŠ›ŽȱœŽŠŽǯ
5.6
ȱ Ȋȱ Š’—ȱžŽ•ȱ“ŽǰȱŽ–ž•œ’˜—ȱž‹Žȱ’—ȱ–Š’—ȱ“Žȱ‹˜¢ǰȱžŽ•ȱ
inlet needle and seat.
• •˜Šǰȱ̘Šȱ‘’—ŽȱŠ—ȱžŽ•ȱ‹˜ •ǯ
DZȱ ˜ȱ—˜ȱœž‹–Ž›Žȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ’—ȱŒ•ŽŠ—Ž›ȱ˜›ȱ
œ˜•ŸŽ—ȱ ‘Ž—ȱ™•Šœ’Œǰȱꋎ›ǰȱ›ž‹‹Ž›ǰȱ˜Š–ȱœŽŠ•œȱ
˜›ȱŠœ”ŽœȱŠ›Žȱ’—œŠ••ŽǯȱŠ›‹ž›Ž˜›ȱŒ•ŽŠ—Ž›ȱ
may damage these components.
Carburetor Inspection
Complete carburetor inspection should include the
˜••˜ ’—DZȱ
ȱ Ȋȱ —œ™ŽŒȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ȱ˜›ȱŒ›ŠŒ”œǰȱ‘˜•ŽœǰȱŠ—ȱ
other wear or damage.
ȱ Ȋȱ —œ™ŽŒȱ̘Šȱ˜›ȱŒ›ŠŒ”œȱŠ—ȱ‘˜•Žœǯȱ‘ŽŒ”ȱ̘Šȱ
hinge and pin for wear or damage.
• Inspect fuel inlet needle and seat for wear or
damage.
ȱ Ȋȱ —œ™ŽŒȱ’™ȱ˜ȱ•˜ ȱ’•ŽǰȱžŽ•ȬŠ“žœ–Ž—ȱ—ŽŽ•Žȱ˜›ȱ
wear or grooves.
ȱ Ȋȱ —œ™ŽŒȱ‘›˜Ĵ•ŽȱŠ—ȱŒ‘˜”Žȱœ‘ŠĞȱŠ—ȱ™•ŠŽȱ
assemblies for wear or excess play.
Gasket Replacement
• Š¢œȱžœŽȱ—Ž ȱŠœ”Žœȱ ‘Ž—ȱœŽ›Ÿ’Œ’—ȱ˜›ȱ›Ž’—œŠ••’—ȱ
ŒŠ›‹ž›Ž˜›œǯȱŽ™Š’›ȱ”’œȱŠ›ŽȱŠŸŠ’•Š‹•Žȱ ‘’Œ‘ȱ’—Œ•žŽȱ
—Ž ȱŠœ”ŽœȱŠ—ȱ˜‘Ž›ȱŒ˜–™˜—Ž—œǯȱ• Š¢œȱ›ŽŽ›ȱ˜ȱ
the Kohler Parts Manual for the engine being serviced
˜ȱŽ—œž›Žȱ‘ŽȱŒ˜››ŽŒȱ›Ž™Š’›ȱ”’ȱ’œȱ˜›Ž›Žǯ
Carburetor Reassembly
ȱ ŗǯȱ —œŠ••ȱ‘Žȱ‘›˜Ĵ•Žȱœ‘ŠĞȱ’—˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ǯ
2. Apply thread sealant around three full threads
˜ȱ‘Žȱ‘›˜Ĵ•Žȱ™•ŠŽȱœŒ›Ž ȱ‹Ž˜›ŽȱŠĴŠŒ‘’—ȱ‘Žȱ
™•ŠŽȱ˜ȱ‘Žȱ‘›˜Ĵ•Žȱœ‘ŠĞǯȱ’™ŽȱŠ Š¢ȱŠ—¢ȱŽ¡ŒŽœœȱ
sealant.
ȱ řǯȱ ĴŠŒ‘ȱ‘ŽȱŒ‘˜”Žȱ›Žž›—ȱœ™›’—ȱ˜ȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞȱ
(if equipped).
ȱ Śǯȱ —œŽ›ȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞȱ’—˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ǯ
ȱ śǯȱ ˜’—ȱ‘Žȱ–Š›”œȱ–ŠŽȱŽŠ›•’Ž›ȱ˜—ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱ
Š—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǰȱ’—œŽ›ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱ’—˜ȱ
‘Žȱœ•˜ȱ’—ȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞǯȱŽŽȱ’ž›ŽȱśȬŗŗǯȱ‘Žȱ
™•ŠŽȱ’œȱ‘Ž•ȱ’—ȱ‘Žȱœ‘ŠĞȱ‹¢ȱ’–™•Žœȱ˜—ȱ‘Žȱ™•ŠŽȇœȱ
surface.

ȱ Ŝǯȱ ĴŠŒ‘ȱ‘ŽȱŒ‘˜”Žȱ›Žž›—ȱœ™›’—ȱ˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ
‹˜¢ǰȱŠ—ȱ’—œŽ›ȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞǯȱ
ȱ ŝǯȱȱ —œŠ••ȱ‘ŽȱŽ––ž•œ’˜—ȱž‹ŽȱŠ—ȱ‘Ž—ȱœŒ›Ž ȱ’—ȱ‘Žȱ
–Š’—ȱ“ŽǯȱŽŽȱ’ž›ŽȱśȬşǯ
ȱ Şǯȱȱ —œŠ••ȱ‘ŽȱžŽ•ȱ’—•Žȱ—ŽŽ•Žǰȱ̘Šǰȱ̘Šȱ™’—ǰȱȬ›’—ȱ
Š—ȱžŽ•ȱ‹˜ •ǯȱŽŽȱ’ž›ŽȱśȬŗŘǯ
High Altitude Operation
‘Ž—ȱ˜™Ž›Š’—ȱ‘ŽȱŽ—’—ŽȱŠȱŠ•’žŽœȱŠ‹˜ŸŽȱŗśŘśȱ
–ŽŽ›œȱǻśŖŖŖȱĞǯǼǰȱ‘Žȱ–Š’—ȱžŽ•ȱ–’¡ž›ŽȱŽ—œȱ˜ȱ
become too rich. When the mixture is too rich it
ŒŠ—ȱŒŠžœŽȱŒ˜—’’˜—œȱœžŒ‘ȱŠœȱ‹•ŠŒ”ǰȱœ˜˜¢ȱŽ¡‘Šžœȱ
œ–˜”Žǰȱ–’œę›’—ǰȱ•˜œœȱ˜ȱœ™ŽŽȱŠ—ȱ™˜ Ž›ǰȱ™˜˜›ȱžŽ•ȱ
economy, and poor or slow governor response.
˜ȱŒ˜–™Ž—œŠŽȱ˜›ȱ‘ŽȱŽěŽŒœȱ˜ȱ‘’‘ȱŠ•’žŽǰȱŠȱ‘’‘ȱ
Š•’žŽȱ–Š’—ȱ“ŽȱŒŠ—ȱ‹Žȱ’—œŠ••Žǯȱ
’‘ȱŠ•’žŽȱ“Žœȱ ȱ Śǯȱ Ў›ȱ‘ŽȱŽ—’—ŽȱœŠ›œǰȱ–˜ŸŽȱ‘ŽȱŒ‘˜”ŽȱŒ˜—›˜•ȱ
Š›Žȱœ˜•ȱ’—ȱ”’œȱ ‘’Œ‘ȱ’—Œ•žŽȱ‘Žȱ“ŽȱŠ—ȱ‘Žȱ—ŽŒŽœœŠ›¢ȱ
Šœ”Žœǯȱ
DZȱ ȱŠȱ‘’‘ȬŠ•’žŽȱ”’ȱ‘Šœȱ‹ŽŽ—ȱ’—œŠ••Žǰȱ‘Žȱ
Ž—’—Žȱ–žœȱ‹Žȱ›ŽŒ˜—ŸŽ›Žȱ˜ȱ‘Žȱ˜›’’—Š•ȱ“Žȱ
size before it is operated at lower altitudes, or
overheating and engine damage may result.
Engine Starting
Starting Engine With Primer Bulb
1. For a Cold Engineǰȱꛖ•¢ push the primer bulb
řȱ’–ŽœǯȱŽŽȱ’ž›ŽȱśȬŗśǯȱ›Žœœ’—ȱ‘Žȱ™›’–Ž›ȱ‹ž•‹ȱ
˜˜ȱ–Š—¢ȱ’–ŽœȱŒŠ—ȱ̘˜ȱ‘ŽȱŽ—’—Žǯȱ˜›ȱŠȱ Š›–ȱ
engine no priming is required. Also refer to the
operating instructions of the equipment this
engine powers.
Figure 5-15. Primer Bulb.
Section 5
Fuel System and Governor
ȱ Řǯȱ ˜ŸŽȱ‘ŽȱŽšž’™–Ž—ȇœȱ‹•ŠŽȱŒ˜—›˜•ȱ‹Š›ȱ’—˜ȱ‘Žȱ
proper start position.
ȱ řǯȱ ž••ȱ‘ŽȱœŠ›Ž›ȱ‘Š—•Žȱœ›Š’‘ȱ˜žȱ ’‘ȱŠȱœ–˜˜‘ǰȱ
steady motion until the engine has started.
Starting Engine With Manual Choke Control
1. For a Cold Engine, p•ŠŒŽȱ‘ŽȱŠ™™•’ŒŠ’˜—ȱŒ‘˜”Žȱ
control into the ON position. For a warm engine
—˜ȱŒ‘˜”Žȱ’œȱ›Žšž’›Žǯȱ•œ˜ȱ›ŽŽ›ȱ˜ȱ‘Žȱ˜™Ž›Š’—ȱ
instructions of the equipment this engine powers.
ȱ Řǯȱ ˜ŸŽȱ‘ŽȱŽšž’™–Ž—ȇœȱ‹•ŠŽȱŒ˜—›˜•ȱ‹Š›ȱ’—˜ȱ‘Žȱ
proper start position.
ȱ řǯȱ ž••ȱ‘ŽȱœŠ›Ž›ȱ‘Š—•Žȱœ›Š’‘ȱ˜žȱ ’‘ȱŠȱœ–˜˜‘ǰȱ
steady motion until the engine has started.
5
from the ON position to the OFF position.
Choke Cable Installation
ȱ ŗǯȱ ˜——ŽŒȱ‘Žȱ˜ Ž—ȱŒŠ‹•Žȱ˜ȱ‘ŽȱŽ—’—ŽȱŒ‘˜”Žȱ
Œ˜—›˜•ȱŠ›–ȱ˜—ȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”ŽǯȱŽŽȱ
’ž›ŽȱśȬŗŜǯ
Bowden Cable
Wire Mount
Control Arm
Figure 5-16. Connect Bowden Cable.
ȱ Řǯȱ Žȱ‘ŽȱŒ‘˜”ŽȱŒ˜—›˜•ȱ˜—ȱ‘ŽȱŽšž’™–Ž—ȱ‘’œȱ
engine powers to the OPEN or OFF position.
ȱ řǯȱ —Š™ȱ‘Žȱ™•Šœ’Œȱ ’›Žȱ–˜ž—ȱ’—˜ȱ‘Žȱœ™ŽŽȱ
Œ˜—›˜•ȱ‹›ŠŒ”ŽǯȱŽŽȱ’ž›ŽȱśȬŗŜǯ
5.7
Section 5
Fuel System and Governor
Install Throttle/Choke Control Cable
˜–ŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠȱžŠ•ȱ‘›˜Ĵ•ŽȦŒ‘˜”Žȱ
Œ˜—›˜•ȱŠ›–ǯȱ‘’œȱŠ••˜ œȱœ’–ž•Š—Ž˜žœȱŠ“žœ–Ž—ȱ˜ȱȱ
‘Žȱ‘›˜Ĵ•ŽȱŠ—ȱŒ‘˜”Žȱ˜Ž‘Ž›ǯ
Dual Throttle/Choke Control Installation
1. Loosen the cable clamp and insert the cable
œ‘ŽŠ‘ȱ‘›˜ž‘ȱ‘ŽȱŒ•Š–™ǯȱŽŽȱ’ž›ŽȱśȬŗŝǯȱ
Control Arm
Bowden Cable
Sheath
Cable Clamp
Figure 5-17. Bowden Cable Connection.
ȱ Řǯȱ ˜——ŽŒȱ‘Žȱ˜ Ž—ȱŒŠ‹•Žȱ˜ȱ‘ŽȱŒ˜—›˜•ȱŠ›–ȱ
˜—ȱ‘Žȱœ™ŽŽȬŒ˜—›˜•ȱ‹›ŠŒ”Žǯȱ˜›ȱŒ˜››ŽŒȱ‘˜•Žȱ
selection, refer to the operating instructions of
the equipment this engine powers. See Figure
śȬŗśǯ
ȱ řǯȱ •ŠŒŽȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ•ŽŸŽ›ȱ˜ȱ‘ŽȱŽšž’™–Ž—ȱ
’—˜ȱ‘Žȱȱ˜›ȱ‘’‘Ȭœ™ŽŽȱ™˜œ’’˜—ǯȱ
DZȱ ‘ŽȱŒ‘˜”Žȱ’œȱ™•ŠŒŽȱȱ‹¢ȱ–˜Ÿ’—ȱ‘Žȱ
‘›˜Ĵ•ŽȱŒ˜—›˜•ȱœ•’‘•¢ȱ™Šœȱ‘Žȱȱ
™˜œ’’˜—ǯȱȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ˜Žœȱ—˜ȱ‘ŠŸŽȱ
a designated CHOKE position, be sure to
•ŽŠŸŽȱœžĜŒ’Ž—ȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ›ŠŸŽ•ȱ™Šœȱ‘Žȱ
ȱ™˜œ’’˜—ǯȱ‘’œȱ ’••ȱŽ—Š‹•Žȱ‘ŽȱŒ‘˜”Žȱ˜ȱ
be placed ON.
ȱ Śǯȱ Š—žŠ••¢ȱ–˜ŸŽȱ‘ŽȱŒ˜—›˜•ȱȱŠ›–ȱŒ•˜Œ” ’œŽȱž—’•ȱ
’ȱ˜žŒ‘Žœȱ‘Žȱœ™ŽŽȬŒ˜—›˜•ȱœŒ›Ž ǯ
ȱ śǯȱ ž••ȱ˜—ȱ‘Žȱ˜žŽ›ȱœ‘ŽŠ‘ȱ˜ȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ
ŒŠ‹•Žȱ˜ȱ›Ž–˜ŸŽȱŠ—¢ȱœ•ŠŒ”ǯȱ
ȱ Ŝǯȱ ’‘Ž—ȱ‘ŽȱŒŠ‹•ŽȱŒ•Š–™ȱœŽŒž›Ž•¢ǯ
5.8
Governor
These engines are equipped with a centrifugal
Ě¢ Ž’‘ǰȱ–ŽŒ‘Š—’ŒŠ•ȱ˜ŸŽ›—˜›ǰȱŽœ’—Žȱ˜ȱ‘˜•ȱ
the engine speed constant under changing load
Œ˜—’’˜—œǯȱ‘Žȱ˜ŸŽ›—˜›ȱŽŠ›ȦĚ¢ Ž’‘ȱ–ŽŒ‘Š—’œ–ȱ
’œȱ–˜ž—Žȱ˜—ȱ‘ŽȱŒ•˜œž›Žȱ™•ŠŽȱ’—ȱ‘ŽȱŒ›Š—”ŒŠœŽǰȱŠ—ȱȱ
›’ŸŽ—ȱ˜ěȱŠȱŽŠ›ȱ˜—ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱȱŽŽȱ’ž›ŽȱśȬŗŞǯ
Governor
Gear
Flyweights
Governor Shaft
Figure 5-18. Governor Assembly.
Operation
As the governor gear rotates, centrifugal force causes
‘ŽȱĚ¢ Ž’‘œȱ˜ȱ–˜ŸŽȱ˜ž Š›ȱŠœȱœ™ŽŽȱ’—Œ›ŽŠœŽœǯȱ
œȱ‘ŽȱĚ¢ Ž’‘œȱ˜™Ž—ǰȱ‘Ž¢ȱŒŠžœŽȱ‘Žȱ›Žž•Š’—ȱ™’—ȱ
to protrude out. The regulating pin contacts the tab
˜—ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞǰȱŒŠžœ’—ȱ‘Žȱœ‘ŠĞȱ˜ȱ›˜ŠŽǯȱ—Žȱ
Ž—ȱ˜ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞȱ™›˜›žŽœȱ‘›˜ž‘ȱ‘Žȱœ’Žȱ
˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱ‘Žȱ˜ŸŽ›—˜›ȱ•ŽŸŽ›ȱ’œȱŒ•Š–™Žȱ˜—ȱ
‘Žȱ™›˜›ž’—ȱŽ—ȱ˜ȱ‘Žȱœ‘ŠĞȱŠ—ȱŒ˜——ŽŒŽȱ ’‘ȱ
•’—”ŠŽȱ˜ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǰȱœ˜ȱŠ—¢ȱ
›˜Š’˜—ȱ˜ȱ‘Žȱœ‘ŠĞȱŒŠžœŽœȱŒ˜››Žœ™˜—’—ȱ–˜ŸŽ–Ž—ȱ
˜ȱ‘Žȱ‘›˜Ĵ•Žȱ™•ŠŽǯ
‘Ž—ȱ‘ŽȱŽ—’—Žȱ’œȱŠȱ›ŽœȱŠ—ȱ‘Žȱ‘›˜Ĵ•Žȱ’œȱ˜™Ž—ȱ
ȯȱŠœȱ ’‘ȱŠȱę¡ŽȬœ™ŽŽȱŽ—’—Žȱǻ™›’–Ž›ȱ‹ž•‹Ǽȱȯȱ˜›ȱ’—ȱ
‘Žȱȱ™˜œ’’˜—ȱȯȱŠœȱ ’‘ȱŠȱŸŠ›’Š‹•ŽȬœ™ŽŽȱŽ—’—Žȱ
ȯȱ‘ŽȱŽ—œ’˜—ȱ˜ȱ‘Žȱ˜ŸŽ›—˜›ȱœ™›’—ȱ‘˜•œȱ‘Žȱ‘›˜Ĵ•Žȱ
plate open. When the engine is operating, and the
governor gear assembly is rotating, the force applied
‹¢ȱ‘Žȱ›Žž•Š’—ȱ™’—ȱŠŠ’—œȱ‘ŽȱŒ›˜œœȱœ‘ŠĞȱŽ—œȱ˜ȱ
Œ•˜œŽȱ‘Žȱ‘›˜Ĵ•Žȱ™•ŠŽǯȱ‘Žȱ˜ŸŽ›—˜›ȱœ™›’—ȱ
tension and the force applied by the regulating pin are
in equilibrium during operation, holding the engine
speed constant. When load is applied, and the engine/
governor gear speed decreases, the governor spring
Ž—œ’˜—ȱ–˜ŸŽœȱ‘Žȱ˜ŸŽ›—˜›ȱŠ›–ȱ˜ȱ˜™Ž—ȱ‘Žȱ‘›˜Ĵ•Žȱ
plate wider. This allows more fuel into the engine,
’—Œ›ŽŠœ’—ȱŽ—’—Žȱœ™ŽŽǯȱ‘’œȱŠŒ’˜—ȱŠ”Žœȱ™•ŠŒŽȱŸŽ›¢ȱ
 Section 5
Fuel System and Governor
rapidly, so a reduction in speed is hardly noticed. As 2. Move the governor lever away from the
‘Žȱœ™ŽŽȱ›ŽŠŒ‘Žœȱ‘Žȱ˜ŸŽ›—ŽȱœŽĴ’—ǰȱ‘Žȱ˜ŸŽ›—˜›ȱ ŒŠ›‹ž›Ž˜›ȱǻ ’Žȱ˜™Ž—ȱ‘›˜Ĵ•ŽǼǯȱŽŽȱ’ž›ŽȱśȬŗşǯȱ
spring tension and the force applied by the regulating Do notȱŠ™™•¢ȱŽ¡ŒŽœœȱ˜›ŒŽȱ‘Šȱ–Š¢ȱ̎¡ȱ˜›ȱ’œ˜›ȱ
pin will again be in equilibrium. This maintains ‘Žȱ‘›˜Ĵ•Žȱ•’—”ǯ
the engine speed at a relatively constant level. The
˜ŸŽ›—Žȱœ™ŽŽȱœŽĴ’—ȱ’œȱŽŽ›–’—Žȱ‹¢ȱ‘Žȱ™˜œ’’˜—ȱ ȱ řǯȱ ›Šœ™ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞȱ ’‘ȱŠȱ™•’Ž›œȱŠ—ȱž›—ȱ‘Žȱ
˜ȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ǯȱȱŒŠ—ȱ‹ŽȱŸŠ›’Š‹•Žȱ˜›ȱŒ˜—œŠ—ǰȱ œ‘ŠĞȱclockwise as far as it will go. Then torque
depending on the application. the hex nut to 9.5 N·m (84 in. lb.)ǯȱŽŽȱ’ž›ŽȱśȬ
20.
Initial Governor Adjustment
Š”Žȱ‘’œȱ’—’’Š•ȱŠ“žœ–Ž—ȱ ‘Ž—ŽŸŽ›ȱ‘Žȱ˜ŸŽ›—˜›ȱ
Š›–ȱ’œȱ•˜˜œŽ—Žȱ˜›ȱ›Ž–˜ŸŽȱ›˜–ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞǯȱ˜ȱ
Ž—œž›Žȱ™›˜™Ž›ȱŠ“žœ–Ž—ǰȱ–Š”Žȱœž›Žȱ‘Žȱ‘›˜Ĵ•Žȱ
•’—”ŠŽȱ’œȱŒ˜——ŽŒŽȱ˜ȱ‹˜‘ȱ‘Žȱ˜ŸŽ›—˜›ȱŠ›–ȱŠ—ȱ‘Žȱ
‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱ

