SERVICEE MANUAL

COURAGE SV470-SV620
VERTICAL CRANKSHAFT
 Contents

1
Section 1. Safety and General Information .............................................................................

2
Section 2. Tools & 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 as
follows: 1) Disconnect the spark plug
lead(s). 2) Disconnect negative (-)
‹ŠĴŽ›¢ȱŒŠ‹•Žȱ›˜–ȱ‹ŠĴŽ›¢ǯ
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 WARNING

¡™•˜œ’ŸŽȱžŽ•ȱŒŠ—ȱŒŠžœŽȱꛎœȱ Carbon Monoxide can cause ¡™•˜œ’ŸŽȱ ŠœȱŒŠ—ȱŒŠžœŽȱꛎœȱŠ—ȱ

and severe burns. severe nausea, fainting or death. severe acid burns.
‘Š›Žȱ‹ŠĴŽ›¢ȱ˜—•¢ȱ’—ȱŠȱ Ž••ȱ
˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ Avoid inhaling exhaust fumes, and ventilated area. Keep sources of
engine is hot or running. never run the engine in a closed ignition away.
‹ž’•’—ȱ˜›ȱŒ˜—ę—ŽȱŠ›ŽŠǯ
Explosive Fuel! Explosive Gas!
Lethal Exhaust Gases! ŠĴŽ›’Žœȱ™›˜žŒŽȱŽ¡™•˜œ’ŸŽȱ‘¢›˜Ž—ȱ
Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱ
Engine exhaust gases contain gas while being charged. To prevent a
its vapors can explode if ignited. Store
poisonous carbon monoxide. Carbon ꛎȱ˜›ȱŽ¡™•˜œ’˜—ǰȱŒ‘Š›Žȱ‹ŠĴŽ›’Žœȱ˜—•¢ȱ
gasoline only in approved containers,
monoxide is odorless, colorless, and can in well ventilated areas. Keep
in well ventilated, unoccupied
cause death if inhaled. Avoid inhaling œ™Š›”œǰȱ˜™Ž—ȱ̊–ŽœǰȱŠ—ȱ˜‘Ž›ȱœ˜ž›ŒŽœȱ
‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ̊–Žœǯȱ
exhaust fumes, and never run the ˜ȱ’—’’˜—ȱŠ Š¢ȱ›˜–ȱ‘Žȱ‹ŠĴŽ›¢ȱŠȱŠ••ȱ
˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ
Ž—’—Žȱ’—ȱŠȱŒ•˜œŽȱ‹ž’•’—ȱ˜›ȱŒ˜—ę—Žȱ ’–Žœǯȱ ŽŽ™ȱ‹ŠĴŽ›’Žœȱ˜žȱ˜ȱ‘Žȱ›ŽŠŒ‘ȱ
engine is hot or running, since spilled
area. of children. Remove all jewelry when
fuel could ignite if it comes in contact
with hot parts or sparks from ignition. œŽ›Ÿ’Œ’—ȱ‹ŠĴŽ›’Žœǯ
Do not start the engine near spilled
fuel. Never use gasoline as a cleaning Before disconnecting the negative
agent. (-) ground cable, make sure all switches
are OFF. If ON, a spark will occur at
the ground cable terminal which could
cause an explosion if hydrogen gas or
WARNING gasoline vapors are present.

CAUTION
Cleaning Solvents can cause
severe injury or death.

Use only in well ventilated areas

away from ignition sources. Electrical Shock can cause injury.
Flammable Solvents!
Do not touch wires while engine is
Carburetor cleaners and solvents are running.
Ž¡›Ž–Ž•¢ȱ̊––Š‹•Žǯȱ ŽŽ™ȱœ™Š›”œǰȱ
̊–ŽœǰȱŠ—ȱ˜‘Ž›ȱœ˜ž›ŒŽœȱ˜ȱ’—’’˜—ȱ Electrical Shock!
away from the area. Follow the Never touch electrical wires or
cleaner manufacturer’s warnings and components while the engine is
instructions on its proper and safe use. running. They can be sources of
Never use gasoline as a cleaning agent. electrical shock.

1.2
 Section 1
Safety and General Information

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When ordering parts, or in any communication
involving an engine, always give the Model, 1
™ŽŒ’ęŒŠ’˜—ǰȱŠ—ȱŽ›’Š•ȱž–‹Ž›œ of the engine.

‘ŽȱŽ—’—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

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A. Model No. SV 540 S

Courage Vertical Shaft Engine Version Code
S = Electric Start
Numerical Designation

B. Spec. No. SV540-0001

Engine Model First spec
Model written in this
SV470 model series
SV480
SV530
SV540
SV590
SV600
SV610
SV620

C. Serial No. 3205810334

Year Manufactured Code Factory Code
Code Year
32 2002
33 2003
34 2004
35 2005
36 2006
37 2007
38 2008

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1.3
Section 1
Safety and General Information

Oil Recommendations Fuel Recommendations

Using the proper type and weight of oil in the
crankcase is extremely important, as is checking oil
Š’•¢ȱŠ—ȱŒ‘Š—’—ȱ˜’•ȱ›Žž•Š›•¢ǯȱŠ’•ž›Žȱ˜ȱžœŽȱ‘Žȱ
correct oil or using dirty oil causes premature engine
wear and failure.
Oil Type
Use high-quality detergent oil of ȱǻ–Ž›’ŒŠ—ȱ
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
˜›ȱ̊–Žœǯȱ˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱ‘˜ȱ
or running, since spilled fuel could ignite if it comes in
contact with hot parts or sparks from ignition. Do not
Ž›˜•Žž–ȱ—œ’žŽǼȱœŽ›Ÿ’ŒŽȱŒ•Šœœȱȱ˜›ȱ‘’‘Ž›. Select start the engine near spilled fuel. Never use gasoline as a
the viscosity based on the air temperature at the time cleaning agent.
of operation as shown below.
General Recommendations
RECOMMENDED SAE VISCOSITY GRADES Purchase gasoline in small quantities and store
10W-30
in clean, approved containers. A container with a
** ŒŠ™ŠŒ’¢ȱ˜ȱŘȱŠ••˜—œȱ˜›ȱ•Žœœȱ ’‘ȱŠȱ™˜ž›’—ȱœ™˜žȱ’œȱ
*
5W-20, 5W-30 recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
Kohler 10W-30

°F -20 0 20 32 40 60 80 100 ˜ȱ—˜ȱžœŽȱŠœ˜•’—Žȱ•ŽĞȱ˜ŸŽ›ȱ›˜–ȱ‘Žȱ™›ŽŸ’˜žœȱ

°C -30 -20 -10 0 10 20 30
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
* Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
up to 4°C (40°F)
** Synthetic oils will provide better starting in extreme cold below
-23°C (-10°F)
NOTE: Using other than service class SJ or higher
oil or extending oil change intervals longer
than recommended can cause engine
damage.
NOTE: Synthetic oils meeting the listed
Œ•Šœœ’ęŒŠ’˜—œȱ–Š¢ȱ‹ŽȱžœŽȱ ’‘ȱ˜’•ȱŒ‘Š—Žœȱ
performed at the recommended intervals.
However to allow piston rings to properly
seat, a new or rebuilt engine should be
operated for at least 50 hours using standard
petroleum based oil before switching to
synthetic oil.
ȱ•˜˜ȱ˜›ȱœ¢–‹˜•ȱ˜—ȱ˜’•ȱŒ˜—Š’—Ž›œȱ’Ž—’ęŽœȱ‘Žȱȱ
œŽ›Ÿ’ŒŽȱŒ•ŠœœȱŠ—ȱȱŸ’œŒ˜œ’¢ȱ›ŠŽǯȱŽŽȱ’ž›ŽȱŗȬŚǯȱ
RVIC
SE
E
API
40 season, to minimize gum deposits in your fuel system
and to ensure easy starting.
Do not add oil to the gasoline.
˜ȱ—˜ȱ˜ŸŽ›ę••ȱ‘ŽȱžŽ•ȱŠ—”ǯȱŽŠŸŽȱ›˜˜–ȱ˜›ȱ‘ŽȱžŽ•ȱ
to expand.
Fuel Type
˜›ȱ‹Žœȱ›Žœž•œǰȱžœŽȱ˜—•¢ȱŒ•ŽŠ—ǰȱ›Žœ‘ǰȱž—•ŽŠŽȱ
gasoline with a pump sticker octane rating of 87 or
‘’‘Ž›ǯȱ—ȱŒ˜ž—›’Žœȱžœ’—ȱ‘ŽȱŽœŽŠ›Œ‘ȱ–Ž‘˜ǰȱ’ȱ
should be 90 octane minimum.
Unleaded gasoline is recommended, as it leaves less
Œ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ȱŽ™˜œ’œǯȱŽŠŽȱŠœ˜•’—Žȱ–Š¢ȱ
be used in areas where unleaded is not available
and exhaust emissions are not regulated. Be aware
however, that the cylinder head will require more
frequent service.
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 not approved. Any

SJ

SAE
failures resulting from use of these fuels will not be
10W-30 warranted.

Figure 1-3. Oil Container Logo.
ŽŽ›ȱ˜ȱŽŒ’˜—ȱŜȱȬȱž‹›’ŒŠ’˜—ȱ¢œŽ–ȱ˜›ȱŽŠ’•Žȱ˜’•ȱ
Œ‘ŽŒ”ǰȱ˜’•ȱŒ‘Š—ŽǰȱŠ—ȱ˜’•ȱꕝŽ›ȱŒ‘Š—Žȱ™›˜ŒŽž›Žœǯ
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,
’œŠ‹•Žȱ‘ŽȱŽ—’—ŽȱŠœȱ˜••˜ œDZȱŗǼȱ’œŒ˜——ŽŒȱ‘Žȱœ™Š›”ȱ™•žȱ•ŽŠǻœǼǯȱŘǼȱ’œŒ˜——ŽŒȱ—ŽŠ’ŸŽȱǻȬǼȱ‹ŠĴŽ›¢ȱŒŠ‹•Žȱ›˜–ȱ‹ŠĴŽ›¢ǯ

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 Ȋȱ ’••ȱžŽ•ȱŠ—”ǯ
Daily or Before • Check oil level.
Starting Engine • Check air cleaner for dirty¹, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary¹.
Every 2 Months • Service precleaner element¹ (if equipped).
or 25 Hours • Service air cleaner element¹ (if not equipped with precleaner).
ȱ Ȋȱ Ž™•ŠŒŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ŵȱǻ’ȱŽšž’™™Žȱ ’‘ȱ™›ŽŒ•ŽŠ—Ž›Ǽǯ
ȱ Ȋȱ ‘Š—Žȱ˜’•ȱŠ—ȱꕝŽ›ȱǻ›ŽŽ›ȱ˜ȱ’œŒ˜œ’¢ȱŠ‹•ŽǰȱŠŽȱŗǯŚǰȱ‹ŠœŽȱ˜—ȱœŽŠœ˜—Š•ȱ
Annually or temperatures).
Every 100 Hours ȱ Ȋȱ Ž–˜ŸŽȱ‹•˜ Ž›ȱ‘˜žœ’—ȱŠ—ȱŒ•ŽŠ—ȱŒ˜˜•’—ȱŠ›ŽŠœǯ
• Check that all fasteners are in place and components are properly secured.
ȱ Ȋȱ Ž™•ŠŒŽȱžŽ•ȱꕝŽ›ǯ
Every 2 Years or • Check spark plug condition and gap.
200 Hours

Every 200 Hours • Have bendix starter drive serviced².

• Have valve lash checked/adjustedŘ.
Every 500 Hours ȱ Ȋȱ Ž™•ŠŒŽȱœ™Š›”ȱ™•žǯ
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
²Have a Kohler Engine Service Dealer perform this service.
Storage
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˜’•ȱŠ—ȱ˜’•ȱꕝŽ›ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱ
still warm from operation. See Change Oil and
’•ȱ’•Ž›ȱ’—ȱŽŒ’˜—ȱŜǯ
3. The fuel system must be completely emptied,
or the gasoline must be treated with a stabilizer
˜ȱ™›ŽŸŽ—ȱŽŽ›’˜›Š’˜—ǯȱȱ¢˜žȱŒ‘˜˜œŽȱ˜ȱ
use a stabilizer, follow the manufacturer’s
recommendations, and add the correct amount
˜›ȱ‘ŽȱŒŠ™ŠŒ’¢ȱ˜ȱ‘ŽȱžŽ•ȱœ¢œŽ–ǯȱ’••ȱ‘ŽȱžŽ•ȱ
Š—”ȱ ’‘ȱŒ•ŽŠ—ǰȱ›Žœ‘ȱŠœ˜•’—Žǯȱž—ȱ‘ŽȱŽ—’—Žȱ
˜›ȱŘȬřȱ–’—žŽœȱ˜ȱŽȱœŠ‹’•’£ŽȱžŽ•ȱ’—˜ȱ‘Žȱ
carburetor.
To empty the system, run the engine until the
tank and system are empty.
ȱ Śǯȱ žŽȱ˜ȱ‘ŽȱŽŽ™ȱ›ŽŒŽœœȱŠ›˜ž—ȱ‘Žȱœ™Š›”ȱ™•žǰȱ
‹•˜ ȱ˜žȱ‘ŽȱŒŠŸ’¢ȱ ’‘ȱŒ˜–™›ŽœœŽȱŠ’›ǯȱŽ–˜ŸŽȱ
the spark plug. The spark plug is most accessible
when the blower housing is removed for
cleaning.
Add one tablespoon of engine oil into the spark
™•žȱ‘˜•Žǯȱ—œŠ••ȱ‘Žȱ™•žǰȱ‹žȱ˜ȱ—˜ȱŒ˜——ŽŒȱ
the plug lead. Crank the engine two or three
revolutions. Connect the plug lead.
ȱȱśǯȱ Ž’—œŠ••ȱ‘Žȱ‹•˜ Ž›ȱ‘˜žœ’—ǰȱ’ȱ›Ž–˜ŸŽȱ
previously, and torque the blower housing screws
to ŝǯśȱȉ–ȱǻŜśȱ’—ǯȱ•‹ǯǼ.
ȱ Ŝǯȱ ˜›Žȱ‘ŽȱŽ—’—Žȱ’—ȱŠȱŒ•ŽŠ—ǰȱ›¢ȱ™•ŠŒŽǯ

1.5
Section 1
Safety and General Information

Dimensions in millimeters. Inch equivalents shown in ().

VALVE COVER VIEW

Figure 1-4. Typical Engine Dimensions.

1.6
 Section 1
Safety and General Information
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ȱ ŚŝŖȱ ............................................................................................................. ŗŗǯŘȱ”ȱǻŗśȱ
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ŚŞŖȱ ............................................................................................................. ŗŗǯşȱ”ȱǻŗŜȱ
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śřŖȱ ............................................................................................................. ŗŘǯŝȱ”ȱǻŗŝȱ
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ȱ śŚŖ .............................................................................................................. ŗřǯŚȱ”ȱǻŗŞȱ
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ȱ śşŖȱ ............................................................................................................. ŗŚǯŗȱ”ȱǻŗşȱ
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ȱ ŜŖŖ .............................................................................................................. ŗŚǯşȱ”ȱǻŘŖȱ
Ǽ
ȱ ŜŗŖ .............................................................................................................. ŗśǯŝȱ”ȱǻŘŗȱ
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ȱ ŜŘŖ .............................................................................................................. ŗŜǯŚȱ”ȱǻŘŘȱ
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Bore
ȱ ŚŝŖǰȱŚŞŖȱǻŠ›•¢ȱ˜Ž•œȱ—•¢Ǽ ............................................................. ŞŚȱ––ȱǻřǯřŖȱ’—ǯǼ
ȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ ........................................................................ 89 mm (3.50 in.)
ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ........................................................................ şŚȱ––ȱǻřǯŝŖȱ’—ǯǼ

Stroke...................................................................................................................... ŞŜȱ––ȱǻřǯřŞȱ’—ǯǼ

Displacement
ȱ ŚŝŖǰȱŚŞŖȱǻŠ›•¢ȱ˜Ž•œȱ—•¢Ǽ ............................................................. ŚŝŝȱŒŒȱǻŘşǯŗȱŒžǯȱ’—ǯǼ
ȱȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ ........................................................................ śřśȱŒŒȱǻřŘǯŜȱŒžǯȱ’—ǯǼ
ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ........................................................................ śşŝȱŒŒȱǻřŜǯŚȱŒžǯȱ’—ǯǼ

˜–™›Žœœ’˜—ȱŠ’˜
ȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ ........................................................................ şǯŚDZŗ
ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ........................................................................ ŞǯśDZŗ

Dry Weight............................................................................................................. 35.8 kg (79 lb.)

’•ȱŠ™ŠŒ’¢ȱǻ ’‘ȱꕝŽ›Ǽ..................................................................................... ŗǯŖŚȬŗǯřŖȱȱǻŗǯŗȬŗǯŚȱšǯǼ

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

Air Cleaner Base

Ž¡ȱžȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................................... śǯśȱȉ–ȱǻŚŞȱ’—ǯȱ•‹ǯǼ

˜ž—’—ȱŒ›Ž ȱŠœŽ—Ž›ȱ˜›šžŽȱǻ—œŠ••ȱ›¢ȱȬȱȱȱǼ .................... ŞǯŖȱȉ–ȱǻŝŖȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž
ȱ ȱ śǯśȱȉ–ȱǻŚŞȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž
Blower Housing and Sheet Metal
ŜȱŠœŽ—Ž›œȱ˜›šžŽ .................................................................. ŗŗǯŜȱȉ–ȱǻşşȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž
ȱ ȱ ȱ ŝǯŝȱȉ–ȱǻŜŞȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž
Cam Lever
Š–ȱŽŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ ...................................................... ȱŞǯŖȬŗŖǯśȱȉ–ȱǻŝŖȬşŚǯŖȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž
ȱ ȱ ȱ ŝǯŗȬŞǯŜȱȉ–ȱǻŜŗǯŞȬŝŚǯŞȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž

Cam Gears
End Play .............................................................................................................. ŖǯśȦŗǯśȱ––ȱǻŖǯŖŗşȦŖǯŖśşȱ’—ǯǼ

ž——’—ȱ’Žȱ•ŽŠ›Š—ŒŽ.................................................................................... ŖǯŖŘȦŖǯŗřȱ––ȱǻŖǯŖŖŗȦŖǯŖŖśȱ’—ǯǼ

Š–ȱ ŽŠ›Ȭ˜ȬŠ–ȱ‘ŠĞȱž——’—ȱœœŽ–‹•¢................................................. ŖǯŖŘȦŖǯŗŖȱ––ȱǻŖǯŖŖŗȦŖǯŖŖŚȱ’—ǯǼ

Carburetor
žŽ•ȱ˜ •ȱŽŠ’—’—ȱŒ›Ž ȱ˜›šžŽ ................................................................. śǯŗȬŜǯŘȱȉ–ȱǻŚśȬśśȱ’—ǯȱ•‹ǯǼ
ŗ
Š•žŽœȱŠ›Žȱ’—ȱ–Ž›’Œȱž—’œǯȱŠ•žŽœȱ’—ȱ™Š›Ž—‘ŽœŽœȱŠ›Žȱ—•’œ‘ȱŽšž’ŸŠ•Ž—œǯȱž‹›’ŒŠŽȱ‘›ŽŠœȱ ’‘ȱŽ—’—Žȱ˜’•ȱ™›’˜›ȱ
to assembly, EXCEPT for air cleaner base thread forming screw - install dry.

1.7
Section 1
Safety and General Information
Closure Plate
•˜œž›Žȱ•ŠŽȱŠœŽ—Ž›ȱ˜›šžŽ ........................................................................ ŘŚǯśȱȉ–ȱǻŘŗŜȱ’—ǯȱ•‹ǯǼ

Balance Weight Guide Channel Width

New.............................................................................................................. ŗŝǯşśȦŗŞǯŖśȱ––ȱǻŖǯŝŖŝȦŖǯŝŗŗȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŗŞǯŗřȱ––ȱǻŖǯŝŗŚȱ’—ǯǼ

Connecting Rod
Š™ȱŠœŽ—Ž›ȱ˜›šžŽȱǻ˜›šžŽȱ’—ȱŘȱ’—Œ›Ž–Ž—œǼ.............................................. śǯśǰȱŗŗǯśȱȉ–ȱǻśŖǰȱŗŖŖȱ’—ǯȱ•‹ǯǼ

˜——ŽŒ’—ȱ˜Ȭ˜Ȭ›Š—”™’—ȱž——’—ȱ•ŽŠ›Š—ŒŽ
New............................................................................................................... ŖǯŖřȦŖǯŖśśȱ––ȱǻŖǯŖŖŗŘȦŖǯŖŖŘŘȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’.......................................................................................... ŖǯŖŝȱ––ȱǻŖǯŖŖŘśȱ’—ǯǼ

˜——ŽŒ’—ȱ˜Ȭ˜Ȭ›Š—”™’—ȱ’Žȱ•ŽŠ›Š—ŒŽ................................................ ŖǯŘśȦŖǯśşȱ––ȱǻŖǯŖŖşŞȦŖǯŖŘřŘȱ’—ǯǼ

˜——ŽŒ’—ȱ˜Ȭ˜Ȭ’œ˜—ȱ’—ȱž——’—ȱ•ŽŠ›Š—ŒŽ....................................... ŖǯŖŗśȦŖǯŖŘŞȱ––ȱǻŖǯŖŖŖŜȦŖǯŖŖŗŗȱ’—ǯǼ

Piston Pin End I.D.

New............................................................................................................... ŘŘǯŖŗśȦŘŘǯŖŘřȱ––ȱǻŖǯŞŜŜŝȦŖǯŞŜŝŖȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’.......................................................................................... ŘŘǯŖřŜȱ––ȱǻŖǯŞŜŝśȱ’—ǯǼ

Crankcase
˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱ˜›Žȱǯǯȱ
New............................................................................................................... ŜǯŖŘśȦŜǯŖśȱ––ȱǻŖǯŘřŝŘȦŖǯŘřŞŘȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’.......................................................................................... ŜǯŖŜřȱ––ȱǻŖǯŘřŞŝȱ’—ǯǼ

Oil Drain Plug Torque ....................................................................................... ŗŚǯŖȱȉ–ȱǻŗŘśȱ’—ǯȱ•‹ǯǼ

Crankshaft
End Play (free) .................................................................................................... ŖǯŘŘśȦŗǯŖŘśȱ––ȱǻŖǯŖŖŞşȦŖǯŖŚŖȱ’—ǯǼ

›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ›Š—”ŒŠœŽȱǯǯ
New.............................................................................................................. ŚŗǯşŜśȦŚŗǯşşŖȱ––ȱǻŗǯŜśŘŗȦŗǯŜśřŗȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŚŘǯŖŗŜȱ––ȱǻŗǯŜśŚȱ’—ǯǼ

›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ•˜œž›Žȱ•ŠŽȱǯǯ
New.............................................................................................................. ŚŚǯşŜśȦŚŚǯşşŖȱ––ȱǻŗǯŝŝŖřȦŗǯŝŝŗřȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŚśǯŖŗŜȱ––ȱǻŗǯŝŝŘřȱ’—ǯǼ

•¢ ‘ŽŽ•ȱ—ȱŠ’—ȱŽŠ›’—ȱ˜ž›—Š•ȱǯǯ
ȱ ȱŽ ȱȬȱŽ˜›ŽȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŖř....................................................... ŚŚǯşŗřȦŚŚǯşřśȱ––ȱǻŗǯŝŜŞŘȦŗǯŝŜşŗȱ’—ǯǼ
ȱ ȱŽ ȱȬȱЎ›ȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŗř......................................................... ŚŚǯŞŝŖȦŚŚǯŞşśȱ––ȱǻŗǯŝŜŜśȦŗǯŝŜŝśȱ’—ǯǼ
ȱ ǯǯȱȬȱŠ¡ǯȱŽŠ›ȱ’–’ ............................................................................. ŚŚǯŞŚȱ––ȱǻŗǯŝŜśȱ’—ǯǼ
Max. Taper .................................................................................................. ŖǯŖŘŘŖȱ––ȱǻŖǯŖŖŖşȱ’—ǯǼ
ȱ Š¡ǯȱžȱ˜ȱ˜ž— .................................................................................... ŖǯŖŘśȱ––ȱǻŖǯŖŖŗȱ’—ǯǼ

PTO End Main Bearing Journal O.D.

ȱ Ž ȱȬȱŽ˜›ŽȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŖř........................................................ ŚŗǯşŗřȦŚŗǯşřśȱ––ȱǻŗǯŜśŖŗȦŗǯŜśŗŖȱ’—ǯǼ
ȱ Ž ȱȬȱЎ›ȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŗř.......................................................... ŚŗǯŞśśȦŚŗǯŞŞŖȱ––ȱǻŗǯŜŚŝŞȦŗǯŜŚŞŞȱ’—ǯǼ
ȱ ǯǯȱȬȱŠ¡ǯȱŽŠ›ȱ’–’ ............................................................................. ŚŗǯŞřȱ––ȱǻŗǯŜŚŝȱ’—ǯǼ
Max. Taper .................................................................................................. ŖǯŖŘŖȱ––ȱǻŖǯŖŖŖŞȱ’—ǯǼ
ȱ Š¡ǯȱžȱ˜ȱ˜ž— .................................................................................... ŖǯŖŘśȱ––ȱǻŖǯŖŖŗȱ’—ǯǼ

1.8
 Section 1
Safety and General Information
Crankshaft (Continued)
›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ•˜œž›Žȱ•ŠŽȱž——’—ȱ•ŽŠ›Š—ŒŽȱ
ȱ Ž ȱȬȱŽ˜›ŽȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŖř........................................................ ŖǯŖřŖȦŖǯŖŝŝȱ––ȱǻŖǯŖŖŗŘȦŖǯŖŖřŖȱ’—ǯǼ 1
ȱ Ž ȱȬȱЎ›ȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŗř.......................................................... ŖǯŖŝŖȦŖǯŗŘŖȱ––ȱǻŖǯŖŖŘŝȦŖǯŖŖŚŝȱ’—ǯǼ

›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ›Š—”ŒŠœŽȱž——’—ȱ•ŽŠ›Š—ŒŽȱ
ȱ Ž ȱȬȱŽ˜›ŽȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŖř........................................................ ŖǯŖřŖȦŖǯŖŝŝȱ––ȱǻŖǯŖŖŗŘȦŖǯŖŖřŖȱ’—ǯǼ
ȱ Ž ȱȬȱЎ›ȱŽ›’Š•ȱ˜ǯȱřŝŖřŘŖŖŖŗř.......................................................... ŖǯŖŞśȦŖǯŗřśȱ––ȱǻŖǯŖŖřřȦŖǯŖŖśřȱ’—ǯǼ

˜——ŽŒ’—ȱ˜ȱ˜ž›—Š•ȱǯǯȱ
New.............................................................................................................. ŚŖǯşŞŘȦŚŗǯŖŖŖȱ––ȱǻŗǯŜŗřŚȦŗǯŜŗŚŗȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŚŖǯşŜŚȱ––ȱǻŗǯŜŗŘȱ’—ǯǼ
Max. Taper .................................................................................................. ŖǯŖŗŘȱ––ȱǻŖǯŖŖŖśȱ’—ǯǼ
ȱ Š¡ǯȱžȱ˜ȱ˜ž— .................................................................................... ŖǯŖŘśȱ––ȱǻŖǯŖŖŗȱ’—ǯǼ

›Š—”œ‘ŠĞȱǯǯǯ
ȱ ȱ—ǰȱ›Š—”œ‘ŠĞȱ’—ȱ—’—Ž............................................................... Ŗǯŗśȱ––ȱǻŖǯŖŖśşȱ’—ǯǼ
ȱ —’›Žȱ›Š—”œ‘ŠĞǰȱ’—ȱȬ•˜Œ”œ ................................................................. ŖǯŗŖȱ––ȱǻŖǯŖŖřşȱ’—ǯǼ

›Š—”œ‘ŠĞȱŒŒŽ—›’Œœȱǯǯ
New.............................................................................................................. ŜŜǯşŚŖȦŜŜǯşŝŖȱ––ȱǻŘǯŜřśŚȦŘǯŜřŜŜȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŜŜǯŞşȱ––ȱǻŘǯŜřřȱ’—ǯǼ

Balance Weight
Š•Š—ŒŽȱŽ’‘ȱŽŠ›’—ȱž›ŠŒŽȱǯǯ
New.............................................................................................................. ŜŝǯŖŗŗȦŜŝǯŖŞŜȱ––ȱǻŘǯŜřŞŘȦŘǯŜŚŗŘȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŜŝǯŗŚŖȱ––ȱǻŘǯŜŚřŖȱ’—ǯǼ

Balance Weight Pin O.D.