ȱ ŗǯȱ ˜˜œŽ—ȱ‘Žȱ˜ŸŽ›—˜›ȱ•ŽŸŽ›ȱŠ“žœ–Ž—ȱœŒ›Ž ǯȱŽŽȱ
’ž›ŽȱśȬŗşǯȱ 5

Figure 5-20. Adjust Governor Lever.

Figure 5-19. Loosen Governor Lever.

5.9
Section 5
Fuel System and Governor

5.10
 Section 6
Lubrication System

Section 6
Lubrication System

Oil Recommendations Check Oil Level

Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
daily and changing oil regularly. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure.
Oil Type
Use high-quality detergent oil of API (American
Petroleum Institute) service class SJ or higher. Select
the viscosity based on the air temperature at the time
of operation. See Figure 6-1.
RE CO M M E N D E D S A E VIS C OS IT Y GR A D E S
The importance of checking and maintaining proper
oil level in the crankcase cannot be overemphasized.
Check oil BEFORE EACH USE as follows:
1. Make sure the engine is stopped, level, and cool
so the oil has had time to drain into the sump.
ȱ Řǯȱ •ŽŠ—ȱ‘ŽȱŠ›ŽŠȱŠ›˜ž—ȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ȱ˜ȱ
keep dirt and grass clippings out of the engine.
6
ȱ řǯȱ —œŒ›Ž ȱŠ—ȱ›Ž–˜ŸŽȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”Dzȱ
 ’™Žȱ˜ěȱ˜’•ǯȱŽ’—œŽ›ȱ‘Žȱ’™œ’Œ”ȱ’—˜ȱ‘Žȱž‹Žȱ
Š—ȱ›Žœȱ‘Žȱ˜’•ȱꕕȱŒŠ™ȱ˜—ȱ‘Žȱž‹Žǯȱȱȱ
screw the cap into the tube. See Figure 6-3.

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

Figure 6-1. Viscosity Grades Table.

NOTE: Using oil other than service class SJ or higher,

or extending oil change intervals longer than
recommended can cause engine damage.

ȱ•˜˜ȱ˜›ȱœ¢–‹˜•ȱ˜—ȱ˜’•ȱŒ˜—Š’—Ž›œȱ’Ž—’ęŽœȱ‘Žȱȱ Figure 6-3. Oil Fill Cap/Dipstick.

service class and SAE viscosity grade. See Figure 6-2. ȱ Śǯȱ Ž–˜ŸŽȱ‘Žȱ’™œ’Œ”ȱŠŠ’—ȱŠ—ȱŒ‘ŽŒ”ȱ‘Žȱ˜’•ȱ
level. Oil should be up to, but not over the "F" or
FULL mark on the dipstick. See Figure 6-4.
RVIC
SE ȱ śǯȱ ȱ‘Žȱ•ŽŸŽ•ȱ’œȱ•˜ ǰȱŠȱ‘Žȱ™›˜™Ž›ȱ¢™Žȱ˜ȱ˜’•ȱž™ȱ˜ȱ
E
API

the FULL mark on the dipstick. Always check the

SJ

level with the dipstick before adding more oil.

10W-30
ȱ Ŝǯȱ Ž’—œŠ••ȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ȱŠ—ȱ’‘Ž—ȱ
securely.

Figure 6-2. Oil Container Logo.

6.1
Section 6
Lubrication System

ȱ řǯȱ Ў›ȱ‘ŽȱŒ›Š—”ŒŠœŽȱ’œȱŒ˜–™•ŽŽ•¢ȱ›Š’—Žǰȱ’•ȱ‘Žȱ
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 ‹Ž˜›ŽȱŠ’—ȱ–˜›Žȱ˜’•ǯȱ˜ȱ—˜ȱœŒ›Ž ȱ‘Žȱ’™œ’Œ”ȱ
Range in when checking oil level.

5. Test run the engine to check for leaks. Stop the

Low Mark
Figure 6-4. Dipstick.
NOTE: To prevent extensive engine wear or damage,
always maintain the proper oil level in the
crankcase. Never operate the engine with the
oil level below the "L" or LOW mark, or over
the FULL mark on the dipstick.
Oil Change
Oil can be changed on this engine by either draining it
from the dipstick tube, or from the drain plug. Change
‘Žȱ˜’•ȱŠĞŽ›ȱ‘Žȱꛜȱ‘›ŽŽȱ˜ȱ꟎ȱ‘˜ž›œȱ˜ȱ˜™Ž›Š’˜—.
Ў›ȱ‘ŠǰȱŒ‘Š—Žȱ‘Žȱ˜’•ȱyearly or every 50 hours of
˜™Ž›Š’˜—ǯȱŽę••ȱ ’‘ȱ˜’•ȱŠœȱœ™ŽŒ’ꮍȱ’—ȱ‘Žȱ’œŒ˜œ’¢ȱ
Grades Table, Figure 6-1.
engine, allow a minute for the oil to drain down
and recheck the level on the dipstick. Add more
oil, if necessary, so the oil level is up to but not
over the FULL mark.
ȱ Ŝǯȱ Ž’—œŠ••ȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ȱŠ—ȱ’‘Ž—ȱ
securely.
Drain Oil Via Crankcase Plug (If Accessible)
ȱ ŗǯȱ ’œŠ‹•Žȱ‘ŽȱŽ—’—Žȱ‹¢ȱ’œŒ˜——ŽŒ’—ȱ‘Žȱœ™Š›”ȱ
plug.
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ǯ
ȱ řǯȱ Ž–˜ŸŽȱ‘ŽȱŒ›Š—”ŒŠœŽȱ™•žȱ˜—ȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ
engine and drain oil into an approved container.
See Figure 6-6.

Change the oil while the engine is still warm. The oil
 ’••ȱ̘ ȱ–˜›Žȱ›ŽŽ•¢ȱŠ—ȱŒŠ››¢ȱŠ Š¢ȱ–˜›Žȱ’–™ž›’’Žœǯȱ

Drain Oil from Dipstick Tube

Change the oil as follows:

1. To keep dirt, grass clippings, and other debris out

˜ȱ‘ŽȱŽ—’—ŽǰȱŒ•ŽŠ—ȱ‘ŽȱŠ›ŽŠȱŠ›˜ž—ȱ‘Žȱ˜’•ȱꕕȱ
ŒŠ™Ȧ’™œ’Œ”ǰȱŠ—ȱ‘Ž—ȱ›Ž–˜ŸŽȱ’ǯ

2. Tilt the engine on its side with the air cleaner

ŠŒ’—ȱž™ǯȱŽŽȱ’ž›ŽȱŜȬśǯȱ›Š’—ȱ˜’•ȱ’—˜ȱŠ—ȱ Crankcase Plug
approved container.
Figure 6-6. Crankcase Plug.
Air Cleaner
4. Apply thread sealant around three full threads
of the drain plug. Clean up any excess sealant
on the inside or outside of the joint. Threads
with pre-applied sealant do not require the use
Up of additional sealant. Approved sealants include
Ž›–ŠȬ˜Œȱ
ȱŗśŖǰȱŽ›–ŠȬ˜ŒȱȱŗŗśǰȱŽ›–ŠȬ
˜Œȱ

ȱŗŘŖǰȱŽ›–ŠȬ˜Œȱ
ȱŗŘŜǯȱ

ȱ śǯȱ Ž’—œŠ••ȱ‘Žȱ›Š’—ȱ™•žȱŠ—ȱ˜›šžŽȱ˜ȱ13.6 N·m

Oil Flow (120 in. lb.).

Figure 6-5. Tilted Engine With Air Cleaner Up.

6.2
 Section 6
Lubrication System

6. Fill the crankcase with the recommended oil
to the FULL mark on the dipstick. See Figure
6-4. Always check the oil level with the dipstick
‹Ž˜›ŽȱŠ’—ȱ–˜›Žȱ˜’•ǯȱ˜ȱ—˜ȱœŒ›Ž ȱ’™œ’Œ”ȱ’—ȱ
when checking oil level.
ȱ ŝǯȱ Ž’—œŠ••ȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ȱŠ—ȱ’‘Ž—ȱ
securely.
Splash Lubrication System
Operation
This engine uses splash lubrication to deliver oil for
internal lubrication. The governor gear, located near
‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ˜’•ȱ™Š—ǰȱ‘ŠœȱŠȱœŽ›’Žœȱ˜ȱ™Š•Žœȱ˜—ȱ’ȱ
that dip into crankcase oil and splash it onto internal
engine parts.

8. Test run the engine to check for leaks. Stop the

engine, allow a minute for the oil to drain down,
and recheck the level on the dipstick. Add more
oil, as necessary, so the oil level is up to, but not
over the FULL mark.

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.

WARNING: Electrical Shock

Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.

Spark Plug
Feeler Gauge
—’—Žȱ–’œę›Žȱ˜›ȱœŠ›’—ȱ™›˜‹•Ž–œȱŠ›Žȱ˜ĞŽ—ȱŒŠžœŽȱ
‹¢ȱŠȱœ™Š›”ȱ™•žȱ‘Šȱ’œȱ’—ȱ™˜˜›ȱŒ˜—’’˜—ȱ˜›ȱ‘ŠœȱŠ—ȱ
’–™›˜™Ž›ȱŠ™ȱœŽĴ’—ǯ Spark Plug

‘ŽȱŽ—’—Žȱ’œȱŽšž’™™Žȱ ’‘ȱ‘Žȱ˜••˜ ’—ȱœ™Š›”ȱ™•žDZ

Type: Champion® RC12YC

Gap: 0.762 mm (0.030 in.)
Thread Size: 14 mm (0.551 in.)
Reach: 19.1 mm (3/4 in.)
Hex Size: 15.9 mm (5/8 in.) 7

Spark Plug Service

Yearly or every 100 hours of operation, remove the Ground
œ™Š›”ȱ™•žǰȱŒ‘ŽŒ”ȱ’œȱŒ˜—’’˜—ǰȱŠ—ȱ›ŽœŽȱ‘ŽȱŠ™ȱ˜›ȱ Electrode Gap
›Ž™•ŠŒŽȱ ’‘ȱŠȱ—Ž ȱ™•žȱŠœȱ—ŽŒŽœœŠ›¢ǯȱ Figure 7-1. Spark Plug Gap.

ȱ ŗǯȱ Ž˜›Žȱ›Ž–˜Ÿ’—ȱ‘Žȱœ™Š›”ȱ™•žǰȱŒ•ŽŠ—ȱ‘ŽȱŠ›ŽŠȱ ȱ Śǯȱ Ž’—œŠ••ȱ‘Žȱœ™Š›”ȱ™•žȱ’—˜ȱ‘ŽȱŒ¢•’—Ž›ȱ‘ŽŠǯȱȱ

Š›˜ž—ȱ‘Žȱ‹ŠœŽȱ˜ȱ‘Žȱ™•žȱ˜ȱ”ŽŽ™ȱ’›ȱŠ—ȱ
Ž‹›’œȱ˜žȱ˜ȱ‘ŽȱŽ—’—Žǯ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ™•žȱŠ—ȱŒ‘ŽŒ”ȱ’œȱŒ˜—’’˜—ǯȱŽ™•ŠŒŽȱ
‘Žȱ™•žȱ’ȱ ˜›—ȱ˜›ȱ›ŽžœŽȱ’œȱšžŽœ’˜—Š‹•Žǯ
DZȱ ˜ȱ—˜ȱŒ•ŽŠ—ȱ‘Žȱœ™Š›”ȱ™•žȱ’—ȱŠȱ–ŠŒ‘’—Žȱ
žœ’—ȱŠ‹›Šœ’ŸŽȱ›’ǯȱ˜–Žȱ›’ȱŒ˜ž•ȱ›Ž–Š’—ȱ
˜—ȱ‘Žȱœ™Š›”ȱ™•žȱŠ—ȱŽ—Ž›ȱ‘ŽȱŽ—’—Žȱ
ŒŠžœ’—ȱŽ¡Ž—œ’ŸŽȱ ŽŠ›ȱŠ—ȱŠ–ŠŽǯ
˜›šžŽȱ‘Žȱ™•žȱ˜ȱ24.5 N·m (217 in. lb.).
Inspection
—œ™ŽŒȱ‘Žȱœ™Š›”ȱ™•žȱŠœȱœ˜˜—ȱŠœȱ’ȱ’œȱ›Ž–˜ŸŽȱ›˜–ȱ
the cylinder head. The deposits on the tip are an
indication of the general condition of the piston rings,
ŸŠ•ŸŽœǰȱŠ—ȱŒŠ›‹ž›Ž˜›ǯ
ŽŸŽ›Š•ȱŽ¡Š–™•Žœȱ˜ȱ—˜›–Š•ȱŠ—ȱ˜ž•Žȱ™•žœȱŠ›Žȱ
œ‘˜ —ȱ’—ȱ‘Žȱ™‘˜˜œȱ˜—ȱ‘Žȱ˜••˜ ’—ȱ™ŠŽǯ

ȱ řǯȱ ‘ŽŒ”ȱœ™Š›”ȱ™•žȱŠ™ȱžœ’—ȱŠȱŽŽ•Ž›ȱŠžŽǯȱŽŽȱ
’ž›ŽȱŝȬŗǯȱ“žœȱ‘ŽȱŠ™ȱ‹¢ȱŒŠ›Žž••¢ȱ‹Ž—’—ȱ
‘Žȱ›˜ž—ȱŽ•ŽŒ›˜Žǯȱ Š™ȱ‘Žȱœ™Š›”ȱ™•žȱ˜ȱ0.762
mm (0.030 in.).

7.1
Section 7
Electrical System and Components

Normal:ȱȱ™•žȱŠ”Ž—ȱ›˜–ȱŠ—ȱŽ—’—Žȱ˜™Ž›Š’—ȱž—Ž›ȱ Carbon Fouled:ȱ˜Ğǰȱœ˜˜¢ǰȱ‹•ŠŒ”ȱŽ™˜œ’œȱ’—’ŒŠŽȱ

—˜›–Š•ȱŒ˜—’’˜—œȱ ’••ȱ‘ŠŸŽȱ•’‘ȱŠ—ȱ˜›ȱ›Š¢ȱŒ˜•˜›Žȱ ’—Œ˜–™•ŽŽȱŒ˜–‹žœ’˜—ǯȱ‘’œȱ’œȱžœžŠ••¢ȱŒŠžœŽȱ‹¢ȱ˜ŸŽ›Ȭ›’Œ‘ȱ
Ž™˜œ’œǯȱȱ‘ŽȱŒŽ—Ž›ȱŽ•ŽŒ›˜Žȱ’œȱ—˜ȱ ˜›—ǰȱŠȱ™•žȱ’—ȱ ŒŠ›‹ž›Ž’˜—ǰȱ ŽŠ”ȱ’—’’˜—ǰȱ˜›ȱ™˜˜›ȱŒ˜–™›Žœœ’˜—ǯȱ˜—œ’Ž›ȱ
‘’œȱŒ˜—’’˜—ȱŒ˜ž•ȱ‹ŽȱŠ™™ŽȱŠŠ’—ȱŠ—ȱ›ŽžœŽǯ ›Ž™•ŠŒ’—ȱ‘Žȱ™•žǯ

Worn: —ȱŠȱ ˜›—ȱ™•žǰȱ‘ŽȱŒŽ—Ž›ȱŽ•ŽŒ›˜Žȱ ’••ȱ‹Žȱ›˜ž—Žȱ Wet Fouled:ȱȱ Žȱ™•žȱ’œȱŒŠžœŽȱ‹¢ȱŽ¡ŒŽœœȱžŽ•ȱ˜›ȱ˜’•ȱ’—ȱ

Š—ȱ‘ŽȱŠ™ȱ ’••ȱ‹ŽȱŽ›˜ŽȱǯŖŗŖȈȱ˜›ȱ–˜›Žȱ‘Š—ȱ‘ŽȱŒ˜››ŽŒȱ
Š™ǯȱŽ™•ŠŒŽȱŠȱ ˜›—ȱœ™Š›”ȱ™•žȱ’––Ž’ŠŽ•¢ǯ
‘ŽȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ǯȱ¡ŒŽœœȱžŽ•ȱŒ˜ž•ȱ‹ŽȱŒŠžœŽȱ‹¢ȱ
˜™Ž›Š’—ȱ‘ŽȱŽ—’—Žȱ ’‘ȱ˜˜ȱ–žŒ‘ȱŒ‘˜”Žȱ˜›ȱŠȱ’›¢ȱŠ’›ȱ
ꕝŽ›ǯȱ’•ȱ’—ȱ‘ŽȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ȱ’œȱžœžŠ••¢ȱŒŠžœŽȱ‹¢ȱ
 ˜›—ȱ™’œ˜—ȱ›’—œȱ˜›ȱŸŠ•ŸŽȱž’Žœǯȱȱ™•žȱ’—ȱ‘’œȱŒ˜—’’˜—ȱ
Œ˜ž•ȱ‹ŽȱŒ•ŽŠ—Žǰȱ›’ŽȱŠ—ȱ‘Ž—ȱ›ŽžœŽǯ

Chalky White Deposits: ‘Š•”¢ȱ ‘’ŽȱŒ˜•˜›ŽȱŽ™˜œ’œȱ

’—’ŒŠŽȱ˜ŸŽ›‘ŽŠ’—ǯȱ‘’œȱŒ˜—’’˜—ȱ’œȱžœžŠ••¢ȱŠŒŒ˜–™Š—’Žȱ
‹¢ȱŽ¡ŒŽœœ’ŸŽȱŠ™ȱŽ›˜œ’˜—ǯȱ•˜Žȱ›ŠœœȱœŒ›ŽŽ—ǰȱŒ˜˜•’—ȱ
ꗜǰȱŠ—ȱ•ŽŠ—ȱŒŠ›‹ž›Ž’˜—ȱŠ›Žȱœ˜–ŽȱŒŠžœŽœȱ˜ȱ˜ŸŽ›‘ŽŠ’—ǯȱ
˜—œ’Ž›ȱ›Ž™•ŠŒ’—ȱ‘Žȱ™•žǯ

7.2
 Section 7
Electrical System and Components

Electronic Ignition System

‘ŽœŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠȱŽ™Ž—Š‹•Žȱ–Š—Ž˜ȱ’—’’˜—ǯȱ—ȱŠȱ–Š—Ž˜ȱ’—’’˜—ȱœ¢œŽ–ǰȱŽ•ŽŒ›’ŒȱŽ—Ž›¢ȱ
’œȱŽ—Ž›ŠŽȱ‹¢ȱ‘Žȱ›˜Š’˜—Š•ȱ–˜’˜—ȱ‹Ž ŽŽ—ȱ‘Žȱ–Š—ŽœȱŽ–‹ŽŽȱ’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŠ—ȱ‘Žȱ’—’’˜—ȱ–˜ž•Žǯȱ
‘’œȱŽ—Ž›¢ȱ’œȱœ˜›Žȱ’—ȱ‘Žȱ’—’’˜—ȱ–˜ž•ŽȱŒ˜’•œǯȱ‘Žȱœ˜›ŽȱŽ—Ž›¢ȱ’œȱ‘Ž—ȱ›Š—œŽ››ŽȱŸ’Šȱ’—’’Š’˜—ȱ˜ȱŠȱ
œŽ–’Œ˜—žŒ˜›ȱœ ’Œ‘ǯȱ‘Žȱ›Žœž•’—ȱŸ˜•ŠŽȱ‹ž’•ȱž™ȱ’—ȱ‘Žȱ™›’–Š›¢ȱŒ˜’•ȱŒŠžœŽœȱŠȱœ’–’•Š›ȱŸ˜•ŠŽȱ‹ž’•ȱž™ȱ’—ȱ‘Žȱ
‘’‘ȱŸ˜•ŠŽȱœŽŒ˜—Š›¢ȱŒ˜’•ǰȱŒŠ••Žȱ›Š—œ˜›–Ž›ȱŠŒ’˜—ǯȱ‘’œȱŸ˜•ŠŽȱ’—’’ŠŽœȱŠȱœ™Š›”ȱ‘Šȱ“ž–™œȱŠŒ›˜œœȱ‘Žȱœ™Š›”ȱ
™•žȂœȱŠ™ȱ ‘’Œ‘ȱ’—’Žœȱ‘ŽȱžŽ•ȬŠ’›ȱ–’¡ž›Žȱ’—ȱ‘ŽȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ǯȱ ˜ȱ¢™Žœȱ˜ȱ’—’’˜—ȱ–˜ž•ŽœȱŠ›ŽȱžœŽȱ
˜—ȱ‘ŽœŽȱŽ—’—ŽœǰȱŒŠ™ŠŒ’’ŸŽȱ’œŒ‘Š›Žȱ’—’’˜—ȱǻǼǰȱŠ—ȱ’—žŒ’ŸŽȱ’œŒ‘Š›Žȱ’—’’˜—ȱǻǼǯȱŽŽȱ’ž›ŽœȱŝȬŘȱŠ—ȱ
ŝȬřǯ

Spark Plug Boot

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

Figure 7-2. Capacitive Discharge Ignition System (CDI).

CDI Module Operation ‘Žȱœ¢œŽ–ȱŒ˜—œ’œœȱ˜ȱ‘Žȱ˜••˜ ’—ȱŒ˜–™˜—Ž—œDZ

œȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›˜ŠŽœȱŠ—ȱ‘Žȱ–Š—Žȱ™ŠœœŽœȱ‘Žȱȱ
’—’’˜—ȱ–˜ž•Žǰȱ‘Žȱ–Š—Ž’Œȱꎕȱ’—žŒŽœȱŒž››Ž—ȱ ȱ Ȋȱ Š—Žœǰȱ™Ž›–Š—Ž—•¢ȱŠĜ¡Žȱ˜ȱĚ¢ ‘ŽŽ•ǯ
’—ȱ‘ŽȱŒ‘Š›’—ȱŒ˜’•ǯȱ‘ŽȱŒž››Ž—ȱ™ž•œŽȱ’œȱ›ŽŒ’ꮍȱ‹¢ȱŠȱ
’˜ŽȱŠ—ȱ‘’œȱœ’—Š•ȱŒ‘Š›ŽœȱŠȱ‘’‘ȬŸ˜•ŠŽȱŒŠ™ŠŒ’˜›ǯȱ ȱ Ȋȱ ™Š›”ȱ™•žȱ ’‘ȱ›ž‹‹Ž›ȱ‹˜˜ǯ
œȱ‘Žȱ–Š—ŽȱŒ˜–™•ŽŽœȱ’œȱ™ŠœœǰȱŠȱŒ‘Š—Žȱ’—ȱ™˜•Š›’¢ȱ
˜ȱ‘Žȱœ’—Š•ȱ™›˜žŒŽȱ‹¢ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ–Š—Žȱž›—œȱ ȱ Ȋȱ •ŽŒ›˜—’ŒǰȱŒŠ™ŠŒ’’ŸŽȱ’œŒ‘Š›Žȱ’—’’˜—ȱ–˜ž•Žȱ
˜—ȱ‘ŽȱœŽ–’Œ˜—žŒ˜›ȱœ ’Œ‘ǰȱŠ—ȱ’›ŽŒ•¢ȱŒ˜——ŽŒœȱ –˜ž—Žȱ˜—ȱŽ—’—ŽȱŒ›Š—”ŒŠœŽǯȱ
the charged capacitor to the primary coil of the
›Š—œ˜›–Ž›ǯȱœȱ‘ŽȱŒŠ™ŠŒ’˜›ȱ’œŒ‘Š›ŽœȱŽ—Ž›¢ǰȱ‘Žȱ ȱ Ȋȱ ’••ȱœ ’Œ‘ȱǻ˜›ȱ”Ž¢ȱœ ’Œ‘ǼDzȱ›˜ž—œȱ–˜ž•Žȱ˜ȱ
•˜ ȱŸ˜•ŠŽȱŠȱ‘Žȱ™›’–Š›¢ȱ ’—’—ȱ’œȱ›Š—œ˜›–Žȱ stop engine.
˜ȱ‘’‘ȱŸ˜•ŠŽȱ’—ȱ‘ŽȱœŽŒ˜—Š›¢ȱ ’—’—ȱ˜ȱ‘Žȱ
–˜ž•Žǯȱȱ‘’‘ȱŸ˜•ŠŽȱ™ž•œŽȱ’œȱ‘Ž—ȱŽ•’ŸŽ›Žȱ˜ȱ‘Žȱ ȱ Ȋȱ ’••ȱŽ›–’—Š•ǰȱ–˜ž—Žȱ˜—ȱ‹ŠŒ”ȱ˜ȱ–˜ž•Žǯ
œ™Š›”ȱ™•žǰȱ ‘Ž›Žȱ’ȱŠ›ŒœȱŠŒ›˜œœȱ‘ŽȱŽ•ŽŒ›˜ŽȱŠ™ȱŠ—ȱ
’—’Žœȱ‘ŽȱžŽ•ȱ’—ȱ‘ŽȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ǯ

7.3
Section 7
Electrical System and Components

Spark Plug Boot

Air Gap
0.254 mm Ignition
(0.010 in.) Module

Spark Plug
Spark Plug
Terminal (C)
Lamination (A)
Magnets

Flywheel
Ignition Module
(Enlarged View)

Kill Switch or Off

Position of Key Switch Kill Terminal

Figure 7-3. Inductive Discharge Ignition System.