New.............................................................................................................. ŗŗǯşśŖȦŗŗǯşŝśȱ––ȱǻŖǯŚŝŖśȦŖǯŚŝŗśȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŗŗǯşŖŖȱ––ȱǻŖǯŚŜŞśȱ’—ǯǼ

ž’Žȱ‘˜Žȱ’‘ȱȬȱŽ˜›ŽȱȱŽ›’Š•ȱ˜ǯȱřŜŗŞŖŖŖŖŖř
New ............................................................................................................. ŗŝǯŞśȦŗŝǯşŖȱ––ȱǻŖǯŝŖřȦŖǯŝŖśȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŗŝǯŝśȱ––ȱǻŖǯŜşŞŞȱ’—ǯǼ

ž’Žȱ‘˜Žȱ
˜•Žȱǯǯȱ
New.............................................................................................................. ŗŘǯŖŖŖȦŗŘǯŖŘśȱ––ȱǻŖǯŚŝŘŚȦŖǯŚŝřŚȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŗŘǯŖśŖȱ––ȱǻŖǯŚŝŚŚȱ’—ǯǼ

’—”ŠŽȱ’—ȱǯǯȱǻ›Š—”ŒŠœŽǼȱȬȱЎ›ȱŽ›’Š•ȱ˜ǯȱřŜŗŞŖŖŖŖŗř
New.............................................................................................................. ŗŗǯşŜŚȦŗŗǯşŝśȱ––ȱǻŖǯŚŝŗŖȦŖǯŚŝŗśȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŗŗǯşŖŖȱ––ȱǻŖǯŚŜŞśȱ’—ǯǼ

Š•Š—ŒŽȱŽ’‘ȱ’—”ŠŽȬȱЎ›ȱŽ›’Š•ȱ˜ǯȱřŜŗŞŖŖŖŖŗř
New.............................................................................................................. ŗŗǯşŞśȦŗŘǯŖŗŖȱ––ȱǻŖǯŚŝŗşȦŖǯŚŝŘŞȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŗŘǯŖřśȱ––ȱǻŖǯŚŝřŞȱ’—ǯǼ

Balance Weight Screw Torque ......................................................................... ŗŖǯşȬŗřǯŘȱȉ–ȱǻşśǯŖȬŗŗśǯŖȱ’—ǯȱ•‹ǯǼ

1.9
Section 1
Safety and General Information
Cylinder Bore
¢•’—Ž›ȱ˜›Žȱǯǯ
New
ȱ ȱ ŚŝŖǰȱŚŞŖȬŖŖ.................................................................................. ŞŚǯŖŖŖȦŞŚǯŖŘśȱ––ȱǻřǯřŖŝȦřǯřŖŞȱ’—ǯǼ
ȱ ȱ ŚŝŖǰȱŚŞŖȬŖŗ.................................................................................. ŞşǯŖŖŖȦŞşǯŖŘśȱ––ȱǻřǯśŖŚȦřǯśŖśȱ’—ǯǼ
ȱ ȱ śřŖǰȱśŚŖ............................................................................................. ŞşǯŖŖŖȦŞşǯŖŘśȱ––ȱǻřǯśŖŚȦřǯśŖśȱ’—ǯǼ
ȱȱ ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ................................................................... şŚǯŖŗŖȦşŚǯŖřśȱ––ȱǻřǯŝŖŗȦřǯŝŖŘȱ’—ǯǼ
ȱȱȱȱ Š¡ǯȱŽŠ›ȱ’–’
ȱ ȱȱŚŝŖǰȱŚŞŖȬŖŖ.................................................................................. ŞŚǯŖŝřȱ––ȱǻřǯřŗŖȱ’—ǯǼ
ȱ ȱȱŚŝŖǰȱŚŞŖȬŖŗ.................................................................................. ŞŚǯŖŝřȱ––ȱǻřǯřŗŖȱ’—ǯǼ
ȱ ȱȱśřŖǰȱśŚŖ............................................................................................. 89.073 mm (3.507 in.)
ȱ ȱȱśşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ................................................................... şŚǯŖŝřȱ––ȱǻřǯŝŖŚȱ’—ǯǼ

Max. Taper .................................................................................................. ŖǯŖśȱ––ȱǻŖǯŖŖŘȱ’—ǯǼ

ȱ Š¡ǯȱžȱ˜ȱ˜ž— .................................................................................... ŖǯŗŘȱ––ȱǻŖǯŖŖŚŝȱ’—ǯǼ

Cylinder Head
¢•’—Ž›ȱ
ŽŠȱŠœŽ—Ž›ȱ˜›šžŽȱǻ˜›šžŽȱ’—ȱŘȱ’—Œ›Ž–Ž—œǼ .......................... ŘŖǯśǰȱŚŗǯŖȱȉ–ȱǻŗŞŖǰȱřŜŖȱ’—ǯȱ•‹ǯǼ

Š¡ǯȱžȬ˜Ȭ•Š—Žœœ ........................................................................................ 0.8 mm (0.003 in.)

˜Œ”Ž›ȱ›–ȱ’Ÿ˜ȱžȱ˜›šžŽ ....................................................................... ŗřǯśȱȉ–ȱǻŗŘŖȱ’—ǯȱ•‹ǯǼ

˜Œ”Ž›ȱ›–ȱ“žœ–Ž—ȱžȱŽȱŒ›Ž  ........................................................ 5.5 N·m (50 in. lb.)

Electric Starter
Thru Bolt Torque ............................................................................................... 3.3-3.9 N·m (30-35 in. lb.)
Mounting Nut Torque ...................................................................................... řǯŜȱȉ–ȱǻřŘȱ’—ǯȱ•‹ǯǼ
žȱǻ˜™Ǽȱ˜œ’’ŸŽȱǻƸǼȱ›žœ‘ȱŽŠȱŽ›–’—Š• ................................................. ŗǯŜȬŘǯŞȱȉ–ȱǻŗśȬŘśȱ’—ǯȱ•‹ǯǼ
žȱǻ•Š—ŽǼȱ˜œ’’ŸŽȱǻƸǼȱ›žœ‘ȱŽŠȱŽ›–’—Š• ............................................ ŘǯŘȬŚǯśȱȉ–ȱǻŘŖȬŚŖȱ’—ǯȱ•‹ǯǼ

Fan/Flywheel
•¢ ‘ŽŽ•ȱŽŠ’—’—ȱŒ›Ž ȱ˜›šžŽȱŗŘ ......................................................... ŞŞǯŖȱȉ–ȱǻŜśȱĞǯȱ•‹ǯǼ
•¢ ‘ŽŽ•ȱŽŠ’—’—ȱŒ›Ž ȱ˜›šžŽȱŗŖ ......................................................... ŜŜǯśȱȉ–ȱǻŚşȱĞǯȱ•‹ǯǼ

Governor
˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȬ˜Ȭ›Š—”ŒŠœŽȱž——’—ȱ•ŽŠ›Š—ŒŽȱ ........................... ŖǯŖŗřȦŖǯŖŝśȱ––ȱǻŖǯŖŖŖśȦŖǯŖŖřȱ’—ǯǼ

˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱǯǯ
New.............................................................................................................. śǯşŝśȦŜǯŖŗŘȱ––ȱǻŖǯŘřśŘȦŖǯŘřŜŝȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... śǯşŜŘȱ––ȱǻŖǯŘřŚŝȱ’—ǯǼ

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

˜ŸŽ›—˜›ȱ ŽŠ›ȱ‘ŠĞȱǯǯ
New ............................................................................................................. śǯşşȦŜǯŖŖȱ––ȱǻŖǯŘřśŞȦŖǯŘřŜŘȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’ȱ........................................................................................ śǯşŝŝȱ––ȱǻŖǯŖŘřśřȱ’—ǯǼ

Ignition
Spark Plug Type (Champion® or Equivalent) ............................................... ŗŘȱ˜›ȱŗŘ

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

1.10
 Section 1
Safety and General Information
Ignition (Continued)
Spark Plug Torque............................................................................................. ŘŚȬřŖȱȉ–ȱǻŗŞȬŘŘȱĞǯȱ•‹ǯǼ
1
—’’˜—ȱ˜ž•Žȱ’›ȱ Š™ȱ ................................................................................ ŖǯŘŖřȦŖǯřŖśȱ––ȱǻŖǯŖŖŞȦŖǯŖŗŘȱ’—ǯǼ

—’’˜—ȱ˜ž•ŽȱŠœŽ—Ž›ȱ˜›šžŽ ................................................................... ŜǯŖȱȉ–ȱǻśśȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž

ȱ ȱ ŚǯŖȱȉ–ȱǻřśȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž
žĝŽ›
žĝŽ›ȱŽŠ’—’—ȱžœȱ˜›šžŽȱ...................................................................... ŘŚǯŚȱȉ–ȱǻŘŗŜȱ’—ǯȱ•‹ǯǼ

Oil Filter
’•ȱ’•Ž›ȱ˜›šžŽ ................................................................................................ ŗŖȬŗřȱȉ–ȱǻşŖȬŗŗŖȱ’—ǯȱ•‹ǯǼ

Oil Filter Pad Pipe Plug

ŗȦŞȄȱǯǯǯǯȱ˜›šžŽ .......................................................................................... ŚǯśȬśǯŖȱȉ–ȱǻŚŖȬŚŜȱ’—ǯȱ•‹ǯǼ

Oil Pump
Mounting Screw Torque.............................................................śǯŖȬŝǯśȱȉ–ȱǻŚŚǯŚȬŜŜǯŖȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž
ȱ ȱ ȱ řǯŞȬŚǯŜȱȉ–ȱǻřřǯřȬŚŖǯřȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž

Pump Gears-to-Crankcase Side Clearance.................................................... ŖǯŗŜśȦŖǯřŗśȱ––ȱǻŖǯŖŖŜśȦŖǯŖŗŘŚȱ’—ǯǼ

Oil Sentry™
Pressure Switch Torque.................................................................................... ŚǯśȬśǯŖȱȉ–ȱǻŚŖȬŚśȱ’—ǯȱ•‹ǯǼ

Piston, Piston Rings, and Piston Pin

’œ˜—ȱ’—ȱ˜›Žȱǯǯ
New.............................................................................................................. ŘŘǯŖŖŜȦŘŘǯŖŗŘȱ––ȱǻŖǯŞŜŞśȦŖǯŞŜŜŜȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŘŘǯŖŘśȱ––ȱǻŖǯŞŜŝŗȱ’—ǯǼ

Piston Pin O.D.

New.............................................................................................................. ŘŗǯşşśȦŘŘǯŖȱ––ȱǻŖǯŞŜśşȦŖǯŞŜŜŗȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŘŗǯşşŚȱ––ȱǻŖǯŞŜśŞȱ’—ǯǼ

˜™ȱ˜–™›Žœœ’˜—ȱ’—Ȭ˜Ȭ ›˜˜ŸŽȱ’Žȱ•ŽŠ›Š—ŒŽȱ ..................................... ŖǯŖŚȱ––ȱǻŖǯŖŖŗŜȱ’—ǯǼ

’•Žȱ˜–™›Žœœ’˜—ȱ’—Ȭ˜Ȭ ›˜˜ŸŽȱ’Žȱ•ŽŠ›Š—ŒŽȱ ............................... ŖǯŖŚȱ––ȱǻŖǯŖŖŗŜȱ’—ǯǼ

˜™ȱŠ—ȱ’•Žȱ˜–™›Žœœ’˜—ȱ’—ȱ—ȱ Š™
New Bore
ȱ ˜™ȱ’— .................................................................................................... ŖǯŗśȦŖǯŚŖȱ––ȱǻŖǯŖŖŜȦŖǯŖŗŜȱ’—ǯǼ
ȱ ’•Žȱ’— .............................................................................................. ŖǯřŖȦŖǯśśȱ––ȱǻŖǯŖŗŘȦŖǯŖŘŘȱ’—ǯǼ
Used Bore (max.)........................................................................................ 0.77 mm (0.030 in.)