IDI Module Operation ȱ Ȋȱ ’••ȱœ ’Œ‘ȱǻ˜›ȱ”Ž¢ȱœ ’Œ‘ǼDzȱ›˜ž—œȱ–˜ž•Žȱ˜ȱ

œȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›˜ŠŽœȱŠ—ȱ‘Žȱ–Š—Žȱ™ŠœœŽœȱ‘Žȱȱ stop engine.
’—’’˜—ȱ–˜ž•Žǰȱ‘Žȱ–Š—Ž’Œȱꎕȱ’—žŒŽœȱŒž››Ž—ȱ
’—ȱ‘Žȱ™›’–Š›¢ȱŒ˜’•ǯȱ‘’œȱœ˜›ŽœȱŽ—Ž›¢ȱ’—ȱ‘ŽȱŒ˜’•Ȃœȱ ȱ Ȋȱ ’••ȱŽ›–’—Š•ǰȱ–˜ž—Žȱ˜—ȱ‘Žȱœ’Žȱ˜ȱ‘Žȱ–˜ž•Žǯ
–Š—Ž’ŒȱŒ’›Œž’ǯȱœȱ‘Žȱ’—’’˜—ȱ–Š—ŽȱŒ˜–™•ŽŽœȱ
’œȱ™Šœœǰȱ’ȱ’—žŒŽœȱŒž››Ž—ȱ’—ȱŠȱœ–Š••ȱ›’Ž›’—ȱŒ˜’•ǰȱ
 ‘’Œ‘ȱ‘Ž—ȱž›—œȱ˜—ȱŠȱœŽ–’Œ˜—žŒ˜›ȱœ ’Œ‘ǯȱ‘’œȱ
Troubleshooting and Testing Ignition
ŒŠžœŽœȱ‘Žȱ™›ŽŸ’˜žœ•¢ȱ’—žŒŽȱ–Š—Ž’Œȱꎕȱ’—ȱ
—’’˜—ȱ™›˜‹•Ž–œȱŠ›Žȱ–˜œȱ˜ĞŽ—ȱžŽȱ˜ȱ™˜˜›ȱ˜›ȱ•˜˜œŽȱ
‘Žȱ™›’–Š›¢ȱŒ˜’•ȱ˜ȱŒ˜••Š™œŽǯȱœȱ‘Žȱ–Š—Ž’Œȱꎕȱ
Œ˜——ŽŒ’˜—œǯȱŽ˜›Žȱ‹Ž’——’—ȱŠ—¢ȱŽœȱ™›˜ŒŽž›Žȱ
‹Ž’—œȱ˜ȱŒ˜••Š™œŽǰȱ‘ŽȱŒ˜’•ȱ›’Žœȱ˜ȱ›Žœ’œȱ‘Žȱ›˜™ȱ
Œ‘ŽŒ”ȱŠ••ȱŽ¡Ž›—Š•ȱ ’›’—ǯȱŽȱŒŽ›Š’—ȱŠ••ȱ’—’’˜—Ȭ›Ž•ŠŽȱ
’—ȱŽ•ŽŒ›’Œ’¢ǯȱ›Š—œ˜›–Ž›ȱŠŒ’˜—ȱ’—ȱž›—ȱŒŠžœŽœȱ‘Žȱ
 ’›ŽœȱŠ›ŽȱŒ˜——ŽŒŽǰȱŠ—ȱŠ••ȱŽ›–’—Š•ȱŒ˜——ŽŒ’˜—œȱęȱ
Ÿ˜•ŠŽȱ’—ȱ‘ŽȱœŽŒ˜—Š›¢ȱŒ˜’•ȱ˜ȱ›’œŽȱšž’Œ”•¢ǯȱ‘’œȱ
œ—ž•¢ǯȱŠ”Žȱœž›Žȱ‘Žȱ’—’’˜—ȱœ ’Œ‘ȱ’œȱ’—ȱ‘Žȱ›ž—ȱ
œ‘Š›™ȱ›’œŽȱ’—ȱŸ˜•ŠŽȱ‹›ŽŠ”œȱ˜ —ȱ‘ŽȱŠ’›Ȭ˜ȬžŽ•ȱ
position.
–’¡ž›Žȱ’—ȱ‘Žȱœ™Š›”ȱ™•žȂœȱŠ™ǰȱŠ—ȱŒ›ŽŠŽœȱŠȱœ™Š›”ȱ
‘Šȱ’—’ŽœȱžŽ•ȱ’—ȱ‘ŽȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ǯ
˜‘ȱ‘ŽȱȱŠ—ȱȱ’—’’˜—ȱœ¢œŽ–œȱŠ›ŽȱŽœ’—Žȱ
‘Žȱœ¢œŽ–ȱŒ˜—œ’œœȱ˜ȱ‘Žȱ˜••˜ ’—ȱŒ˜–™˜—Ž—œDZ ˜ȱ‹Žȱ›˜ž‹•Žȱ›ŽŽȱ˜›ȱ‘Žȱ•’Žȱ˜ȱ‘ŽȱŽ—’—Žǯȱ‘Ž›ȱ‘Š—ȱ
™Ž›’˜’ŒŠ••¢ȱŒ‘ŽŒ”’—ȱ˜›ȱ›Ž™•ŠŒ’—ȱ‘Žȱœ™Š›”ȱ™•žǰȱ
ȱ Ȋȱ Š—Žœǰȱ™Ž›–Š—Ž—•¢ȱŠĜ¡Žȱ˜ȱĚ¢ ‘ŽŽ•ǯ —˜ȱ–Š’—Ž—Š—ŒŽȱ˜›ȱ’–’—ȱŠ“žœ–Ž—ȱ’œȱ—ŽŒŽœœŠ›¢ȱ˜›ȱ
™˜œœ’‹•Žǯȱ‘Žȱ’—’’˜—ȱ–˜ž•ŽȱŠž˜–Š’ŒŠ••¢ȱŒ˜—›˜•œȱ
ȱ Ȋȱ ™Š›”ȱ™•žȱ ’‘ȱ–ŽŠ•ȱ‹˜˜ǯ ‘Žȱ’–’—ȱ˜ȱ‘Žȱœ™Š›”ǯȱ

ȱ Ȋȱ •ŽŒ›˜—’Œǰȱ’—žŒ’ŸŽȱ’œŒ‘Š›Žȱ’—’’˜—ȱ–˜ž•Žȱ ŽŒ‘Š—’ŒŠ•ȱœ¢œŽ–œȱ˜ȱ˜ŒŒŠœ’˜—Š••¢ȱŠ’•ȱ˜›ȱ‹›ŽŠ”ȱ
–˜ž—Žȱ˜—ȱŽ—’—ŽȱŒ›Š—”ŒŠœŽǯȱ ˜ —ǰȱ‘˜ ŽŸŽ›ǰȱœ˜ȱ‘Žȱ˜••˜ ’—ȱ›˜ž‹•Žœ‘˜˜’—ȱ
information is provided to help systematically
ŽŽ›–’—Žȱ‘ŽȱŒŠžœŽȱ˜ȱŠȱ›Ž™˜›Žȱ™›˜‹•Ž–ǯ

7.4

Ignition System Troubleshooting Guide
Problem Test
ŗǯȱȱ Š”Žȱœž›Žȱœ™Š›”ȱ™•žȱ•ŽŠȱ’œȱ
Œ˜——ŽŒŽȱ˜ȱ‘Žȱœ™Š›”ȱ™•žǯ
Řǯȱȱ ‘ŽŒ”ȱŒ˜—’’˜—ȱ˜ȱœ™Š›”ȱ™•žǯȱŠ”Žȱ 2.
œž›ŽȱŠ™ȱ’œȱœŽȱ˜ 0.762 mm (0.030 in.).
řǯȱȱ Žœȱ˜›ȱœ™Š›”ȱ ’‘ȱ’—’’˜—ȱŽœŽ›ǯȱ
ǯȱȱŸ’œ’‹•ŽȱŠ—ȱŠž’‹•Žȱ
a. ’œŒ˜——ŽŒȱœ™Š›”ȱ™•žȱ•ŽŠȱŠ—ȱ
connect to post terminal of tester.
ŽŽȱ’ž›ŽȱŝȬŚǯȱ˜——ŽŒȱŒ•’™ȱ˜ȱ
›˜ž—ǰȱ—˜ȱ˜ȱœ™Š›”ȱ™•žǯ
DZȱ˜ȱ–Š’—Š’—ȱŽ—’—Žȱ
œ™ŽŽœȱ˜‹Š’—Žȱž›’—ȱŒ›Š—”’—ǰȱ
˜ȱ—˜ȱ›Ž–˜ŸŽȱœ™Š›”ȱ™•žǯ
Engine Will Not Start
ǰȱ’—’’˜—ȱ
‹ǯȱ ž›—ȱŽ—’—Žȱ’—’’˜—ȱœ ’Œ‘ȱ˜ȱ
ȱ™˜œ’’˜—ȱ˜ȱ’—’’ŠŽȱŽœǯ
c. ›Š—”ȱŽ—’—Žȱ˜ȱ–’—’–ž–ȱ˜ȱśŖŖȱ
ǰȱŠ—ȱ˜‹œŽ›ŸŽȱŽœŽ›ǯȱ’œ’‹•Žȱ
Š—ȱŠž’‹•Žȱœ™Š›”œȱœ‘˜ž•ȱ‹Žȱ
™›˜žŒŽǯ
ǯȱ Ž•ŽŠœŽȱœ ’Œ‘ȱ˜ȱȱ™˜œ’’˜—ǯȱ
’œ’‹•ŽȱŠ—ȱŠž’‹•Žȱœ™Š›”œȱ
œ‘˜ž•ȱ‹Žȱ™›˜žŒŽǯ
Śǯȱȱ ŽŠœž›Žȱ‘Žȱ›Žœ’œŠ—ŒŽȱ˜ȱ–˜ž•Žȱ
œŽŒ˜—Š›¢ȱžœ’—ȱŠ—ȱ˜‘––ŽŽ›ǯȱŽŽȱ
’ž›ŽȱŝȬśǼǯ
Ž›˜ȱ˜‘––ŽŽ›ȱ‹Ž˜›ŽȱŽœ’—ǯȱ
Connect one ohmmeter lead to
•Š–’—Š’˜—œȱǻǼǯȱ˜——ŽŒȱ‘Žȱ˜‘Ž›ȱ
ǯ
•ŽŠȱ˜ȱ‘Žȱœ™Š›”ȱ™•žȱŽ›–’—Š•ȱ
ǻǼȱ˜ȱ‘’‘ȬŽ›–’—Š•ȱ•ŽŠǯȱ’‘ȱ
ohmmeter leads connected in this
–Š——Ž›ǰȱ›Žœ’œŠ—ŒŽȱ˜ȱ‘Žȱȱ–˜ž•Žȱ
œŽŒ˜—Š›¢ȱœ‘˜ž•ȱ‹Žȱ4000 to 12,000
ohmsǯȱŽœ’œŠ—ŒŽȱ˜ȱ‘Žȱȱ–˜ž•Žȱ
œŽŒ˜—Š›¢ȱœ‘˜ž•ȱ‹Žȱ2700 to 8600
ohms.
DZȱ ‘’œȱŽœȱŒŠ——˜ȱ‹Žȱ
™Ž›˜›–Žȱž—•Žœœȱ–˜ž•Žȱ
‘Šœȱ‹ŽŽ—ȱꛎȱŠȱ•ŽŠœȱ˜—ŒŽǯ
Section 7
Electrical System and Components
Conclusion
ŗǯȱȱ ™Š›”ȱ™•žȱ’œȱ—˜ȱ›ŽŒŽ’Ÿ’—ȱ’—’’˜—ȱ™ž•œŽǯ
ȱ™•žȱ’œȱ’—ȱ˜˜ȱŒ˜—’’˜—ǰȱŒ‘ŽŒ”ȱŠ™ȱŠ—ȱŠ“žœȱ
’ȱ—ŽŒŽœœŠ›¢Dzȱ›Ž’—œŠ••ȱ™•žǯ
3. ȱŸ’œ’‹•ŽȱŠ—ȱŠž’‹•Žȱœ™Š›”œȱareȱ™›˜žŒŽǰȱ
’—’’˜—ȱ–˜ž•Žȱ’œȱ
œ™Š›”œȱare notȱ™›˜žŒŽDZȱ
a. Š”Žȱœž›Žȱ’—’’˜—ȱœ ’Œ‘ǰȱ”’••ȱœ ’Œ‘ȱ˜›ȱ”Ž¢ȱ
œ ’Œ‘ȱ’œȱ’—ȱ‘Žȱȱ™˜œ’’˜—ǯ
‹ǯȱ ‘ŽŒ”ȱ ’›ŽœȱŠ—ȱŽ›–’—Š•œȱ˜ȱ’—’’˜—ȱ
–˜ž•Ž and other components for accidental
›˜ž—’—ȱŠ—ȱŠ–ŠŽȱ’—œž•Š’˜—ǯ
c. ȱ ’›ŽœȱŠ—ȱŽ›–’—Š•œȱŠ›Žȱ
–˜ž•Žȱ’œȱ™›˜‹Š‹•¢ȱŠž•¢ȱŠ—ȱœ‘˜ž•ȱ‹Žȱ
›Ž™•ŠŒŽǯȱŽœȱ–˜ž•Žȱž›‘Ž›ȱžœ’—ȱŠ—ȱ
ohmmeter (Test 4).
ǯȱ ‘ŽŒ”ȱœŠŽ¢ȱœ ’Œ‘Žœȱǻ˜›ȱŽ¡Š–™•ŽDZȱœŽŠȬ
–˜ž—Žȱ”’••ȱœ ’Œ‘Ǽȱand other components
for ŠŒŒ’Ž—Š•ȱ›˜ž—’—ǯ
7
DZȱ˜›ȱž›‘Ž›ȱ’—˜›–Š’˜—ǰȱ›ŽŽ›ȱ˜ȱ‘Žȱ
˜™Ž›Š’—ȱ’—œ›žŒ’˜—œȱ˜›ȱ‘ŽȱŽšž’™–Ž—ȱ‘’œȱ
Ž—’—Žȱ™˜ Ž›œǯ
4. If the resistance is low or 0 ohmsǰȱ‘Žȱ–˜ž•Žȱ
œŽŒ˜—Š›¢ȱ’œȱœ‘˜›ŽǯȱŽ™•ŠŒŽȱ‘Žȱ–˜ž•Žǯ1
If the resistance is ‘’‘ȱ˜›ȱ’—ę—’¢ȱ˜‘–œ, the
–˜ž•ŽȱœŽŒ˜—Š›¢ȱ’œȱ˜™Ž—ǯȱŽ™•ŠŒŽȱ‘Žȱ–˜ž•Žǯ1
ȱ‘Žȱ›Žœ’œŠ—ŒŽȱ’œȱ ’‘’—ȱ‘Žȱœ™ŽŒ’ꮍȱ›Š—Žǰȱ‘Žȱ
–˜ž•ŽȱœŽŒ˜—Š›¢ȱ’œȱ
1
ŽŽ›ȱ˜ȱ‘Žȱ’œŠœœŽ–‹•¢ȱŠ—ȱŽŠœœŽ–‹•¢ȱŽŒ’˜—œȱ
˜›ȱŒ˜–™•ŽŽȱ’—’’˜—ȱ–˜ž•Žȱ›Ž–˜ŸŠ•ȱŠ—ȱ’—œŠ••Š’˜—ȱ
™›˜ŒŽž›Žœǯ
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

WARNING: Accidental Starts!

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.
The following sequence is a step-by-step guide for 19. Remove governor spring.
complete engine disassembly. This procedure may 20. Remove speed control bracket.
vary depending on the options included. 22. Remove governor lever.
23. Remove fuel tank.
Thoroughly clean all engine parts during the 24. Disconnect kill lead from ignition module.
disassembly process. This allows for more accurate 25. Remove ignition module.
inspection and gauging of the engine for wear or ŘŜǯȱ ’œŒ˜——ŽŒȱĚ¢ ‘ŽŽ•ȱ‹›Š”Žȱœ™›’—ǯ
damage. Use a commercial cleaner to remove grease, Řŝǯȱ Ž–˜ŸŽȱĚ¢ ‘ŽŽ•ȱ—žȱŠ—ȱ›’ŸŽȱŒž™ǯ
oil, and grime from engine parts. When such a cleaner 28. Remove fan.
is used, follow the manufacturer’s instructions and Řşǯȱ Ž–˜ŸŽȱĚ¢ ‘ŽŽ•ǯ
safety precautions carefully. 30. Remove breather cover.
31. Remove breather spring, disc and screen.
Remove all traces of cleaners before the engine is 32. Remove spark plug.
reassembled and placed into operation. Even small řřǯȱ Ž–˜ŸŽȱĚ¢ ‘ŽŽ•ȱ‹›Š”ŽȱŠœœŽ–‹•¢ǯ
amounts of these cleaners can quickly break down the 34. Remove valve cover and gasket.
lubricating properties of engine oil. 35. Remove jam nuts and rocker arm pivots.
36. Remove rocker arms
Basic Disassembly Sequence 37. Remove push rods.
1. Disconnect spark plug lead.
38. Remove guide plate. 8
39. Remove rocker studs.
2. Ensure fuel tank is empty.
40. Remove cylinder head.
3. Remove fuel cap.
41. Remove valves.
4. Drain oil from crankcase.
42. Remove dipstick tube.
5. Remove engine cover insert.
43. Remove oil pan and gasket.
6. Remove engine cover.
ŚŚǯȱ Ž–˜ŸŽȱŒŠ–œ‘ŠĞǯ
7. Remove recoil.
45. Remove governor gear and retainer.
8. Remove blower housing.
ŚŜǯȱ Ž–˜ŸŽȱ˜ŸŽ›—˜›ȱ‘’Œ‘™’—ȱŠ—ȱœ‘ŠĞǯ
şǯȱ Ž–˜ŸŽȱ–žĝŽ›ȱžŠ›ǯ
47. Remove tappets.
ŗŖǯȱ Ž–˜ŸŽȱ–žĝŽ›ȱŠ—ȱ‘ŽŠȱŽĚŽŒ˜›ȱŠœ”Žǯ
48. Remove connecting rod cap.
ŗŗǯȱ Ž–˜ŸŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŒ˜ŸŽ›ȱŠ—ȱꕝŽ›ǻœǼǯ
49. Remove piston with connecting rod.
12. Disconnect breather hose.
śŖǯȱ Ž–˜ŸŽȱŒ›Š—”œ‘ŠĞǯ
13. Remove air cleaner base.
14. Disconnect primer hose.
15. Disconnect fuel line.
16. Remove carburetor.
17. Disconnect carburetor linkage.
18. Remove carburetor gaskets.

8.1
Section 8
Disassembly

Detailed Disassembly Sequence ȱ Śǯȱ Ў›ȱ‘ŽȱŒ›Š—”ŒŠœŽȱ’œȱŒ˜–™•ŽŽ•¢ȱ›Š’—Žǰȱ’•ȱ‘Žȱ

engine back to level.

WARNING: Explosive Fuel!

Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ Drain Oil Via Crankcase Plug (If Accessible)
’ȱ’—’Žǯȱ˜›ŽȱŠœ˜•’—Žȱ˜—•¢ȱ’—ȱŠ™™›˜ŸŽȱŒ˜—Š’—Ž›œǰȱ’—ȱ 1. To keep dirt, grass clippings, and other debris out
 Ž••ȱŸŽ—’•ŠŽǰȱž—˜ŒŒž™’Žȱ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ ˜ȱ‘ŽȱŽ—’—ŽǰȱŒ•ŽŠ—ȱ‘ŽȱŠ›ŽŠȱŠ›˜ž—ȱ‘Žȱ˜’•ȱꕕȱ
̊–ŽœǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—ŽȱŠœȱŠȱŒ•ŽŠ—’—ȱŠŽ—ǯ cap/dipstick, and then remove it.

Disconnect Spark Plug ȱ Řǯȱ Ž–˜ŸŽȱ‘ŽȱŒ›Š—”ŒŠœŽȱ™•žȱ˜—ȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ

1. Disconnect the spark plug lead. engine. See Figure 8-2.

Empty Fuel Tank

1. Ensure the fuel tank is empty by running the
engine until it stops, and is completely out of
fuel.

2. Remove the gas cap.

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
˜ȱ‘ŽȱŽ—’—ŽǰȱŒ•ŽŠ—ȱ‘ŽȱŠ›ŽŠȱŠ›˜ž—ȱ‘Žȱ˜’•ȱꕕȱ
cap/dipstick.
Remove Engine Cover Insert and Cover
1. Remove the four Torx screws securing the engine
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ǯ
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

Figure 8-3. Removing Engine Cover Insert

Oil Flow
Figure 8-1. Draining Oil from Dipstick Tube.

8.2
 Section 8
Disassembly

ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‘›ŽŽȱ‘Ž¡ȱ̊—Žȱ—žœȱŠ—ȱ ˜ȱ‘Ž¡ȱ Remove Blower Housing

̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘ŽȱȱŽ—’—ŽȱŒ˜ŸŽ›ǯȱŽŽȱ ȱ ŗǯȱ ’Ğȱ˜ěȱ‘Žȱ‹•˜ Ž›ȱ‘˜žœ’—ȱŠ—ȱ›ŽŠ’—ȱ‘Žȱ‘›ŽŽȱ
Figure 8-4. stud spacers. See Figure 8-6.

3. Remove the engine cover.

.001 Figure 8-6. Removing Blower Housing.

Figure 8-4. Removing Engine Cover.

5HPRYH0XIÀHU$VVHPEO\
Remove Recoil Starter ȱ ŗǯȱ Ž–˜ŸŽȱ ˜ȱ‘Ž¡ȱ̊—Žȱ—žœȱœŽŒž›’—ȱ‘Žȱ‘ŽŠȱ
ȱ ŗǯȱ ’Ğȱ˜ěȱ‘Žȱ›ŽŒ˜’•ȱœŠ›Ž›ǯȱŽŽȱ’ž›ŽȱŞȬśǯ guard to the cylinder head. See Figure 8-7.

.001 Figure 8-5. Removing Recoil. )LJXUH5HPRYLQJ0XIÀHU+HDW*XDUG

8.3
Section 8
Disassembly
ȱ Řǯȱ ȱ•’Žȱ‘Žȱ–žĝŽ›ȱ˜ěȱ‘ŽȱœžœǯȱŽŽȱ’ž›ŽȱŞȬŞǯ

Hex Nuts
Hex Flange Screw

Figure 8-10. Removing Air Cleaner Base.

4. Detach the breather hose from the crankcase. See

)LJXUH5HPRYLQJ0XIÀHU Figure 8-11.

ȱ řǯȱ Ž–˜ŸŽȱ‘Žȱ‘ŽŠȱŽĚŽŒ˜›ȱŠœ”Žȱ›˜–ȱ‘Žȱ
exhaust studs, noting orientation.

Remove Air Cleaner Assembly

1. Unscrew the knob on the air cleaner assembly
and remove the cover. See Figure 8-9.

Figure 8-11. Detaching Breather Hose.

5. Remove the air cleaner base and detach the

™›’–Ž›ȱ‘˜œŽȱ›˜–ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱǻ™›’–Ž›ȱ‹ž•‹ȱ
Žšž’™™Žȱ–˜Ž•œȱ˜—•¢ǼǯȱŽŽȱ’ž›ŽȱŞȬŗŘǯ

Air Cleaner
Base Gasket
Figure 8-9. Removing Air Cleaner Cover.
Primer
2. Remove the paper element and the foam
Hose
™›ŽŒ•ŽŠ—Ž›ȱǻ’ȱŽšž’™™ŽǼǯ

ȱ řǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ—žœȱŠ—ȱ‘Žȱ‘Ž¡ȱ̊—Žȱ
screw securing the air cleaner base to the cylinder
head and the crankcase. See Figure 8-10.

Figure 8-12. Disconnecting Primer Hose.

6. Remove the air cleaner base gasket from the

carburetor, noting orientation. See Figure 8-12.

8.4
 Section 8
Disassembly

Remove Carburetor Assembly

NOTE: Ensure the fuel tank is empty by running the Spring Linkage
engine until it stops, and is completely out of Rod Linkage
fuel.

Remove Choke-less Carburetor

1. Squeeze the hose clamp and slide it and the fuel
‘˜œŽȱ˜ěȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱŽŽȱ’ž›ŽȱŞȬŗřǯȱ

Throttle Lever
Figure 8-15. Disconnecting Carburetor Linkage.

ȱ Śǯȱ •’Žȱ˜ěȱ‘ŽȱŒŠ›‹ž›Ž˜›ȇœȱ‘ŽŠȱœ‘’Ž•ǰȱ‘ŽŠȱœ™ŠŒŽ›ǰȱ
and spacer gasket, noting the sequence. See
Figure 8-16.

Hose Clamp

Figure 8-13. Disconnecting Fuel Line.

2. Slide carburetor to the end of the intake studs.

See Figure 8-14.
Spacer Gasket
ȱ Řǯȱ ’‘ȱ‘Žȱ‘›˜Ĵ•Žȱ•’—”ŠŽȱœ’••ȱŠĴŠŒ‘Žǰȱœ•’Žȱ
‘ŽȱŠœ”ŽȱŠ—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ˜ěȱ‘ŽȱœžœǯȱŽŽȱ Head Spacer
Figure 8-15. Heat Shield
8
Figure 8-16. Carburetor Gasket Sequence.

Remove Carburetor with Choke

1. Squeeze the hose clamp and slide it and the fuel
‘˜œŽȱ˜ěȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱŽŽȱ’ž›ŽȱŞȬŗŝǯ

Figure 8-14. Removing Carburetor.

ȱ řǯȱ ž›—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱŒ•˜Œ” ’œŽȱž—’•ȱ’ȱœ˜™œǯ
Gently push the rod and spring linkages up
˜ȱ’œŒ˜——ŽŒȱ‘Ž–ȱ›˜–ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ǯȱŽŽȱ
Figure 8-15.

Figure 8-17. Disconnecting Fuel Line.

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 ž›—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱŒ•˜Œ” ’œŽȱž—’•ȱ’ȱœ˜™œǯ
Gently push the rod and spring linkages up
˜ȱ’œŒ˜——ŽŒȱ‘Ž–ȱ›˜–ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ǯȱŽŽȱ
Figure 8-15.

4. Rotate the carburetor until the choke linkage can

be disconnected from the carburetor. See Figure
8-18.

Figure 8-20. Removing Governor Spring.

Remove Speed Control Bracket

ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ
speed control bracket. See Figure 8-21.
Choke Linkage
Figure 8-18. Disconnecting Choke Linkage.

ȱ śǯȱ •’Žȱ˜ěȱ‘ŽȱŒŠ›‹ž›Ž˜›ȇœȱ‘ŽŠȱœ‘’Ž•ǰȱ‘ŽŠȱœ™ŠŒŽ›ǰȱ
and spacer gasket, noting the sequence. See
Figure 8-19.

Figure 8-21. Removing Speed Control Bracket.

Spacer Gasket
NOTE: The fuel hose connecting the carburetor
Head Spacer and the fuel tank is held in place by a
plastic ring, mounted on the back of
Heat Shield the speed control bracket. If the bracket
is removed from the crankcase, it will
›Ž–Š’—ȱŠĴŠŒ‘Žȱ˜ȱ‘ŽȱžŽ•ȱ‘˜œŽȱ‹¢ȱ
Figure 8-19. Carburetor Gasket Sequence. ‘ŽȱžŽ•ȱꕝŽ›ȱǻ—˜ȱ’—Œ•ž’—ȱŠ•’˜›—’Šȱ
Ž—’—ŽœǼǯȱ‘˜ž•ȱ›Ž™•ŠŒŽ–Ž—ȱ˜ȱ‘Žȱ
speed bracket be required, disconnect
‘ŽȱžŽ•ȱꕝŽ›ȱŠ—ȱœ•’Žȱ‘Žȱ‹›ŠŒ”Žȱ˜ěȱ
the hose. Do not disconnect the fuel hose
from the fuel tank.

8.6
 Section 8
Disassembly

Remove Governor Lever

1. Loosen the governor lever hex nut and slide the
•ŽŸŽ›ȱ˜ěȱ‘Žȱ˜ŸŽ›—˜›ȱœ‘ŠĞǯȱŽŽȱ’ž›ŽȱŞȬŘŘǯ

Figure 8-24. Removing Fuel Tank.

Governor Lever Hex Nut Remove Ignition Module

1. Disconnect the kill lead from the ignition module.
Figure 8-22. Removing Governor Lever. See Figure 8-25.

Remove Fuel Tank

1. Ensure the fuel tank is empty by running the
engine until it stops, and is completely out of
fuel.

2. Detach the fuel tank from the crankcase bracket

‹¢ȱ›Ž–˜Ÿ’—ȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œǯȱŽŽȱ
Figure 8-23

8
Bracket Screws Figure 8-25. Disconnecting Kill Lead.

ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱŠ—ȱ‘Žȱœžȱ
securing the ignition module. Mark the stud for
Hex Nut Bracket ’Ž—’ęŒŠ’˜—ȱž›’—ȱ›ŽŠœœŽ–‹•¢ǯȱŽŽȱ’ž›ŽȱŞȬŘŜǯ

Figure 8-23. Detaching Fuel Tank Bracket.

3. Remove the two studs securing the top of the fuel

Š—”ȱŠ—ȱ•’Ğȱ˜ěȱ‘ŽȱŠ—”ǯȱŽŽȱ’ž›ŽȱŞȬŘŚǯ

NOTE: Disassembly does not require the fuel tank

‹›ŠŒ”Žȱ‹Žȱ›Ž–˜ŸŽȱ›˜–ȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ
tank. If removal is to be performed, unscrew
the two hex bracket screws. See Figure 8-23.
Figure 8-26. Removing Ignition Module.

8.7
Section 8
Disassembly

Disconnect Flywheel Brake Spring

ȱ ŗǯȱ ›Šœ™ȱ˜—ŽȱŽ—ȱ˜ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ‹›ŽŠ”ȱœ™›’—ȱ ’‘ȱ
a pliers and stretch it to disconnect it. See Figure
8-27.

Figure 8-29. Removing Flywheel (Top View).

ȱ Śǯȱ Ž–˜ŸŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ”Ž¢ȱ›˜–ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱ
See Figure 8-30.

Remove Breather Assembly

ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ
Figure 8-27. Disconnecting Flywheel Brake Spring. breather cover. See Figure 8-30. Remove cover.

Remove Flywheel Flywheel

ȱ ŗǯȱ œ’—ȱŠȱĚ¢ ‘ŽŽ•ȱœ›Š™ȱ ›Ž—Œ‘ȱ˜ȱ‘˜•ȱ‘Žȱ Key
Ě¢ ‘ŽŽ•ȱ’—ȱ™•ŠŒŽǰȱ›Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ—žȱ’—œ’Žȱ‘Žȱ
drive cup. See Figure 8-28.

Breather
Cover

Figure 8-30. Removing Breather Cover.

2. Remove the breather spring, disc and screen. See

Drive Cup
Figure 8-31.

Figure 8-28. Removing Flywheel Nut (Top View).

ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ›’ŸŽȱŒž™ȱŠ—ȱ•’Ğȱ˜ěȱ‘ŽȱŠ—ǰȱ—˜’—ȱ
˜›’Ž—Š’˜—ȱ˜—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ˜›ȱ›ŽŠœœŽ–‹•¢ǯ

ȱ řǯȱ ‘ŽȱĚ¢ ‘ŽŽ•ȱ’œȱ–˜ž—Žȱ˜—ȱŠȱŠ™Ž›Žȱœ‘ŠĞǯȱ˜ȱ
›Ž–˜ŸŽȱ’ǰȱžœŽȱŠȱ›ž‹‹Ž›ȱ–Š••Žȱ˜ȱ•Š—ȱŠȱꛖȱ‹•˜ ǰȱ
œ•’‘•¢ȱ˜ěȱŒŽ—Ž›ȱ˜—ȱ‘ŽȱĚ¢ ‘ŽŽ•ǯȱŽŽȱ’ž›ŽȱŞȬ
29.