’œ˜—ȱ‘›žœȱŠŒŽȱǯǯŶ
ȱȱȱȱ ŚŝŖǰȱŚŞŖȬŖŖ
New ............................................................................................................ ŞřǯşŚŞȦŞřǯşŜŘȱ––ȱǻřǯřŖśŖȦřǯřŖśŜȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’....................................................................................... ŞřǯŞŘŞȱ––ȱǻřǯřŖŖřȱ’—ǯǼ

ȱ ȱŚŝŖǰȱŚŞŖȬŖŗ
New ............................................................................................................ ŞŞǯşŚŞȦŞŞǯşŜŘȱ––ȱǻřǯśŖŗŞȦřǯśŖŘŚȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’....................................................................................... ŞŞǯŞŘŞȱ––ȱǻřǯŚşŝŘȱ’—ǯǼ

ŶŽŠœž›ŽȱŞȱ––ȱǻŖǯřŗŚȱ’—ǯǼȱŠ‹˜ŸŽȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ™’œ˜—ȱœ”’›ȱŠȱ›’‘ȱŠ—•Žœȱ˜ȱ‘Žȱ™’œ˜—ȱ™’—ǯȱ

1.11
Section 1
Safety and General Information
Piston, Piston Rings, and Piston Pin (Continued)
śřŖǰȱśŚŖ
New ............................................................................................................ ŞŞǯşŚŞȦŞŞǯşŜŘȱ––ȱǻřǯśŖŗŞȦřǯśŖŘŚȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’....................................................................................... ŞŞǯŞŘŞȱ––ȱǻřǯŚşŝŘȱ’—ǯǼ

śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ
New ............................................................................................................ şřǯşŘŞȦşřǯşŚŘȱ––ȱǻřǯŜşŞŖȦřǯŜşŞśȱ’—ǯǼ
ȱ ȱ Š¡ǯȱŽŠ›ȱ’–’....................................................................................... şřǯŞŘŞȱ––ȱǻřǯŜşŚŖȱ’—ǯǼ

’œ˜—ȱ‘›žœȱŠŒŽȬ˜Ȭ¢•’—Ž›ȱ˜›ŽŘȱž——’—ȱ•ŽŠ›Š—ŒŽ
ȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ .................................................................... ŖǯŖŚśȱ––ȱǻŖǯŖŖŗŞȱ’—ǯǼ
ȱ śŜŖǰȱśşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ....................................................... 0.0880 mm (0.0035 in.)

5HFWL¿HU5HJXODWRU
Mounting Screw Torque................................................................................... ŜǯŖȱȉ–ȱǻśśȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȱŒŠœȱ‘˜•Ž
ȱ ȱ ŚǯŖȱȉ–ȱǻřśȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž
Speed Control
™ŽŽȱ˜—›˜•ȱ›ŠŒ”ŽȱœœŽ–‹•¢ȱŠœŽ—Ž›ȱ˜›šžŽ ......................................ŗŗǯŖȱȉ–ȱǻşśȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž
ȱ ȱ ŝǯśȱȉ–ȱǻŜśȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž
Stator
Stator Mounting Screw Torque ....................................................................... ŜǯŖȱȉ–ȱǻśśȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž
ȱ ȱ ŚǯŖȱȉ–ȱǻřśȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Ž
Throttle/Choke Controls
˜ŸŽ›—˜›ȱ˜—›˜•ȱŽŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ ..................................................... ŝǯŖȬŞǯśȱȉ–ȱǻŜŖȬŝśȱ’—ǯȱ•‹ǯǼ

Valve Cover
Š•ŸŽȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ........................................................................... ŗŗǯŖȱȱȉ–ȱǻşśȱ’—ǯȱ•‹ǯǼȱ—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•Ž
ȱ ȱ ŝǯśȱȉ–ȱǻŜśȱ’—ǯȱ•‹ǯǼȱ—˜ȱžœŽȱ‘˜•Žȱ
Valves and Valve Lifters
—Š”ŽȱŠ•ŸŽȱŠœ‘3 ............................................................................................. ŖǯŗŘŝȱ––ȱǻŖǯŖŖśȱ’—ǯǼ

¡‘ŠžœȱŠ•ŸŽȱŠœ‘3 .......................................................................................... ŖǯŗŝŞȱ––ȱǻŖǯŖŖŝȱ’—ǯǼ

—Š”ŽȱŠ•ŸŽȱ’—’–ž–ȱ’Ğ ............................................................................. 8.9 mm (0.350 in.)

¡‘ŠžœȱŠ•ŸŽȱ’—’–ž–ȱ’Ğ .......................................................................... 8.9 mm (0.350 in.)

˜–’—Š•ȱŠ•ŸŽȱŽŠȱ—•Ž ............................................................................... Śśǚ

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

¡‘ŠžœȱŠ•ŸŽȱŽ–Ȭ˜ȬŠ•ŸŽȱ ž’Žȱž——’—ȱ•ŽŠ›Š—ŒŽ ............................ ŖǯŖśŖȦŖǯŞŞȱ––ȱǻŖǯŖŖŘŖȦŖǯŖŖřśȱ’—ǯǼ

—Š”ŽȱŠ•ŸŽȱ ž’Žȱǯǯ

New.............................................................................................................. ŜǯŖřŞȦŜǯŖśŞȱ––ȱǻŖǯŘřŝŝȦŖǯŘřŞśȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... Ŝǯŗřśȱ––ȱǻŖǯŘŚŗśȱ’—ǯǼ

Ř
ŽŠœž›ŽȱŞȱ––ȱǻŖǯřŗŚȱ’—ǯǼȱŠ‹˜ŸŽȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ™’œ˜—ȱœ”’›ȱŠȱ›’‘ȱŠ—•Žœȱ˜ȱ‘Žȱ™’œ˜—ȱ™’—ǯȱ
3
‘ŽŒ”ȱŸŠ•ŸŽȱ•Šœ‘ȱŽŸŽ›¢ȱŘŖŖȱ‘˜ž›œǰȱŠ“žœȱŠœȱ›Žšž’›Žǯ

1.12
 Section 1
Safety and General Information
Valves and Valve Lifters (Continued)
ȱ—Š”ŽȱŠ•ŸŽȱŽ–ȱ’Š–ŽŽ›
New.............................................................................................................. śǯşŞŘȦŜǯŖȱ––ȱǻŖǯŘřśśȦŖǯŘřŜŘȱ’—ǯǼ 1
¡‘ŠžœȱŠ•ŸŽȱ ž’Žȱǯǯ
New.............................................................................................................. ŜǯŖřŞȦŜǯŖśŞȱ––ȱǻŖǯŘřŝŝȦŖǯŘřŞśȱ’—ǯǼ
ȱ Š¡ǯȱŽŠ›ȱ’–’......................................................................................... ŜǯŗŜŖȱ––ȱǻŖǯŘŚŘśȱ’—ǯǼ

ȱ¡‘ŠžœȱŠ•ŸŽȱŽ–ȱ’Š–ŽŽ›
New.............................................................................................................. śǯşŝŖȦśǯşŞŞȱ––ȱǻŖǯŘřśȦŖǯŘřśŝȱ’—ǯǼ

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
Ŝȱ ŚǯřȱǻřŞǼȱ śǯŝȱǻśŖǼȱ şǯşȱǻŞŞǼȱ ŗŚǯŖȱǻŗŘŚǼȱ ŗŜǯśȱǻŗŚŜǼȱ ŜǯŞȱǻŜŖǼ
M8ȱ ŗŖǯśȱǻşřǼȱ ŗřǯŜȱǻŗŘŖǼȱ ŘŚǯŚȱǻŘŗŜǼȱ řřǯşȱǻřŖŖǼȱ ŚŖǯŝȱǻřŜŖǼȱ ŗŝǯŖȱǻŗśŖǼ
Tightening Torque: N·m (ft. lb.) + or - 10%
Property Class
Noncritical
Fasteners
4.8 5.8 8.8 10.9 12.9
Into Aluminum
M10 ŘŗǯŝȱǻŗŜǼȱ ŘŝǯŗȱǻŘŖǼȱ ŚŝǯśȱǻřśǼȱ ŜŜǯŚȱǻŚşǼȱ ŞŗǯŚȱǻŜŖǼȱ řřǯşȱǻŘśǼ
M12 řŜǯŜȱǻŘŝǼȱ ŚŝǯśȱǻřśǼȱ ŞŘǯŝȱǻŜŗǼȱ ŗŗŜǯŜȱǻŞŜǼȱ ŗřşǯŝȱǻŗŖřǼȱ ŜŗǯŖȱǻŚśǼ
M14 śŞǯřȱǻŚřǼȱ ŝŜǯŚȱǻśśǼȱ ŗřŗǯśȱǻşŝǼȱ ŗŞŚǯŚȱǻŗřŜǼȱ ŘŗşǯŝȱǻŗŜŘǼȱ şŚǯşȱǻŝŖǼ

Oil Drain Plugs Tightening Torque: N•m (English) 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

1.13
 Section 2
Tools & Aids

Section 2
Tools & Aids
2

Ž›Š’—ȱšžŠ•’¢ȱ˜˜•œȱŠ›ŽȱŽœ’—Žȱ˜ȱ‘Ž•™ȱ¢˜žȱ™Ž›˜›–ȱœ™ŽŒ’ęŒȱ’œŠœœŽ–‹•¢ǰȱ›Ž™Š’›ǰȱŠ—ȱ›ŽŠœœŽ–‹•¢ȱ™›˜ŒŽž›Žœǯȱ
¢ȱžœ’—ȱ˜˜•œȱŽœ’—Žȱ˜›ȱ‘Žȱ“˜‹ǰȱ¢˜žȱŒŠ—ȱ™›˜™Ž›•¢ȱœŽ›Ÿ’ŒŽȱŽ—’—ŽœȱŽŠœ’Ž›ǰȱŠœŽ›ǰȱŠ—ȱœŠŽ›Ƿȱ—ȱŠ’’˜—ǰȱ¢˜žȂ••ȱ
’—Œ›ŽŠœŽȱ¢˜ž›ȱœŽ›Ÿ’ŒŽȱŒŠ™Š‹’•’’ŽœȱŠ—ȱŒžœ˜–Ž›ȱœŠ’œŠŒ’˜—ȱ‹¢ȱŽŒ›ŽŠœ’—ȱŽ—’—Žȱ˜ —’–Žǯ

Ž›Žȱ’œȱ‘Žȱ•’œȱ˜ȱ˜˜•œȱŠ—ȱ‘Ž’›ȱœ˜ž›ŒŽǯȱȱ

Separate Tool Suppliers:

Kohler Tools SE Tools Žœ’—ȱŽŒ‘—˜•˜¢ȱ—Œǯ
Contact your source Śŗśȱ
˜ Š›ȱǯ ŝŜŞȱž››ȱŠ”ȱ›’ŸŽ
˜ȱœž™™•¢ǯȱ Š™ŽŽ›ǰȱȱȱŚŞŚŚŜ Žœ–˜—ǰȱȱȱŜŖśśş
‘˜—ŽȱŞŗŖȬŜŜŚȬŘşŞŗȱȱ ‘˜—ŽȱŜřŖȬşŘŖȬŗřŖŖ
˜••ȱ›ŽŽȱŞŖŖȬŜŜŚȬŘşŞŗȱ
Š¡ȱŞŗŖȬŜŜŚȬŞŗŞŗ

Tools
Description Source/Part No.
Balance Gear Timing Tool (K & M Series) ˜‘•Ž›ȱŘśȱŚśśȱŖŜȬ
˜ȱ‘˜•ȱ‹Š•Š—ŒŽȱŽŠ›œȱ’—ȱ’–Žȱ™˜œ’’˜—ȱ ‘Ž—ȱŠœœŽ–‹•’—ȱŽ—’—Žǯ ǻ˜›–Ž›•¢ȱȬřśŝǼ
Š–œ‘ŠĞȱ—™•Š¢ȱ•ŠŽ
ȱ˜˜•œȱ ȬŞŘŚŖś
˜›ȱŒ‘ŽŒ”’—ȱŒŠ–œ‘ŠĞȱŽ—™•Š¢ǯ
Š–œ‘ŠĞȱŽŠ•ȱ›˜ŽŒ˜›ȱǻŽ’œǼ
ȱ˜˜•œȱ ȬŞŘŚŗŝ
˜ȱ™›˜ŽŒȱœŽŠ•ȱž›’—ȱŒŠ–œ‘ŠĞȱ’—œŠ••Š’˜—ǯ
¢•’—Ž›ȱŽŠ”˜ —ȱŽœŽ›
˜‘•Ž›ȱŘśȱŝŜŗȱŖśȬ
˜›ȱŒ‘ŽŒ”’—ȱŒ˜–‹žœ’˜—ȱ›ŽŽ—’˜—ȱŠ—ȱ’ȱŒ¢•’—Ž›ǰȱ™’œ˜—ǰȱ›’—œǰȱ˜›ȱŸŠ•ŸŽœȱŠ›Žȱ ˜›—ǯ
•ŽŒ›˜—’ŒȱžŽ•ȱ—“ŽŒ’˜—ȱǻǼȱ’Š—˜œ’Œȱ˜Ğ Š›Ž
ȱ ˜‘•Ž›ȱŘśȱŝŜŗȱŘřȬ
œŽȱ ’‘ȱŠ™˜™ȱ˜›ȱŽœ”˜™ȱǯ
ȱŽ›Ÿ’ŒŽȱ ’ ˜‘•Ž›ȱŘŚȱŝŜŗȱŖŗȬ
˜›ȱ›˜ž‹•Žœ‘˜˜’—ȱŠ—ȱœŽĴ’—ȱž™ȱŠ—ȱȱŽ—’—Žǯ
ȱȱ—’Ÿ’žŠ•ȱ˜–™˜—Ž—œȱŸŠ’•Š‹•Ž Žœ’—ȱŽŒ‘—˜•˜¢ȱ—Œǯ
Pressure Tester ȬŖŗş
Noid Light ȬŖŘŗ
ȱȱȱȱşŖǚȱŠ™Ž› ȬŖŘř
ȱȱȱȱŽ’”Ž›ȱ•Š–™ȱ•’Ž›œ ȬŖŘś
ȱȱȱȱ˜Žȱ•žǰȱŽȱ’›Ž ȬŖŘŝ
ȱȱȱȱ˜Žȱ•žǰȱ•žŽȱ’›Žȱ ȬŖŘş
•¢ ‘ŽŽ•ȱ
˜•’—ȱ˜˜•ȱǻȱŽ›’ŽœǼ ȱ˜˜•œȱ ȬŞŘŚŖŝ
•¢ ‘ŽŽ•ȱž••Ž›ȱ
ȱ˜˜•œȱ ȬŞŘŚŖŞ
˜ȱ›Ž–˜ŸŽȱĚ¢ ‘ŽŽ•ȱ›˜–ȱŽ—’—Žǯ
•¢ ‘ŽŽ•ȱ›Š™ȱ›Ž—Œ‘
ȱ˜˜•œȱ ȬŞŘŚŖş
˜ȱ‘˜•ȱĚ¢ ‘ŽŽ•ȱž›’—ȱ›Ž–˜ŸŠ•ǯ

2.1
Section 2
Tools & Aids

Tools (Continued)
Description Source/Part No.

¢›Šž•’ŒȱŠ•ŸŽȱ’ĞŽ›ȱ˜˜•
˜‘•Ž›ȱŘśȱŝŜŗȱřŞȬ
˜ȱ›Ž–˜ŸŽȱŠ—ȱ’—œŠ••ȱ‘¢›Šž•’Œȱ•’ĞŽ›œǯ
—’’˜—ȱ¢œŽ–ȱŽœŽ›
˜‘•Ž›ȱŘśȱŚśśȱŖŗȬ
˜›ȱŽœ’—ȱ˜ž™žȱ˜—ȱŠ••ȱœ¢œŽ–œǰȱŽ¡ŒŽ™ȱǯ
˜‘•Ž›ȱŘŚȱŚśśȱŖŘȬ
˜›ȱŽœ’—ȱ˜ž™žȱ˜—ȱŒŠ™ŠŒ’’ŸŽȱ’œŒ‘Š›ŽȱǻǼȱ’—’’˜—ȱœ¢œŽ–ǯ
윎ȱ›Ž—Œ‘ȱǻ ȱǭȱȱŽ›’ŽœǼȱ
ȱ˜˜•œȱ ȬŞŘŚŗŖ
˜ȱ›Ž–˜ŸŽȱŠ—ȱ›Ž’—œŠ••ȱŒ¢•’—Ž›ȱ‹Š››Ž•ȱ›ŽŠ’—’—ȱ—žœǯ
’•ȱ›Žœœž›ŽȱŽœȱ ’
˜‘•Ž›ȱŘśȱŝŜŗȱŖŜȬȱ
˜ȱŽœȱŠ—ȱŸŽ›’¢ȱ˜’•ȱ™›Žœœž›Žǯȱ
ŽŒ’ꎛȬŽž•Š˜›ȱŽœŽ›ȱǻŗŘŖȱŸ˜•ȱŒž››Ž—Ǽ ˜‘•Ž›ȱŘśȱŝŜŗȱŘŖȬ
ŽŒ’ꎛȬŽž•Š˜›ȱŽœŽ›ȱǻŘŚŖȱŸ˜•ȱŒž››Ž—Ǽ ˜‘•Ž›ȱŘśȱŝŜŗȱŚŗȬ
œŽȱ˜ȱŽœȱ›ŽŒ’ꎛȬ›Žž•Š˜›œǯȱ
ȱ—’Ÿ’žŠ•ȱ˜–™˜—Ž—œȱŸŠ’•Š‹•Ž Žœ’—ȱŽŒ‘—˜•˜¢ȱ—Œǯ
ȱȱȱȬȱŽž•Š˜›ȱŽœȱ
Š›—Žœœ ȬŖřŗ
ȱȱȱ™ŽŒ’Š•ȱŽž•Š˜›ȱŽœȱ
Š›—Žœœȱ ’‘ȱ’˜Ž ȬŖřř
™Š›”ȱŸŠ—ŒŽȱ˜ž•ŽȱǻǼȱŽœŽ›
˜ȱŽœȱ‘ŽȱȱǻȱŠ—ȱǼȱ˜—ȱŽ—’—Žœȱ ’‘ȱȬ Ȝǯ ˜‘•Ž›ȱŘśȱŝŜŗȱŚŖȬ

Š›Ž›ȱŽŠ’—’—ȱ’—ȱ˜˜•ȱǻ—Ž›’Šȱ›’ŸŽǼ
˜ȱ›Ž–˜ŸŽȱŠ—ȱ›Ž’—œŠ••ȱ›’ŸŽȱ›ŽŠ’—’—ȱ›’—œȱǻŽ¡Œ•ž’—ȱȱœŠ›Ž›œǼǯ ˜‘•Ž›ȱŘśȱŝŜŗȱŗŞȬ

Š›Ž›ȱŽ›Ÿ’Œ’—ȱ ’ȱǻ••ȱŠ›Ž›œǼ
SE Tools KLR-82411
To remove and reinstall drive retaining rings and brushes.
Individual Component Available
SE Tools KLR-82416
Starter Brush Holding Tool (Solenoid Shift)
Tachometer (Digital Inductive) Design Technology Inc.
For checking operating speed (RPM) of an engine. DTI-110
Vacuum/Pressure Tester
Kohler 25 761 22-S
Alternative to a water manometer.
Valve Guide Reamer (K & M Series)
SE Tools KLR-11843
For sizing valve guides after installation.

2.2
 Section 2
Tools & Aids

Aids
Description Source/Part No.
Š–œ‘ŠĞȱž‹›’ŒŠ—ȱǻŠ•œ™Š›ȱŜŗřǼ ˜‘•Ž›ȱŘśȱřśŝȱŗŚȬ
’Ž•ŽŒ›’Œȱ ›ŽŠœŽȱǻ Ȧ˜ŸŠžŠ›ȱ ŜŜŗǼ ˜‘•Ž›ȱŘśȱřśŝȱŗŗȬ
’Ž•ŽŒ›’Œȱ ›ŽŠœŽȱǻŽ•Ȭ›˜Ǽ ž‹›’ȬŽ•
•ŽŒ›’ŒȱŠ›Ž›ȱ›’ŸŽȱž‹›’ŒŠ—ȱǻ—Ž›’Šȱ›’ŸŽǼ ȱ ˜‘•Ž›ȱśŘȱřśŝȱŖŗȬ 2
•ŽŒ›’ŒȱŠ›Ž›ȱ›’ŸŽȱž‹›’ŒŠ—ȱǻ˜•Ž—˜’ȱ‘’ĞǼȱ ˜‘•Ž›ȱśŘȱřśŝȱŖŘȬȱ
ȱ’•’Œ˜—ŽȱŽŠ•Š— ˜‘•Ž›ȱŘśȱśşŝȱŖŝȬ
˜Œ’ŽțȱśşŖŖȱ
ŽŠŸ¢ȱ˜¢ȱ’—ȱŚȱ˜£ȱŠŽ›˜œ˜•ȱ’œ™Ž—œŽ›ǯ
—•¢ȱ˜¡’–ŽȬ‹ŠœŽǰȱ˜’•ȱ›Žœ’œŠ—ȱȱœŽŠ•Š—œǰȱœžŒ‘ȱŠœȱ‘˜œŽȱ•’œŽǰȱŠ›ŽȱŠ™™›˜ŸŽȱ
˜›ȱžœŽǯȱ˜Œ’Žțȱ˜œǯȱśşŖŖȱ˜›ȱśşŗŖȱŠ›Žȱ›ŽŒ˜––Ž—Žȱ˜›ȱ‹ŽœȱœŽŠ•’—ȱŒ‘Š›ŠŒŽ›’œȬ
’Œœǯ
ȱȱ˜Œ’ŽțȱśşŗŖȱ
ȱȱ˜Œ’Žțȱ•›Šȱ•ŠŒ”ȱśşŞȱ
ȱȱ˜Œ’Žțȱ•›Šȱ•žŽȱśŞŝ
Loctite® Ultra Copper
™•’—Žȱ›’ŸŽȱž‹›’ŒŠ— ˜‘•Ž›ȱŘśȱřśŝȱŗŘȬ

2.3
Section 2
Tools & Aids

Special Tools You Can Make ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱœžœȱ˜ȱŠȱ˜œ’Ȭ˜Œ”ȱ›˜ȱ˜›ȱ›’—ȱ˜ěȱ

Flywheel Holding Tool
ȱĚ¢ ‘ŽŽ•ȱ‘˜•’—ȱ˜˜•ȱŒŠ—ȱ‹Žȱ–ŠŽȱ˜žȱ˜ȱŠ—ȱ˜•ȱ
“ž—”ȱĚ¢ ‘ŽŽ•ȱ›’—ȱŽŠ›ȱŠœȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŘȬŗǰȱŠ—ȱ
žœŽȱ’—ȱ™•ŠŒŽȱ˜ȱŠȱœ›Š™ȱ ›Ž—Œ‘ǯ
‘ŽȱŠ•’—’—ȱœŽ™œȱ˜ȱŠȱ˜––Š—ȱ›˜ǰȱœ˜ȱ‘Žȱ“˜’—ȱ
œž›ŠŒŽȱ’œȱ̊ǯȱ
ȱ řǯȱ ’—ȱŠȱŗȱ’—ǯȱ•˜—ȱŒŠ™œŒ›Ž ȱ ’‘ȱ‘ŽȱŒ˜››ŽŒȱ‘›ŽŠȱ
œ’£Žȱ˜ȱ–ŠŒ‘ȱ‘Žȱ‘›ŽŠœȱ’—ȱ‘ŽȱŒ˜——ŽŒ’—ȱ›˜ǯȱ

ŗǯȱ œ’—ȱŠ—ȱŠ‹›Šœ’ŸŽȱŒžȬ˜ěȱ ‘ŽŽ•ǰȱŒžȱ˜žȱŠȱœ’¡ȱ ȱ Śǯȱ œŽȱŠȱ̊ȱ Šœ‘Ž›ȱ ’‘ȱ‘ŽȱŒ˜››ŽŒȱǯǯȱ˜ȱœ•’™ȱ˜—ȱ

˜˜‘ȱœŽ–Ž—ȱ˜ȱ‘Žȱ›’—ȱŽŠ›ȱŠœȱœ‘˜ —ǯȱ ‘ŽȱŒŠ™œŒ›Ž ȱŠ—ȱŠ™™›˜¡’–ŠŽ•¢ȱŗȄȱǯǯȱǻ ˜‘•Ž›ȱ
Š›ȱ˜ǯȱŗŘȱŚŜŞȱŖśȬǼ. œœŽ–‹•Žȱ‘ŽȱŒŠ™œŒ›Ž ȱ
ȱ Řǯȱ ›’—ȱ˜ěȱŠ—¢ȱ‹ž››œȱ˜›ȱœ‘Š›™ȱŽŽœǯȱ Š—ȱ Šœ‘Ž›ȱ˜ȱ‘Žȱ“˜’—ȱœž›ŠŒŽȱ˜ȱ‘Žȱ›˜ǰȱŠœȱ
œ‘˜ —ȱ’—ȱ’ž›ŽȱŘȬŘǯ
ȱ řǯȱ —ŸŽ›ȱ‘ŽȱœŽ–Ž—ȱŠ—ȱ™•ŠŒŽȱ’ȱ‹Ž ŽŽ—ȱ‘Žȱ
’—’’˜—ȱ‹˜œœŽœȱ˜—ȱ‘ŽȱŒ›Š—”ŒŠœŽȱœ˜ȱ‘Šȱ‘Žȱ˜˜•ȱȱ
ŽŽ‘ȱŽ—ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›’—ȱŽŠ›ȱŽŽ‘ǯȱ‘Žȱ
‹˜œœŽœȱ ’••ȱ•˜Œ”ȱ‘Žȱ˜˜•ȱŠ—ȱĚ¢ ‘ŽŽ•ȱ’—ȱȱ ȱ
™˜œ’’˜—ȱ˜›ȱ•˜˜œŽ—’—ǰȱ’‘Ž—’—ȱ˜›ȱ›Ž–˜Ÿ’—ȱ
 ’‘ȱŠȱ™ž••Ž›ǯ

Figure 2-2. Rocker Arm/Crankshaft Tool.

Figure 2-1. Flywheel Holding Tool.