Figure 8-31. Removing Spring, Disc, and Screen

8.8
 Section 8
Disassembly

Remove Spark Plug Remove Valve Cover

1. Remove the spark plug from the cylinder head. ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ˜ž›ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱ›˜–ȱ‘ŽȱŸŠ•ŸŽȱ
See Figure 8-32. cover.
2. Remove the cover and the gasket. See Figure 8-34.

Figure 8-32. Removing Spark Plug.

Figure 8-34. Removing Valve Cover.

Remove Flywheel Brake Assembly

ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ Remove Jam Nuts and Pivots
Ě¢ ‘ŽŽ•ȱ‹›Š”ŽȱŠœœŽ–‹•¢Dzȱ›ŽŠ’—ȱ‘Žȱœ™ŠŒŽ›œǯȱŽŽȱ 1. Use a socket and wrench to remove the jam nuts
Figure 8-33. and the rocker-arm pivots from the rocker studs.
See Figure 8-35.

Figure 8-33. Removing Flywheel Brake Assembly.

Figure 8-35. Removing Jam Nuts and Pivots.

8.9
Section 8
Disassembly

Remove Rocker Arms Remove Rocker Studs

ȱ ŗǯȱ ˜’—ȱ˜›’Ž—Š’˜—ǰȱ•’Ğȱ‘Žȱ›˜Œ”Ž›ȱŠ›–œȱ˜ěȱ˜ȱ‘Žȱ 1. Unscrew and remove the rocker studs from the
rocker studs. See Figure 8-36. cylinder head. See Figure 8-38.

Figure 8-36. Removing Rocker Arms.

Figure 8-38. Removing Rocker Studs.
Remove Push Rods
1. Remove the push rods and mark them for Remove Guide Plate
reinstallation. See Figure 8-37. 1. Remove the guide plate from the rocker studs.
See Figure 8-39.

Figure 8-37. Removing Push Rods. Figure 8-39. Removing Guide Plate.

8.10
 Section 8
Disassembly

Remove Cylinder Head

ȱȱŗǯȱ Ž–˜ŸŽȱ‘Žȱ˜ž›ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ
cylinder head. See Figure 8-40.

Figure 8-42. Removing Valve Spring Keepers.

ȱ řǯȱ žœ‘ȱ‘ŽȱŽ—ȱ˜ȱ‘Žȱ’—Š”ŽȱŸŠ•ŸŽȱǻ’ž›ŽȱŞȬŚŘǼȱ˜ȱ
›Ž•ŽŠœŽȱ‘ŽȱŸŠ•ŸŽȱœŽŠ•ȱǻ’ž›ŽȱŞȬŚřǼǰȱŠ—ȱ›Ž–˜ŸŽȱ
both valves from the opposite end of the head
Figure 8-40. Removing Cylinder Head. ǻ’ž›ŽȱŞȬŚŚǼǯȱŠ›”ȱ‘ŽȱŸŠ•ŸŽœȱ ȱŠ—ȱ
EXHAUST for reinstallation.
2. Remove the cylinder head, noting the positioning
of the dowels. See Figure 8-41.
DZȱ —•¢ȱ‘ŽȱŒ¢•’—Ž›ȇœȱ’—Š”ŽȱŸŠ•ŸŽȱ‘Šœȱ
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.

3. Remove the head gasket and discard. See Figure

8-40. Figure 8-43. Removing Valve Seal, Intake Valve

Remove Valve Assembly

1. Push down on the valve spring keepers to release
the valve springs from the valve stems. See Figure
8-42.

2. Remove the valve spring keepers and springs.

Figure 8-44. Removing Valves.

8.11
Section 8
Disassembly

Remove Dipstick Tube

ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱœŽŒž›’—ȱ‘Žȱ
dipstick tube. See Figure 8-45. Remove the tube.

Figure 8-47. Separating Oil Pan from Crankcase.

3. Remove the old gasket and discard.

Figure 8-45. Removing Dipstick Tube.

Remove Camshaft
ŗǯȱ Ž–˜ŸŽȱ‘ŽȱŒŠ–œ‘ŠĞȱ›˜–ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱŽŽȱ
Remove Oil Pan and Gasket Figure 8-48.
ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱœ’¡ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ˜’•ȱ
pan. See Figure 8-46.

Figure 8-48. Removing Camshaft.

Figure 8-46. Removing Oil Pan Screws.

Remove Governor Gear and Shaft
ȱ Řǯȱ œ’—ȱŠȱ̊‘ŽŠȱœŒ›Ž ›’ŸŽ›ȱŠœȱŠȱ ŽŽǰȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱŠ—ȱ‘Žȱ›ŽŠ’—Ž›ȱ
carefully separate the oil pan from the crankcase. securing the governor gear. See Figure 8-49.
See Figure 8-47.

8.12
 Section 8
Disassembly

Retainer Remove Connecting Rod Cap

ȱ ŗǯȱ ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ˜ȱŠ••˜ ȱŠŒŒŽœœȱ˜ȱ‘Žȱ ˜ȱ
‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱ˜—ȱ‘ŽȱŒ˜——ŽŒ’—ȱ›˜ȱŒŠ™ǯȱŽŽȱ
Figure 8-52. Remove the screws and cap.

Gear

Figure 8-49. Removing Governor Gear, Retainer.

ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‘’Œ‘™’—ȱœŽŒž›’—ȱ‘Žȱ˜ŸŽ›—˜›ȱœ‘ŠĞǯȱ
See Figure 8-50. Figure 8-52. Removing Connecting Rod Cap.

Remove Piston
Hitchpin ȱ ŗǯȱ Š›Žž••¢ȱž’Žȱ‘Žȱ™’œ˜—ȱŠ—ȱ‘ŽȱŠĴŠŒ‘Žȱ
connecting rod out of the cylinder bore. See
Figure 8-53.
Governor
Shaft

Figure 8-50. Removing Governor Hitchpin, Shaft. 8

Remove Tappets Figure 8-53. Removing Piston.
ȱ ŗǯȱ Ž–˜ŸŽȱ‘ŽȱŠ™™ŽœǯȱŠ›”ȱ‘Ž–ȱ ȱŠ—ȱȱ
EXHAUST for reinstallation. See Figure 8-51.
Remove Crankshaft
ȱ ŗǯȱ Ž–˜ŸŽȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱŽŽȱ’ž›ŽȱŞȬśŚǯ

Figure 8-51. Removing Tappets.

Figure 8-54. Removing Crankshaft.

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:

Air Cleaner, Section 4

Carburetor and Governor, Section 5
Ignition, Section 7

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

Inspection and Service

Check all gasket surfaces to make sure they are free of gasket fragments and deep scratches or nicks.

‘ŽŒ”ȱ‘ŽȱŒ¢•’—Ž›ȱ Š••ȱ˜›ȱœŒ˜›’—ǯȱ—ȱœŽŸŽ›ŽȱŒŠœŽœǰȱž—‹ž›—ŽȱžŽ•ȱŒŠ—ȱ’œœ˜•ŸŽȱ•ž‹›’ŒŠ’—ȱ˜’•ȱ˜ěȱ‘Žȱ™’œ˜—ȱŠ—ȱ
cylinder wall. Without lubrication, the piston rings would make metal to metal contact with the wall, causing
œŒžĜ—ȱŠ—ȱœŒ˜›’—ǯȱŒ˜›’—ȱ˜ȱ‘ŽȱŒ¢•’—Ž›ȱ Š••ȱŒŠ—ȱŠ•œ˜ȱ‹ŽȱŒŠžœŽȱ‹¢ȱ•˜ŒŠ•’£Žȱ‘˜ȱœ™˜œȱ›˜–ȱ‹•˜Œ”ŽȱŒ˜˜•’—ȱ
ꗜȱ˜›ȱ›˜–ȱ’—ŠŽšžŠŽȱ˜›ȱŒ˜—Š–’—ŠŽȱ•ž‹›’ŒŠ’˜—ǯ
9
Flywheel

Inspection
—œ™ŽŒȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ˜›ȱŒ›ŠŒ”œȱŠ—ȱŒ‘ŽŒ”ȱ‘Žȱ”Ž¢ Š¢ȱ˜›ȱ ŽŠ›ȱ˜›ȱŠ–ŠŽǯȱŽ™•ŠŒŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ’ȱŒ›ŠŒ”Žǯȱȱ‘Žȱ
Ě¢ ‘ŽŽ•ȱ”Ž¢ȱ’œȱœ‘ŽŠ›Žȱ˜›ȱ‘Žȱ”Ž¢ Š¢ȱ’œȱŠ–ŠŽǰȱ›Ž™•ŠŒŽȱ‘ŽȱŒ›Š—”œ‘ŠĞǰȱĚ¢ ‘ŽŽ•ǰȱŠ—ȱ”Ž¢ǯ

—œ™ŽŒȱ‘Žȱ›’—ȱŽŠ›ȱ˜›ȱŒ›ŠŒ”œȱ˜›ȱŠ–ŠŽǯȱ’—ȱŽŠ›œȱŠ›Žȱ—˜ȱŠŸŠ’•Š‹•ŽȱœŽ™Š›ŠŽ•¢ǯȱŽ™•ŠŒŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ’ȱ‘Žȱ
ring gear is damaged.

Cylinder Head and Valves

Inspection and Service

Carefully inspect the valve mechanism parts. Inspect the valve springs and related hardware for excessive wear
˜›ȱ’œ˜›’˜—ǯȱ‘ŽŒ”ȱ‘ŽȱŸŠ•ŸŽœȱŠ—ȱŸŠ•ŸŽȱœŽŠœȱ˜›ȱŽŸ’Ž—ŒŽȱ˜ȱŽŽ™ȱ™’Ĵ’—ǰȱŒ›ŠŒ”œǰȱ˜›ȱ’œ˜›’˜—ǯȱ‘Žȱ˜••˜ ’—ȱ
diagram outlines valve running clearances between the valve stems and guides.

9.1
Section 9
Inspection and Reconditioning

Intake Valve Exhaust Valve

D E A E D
A

F F

B B

C C

Dimension Intake Exhaust

A ŽŠȱ—•Ž 90° 90°
B Guide Depth 22.6 mm 20.5 mm
C Guide I.D. 5.500/5.5.12 mm 5.500/5.5.12 mm
D Valve Head Diameter 25.875/26.125 mm 23.875/24.125 mm
E Š•ŸŽȱŠŒŽȱ—•Ž 45° 45°
F Valve Margin (Min.) 0.80 mm 0.80 mm
G Š•ŸŽȱŽ–ȱ’Š–ŽŽ› 5.465/5.480 mm 5.465/5.480 mm
Figure 9-1. Valve Details.

9.2
 Section 9
Inspection and Reconditioning

Hard starting, or loss of power accompanied by high fuel consumption, may be symptoms of faulty valves.
•‘˜ž‘ȱ‘ŽœŽȱœ¢–™˜–œȱŒ˜ž•ȱŠ•œ˜ȱ‹ŽȱŠĴ›’‹žŽȱ˜ȱ ˜›—ȱ›’—œǰȱ›Ž–˜ŸŽȱŠ—ȱŒ‘ŽŒ”ȱ‘ŽȱŸŠ•ŸŽœȱꛜǯȱЎ›ȱ
removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for
ŽŽŒœȱœžŒ‘ȱŠœȱ Š›™Žȱ‘ŽŠǰȱŽ¡ŒŽœœ’ŸŽȱŒ˜››˜œ’˜—ǰȱ˜›ȱ ˜›—ȱœŽ–ȱŽ—ǯȱŽ™•ŠŒŽȱŸŠ•ŸŽœȱ˜ž—ȱ˜ȱ‹Žȱ’—ȱ‹ŠȱŒ˜—’’˜—ǯȱ
ȱ—˜›–Š•ȱŸŠ•ŸŽȱŠ—ȱŸŠ•ŸŽœȱ’—ȱ‹ŠȱŒ˜—’’˜—ȱŠ›Žȱœ‘˜ —ȱ’—ȱ‘ŽȱŠŒŒ˜–™Š—¢’—ȱ’••žœ›Š’˜—œǯ

Normal:ȱŸŽ—ȱŠĞŽ›ȱ•˜—ȱ‘˜ž›œȱ˜ȱ˜™Ž›Š’˜—ȱŠȱŸŠ•ŸŽȱ Leakage:ȱȱ™˜˜›ȱ›’—ȱ˜—ȱŠȱŸŠ•ŸŽȱŠŒŽȱ˜›ȱœŽŠȱ ’••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
replaced. Note the warped head; margin damaged
Š—ȱ˜˜ȱ—Š››˜ ǯȱ‘ŽœŽȱŒ˜—’’˜—œȱŒ˜ž•ȱ‹ŽȱŠĴ›’‹žŽȱ
to excessive hours or a combination of poor operating
conditions.
Coking: Coking is normal on intake valves and is not
harmful. If the seat is good, the valve could be reused
ŠĞŽ›ȱŒ•ŽŠ—’—ǯ

9.3
Section 9
Inspection and Reconditioning
Excessive Combustion Temperatures: The white
deposits seen here indicate very high combustion
temperatures, usually due to a lean fuel mixture.
Gum: Gum deposits usually result from using stale
Šœ˜•’—Žǯȱ‘’œȱŒ˜—’’˜—ȱ’œȱ˜ĞŽ—ȱ—˜Žȱ’—ȱŠ™™•’ŒŠ’˜—œȱ
 ‘Ž›ŽȱžŽ•ȱ’œȱ—˜ȱ›Š’—Žȱ˜žȱ˜ȱŠ—”ȱž›’—ȱ‘Žȱ˜ěȱ
season. Gum is a prevalent cause of valve sticking. The
cure is to ream the valve guides and clean or replace
the valves, depending on their condition.
9.4
Stem Corrosion: Moisture in fuel or from
condensation are the most common causes of valve
stem corrosion. Condensation occurs from improper
preservation during storage and when engine is
repeatedly stopped before it has a chance to reach
—˜›–Š•ȱ˜™Ž›Š’—ȱŽ–™Ž›Šž›ŽœǯȱŽ™•ŠŒŽȱŒ˜››˜Žȱ
valves.
Overheating:ȱ—ȱŽ¡‘ŠžœȱŸŠ•ŸŽȱœž‹“ŽŒȱ˜ȱ˜ŸŽ›‘ŽŠ’—ȱ
will have a dark discoloration in the area above the
valve guide. Worn guides and faulty valve springs
–Š¢ȱŒŠžœŽȱ‘’œȱŒ˜—’’˜—ǯȱ•œ˜ȱŒ‘ŽŒ”ȱ˜›ȱŒ•˜ŽȱŠ’›ȱ
’—Š”ŽǰȱŠ—ȱ‹•˜Œ”Žȱꗜȱ ‘Ž—ȱ‘’œȱŒ˜—’’˜—ȱ’œȱ—˜Žǯ
 Section 9
Inspection and Reconditioning

Valve Guides
ȱŠȱŸŠ•ŸŽȱž’Žȱ’œȱ ˜›—ȱ‹Ž¢˜—ȱœ™ŽŒ’ęŒŠ’˜—œǰȱ’ȱ ’••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.

To check valve guide-to-valve stem clearance, Valve Seat Cutter

thoroughly clean the valve guide and, using a split-
ball gauge, measure the inside diameter. Then, using
an outside micrometer, measure the diameter of
the valve stem at several points on the stem where
it moves in the valve guide. Use the largest stem
diameter to calculate the clearance. If the intake Pilot
clearance exceeds 0.047 mm (.0018 in.) or the exhaust
clearance exceeds 0.082 mm (.0032 in.), determine
whether the valve stem or guide is responsible for the .001

excessive clearance. Figure 9-2. Typical Valve Seat Cutter.