Rocker Arm/Crankshaft Tool

ȱœ™Š——Ž›ȱ ›Ž—Œ‘ȱ˜ȱ•’Ğȱ‘Žȱ›˜Œ”Ž›ȱŠ›–œȱ˜›ȱž›—ȱ‘Žȱ
Œ›Š—”œ‘ŠĞȱ–Š¢ȱ‹Žȱ–ŠŽȱ˜žȱ˜ȱŠ—ȱ˜•ȱ“ž—”ȱŒ˜——ŽŒ’—ȱ
›˜ǯȱ

ȱ ŗǯȱ ’—ȱŠȱžœŽȱŒ˜——ŽŒ’—ȱ›˜ȱ›˜–ȱŠȱŗŖȱ
ȱ˜›ȱ
•Š›Ž›ȱŽ—’—ŽǯȱŽ–˜ŸŽȱŠ—ȱ’œŒŠ›ȱ‘Žȱ›˜ȱŒŠ™ǯȱ

2.4

Section 3
Troubleshooting
Troubleshooting Guide
When troubles occur, be sure to check the simple
ŒŠžœŽœȱ ‘’Œ‘ǰȱŠȱꛜǰȱ–Š¢ȱœŽŽ–ȱ˜˜ȱ˜‹Ÿ’˜žœȱ˜ȱ‹Žȱ
considered. For example, a starting problem could be
ŒŠžœŽ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 žŽ•ȱœ‘žȬ˜ěȱŸŠ•ŸŽȱŒ•˜œŽǯ
ȱ řǯȱ ˜˜›ȱžŽ•ǰȱ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱ‘ŽȱžŽ•ȱœ¢œŽ–ǯ
ȱ Śǯȱ •˜ŽȱžŽ•ȱ•’—Žǯ
5. Spark plug lead disconnected.
ȱ Ŝǯȱ
’••ȱœ ’Œ‘ȱ’—ȱ˜ěȱ™˜œ’’˜—ǯ ŗǯȱ ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱ‘ŽȱžŽ•ȱœ¢œŽ–ǯ
ȱ ŝǯȱ Šž•¢ȱœ™Š›”ȱ™•žǯ
ȱ Şǯȱ Šž•¢ȱ’—’’˜—ȱ–˜ž•Žǯ
ȱ şǯȱ žŽ•ȱœ˜•Ž—˜’ȱ–Š•ž—Œ’˜—ǯ
10. Choke not closing.
ŗŗǯȱ ŠĴŽ›¢ȱŒ˜——ŽŒŽȱ‹ŠŒ” Š›œǯ
ŗŘǯȱ ŠŽ¢ȱ’—Ž›•˜Œ”ȱœ¢œŽ–ȱŽ—ŠŽǯ
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‘ŽȱžŽ•ȱœ¢œŽ–ǯ
ȱ řǯȱ Šž•¢ȱ˜›ȱ–’œŠ“žœŽȱŒ‘˜”Žȱ˜›ȱ‘›˜Ĵ•ŽȱŒ˜—›˜•œǯ
4. Loose wires or connections that short the kill
Ž›–’—Š•ȱ˜ȱ’—’’˜—ȱ–˜ž•Žȱ˜ȱ›˜ž—ǯ
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›’ŸŽȱ’œȱŽ—ŠŽǯ
ȱ Řǯȱ ˜˜›ȱžŽ•ǰȱ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱ‘ŽȱžŽ•ȱœ¢œŽ–ǯ
ȱ řǯȱ •˜ŽȱžŽ•ȱ•’—Žǯ
ȱ Śǯȱ ˜˜œŽȱ˜›ȱŠž•¢ȱ ’›Žœȱ˜›ȱŒ˜——ŽŒ’˜—œǯ
ȱ śǯȱ Šž•¢ȱ˜›ȱ–’œŠ“žœŽȱŒ‘˜”Žȱ˜›ȱ‘›˜Ĵ•ŽȱŒ˜—›˜•œǯ
ȱ Ŝǯȱ Šž•¢ȱœ™Š›”ȱ™•žǯ
7. Low compression.
ȱ Şǯȱ Šž•¢ȱȱ–ŽŒ‘Š—’œ–ǯ
9. Weak spark.
ȱŗŖǯȱ žŽ•ȱ™ž–™ȱ–Š•ž—Œ’˜—ȱŒŠžœ’—ȱ•ŠŒ”ȱ˜ȱžŽ•ǯ
Section 3
Troubleshooting
3
ŗŗǯȱ —’—Žȱ˜ŸŽ›‘ŽŠŽȬŒ˜˜•’—ȦŠ’›ȱŒ’›Œž•Š’˜—ȱ
restricted.
ŗŘǯȱ •¢ ‘ŽŽ•ȱ”Ž¢ȱœ‘ŽŠ›Žǯ
ȱŗřǯȱ —Š”Žȱœ¢œŽ–ȱ•ŽŠ”ǯ
Engine Will Not Crank
ȱ ŗǯȱ ȱ›’ŸŽȱ’œȱŽ—ŠŽǯ
ȱ Řǯȱ ŠĴŽ›¢ȱ’œȱ’œŒ‘Š›Žǯ
ȱ řǯȱ ŠŽ¢ȱ’—Ž›•˜Œ”ȱœ ’Œ‘ȱ’œȱŽ—ŠŽǯ
ȱ Śǯȱ ˜˜œŽȱ˜›ȱŠž•¢ȱ ’›Žœȱ˜›ȱŒ˜——ŽŒ’˜—œǯ
ȱ śǯȱ Šž•¢ȱ”Ž¢ȱœ ’Œ‘ȱ˜›ȱ’—’’˜—ȱœ ’Œ‘ǯ
ȱ Ŝǯȱ Šž•¢ȱŽ•ŽŒ›’ŒȱœŠ›Ž›ǯ
7. Seized internal engine components.
Engine Runs But Misses
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‘Šȱ’—Ž›–’ĴŽ—•¢ȱ
œ‘˜›ȱ‘Žȱ”’••ȱŽ›–’—Š•ȱ˜ȱ’—’’˜—ȱ–˜ž•Žȱ˜ȱ
ground.
ȱ Ŝǯȱ —’—Žȱ˜ŸŽ›‘ŽŠŽǯ
ȱ ŝǯȱ Šž•¢ȱ’—’’˜—ȱ–˜ž•Žȱ˜›ȱ’–™›˜™Ž›•¢ȱŠ™™Žǯ
ȱ Şǯȱ Š›‹ž›Ž˜›ȱŠ“žœŽȱ’—Œ˜››ŽŒ•¢ǯ
Engine Will Not Idle
ȱ ŗǯȱ ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱ‘Žȱ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ȬŒ˜˜•’—ȱœ¢œŽ–ȦŠ’›ȱŒ’›Œž•Š’˜—ȱ
problem.
3.1
Section 3
Troubleshooting
Engine Overheats
ȱ ŗǯȱ ’›ȱ’—Š”ŽȦ›ŠœœȱœŒ›ŽŽ—ǰȱŒ˜˜•’—ȱꗜǰȱ˜›ȱŒ˜˜•’—ȱ
shrouds clogged.
ȱ Řǯȱ ¡ŒŽœœ’ŸŽȱŽ—’—Žȱ•˜Šǯ
ȱ řǯȱ ˜ ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ
ȱ Śǯȱ
’‘ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ
ȱ śǯȱ Šž•¢ȱŒŠ›‹ž›Ž˜›ǯ
ȱ Ŝǯȱ ŽŠ—ȱžŽ•ȱ–’¡ž›Žǯ
Engine Knocks
ȱ ŗǯȱ ¡ŒŽœœ’ŸŽȱŽ—’—Žȱ•˜Šǯ
ȱ Řǯȱ ˜ ȱŒ›Š—”ŒŠœŽȱ˜’•ȱ•ŽŸŽ•ǯ
ȱ řǯȱ •ȱ˜›ȱ’–™›˜™Ž›ȱžŽ•ǯ
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 řǯȱ ’›¢ȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ǯ
ȱ Śǯȱ ’›ȱ˜›ȱ ŠŽ›ȱ’—ȱ‘Žȱ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 ˜ ȱ‹ŠĴŽ›¢ǯ
ŗŗǯȱ —Œ˜››ŽŒȱ˜ŸŽ›—˜›ȱœŽĴ’—ǯ
Engine Uses Excessive Amount of Oil
ȱ ŗǯȱ —Œ˜››ŽŒȱ˜’•ȱŸ’œŒ˜œ’¢Ȧ¢™Žǯ
ȱ Řǯȱ •˜Žǰȱ‹›˜”Ž—ǰȱ˜›ȱ’—˜™Ž›Š’ŸŽȱ‹›ŽŠ‘Ž›ǯ
3. Worn or broken piston rings.
ȱ Śǯȱ ˜›—ȱŒ¢•’—Ž›ȱ‹˜›Žǯ
ȱ śǯȱ ˜›—ȱŸŠ•ŸŽȱœŽ–œȦŸŠ•ŸŽȱž’Žœǯ
ȱ Ŝǯȱ ›Š—”ŒŠœŽȱ˜ŸŽ›ę••Žǯ
ȱ ŝǯȱ •˜ —ȱ‘ŽŠȱŠœ”ŽȦ˜ŸŽ›‘ŽŠŽǯ
Oil Leaks from Oil Seals, Gaskets
ȱ ŗǯȱ •˜Žǰȱ‹›˜”Ž—ǰȱ˜›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.
3.2
ȱ Ȋȱ ‘ŽŒ”ȱ˜›ȱ‹ž’•ž™ȱ˜ȱ’›ȱŠ—ȱŽ‹›’œȱ˜—ȱ‘Žȱ
Œ›Š—”ŒŠœŽǰȱŒ˜˜•’—ȱꗜǰȱ›ŠœœȱœŒ›ŽŽ—ȱŠ—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
ȱ Ȋȱ ‘ŽŒ”ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŒ˜ŸŽ›ȱŠ—ȱ‹ŠœŽȱ˜›ȱŠ–ŠŽȱ
˜›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.
ȱ Ȋȱ ‘ŽŒ”ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‘›˜Šȱ˜›ȱ’›ǯȱ’›ȱ’—ȱ‘Žȱ
‘›˜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Šœ˜•’—Žȱ
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’˜—DzȱŠȱœ–Š••ȱ
ŠŒŒž–ž•Š’˜—ȱ’œȱ—˜›–Š•ǯȱ¡ŒŽœœ’ŸŽȱœ•žŽȱ˜›–Š’˜—ȱ
Œ˜ž•ȱ’—’ŒŠŽȱ‘Žȱ ›˜—ȱ¢™Žȱ˜›ȱ Ž’‘ȱ˜ȱ˜’•ȱ Šœȱ
used, the oil was not changed at the recommended
’—Ž›ŸŠ•œǰȱŠ—ȱ˜ŸŽ›Ȭ›’Œ‘ȱžŽ•ȱ–’¡ž›Žǰȱ˜›ȱ ŽŠ”ȱ’—’’˜—ǰȱ
˜ȱ—Š–ŽȱŠȱŽ ȱ™˜œœ’‹•ŽȱŒŠžœŽœǯ
NOTE: It is good practice to drain oil at a location
Š Š¢ȱ›˜–ȱ‘Žȱ ˜›”‹Ž—Œ‘ǯȱŽȱœž›Žȱ˜ȱŠ••˜ ȱ
Š–™•Žȱ’–Žȱ˜›ȱŒ˜–™•ŽŽȱ›Š’—ŠŽǯ
Cleaning the Engine
Ў›ȱ’—œ™ŽŒ’—ȱ‘ŽȱŽ¡Ž›—Š•ȱŒ˜—’’˜—ȱ˜ȱ‘ŽȱŽ—’—Žǰȱ
Œ•ŽŠ—ȱ‘ŽȱŽ—’—Žȱ‘˜›˜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
 ’••ȱšž’Œ”•¢ȱ›Ž–˜ŸŽȱ›ŽŠœŽǰȱ˜’•ǰȱŠ—ȱ›’–Žȱ›˜–ȱ
engine 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
ŽŒ’˜—ȱŘǯȱ˜–™•ŽŽȱ’—œ›žŒ’˜—œȱŠ›Žȱ™›˜Ÿ’Žȱ ’‘ȱ‘Žȱ
testers.
Žœȱ‘ŽȱŒ›Š—”ŒŠœŽȱŸŠŒžž–ȱ ’‘ȱ‘Žȱ–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.
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
2. Start the engine and run at no-load high idle
speed (3200 to 3750 RPM).
ȱ řǯȱ ™Ž—ȱ‘ŽȱŒ•Š–™ȱŠ—ȱ—˜Žȱ‘Žȱ ŠŽ›ȱ•ŽŸŽ•ȱ’—ȱ‘Žȱ
tube.
ȱ ȱ ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘ŽȱŽ—’—Žȱœ’Žȱœ‘˜ž•ȱ‹ŽȱŠȱ–’—’–ž–ȱ
˜ȱ10.2 cm (4 in.)ȱŠ‹˜ŸŽȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘Žȱ˜™Ž—ȱœ’Žǯ
ȱ ȱ ȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘ŽȱŽ—’—Žȱœ’Žȱ’œȱ‘ŽȱœŠ–ŽȱŠœȱ‘Žȱ
˜™Ž—ȱœ’Žȱǻ—˜ȱŸŠŒžž–Ǽǰȱ˜›ȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘ŽȱŽ—’—Žȱ
3
œ’Žȱ’œȱ•˜ Ž›ȱ‘Š—ȱ‘Žȱ•ŽŸŽ•ȱ’—ȱ‘Žȱ˜™Ž—ȱœ’Žȱ
ǻ™›Žœœž›ŽǼǰȱŒ‘ŽŒ”ȱ˜›ȱ‘ŽȱŒ˜—’’˜—œȱ’—ȱ‘ŽȱŠ‹•Žȱ
below.
4. Close the pinch clamp before stopping the
engine.
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’—ȱœ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–ȱǻŚȱ’—ǯǼȱ
˜ȱŸŠŒžž–ȱœ‘˜ž•ȱ‹Žȱ™›ŽœŽ—ǯ
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’›Ȧ›Ž™•ŠŒŽȱ›Žœ›’ŒŽȱ–žĝŽ›ȦŽ¡‘Šžœȱ
œ¢œŽ–ǯ
3.3
Section 3
Troubleshooting
Compression Test
These engines are equipped with an automatic
Œ˜–™›Žœœ’˜—ȱ›Ž•ŽŠœŽȱǻǼȱ–ŽŒ‘Š—’œ–ǯȱŽŒŠžœŽȱ
˜ȱ‘Žȱȱ–ŽŒ‘Š—’œ–ǰȱ’ȱ’œȱ’ĜŒž•ȱ˜ȱ˜‹Š’—ȱŠ—ȱ
ŠŒŒž›ŠŽȱŒ˜–™›Žœœ’˜—ȱ›ŽŠ’—ǯȱœȱŠ—ȱŠ•Ž›—ŠŽǰȱžœŽȱ‘Žȱ
leakdown test described below.
Cylinder Leakdown Test
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
‘Žȱœ•˜ȱ˜ȱ‘Žȱ‘˜•’—ȱ˜˜•ǰȱœ˜ȱ’ȱ’œȱ™Ž›™Ž—’Œž•Š›ȱ
˜ȱ‹˜‘ȱ‘Žȱ‘˜•’—ȱ˜˜•ȱŠ—ȱŒ›Š—”œ‘ŠĞǰȱ˜›ȱ’—œŽ›ȱ
a shoulder bolt through the slot and thread it into
‘Žȱ–˜ž—’—ȱ‘˜•Žǯȱȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŽ—ȱ’œȱ–˜›Žȱ
ŠŒŒŽœœ’‹•Žǰȱ¢˜žȱŒŠ—ȱžœŽȱŠȱ‹›ŽŠ”Ž›ȱ‹Š›ȱŠ—ȱœ˜Œ”Žȱ
˜—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ—žȦœŒ›Ž ȱ˜ȱ‘˜•ȱ’ȱ’—ȱ™˜œ’’˜—ǯȱ
˜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’—ȱ
Šȱ™’ŽŒŽȱ˜ȱŽšž’™–Ž—ǰȱ¢˜žȱ–Š¢ȱ‹ŽȱŠ‹•Žȱ˜ȱ‘˜•ȱ
’ȱ‹¢ȱŒ•Š–™’—ȱ˜›ȱ Ž’—ȱŠȱ›’ŸŽ—ȱŒ˜–™˜—Ž—ǯȱ
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
‘ŽȱŒ¢•’—Ž›ȱ•ŽŠ”˜ —ȱŽœŽ›ȱ’œȱŠȱ›Ž•Š’ŸŽ•¢ȱœ’–™•Žǰȱ
’—Ž¡™Ž—œ’ŸŽȱ•ŽŠ”˜ —ȱŽœŽ›ȱ˜›ȱœ–Š••ȱŽ—’—Žœǯȱ
‘ŽȱŽœŽ›ȱ’—Œ•žŽœȱŠȱšž’Œ”ȱ’œŒ˜——ŽŒȱŒ˜ž™•’—ȱ˜›ȱ
ŠĴŠŒ‘’—ȱ‘ŽȱŠŠ™Ž›ȱ‘˜œŽȱŠ—ȱŠȱ‘˜•’—ȱ˜˜•ǯ
žœȱ‹ŽȱŒŽ›Š’—ȱ‘Šȱ‘ŽȱŽ—’—ŽȱŒŠ——˜ȱ›˜ŠŽȱ˜ěȱ˜ȱ
TDC in either direction.
4. Install the adapter into the spark plug hole, but
˜ȱ—˜ȱŠĴŠŒ‘ȱ’ȱ˜ȱ‘ŽȱŽœŽ›ȱŠȱ‘’œȱ’–Žǯ
5. Connect an adequate air source (80-100 psi) to the
tester.