Maximum (I.D.) wear on the intake valve guide is Lapping Valves

5.512 mm (0.2170 in.), while 5.512 mm (0.2170 in.)
is the maximum allowed on the exhaust guide. The
guides are not removable. If the guides are within
limits but the valve stems are worn beyond limits,
replace the valves.
Valve Seat Inserts
Hardened steel alloy intake and exhaust valve
œŽŠȱ’—œŽ›œȱŠ›Žȱ™›ŽœœȱęĴŽȱ’—˜ȱ‘ŽȱŒ¢•’—Ž›ȱ‘ŽŠǯȱ
The inserts are not replaceable, but they can be
›ŽŒ˜—’’˜—Žȱ’ȱ—˜ȱ˜˜ȱ‹Š•¢ȱ™’ĴŽȱ˜›ȱ’œ˜›Žǯȱȱ
the seats are cracked or badly warped, the cylinder
head should be replaced.
Ž›˜ž—ȱ˜›ȱ—Ž ȱŸŠ•ŸŽœȱ–žœȱ‹Žȱ•Š™™Žȱ’—ǰȱ˜ȱ
provide a good seal. Use a hand valve grinder with
œžŒ’˜—ȱŒž™ȱ˜›ȱꗊ•ȱ•Š™™’—ǯȱ’‘•¢ȱŒ˜ŠȱŸŠ•ŸŽȱŠŒŽȱ
 ’‘ȱꗎȱ›ŠŽȱ˜ȱ›’—’—ȱŒ˜–™˜ž—ǰȱ‘Ž—ȱ›˜ŠŽȱ
valve on seat with grinder. Continue grinding until
smooth surface is obtained on seat and on valve face.
Thoroughly clean cylinder head in soap and hot water
˜ȱ›Ž–˜ŸŽȱŠ••ȱ›ŠŒŽœȱ˜ȱ›’—’—ȱŒ˜–™˜ž—ǯȱЎ›ȱ
drying cylinder head, apply a light coating of engine
oil to prevent rusting.

ŽŒ˜—’’˜—ȱ‘ŽȱŸŠ•ŸŽȱœŽŠȱ’—œŽ›œȱ˜••˜ ’—ȱ‘Žȱ
’—œ›žŒ’˜—œȱ™›˜Ÿ’Žȱ ’‘ȱ‘ŽȱŸŠ•ŸŽȱœŽŠȱŒžĴŽ›ȱ‹Ž’—ȱ
žœŽǯȱȱ¢™’ŒŠ•ȱŒžĴŽ›ȱ’œȱœ‘˜ —ȱ’—ȱ’ž›ŽȱşȬŘǯȱ‘Žȱꗊ•ȱ 9
Œžȱœ‘˜ž•ȱ‹Žȱ–ŠŽȱ ’‘ȱŠ—ȱşŖǚȱŒžĴŽ›ȱŠœȱœ™ŽŒ’ꮍȱ˜›ȱ
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

The following sequence is a step-by-step guide 11. Install guide plate.

for complete engine reassembly. This procedure 12. Install rocker studs.
assumes that all components are new or have been 13. Install push rods.
reconditioned, and all component subassembly work 14. Install rocker arms.
has been completed. This procedure may vary to 15. Install rocker pivots.
accommodate engine options or special equipment. 16. Install jam nuts.
17. Install valve cover gasket and cover.
NOTE: Properly clean all components BEFORE 18. Install spark plug.
reassembly. ŗşǯȱ —œŠ••ȱĚ¢ ‘ŽŽ•ȱ‹›Š”ŽȱŠœœŽ–‹•¢ǯ
20. Install breather cover.
NOTE: Remove all traces of cleaners before the Řŗǯȱ —œŠ••ȱĚ¢ ‘ŽŽ•ȱ”Ž¢ǯ
engine is reassembled and placed into ŘŘǯȱ —œŠ••ȱĚ¢ ‘ŽŽ•ǯ
operation. Even small amounts of these 23. Install fan.
cleaners can quickly break down the 24. Install ignition module.
lubricating properties of engine oil. 25. Install fuel tank bracket (if removed).
26. Install fuel tank.
NOTE:ȱ œœŽ–‹•Žȱ‘ŽȱŽ—’—Žȱžœ’—ȱŠ••ȱœ™ŽŒ’ꮍȱ Řŝǯȱ —œŠ••ȱĚ¢ ‘ŽŽ•ȱ‹›Š”Žȱœ™›’—ǯ
torque values, tightening sequences, and 28. Install governor.
Œ•ŽŠ›Š—ŒŽœǯȱŠ’•ž›Žȱ˜ȱ˜‹œŽ›ŸŽȱœ™ŽŒ’ęŒŠ’˜—œȱ 29. Install speed control bracket.
could cause severe engine wear or damage. 30. Install governor. spring
31. Install carburetor gaskets.
NOTE: Always use new gaskets. 32. Install carburetor.
33. Reconnect carburetor linkage.
34. Reconnect fuel line.
Typical Reassembly Sequence 35. Install primer hose (if equipped).
36. Install air cleaner base.
ȱ ŗǯȱ —œŠ••ȱŒ›Š—”œ‘ŠĞǯ 37. Reconnect breather hose.
2. Install piston and connecting rod. řŞǯȱ —œŠ••ȱŠ’›ȱꕝŽ›ǻœǼȱŠ—ȱŒ˜ŸŽ›ǯ
ȱ řǯȱ ĴŠŒ‘ȱŒ˜——ŽŒ’—ȱ›˜ȱŒŠ™ǯ 39. Install dipstick tube.
4. Install tappets. ŚŖǯȱ —œŠ••ȱ–žĝŽ›ȱŠœœŽ–‹•¢ǯ 10
ȱ śǯȱ —œŠ••ȱŒŠ–œ‘ŠĞǯ 41. Install blower housing.
6. Install governor gear. 42. Install recoil.
7. Install crankcase dowels and gasket.
8. Install oil pan cover.
9. Install valves (if removed).
10. Install cylinder head.

10.1
Section 10
Reassembly

Install Crankshaft 3. Aim the triangle on top of the piston towards the
ȱ ŗǯȱ Š›Žž••¢ȱ’—œŠ••ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ’—˜ȱ‘ŽȱŒ›Š—”ŒŠœŽȱ push rod chamber. See Figure 10-3.
through the front seal, and fully seat into place.
ŽŽȱ’ž›ŽȱŗŖȬŗǯȱ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱž—’•ȱ‘Žȱ
journal for the connecting rod is away from the
cylinder.

Triangle

Figure 10-3. Piston Orientation (After Installation).

4. Carefully guide the connecting rod, with piston

ŠĴŠŒ‘Žǰȱ’—˜ȱ‘Žȱ‹˜›ŽǯȱŽŽȱ’ž›ŽȱŗŖȬŚǯȱ
Figure 10-1. Installing Crankshaft.

Install Piston and Connecting Rod

NOTE: Proper orientation of the piston and
connecting rod inside the engine is extremely
important. Improper orientation can cause
extensive wear or damage.

1. Stagger the piston rings in the grooves until the

end gaps are 120° apart. Lubricate the cylinder
‹˜›ŽǰȱŒ›Š—”œ‘ŠĞȱ“˜ž›—Š•ǰȱŒ˜——ŽŒ’—ȱ›˜ȱ“˜ž›—Š•ǰȱ
piston, and rings with engine oil.

2. Compress the piston rings using a piston ring Figure 10-4. Installing Piston.
compressor. See Figure 10-2.
ȱ śǯȱ œŽȱ‘Žȱ‘Š—•Žȱ˜ȱŠȱœ˜Ğǰȱ›ž‹‹Ž›Ȭ›’™ȱ‘Š––Ž›ȱ˜ȱ
tap the piston into the bore. See Figure 10-5.

Figure 10-2. Compressing Piston Rings.

Figure 10-5. Tapping Piston.

10.2
 Section 10
Reassembly
ȱ Ŝǯȱ ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ˜ȱ–ŠŽȱ ’‘ȱ‘ŽȱŒ˜——ŽŒ’—ȱ
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

Figure 10-8. Aligning Timing Marks.

Install Governor Gear Assembly

1. Install the governor gear and retainer, and torque
‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱ˜ȱ9.5 N·m (84 in. lb.). See
Figure 10-6. Aligning Match Marks. Figure 10-9.

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 —œŠ••ȱ‘Žȱ˜ŸŽ›—˜›ȱŒ›˜œœȱœ‘ŠĞȱŠ—ȱœŽŒž›Žȱ’ȱ ’‘ȱ
the hitch pin. See Figure 10-10.
10
Figure 10-7. Installing Tappets.
Hitch Pin

Install Camshaft
ȱ ŗǯȱ ž‹›’ŒŠŽȱ‘ŽȱŒŠ–œ‘ŠĞȱŠ—ȱŒŠ–ȱŽŠ›ȱœž›ŠŒŽœȱ Shaft
with light grease or oil.

ȱ Řǯȱ —œŠ••ȱ‘ŽȱŒŠ–œ‘ŠĞȱŠ—ȱŠ•’—ȱ‘Žȱ’–’—ȱ–Š›”œǯȱ
See Figure 10-8.

Figure 10-10. Installing Governor Shaft, Hitch Pin.

10.3
Section 10
Reassembly

Install Oil Pan 6. Using the torque sequence shown in Figure

1. The sealing surfaces of the crankcase and oil pan 10-13.
should be clean, dry and free of any nicks or
burrs. 1
3
2. Install the two crankcase dowels into the 6
crankcase. See Figure 10-11.

Dowels
5

4
2
Figure 10-13. Torque Sequence.

7. Torque the oil pan screws to 12.3 N·m (109 in.

lb.). See Figure 10-14.
Figure 10-11. Installing Crankcase Dowels.

3. Using the crankcase dowels as a guide, install a

new oil pan gasket onto the crankcase.

4. Ensure the gasket, oil pan, and governor gear

assembly have been accurately matched with the
crankcase. Guide the oil pan onto the crankcase,
Ž—œž›’—ȱ‘ŽȱŒŠ–œ‘ŠĞȱŠ—ȱ˜ŸŽ›—˜›ȱŽŠ›ȱŠ•’—ȱ
 ’‘ȱ‘Ž’›ȱ–Š’—ȱœž›ŠŒŽœǯȱ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ
slightly to help engage the governor gear.

ȱ śǯȱ —œŠ••ȱŠ—ȱꗐŽ›ȱ’‘Ž—ȱ‘Žȱœ’¡ȱ‘Ž¡ȱ̊—Žȱ
screws, securing the oil pan to the crankcase. See
Figure 10-12. Figure 10-14. Torquing Oil Pan Screws.

Figure 10-12. Installing Oil Pan Screws.

10.4

Install Cylinder Head Assembly
Prior to assembly, lubricate all the components with
engine oil, including the tips of the valve stems and
valve guides.
Install Valve Assembly
1. Install the INTAKE and the EXHAUST valves
into their respective positions in the cylinder
head. See Figure 10-15.
Figure 10-15. Installing Valves.
2. Install the intake valve seal onto the intake valve.
Next, slide the valve springs onto both valves
and lock them in place with the valve spring
keepers. See Figure 10-16.
Keeper Spring
Intake
Seal
Figure 10-16. Installing Valve Assembly.
Section 10
Reassembly
Install Cylinder Head
NOTE: Do not reuse cylinder head screws or gasket.
Always replace with new parts.
1. Examine the sealing surfaces of the cylinder head
and crankcase for nicks or burrs.
2. Using the two cylinder head dowels as a guide,
install a new head gasket. See Figure 10-17.
Gasket
Dowels
Figure 10-17. Installing Cylinder Dowels.
3. Match the two sides of the head together and
ꗐŽ›ȱ’‘Ž—ȱ‘Žȱ˜ž›ȱ‘Ž¡ȱœŒ›Ž œǯȱŽŽȱ’ž›Žȱ
10-18.
3
2
10
1 4
Figure 10-18. Torquing the Screws.
4. Follow the torque sequence in Figure 10-18 and
torque the head screws to 27.8 N·m (246 in. lb.).
10.5
Section 10
Reassembly

Install Push Rod Assembly

1. Install the rocker studs through the guide plate.
See Figure 10-19.

Figure 10-21. Installing Rocker Arms.

6. Loosely install the pivots and the jam nuts onto

the rocker studs. See Figure 10-22.
Figure 10-19. Installing Guide Plate and Studs.

2. Torque the rocker studs to 13.6 N·m (120 in. lb.).

3. Install the push rods into the intake and exhaust

positions, as previously marked. See Figure 10-
20.

NOTE: Installation and seating of the push rods into

the tappet recesses during this sequence is
critical. To aid with proper installation of the
push rods and rocker arms, and for adjusting
the valve lash, position the engine with the
cylinder head up. When properly installed
the push rods extend approximately Figure 10-22. Installing Pivots.
1 in. (25.4 mm) above the guide plate.
7. With the piston at top dead center of the
compression stroke, insert a 0.1 mm (.004 in.)ȱ̊ȱ
feeler gauge between one valve stem and rocker
arm. See Figure 10-23.

Figure 10-20. Installing Push Rods.

4. Apply grease to the contact surfaces of the rocker
arms and the pivots.
Figure 10-23. Setting Valve Lash.
5. Install the rocker arms onto the rocker studs.
9DOYH&OHDUDQFH6SHFL¿FDWLRQV
Match the rocker arm dimples with the round
Intake Valve 0.0762-0.127 mm (0.003-0.005 in.)
push rod ends. See Figure 10-21.
Exhaust Valve 0.0762-0.127 mm (0.003-0.005 in.)

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.

9. Position a new valve cover gasket on the cylinder

head.

ȱŗŖǯȱ —œŠ••ȱ‘ŽȱŸŠ•ŸŽȱŒ˜ŸŽ›ȱŠ—ȱꗐŽ›ȱ’‘Ž—ȱ‘Žȱ˜ž›ȱ
screws.

11. Using the sequence shown in Figure 10-24, torque

the cover screws to 8 N·m (71 in. lb.).

2
3
Figure 10-25. Installing Flywheel Brake Assembly.

Install Breather Assembly

1. Install the breather screen, spring, and disc. See
Figure 10-26.
1
4

Figure 10-24. Valve Cover Torque Sequence.

Install New Spark Plug

1. Set the gap on a new Champion® RC12YC (or
equivalent) to 0.762 mm (0.030 in.).

2. Install the spark plug and torque it to

24.5 N·m (217 in. lb.).
10
Figure 10-26. Installing Screen, Spring, and Disc.

2. Install the breather cover and torque it to

10 N·m (88 in. lb.). See Figure 10-27.

10.7
Section 10
Reassembly
ȱ ŗǯȱ —œŠ••ȱ‘Žȱ”Ž¢ȱ’—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ”Ž¢ Š¢ǯȱŠ”Žȱ
sure key is fully seated. See Figures 10-27 and
Flywheel Key 10-28.

ȱ Řǯȱ —œŠ••ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ˜—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ•’—’—ȱ
Breather the keyway with the key. See Figure 10-28.
Cover

Keyway

Teardrop

Figure 10-27. Installing Breather Cover.

Install Flywheel Assembly

:$51,1*'DPDJLQJ&UDQNVKDIWDQG
Flywheel can Cause Personal Injury!
œ’—ȱ’–™›˜™Ž›ȱ™›˜ŒŽž›Žœȱ˜ȱ’—œŠ••ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŒŠ—ȱŒ›ŠŒ”ȱ
˜›ȱŠ–ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ—Ȧ˜›ȱĚ¢ ‘ŽŽ•ǯȱ‘’œȱ—˜ȱ˜—•¢ȱ
causes extensive engine damage, but can also cause personal
’—“ž›¢ǰȱœ’—ŒŽȱ‹›˜”Ž—ȱ›Š–Ž—œȱŒ˜ž•ȱ‹Žȱ‘›˜ —ȱ›˜–ȱ‘Žȱ
Ž—’—Žǯȱ• Š¢œȱ˜‹œŽ›ŸŽȱŠ—ȱžœŽȱ‘Žȱ˜••˜ ’—ȱ™›ŽŒŠž’˜—œȱ
Š—ȱ™›˜ŒŽž›Žœȱ ‘Ž—ȱ’—œŠ••’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ǯ
Figure 10-28. Installing Flywheel.
3. Align the teardrop slot on the fan with the raised
ŽŠ››˜™ȱ˜—ȱ‘ŽȱĚ¢ ‘ŽŽ•ǯȱ•’—ȱ‘Žȱ›’ŸŽȱŒž™ȱ˜—ȱ
‘ŽȱĚ¢ ‘ŽŽ•ǰȱŠ—ȱ’—œŠ••ȱŠ—ȱ‘Š—ȱ’‘Ž—ȱ‘Žȱ
nut.

DZȱ Ž˜›Žȱ’—œŠ••’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ–Š”Žȱœž›Žȱ‘Žȱ ȱ Śǯȱ œ’—ȱŠȱĚ¢ ‘ŽŽ•ȱœ›Š™ȱ ›Ž—Œ‘ǰȱ‘˜•ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ

Œ›Š—”œ‘ŠĞȱŠ™Ž›ȱŠ—ȱĚ¢ ‘ŽŽ•ȱ‘ž‹ȱŠ›ŽȱŒ•ŽŠ—ǰȱ still while simultaneously torquing the nut to
dry and completely free of lubricants. The 51.5 N·m (456 in. lb.). See Figure 10-29.
™›ŽœŽ—ŒŽȱ˜ȱ•ž‹›’ŒŠ—œȱŒŠ—ȱŒŠžœŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ
to be over stressed and damaged when the
–˜ž—’—ȱ—žȱ’œȱ˜›šžŽȱ˜ȱœ™ŽŒ’ęŒŠ’˜—ǯ

DZȱ Š”Žȱœž›Žȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ”Ž¢ȱ’œȱ’—œŠ••Žȱ
™›˜™Ž›•¢ȱ’—ȱ‘Žȱ”Ž¢ Š¢ǯȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŒŠ—ȱ
become cracked or damaged if the key is not
properly installed.

DZȱ • Š¢œȱžœŽȱŠȱĚ¢ ‘ŽŽ•ȱœ›Š™ȱ ›Ž—Œ‘ȱ˜ȱ‘˜•ȱ
‘ŽȱĚ¢ ‘ŽŽ•ȱ ‘Ž—ȱ’‘Ž—’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ
fastener. Do not use any type of bar or
 ŽŽȱ˜ȱ™›ŽŸŽ—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›˜–ȱ›˜Š’—ǰȱ
as these parts could become cracked or
damaged.
Figure 10-29. Torquing Flywheel Nut.

10.8

Install Ignition Module
ȱ ŗǯȱ ˜ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱœ˜ȱ‘Žȱ’—’’˜—ȱ–Š—ŽœȱŠ›Žȱ
away from the ignition module legs. Position
the ignition module on the legs with the kill tab
down. See Figures 10-30 and 10-32.
Magnets
Ignition
Module
Leg
Figure 10-30. Positioning Ignition Module/Magnets
2. Loosely thread the stud in a mounting leg and
‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱ’—ȱŠ—˜‘Ž›ȱ•ŽǯȱŽŽȱ’ž›Žȱ
ŗŖȬřŗǯȱž••ȱ‘Žȱ–˜ž•ŽȱŠ Š¢ȱ›˜–ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ
and tighten the stud to hold it in place. Rotate the
Ě¢ ‘ŽŽ•ȱœ˜ȱ‘Žȱ’—’’˜—ȱ–Š—Žȱ’œȱŠ•’—Žȱ ’‘ȱ
the module.
NOTE: If the stud for mounting the ignition module
was not kept segregated from the two studs
for mounting the fuel tank, compare their
lengths and choose the short one.
Hex Flange Screw
Stud
Spacer
Figure 10-31. Tightening Ignition Module Stud.
3. Install the spacer onto the ignition module stud.
See Figure 10-31.
Section 10
Reassembly
4. Set the air gap by placing a 0.254 mm (0.010 in.)
plastic feeler gauge between the magnet and the
module. Loosen the stud and let the magnet draw
the module against the feeler gauge. See Figure
10-32. Torque the fasteners to 10 N·m (88 in. lb.).
Feeler
Gauge
Kill Tab
Figure 10-32. Feeler Gauge.
ȱ śǯȱ ˜ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ˜ȱ›Ž•ŽŠœŽȱ‘ŽȱŽŽ•Ž›ȱŠžŽǰȱ
and check that the module does not come in
contact with the magnet. Recheck the air gap.
6. Connect the kill lead to the ignition module. See
Figure 10-32.
Install Fuel Tank
ȱ ŗǯȱ ĴŠŒ‘ȱ‘ŽȱžŽ•ȱŠ—”ȱ‹›ŠŒ”Žȱ˜ȱ‘ŽȱŠ—”ȱǻ’ȱ
removed) with the two bracket screws. See Figure
10-33. Torque the screws to 4.5 N·m (40 in. lb.).
Bracket Screws
10
Bracket
Bracket Nut
Figure 10-33. Attaching Fuel Tank Bracket.
ȱ Řǯȱ ˜˜œŽ•¢ȱŠĴŠŒ‘ȱ‘ŽȱžŽ•ȱŠ—”ȱ‹›ŠŒ”Žȱ˜ȱ‘Žȱ
Œ›Š—”ŒŠœŽȱ ’‘ȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žǯȱŽŽȱ’ž›Žȱ
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

Figure 10-36. Installing Governor Lever.

ȱ Řǯȱ ĴŠŒ‘ȱ‘Žȱ‘›˜Ĵ•Žȱ•’—”ŠŽȱŠ—ȱ•’—”ŠŽȱœ™›’—ȱ˜ȱ
the top of the governor lever. See Figure 10-37.

Throttle Linkage

Figure 10-34. Installing Fuel Tank Studs.

4. Install spacers on both studs. See Figure 10-34.

5. Secure the fuel tank bracket to the crankcase by

˜›šž’—ȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žȱ˜ȱ8 N·m (71 in. lb.).
See Figure 10-33. Linkage Spring

Install Flywheel Brake Spring Figure 10-37. Attaching Governor Linkage.

ȱ ŗǯȱ œ’—ȱŠȱ™•’Ž›œǰȱŠĴŠŒ‘ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ‹›Š”Žȱœ™›’—ȱ
onto the bracket hook. See Figure 10-35.
Install Speed-Control Bracket
ȱ ŗǯȱ ˜˜œŽ•¢ȱŠĴŠŒ‘ȱ‘Žȱœ™ŽŽȬŒ˜—›˜•ȱ‹›ŠŒ”Žȱ˜ȱ‘Žȱ
crankcase using the two shorter hex screws. The
•˜—ȱ‘Ž¡ȱœŒ›Ž ȱ ’••ȱ‹ŽȱžœŽȱ•ŠŽ›ȱ˜›ȱŠĴŠŒ‘–Ž—ȱ
of the air cleaner body. See Figure 10-38.

Hook
Spring

Figure 10-35. Attaching Flywheel Brake Spring.

Install Governor Assembly

ȱ ŗǯȱ —œŠ••ȱ‘Žȱ˜ŸŽ›—˜›ȱ•ŽŸŽ›ȱ˜—˜ȱ‘Žȱ˜ŸŽ›—˜›ȱœ‘ŠĞȱ
with the lever section up. See Figure 10-36. Figure 10-38. Installing Speed Bracket.

10.10
 Section 10
Reassembly
DZȱȱ ‘Ž›ŽȱŠ›Žȱ‘›ŽŽȱ’쎛Ž—ȱœ™ŽŽȱ‹›ŠŒ”ŽȱŸŠ›’Š’˜—œȱ˜›ȱ‘’œȱŽ—’—Žǯȱ’ž›ŽœȱŗŖȬřşǰȱŗŖȬŚŖǰȱŠ—ȱŗŖȬŚŗȱ’Ž—’¢ȱ
‘˜ ȱ’쎛Ž—ȱ‹›ŠŒ”ŽœȱŒ˜——ŽŒȱ˜ȱŒŠ›‹ž›Ž˜›œȱ ’‘ȱŠ—ȱ ’‘˜žȱŒ‘˜”Žǯ

Throttle Linkage
Linkage Spring
Speed Control Bracket
Throttle
Lever

Governor Spring

Governor Lever

Figure 10-39. Fixed Speed with Primer (No Choke).

Throttle
Linkage Spring Throttle Linkage
Lever
Speed Control Bracket
Choke
Lever

Choke Linkage

Governor Lever

Governor Spring

Figure 10-40. Fixed Speed with Choke.

Throttle Throttle Linkage

Lever
Linkage Spring
Dual Throttle/
10
Choke Choke Control
Lever

Choke Linkage

Speed Control Screw

Governor Lever
Speed Control Bracket

Governor Spring
Figure 10-41. Variable Speed with Choke.

10.11
Section 10
Reassembly

Install Governor Spring Install Carburetor with Primer

1. Install the governor spring between the governor 1. With the carburetor not yet mounted on the
lever and the speed control bracket. See Figure studs, rotate it slightly to allow connection of the
10-42 and 10-39. ‘›˜Ĵ•Žȱ•’—”ŠŽȱŠ—ȱ•’—”ŠŽȱœ™›’—ȱ˜ȱ‘Žȱ‘›˜Ĵ•Žȱ
lever. See Figure 10-44.

Spring
Linkage Throttle
Linkage

Throttle Lever

Figure 10-42. Installing Governor Spring. Figure 10-44. Installing Throttle Linkage.

2. Slide the carburetor onto the mounting studs. See

Install Carburetor Gaskets Figure 10-45. Install the air cleaner gasket onto
1. Place the spacer gasket, cylinder head spacer and the studs.
‘Žȱ‘ŽŠȱŽĚŽŒ˜›ȱŠœ”Žȱ˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱœžœȱ
in the order shown in Figure 10-43.

Spacer Gasket
Head Spacer
Heat Shield
Figure 10-45. Installing Carburetor (Primer Model).

Figure 10-43. Installing Carburetor Gaskets

Install Carburetor with Choke
1. With the carburetor not yet mounted on the
Install Carburetor Linkage studs, rotate it slightly and slot the elbow, at
the end of the linkage, into the choke lever. See
DZȱ ‘Ž›ŽȱŠ›ŽȱœŽŸŽ›Š•ȱ’쎛Ž—ȱ Š¢œȱ˜ȱŠĴŠŒ‘ȱ Figure 10-46.
the carburetor linkage depending on the
carburetor and speed bracket used. For more
detailed illustrations, refer to Figures 10-39,
10-40, and 10-41.

10.12
 Section 10
Reassembly

Connect Fuel Line

1. Slide the fuel line tight up against the carburetor,
and secure the connection with a hose clamp. See
Figure 10-48.

Figure 10-46. Attaching Choke Linkage.

ȱ Řǯȱ ˜——ŽŒȱ‘Žȱ‘›˜Ĵ•Žȱ•’—”ŠŽȱŠ—ȱ•’—”ŠŽȱœ™›’—ȱ
˜ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱŽŽȱ’ž›Žȱ
10-44. Figure 10-48. Connecting Fuel Hose.

3. Slide the carburetor onto the mounting studs. See

Figure 10-45. Install Air Cleaner Assembly
ȱ ŗǯȱ ĴŠŒ‘ȱ‘Žȱ™›’–Ž›ȱ‘˜œŽȱ˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱǻ’ȱ
equipped). See Figure 10-49.
Adjust Governor
1. Move the governor lever away from the 2. Slide the air cleaner gasket onto the carburetor
carburetor to the limit of its travel (wide-open studs. See Figure 10-49.
‘›˜Ĵ•ŽǼǰȱŠ—ȱ‘˜•ȱ’—ȱ‘’œȱ™˜œ’’˜—ǯȱ˜ȱ—˜ȱœ›Žœœǰȱ
̎¡ȱ˜›ȱ’œ˜›ȱ‘Žȱ•’—”ŠŽǯȱ ›Šœ™ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞȱ
 ’‘ȱŠȱ™•’Ž›œȱŠ—ȱž›—ȱ‘Žȱœ‘ŠĞȱŒ•˜Œ” ’œŽȱŠœȱŠ›ȱ
Air Cleaner
as it will go, while simultaneously tightening the
Base Gasket
hex nut. See Figure 10-47. Torque the hex nut to
9.5 N·m (84 in. lb.). Primer
Hose

10
Figure 10-49. Installing Primer Hose (If Equipped).

Figure 10-47. Adjusting Governor.

10.13
Section 10
Reassembly
3. Slide the air cleaner base onto the carburetor 6. Install the paper element and the foam precleaner
œžœǯȱĴŠŒ‘ȱ‘Žȱ‹ŠœŽȱ‹¢ȱ•˜˜œ•Ž¢ȱœŒ›Ž ’—ȱ‘Žȱ (if equipped) into the air cleaner body. See Figure
 ˜ȱ‘Ž¡ȱ—žœȱ˜—˜ȱ‘ŽȱœžœǰȱŠ—ȱ‘Žȱ‘Ž¡ȱ̊—Žȱ ŗŖȬśŘǯȱĴŠŒ‘ȱŠ—ȱ‘Š—ȱ’‘Ž—ȱ‘Žȱ”—˜‹ǯ
screw into the crankcase. See Figure 10-50.

Hex Nuts
Hex Flange
Screw

Figure 10-50. Installing Air Cleaner Base.
ȱ Śǯȱ ĴŠŒ‘ȱ‘Žȱ‹›ŽŠ‘Ž›ȱ‘˜œŽȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱŽŽȱ
Figure 10-51.
Figure 10-52. Installing Air Cleaner.
Install Dipstick Tube
1. Install the dipstick tube to the crankcase. See
Figure 10-53.

ȱ Řǯȱ ˜›šžŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱ˜ 8 N·m (71 in. lb.).

Figure 10-51. Attaching Breather Hose.

5. Secure the air cleaner base by torquing the two

‘Ž¡ȱ—žœȱŠ—ȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱ˜ȱ
8 N·m (71 in. lb.).

Figure 10-53. Installing Dipstick Tube.

10.14
 Section 10
Reassembly

,QVWDOO0XIÀHU$VVHPEO\ Install Blower Housing

ȱ ŗǯȱ —œŠ••ȱ‘Žȱ‘ŽŠȱŽĚŽŒ˜›ȱŠœ”Žȱ˜—˜ȱ‘ŽȱŽ¡‘Šžœȱ 1. Install the blower housing onto the studs. See
mounting studs, with the gasket folds facing the Figure 10-57.
cylinder head. See Figure 10-54.

Figure 10-57. Installing Blower Housing.

)LJXUH,QVWDOOLQJ0XIÀHU+HDW'HÀHFWRU

ȱ Řǯȱ •’Žȱ‘Žȱ–žĝŽ›ȱ˜—˜ȱ‘ŽȱŽ¡‘ŠžœȱœžœǯȱŽŽȱ
Install Recoil
Figure 10-55.
1. Place the recoil onto the studs protruding from
the blower housing. See Figure 10-58.

)LJXUH,QVWDOOLQJ0XIÀHU

ȱ řǯȱ —œŠ••ȱ‘Žȱ–žĝŽ›ȱžŠ›ȱ˜—˜ȱ‘ŽȱŽ¡‘Šžœȱœžœǯȱ Figure 10-58. Installing Recoil.

See Figure 10-56. Torque to 9.5 N·m (84 in. lb.).
10

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10.15
Section 10
Reassembly

Install Engine Cover Install Fuel Cap

1. Install the engine cover and secure it with the 1. Screw the fuel cap tightly onto the fuel tank. See
‘›ŽŽȱ‘Ž¡ȱ—žœȱŠ—ȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œǯ Figure 10-61.

2. Torque the nuts to 2.8 N·m (25 in. lb.). See Figure
10-59.

Figure 10-61. Installing Fuel Cap.

Figure 10-59. Installing Engine Cover.

2. Install the engine cover insert onto the engine
cover, and secure with the four Torx screws. See
Figure 10-60. Torque to 2.3 N·m (20 in. lb.).

Figure 10-60. Installing Engine Cover Insert.

10.16
 FORM NO.: TP-2601
ISSUED: 3/08
REVISED:
LITHO IN U.S.A.

FOR SALES AND SERVICE INFORMATION

IN THE U.S. AND CANADA, CALL 1-800-544-2444

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ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044