Leakdown Test Instructions 6. Turn the regulator knob in the increase

ȱ ŗǯȱ ž—ȱ‘ŽȱŽ—’—Žȱ˜›ȱřȬśȱ–’—žŽœȱ˜ȱ Š›–ȱ’ȱž™ǯ (clockwise) direction until the gauge needle is in
‘Žȱ¢Ž••˜ ȱœŽȱŠ›ŽŠȱŠȱ‘Žȱ•˜ ȱǻ›’‘ǼȱŽ—ȱ˜ȱ‘Žȱ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱœ™Š›”ȱ™•žǯ scale.

ȱ řǯȱ ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱž—’•ȱ‘Žȱ™’œ˜—ȱ’œȱŠȱ˜™ȱ 7. Connect the tester quick-disconnect to the

ŽŠȱŒŽ—Ž›ȱ˜ȱ‘ŽȱŒ˜–™›Žœœ’˜—ȱœ›˜”Žǯȱ˜žȱ ŠŠ™Ž›ǯȱ˜Žȱ‘ŽȱŠžŽȱ›ŽŠ’—ȱŠ—ȱ•’œŽ—ȱ˜›ȱ
will need to hold the engine in this position escaping air at the carburetor inlet, exhaust
while testing. The holding tool supplied with ˜ž•ŽǰȱŠ—Ȧ˜›ȱŒ›Š—”ŒŠœŽȱ‹›ŽŠ‘Ž›ǯ
‘ŽȱŽœŽ›ȱŒŠ—ȱ‹ŽȱžœŽȱ’ȱ‘ŽȱȱŽ—ȱ˜ȱ‘Žȱ
Œ›Š—”œ‘ŠĞȱ’œȱŠŒŒŽœœ’‹•Žǯȱ•’Žȱ‘Žȱ‘˜•’—ȱ˜˜•ȱ ȱ Şǯȱ ‘ŽŒ”ȱ¢˜ž›ȱŽœȱ›Žœž•œȱŠŠ’—œȱ‘ŽȱŠ‹•Žȱ‹Ž•˜ DZ
˜—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞǰȱŠ•’—ȱ‘Žȱœ•˜ȱ ’‘ȱ˜—Žȱ˜ȱ‘Žȱ
–˜ž—’—ȱ‘˜•Žœȱ˜—ȱ‘ŽȱȱŠŒŽǰȱŠ—ȱ’‘Ž—ȱ’ȱ
˜—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱ—œŠ••ȱŠȱřȦŞȈȱ‹›ŽŠ”Ž›ȱ‹Š›ȱ’—˜ȱ

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

Section 4
Air Cleaner and Air Intake System

Air Cleaner
These engines are equipped with a replaceable, high
density, paper air cleaner element. Some engines also
have an oiled, foam precleaner, located in the outer air
cleaner cover. See Figure 4-1.
Intake air is drawn in through the upper opening from
the blower housing, passes through the precleaner
(if so equipped), the paper element and then into
the carburetor. The outer air cleaner cover is secured 4
by two knobs, and removed by turning the knobs
counterclockwise.

Air Cleaner
Base

Air Cleaner Element

Air Cleaner Cover

Optional Foam Precleaner

Air
Cleaner
Cover
Knobs

Figure 4-1. Air Cleaner Assembly - Exploded View.

Check the air cleaner daily or before starting the
engine. Check for and correct any buildup of dirt and
debris, and loose or damaged components.
NOTE: Operating the engine with loose or
damaged air cleaner components could
Š••˜ ȱž—ę•Ž›ŽȱŠ’›ȱ’—˜ȱ‘ŽȱŽ—’—ŽȱŒŠžœ’—ȱ
premature wear and failure.
Precleaner Service
If so equipped, wash and oil the precleaner every two
months or every 25 hoursȱ˜ȱ˜™Ž›Š’˜—ȱǻ–˜›Žȱ˜ĞŽ—ȱ
under extremely dusty or dirty conditions).
1. Loosen the air cleaner cover knobs and remove
the cover.
2. Remove the precleaner.

4.1
Section 4
Air Cleaner and Air Intake System
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until
all traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry.
4. Saturate the precleaner with new engine oil.
Squeeze out all excess oil.
5. Reinstall the precleaner into the outer cover.
6. Install the air cleaner cover and secure with the
two knobs.
7. When precleaner replacement is necessary, order
Kohler Part No. 20 083 03-S.
Paper Element Service
Check the paper element every two months or every
25 hoursȱ˜ȱ˜™Ž›Š’˜—ȱǻ–˜›Žȱ˜ĞŽ—ȱž—Ž›ȱŽ¡›Ž–Ž•¢ȱ
dusty or dirty conditions). Clean or replace the
element as necessary. Replace the air cleaner element
annually or every 100 hours.
1. Remove the air cleaner cover and the precleaner
(if so equipped), service as required.
2. Remove the air cleaner element with the integral
rubber seal.
3. Gently tap the pleated side of the paper element
to dislodge dirt. 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. Handle
new elements carefully; do not use if the rubber
seal is damaged.
4. Clean all air cleaner components of any
accumulated dirt or foreign material. Prevent any
dirt from entering the throat of the carburetor.
5. Install the air cleaner element with the pleated
side out and seat the rubber seal onto the edges
of the air cleaner base.
6. Reinstall the precleaner (if so equipped), into
the upper section of the air cleaner cover. Make
sure the hole in the precleaner is aligned with the
upper mounting knob. See Figure 4-1.
7. Reinstall the air cleaner cover and secure with the
two knobs.
4.2
8. When element replacement is necessary, order
Kohler Part No. 20 083 02-S.
Inspect Air Cleaner Components
Whenever the air cleaner cover is removed, or the
paper element or precleaner is serviced, check the
following areas/components:
Outer Air Cleaner Cover - Make sure the air cleaner
cover is in good condition, not cracked, damaged, or
–’œœ’—ȱŠȱ›ŽŠ’—’—ȱ”—˜‹ǰȱ ‘’Œ‘ȱŒŠ—ȱŠěŽŒȱ‘ŽȱœŽŠ•’—ȱ
ability of the air cleaner element.
Air Cleaner Base - Make sure the base is properly
secured and not cracked or damaged. Since the
air cleaner base and carburetor are secured to the
intake port with common hardware, it is extremely
important that the fasteners securing these
components are tight at all times. The air cleaner
base also provides the mounting points for the air
cleaner cover retaining studs. Make sure the bosses
are not cracked, broken or damaged, and the studs are
properly secured.
Before reinstalling an air cleaner base that has been
removed, make sure the metal bushings in the base
mounting holes are present. See Figure 4-2. The
bushings prevent damage to the base and maintain
the proper mounting torque.
Figure 4-2. Bushings in Air Cleaner Base.
Breather Hose - Make sure the hose is not cracked or
Š–ŠŽǰȱŠ—ȱŠĴŠŒ‘Žȱ˜ȱ‹˜‘ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽȱ
and valve cover.
NOTE: Damaged, worn, or loose air cleaner
Œ˜–™˜—Ž—œȱŒŠ—ȱŠ••˜ ȱž—ę•Ž›ŽȱŠ’›ȱ’—˜ȱ‘Žȱ
engine causing premature wear and failure.
Tighten or replace all loose or damaged
components.

Reassembly
The following procedure is for complete assembly of
all air cleaner components. Steps 1-3 are necessary
only if the air cleaner base and/or the cover mounting
studs were removed in Section 8, Disassembly.
Figure 4-3. Breather Hose.
Disassembly
The following procedure is for complete disassembly
of all air cleaner components. As the removal of the
Š’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽȱŠ•œ˜ȱŠěŽŒœȱŒŠ›‹ž›Ž˜›ȱ–˜ž—’—ȱŠ—ȱ
governor adjustment, steps 3 and 4 should only be
performed if required. Detailed photos are provided
in Sections 5, 8, and 10 for the various individual
steps.
1. Loosen the air cleaner cover retaining knobs and
remove the air cleaner cover.
2. Remove the foam precleaner (if so equipped),
and the air cleaner element with formed rubber
seal.
3. Disconnect the breather hose from the valve
cover or air cleaner base.
NOTE: The air cleaner base should be removed
only if necessary.
ȱ Śǯȱȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—Žȱ—žœȱ›˜–ȱ‘Žȱ
mounting studs. If one stud and one thread
˜›–’—ȱœŒ›Ž ȱ’œȱžœŽDzȱꛜȱ›Ž–˜ŸŽȱ‘Žȱ‘›ŽŠȱ
forming screw on the right side of the carburetor
inlet, which secures the air cleaner base,
carburetor and gaskets. Insert a 3/16” diameter
rod approximately 4” long, into the hole to serve
as a temporary alignment pin. Be careful not
to force the rod or damage the threads. Then
›Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žȱ›˜–ȱ‘Žȱœžȱ˜—ȱ
‘Žȱ•ŽĞȱœ’Žȱ˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ’—•ŽǯȱŠ›Žž••¢ȱ
remove the air cleaner base and gasket. The cover
mounting studs thread into the air cleaner base,
and they should only be removed if necessary.
Section 4
Air Cleaner and Air Intake System
1. Install the mounting studs into the air cleaner
base if removed previously. Tighten the studs
ž—’•ȱ‹˜Ĵ˜–Žǰȱ˜›ȱ˜ȱ‘ŽȱŽ—ȱ˜ȱ‘›ŽŠœȱǻ˜ȱ—˜ȱ
force).
2. Install the air cleaner base gasket and air cleaner
base, with the two metal spacers, onto the
mounting stud(s) and/or alignment pin. Make 4
sure the upper mounting tab is located above the
Œ•˜œž›Žȱ™•ŠŽǯȱ—œŠ••ȱŠ—ȱꗐŽ›ȱ’‘Ž—ȱ‘Žȱ‘Ž¡ȱ
̊—Žȱ—žǻœǼǯȱ‘Ž—ȱŠȱ•˜—ȱŜȱ‘›ŽŠȱ˜›–’—ȱ
mounting screw is used, apply hand pressure
˜ȱ”ŽŽ™ȱ‘Žȱ™Š›œȱ›˜–ȱœ‘’Ğ’—ǰȱ‘Ž—ȱ›Ž–˜ŸŽȱ‘Žȱ
alignment pin and install the M6 thread forming
screw. DO NOT OIL. Torque the nut(s) to
5.5 N·m (48 in. lb.). Torque the screw to 8.0 N·m
(70 in. lb.) into a new hole, or 5.5 N·m (48 in. lb.)
into a used hole, do not over tighten.
3. Reconnect the breather hose and perform the
governor adjustment (Section 5, Initial Governor
Adjustment).
4. Install the air cleaner element with the pleated
side out and seat the rubber seal onto the edges
of the air cleaner base.
5. Install the serviced precleaner (if so equipped)
into the air cleaner cover. Make sure the hole
in the precleaner is aligned with the upper
mounting knob.
6. Reinstall the air cleaner cover and secure with the
two knobs.
4.3
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˜˜•’—ȱꗜǰȱŠ—ȱ˜‘Ž›ȱŽ¡Ž›—Š•ȱœž›ŠŒŽœȱ˜ȱ‘ŽȱŽ—’—Žȱ
are kept clean at all times.

Annually or every 100 hoursȱ˜ȱ˜™Ž›Š’˜—ǰȱǻ–˜›Žȱ˜ĞŽ—ȱ

under extremely dusty, dirty conditions), remove the
blower housing and any other cooling shrouds. Clean
‘ŽȱŒ˜˜•’—ȱꗜȱŠ—ȱŽ¡Ž›—Š•ȱœž›ŠŒŽœȱŠœȱ—ŽŒŽœœŠ›¢ǯȱ
Make sure all parts are reinstalled. Torque the M6
blower housing fasteners to 7.7 N·m (68.3 in. lb.).

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

Section 5
Fuel System and Governor
Fuel Recommendations
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˜›ȱ
̊–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’—ȱŒ˜—ŠŒȱ
 ’‘ȱ‘˜ȱ™Š›œȱ˜›ȱœ™Š›”œȱ›˜–ȱ’—’’˜—ǯȱ˜ȱ—˜ȱœŠ›ȱ‘Žȱ
Ž—’—Žȱ—ŽŠ›ȱœ™’••ŽȱžŽ•ǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—ŽȱŠœȱŠȱŒ•ŽŠ—’—ȱ
Š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.
ȱ Ȋȱ ˜ȱ—˜ȱžœŽȱŠœ˜•’—Žȱ•ŽĞȱ˜ŸŽ›ȱ›˜–ȱ‘Žȱ™›ŽŸ’˜žœȱ
season, to minimize gum deposits in your fuel
system and to ensure easy starting.
• Do not add oil to the gasoline.
ȱ Ȋȱ ˜ȱ—˜ȱ˜ŸŽ›ę••ȱ‘ŽȱžŽ•ȱŠ—”ǯȱŽŠŸŽȱ›˜˜–ȱ˜›ȱ‘Žȱ
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.
Unleaded gasoline is recommended, as it leaves less
Œ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ȱŽ™˜œ’œǯȱŽŠŽȱŠœ˜•’—Žȱ–Š¢ȱ
be used in areas where unleaded is not available
and exhaust emissions are not regulated. Be aware
however, that the cylinder head will require more
frequent service.
Section 5
Fuel System and Governor
Gasoline/Alcohol blends
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
Š—ȱŞśȱŠ›Žȱ—˜ȱ˜ȱ‹ŽȱžœŽȱŠ—ȱ—˜ȱŠ™™›˜ŸŽǯȱ—¢ȱ
failures resulting from use of these fuels will not be
warranted.
5
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
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
The typical fuel system and related components
’—Œ•žŽȱ‘ŽȱžŽ•ȱŠ—”ǰȱ’—Ȭ•’—ŽȱžŽ•ȱꕝŽ›ǰȱžŽ•ȱ™ž–™ǰȱ
carburetor, and fuel lines. Some applications use
gravity feed without a fuel pump.
Operation
‘ŽȱžŽ•ȱ›˜–ȱ‘ŽȱŠ—”ȱ’œȱ–˜ŸŽȱ‘›˜ž‘ȱ‘Žȱ’—Ȭ•’—Žȱ
ꕝŽ›ȱŠ—ȱžŽ•ȱ•’—Žœȱ‹¢ȱ‘ŽȱžŽ•ȱ™ž–™ǯȱ—ȱŽ—’—Žœȱ—˜ȱ
Žšž’™™Žȱ ’‘ȱŠȱžŽ•ȱ™ž–™ǰȱ‘ŽȱžŽ•ȱŠ—”ȱ˜ž•Žȱ’œȱ
located above the carburetor inlet and gravity moves
the fuel.
žŽ•ȱ‘Ž—ȱŽ—Ž›œȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ̘Šȱ‹˜ •ȱŠ—ȱ’œȱ
moved into the carburetor body. There, the fuel is
–’¡Žȱ ’‘ȱŠ’›ǯȱ‘’œȱžŽ•ȬŠ’›ȱ–’¡ž›Žȱ’œȱ‘Ž—ȱ‹ž›—Žȱ’—ȱ
the engine combustion chamber.
Troubleshooting
œŽȱ‘Žȱ˜••˜ ’—ȱ™›˜ŒŽž›Žȱ˜ȱŒ‘ŽŒ”ȱ’ȱžŽ•ȱ’œȱ
reaching the combustion chamber.
5.1
Section 5
Fuel System and Governor
Fuel System Troubleshooting Guide
Test
ȱ ŗǯȱ ‘ŽŒ”ȱ˜›ȱ‘Žȱ˜••˜ ’—DZ
ȱ Šǯȱ Š”Žȱœž›Žȱ‘ŽȱžŽ•ȱŠ—”ȱŒ˜—Š’—œȱŒ•ŽŠ—ǰȱ›Žœ‘ǰȱ
proper fuel.
ȱ ‹ǯȱ Š”Žȱœž›Žȱ‘ŽȱŸŽ—ȱ’—ȱžŽ•ȱŒŠ™ȱ’œȱ˜™Ž—ǯ
ȱ Œǯȱ Š”Žȱœž›Žȱ‘ŽȱžŽ•ȱŸŠ•ŸŽȱ’œȱ˜™Ž—ǯ
ȱ Řǯȱ ‘ŽŒ”ȱ˜›ȱžŽ•ȱ’—ȱ‘ŽȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ǯ
ȱ Šǯȱ ’œŒ˜——ŽŒȱŠ—ȱ›˜ž—ȱœ™Š›”ȱ™•žȱ•ŽŠǯ
ȱ ‹ǯȱ •˜œŽȱ‘ŽȱŒ‘˜”Žȱ˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯ
ȱ Œǯȱ ›Š—”ȱ‘ŽȱŽ—’—ŽȱœŽŸŽ›Š•ȱ’–Žœǯ
ȱ ǯȱ Ž–˜ŸŽȱ‘Žȱœ™Š›”ȱ™•žȱŠ—ȱŒ‘ŽŒ”ȱ˜›ȱžŽ•ȱŠȱ
the tip.
ȱ řǯȱ ‘ŽŒ”ȱ˜›ȱžŽ•ȱ̘ ȱ›˜–ȱ‘ŽȱŠ—”ȱ˜ȱ‘ŽȱžŽ•ȱ™ž–™ǯ ȱ řǯȱ ȱžŽ•ȱdoesȱ̘ ȱ›˜–ȱ‘Žȱ•’—Žǰȱ›ŽŒ˜——ŽŒȱ•’—ŽȱŠ—ȱ
ȱ Šǯȱ Ž–˜ŸŽȱ‘ŽȱžŽ•ȱ•’—Žȱ›˜–ȱ‘Žȱ’—•ŽȱęĴ’—ȱ˜ȱ
the fuel pump.
ȱ ‹ǯȱ
˜•ȱ‘Žȱ•’—Žȱ‹Ž•˜ ȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘ŽȱŠ—”ǯȱ If fuel does notȱ̘ ȱ›˜–ȱ‘Žȱ•’—ŽǰȱŒ‘ŽŒ”ȱ˜›ȱ
™Ž—ȱ‘Žȱœ‘ž˜ěȱŸŠ•ŸŽȱǻ’ȱœ˜ȱŽšž’™™ŽǼȱŠ—ȱ
˜‹œŽ›ŸŽȱ̘ ǯ
ȱ Śǯȱ ‘ŽŒ”ȱ‘Žȱ˜™Ž›Š’˜—ȱ˜ȱžŽ•ȱ™ž–™ǯ
ȱ Šǯȱ Ž–˜ŸŽȱ‘ŽȱžŽ•ȱ•’—Žȱ›˜–ȱ‘Žȱ’—•ŽȱęĴ’—ȱ˜ȱ
the carburetor.
ȱ ‹ǯȱ ›Š—”ȱ‘ŽȱŽ—’—ŽȱœŽŸŽ›Š•ȱ’–ŽœȱŠ—ȱ˜‹œŽ›ŸŽȱ
̘ ǯ
Fuel Filter
˜–ŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠ—ȱ’—Ȭ•’—ŽȱžŽ•ȱꕝŽ›ǯȱ
Ž›’˜’ŒŠ••¢ȱ’—œ™ŽŒȱ‘ŽȱꕝŽ›ȱŠ—ȱ›Ž™•ŠŒŽȱ ‘Ž—ȱ’›¢ǯȱ
Replacement is recommended annually or every 100
hoursǯȱœŽȱŠȱŽ—ž’—Žȱ
˜‘•Ž›ȱꕝŽ›ǯ carburetor.
Fuel Pump
Some engines are equipped with an optional pulse
žŽ•ȱ™ž–™ǯȱŽŽȱ’ž›ŽȱśȬŗǯ
Operation
The fuel pump has two internal chambers separated
by a diaphragm. The air chamber is connected to the
Ž—’—ŽȱŒ›Š—”ŒŠœŽȱ‹¢ȱŠȱ›ž‹‹Ž›ȱ‘˜œŽǯȱ‘ŽȱžŽ•ȱŒ‘Š–‹Ž›ȱ
‘ŠœȱŠ—ȱ’—•Žȱ›˜–ȱ‘ŽȱžŽ•ȱŠ—”ǰȱŠ—ȱŠ—ȱ˜ž•Žȱ˜ȱ‘Žȱ
carburetor. The inlet and outlet each have an internal,
˜—ŽȬ Š¢ȱŒ‘ŽŒ”ȱŸŠ•ŸŽǯȱ
Alternating negative and positive pressures in the
Œ›Š—”ŒŠœŽȱŠŒ’ŸŠŽȱ‘Žȱ™ž–™ǯȱ‘Ž—ȱ‘Žȱ™’œ˜—ȱ–˜ŸŽœȱ
upward in the cylinder, negative pressure (vacuum)
’œȱŒ›ŽŠŽȱ’—ȱ‘ŽȱŒ›Š—”ŒŠœŽȱŠ—ȱ’—ȱ‘ŽȱŠ’›ȱŒ‘Š–‹Ž›ȱ˜ȱ
‘Žȱ™ž–™ǯȱ‘Žȱ’Š™‘›Š–ȱ̎¡Žœȱ˜ Š›ȱ‘Žȱ—ŽŠ’ŸŽȱ
pressure, and the suction draws fuel past the inlet
Œ‘ŽŒ”ȱŸŠ•ŸŽǰȱ’—˜ȱ‘ŽȱžŽ•ȱŒ‘Š–‹Ž›ǯȱ˜ — Š›ȱ
movement of the piston causes a positive pressure
5.2
Conclusion
2. If there isȱžŽ•ȱŠȱ‘Žȱ’™ȱ˜ȱ‘Žȱœ™Š›”ȱ™•žǰȱžŽ•ȱ’œȱ
reaching the combustion chamber.
If there is noȱžŽ•ȱŠȱ‘Žȱ’™ȱ˜ȱ‘Žȱœ™Š›”ȱ™•žǰȱŒ‘ŽŒ”ȱ
˜›ȱžŽ•ȱ̘ ȱ›˜–ȱ‘ŽȱžŽ•ȱŠ—”ȱǻŽœȱřǼǯ
Œ‘ŽŒ”ȱ˜›ȱŠž•¢ȱžŽ•ȱ™ž–™ȱǻŽœȱŚǼǯ
Œ•˜ŽȱžŽ•ȱŠ—”ȱŸŽ—ǰȱžŽ•ȱ™’Œ”ž™ȱœŒ›ŽŽ—ǰȱœ‘ž˜ěȱ
valve, and fuel lines.
ȱ Śǯȱ ȱžŽ•ȱdoesȱ̘ ȱ›˜–ȱ‘Žȱ•’—ŽǰȱŒ‘ŽŒ”ȱ˜›ȱŠž•¢ȱ
carburetor. (Refer to the "Carburetor" portions of
this section.)
If fuel does notȱ̘ ȱ›˜–ȱ‘Žȱ•’—ŽǰȱŒ‘ŽŒ”ȱ˜›ȱ
clogged fuel line. If the fuel line is unobstructed,
the fuel pump is faulty and must be replaced.
’—ȱ‘ŽȱŒ›Š—”ŒŠœŽȱŠ—ȱŠ’›ȱŒ‘Š–‹Ž›ǰȱ™žœ‘’—ȱ‘Žȱ
’Š™‘›Š–ȱ’—ȱ‘Žȱ˜™™˜œ’Žȱ’›ŽŒ’˜—ǰȱ™žĴ’—ȱ™›Žœœž›Žȱ
˜—ȱ‘ŽȱžŽ•ǯȱ‘Žȱ’—•ŽȱŒ‘ŽŒ”ȱŸŠ•ŸŽȱ‘Šœȱ—˜ ȱŒ•˜œŽǰȱœ˜ȱ
‘ŽȱžŽ•ȱ’œȱ˜›ŒŽȱ™Šœȱ‘Žȱ˜ž•ŽȱŒ‘ŽŒ”ȱŸŠ•ŸŽǰȱ˜ȱ‘Žȱ
Repair
Pulse fuel pumps are not serviceable and must be
replaced when faulty.
Removal
1. Disconnect the inlet, outlet, and pulse lines
›˜–ȱ‘ŽȱžŽ•ȱ™ž–™ǯȱŠ›”ȱ‘Žȱ•’—Žœȱ˜›ȱ™›˜™Ž›ȱ
reassembly.
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱŠĴŠŒ‘’—ȱ‘ŽȱžŽ•ȱ
pump.
Installation
1. Install the new fuel pump, and secure with the
‘Ž¡ȱ̊—ŽȱœŒ›Ž œǯȱ˜›šžŽȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱ
to 5.9 N·m (52 in. lb.). Do not over tighten.
2. Connect the inlet, outlet, and pulse lines to their
›Žœ™ŽŒ’ŸŽȱęĴ’—œȱ˜—ȱ™ž–™ǯȱŽŒž›Žȱ ’‘ȱ‘Žȱ
Œ•Š–™œǯȱŽŽȱ’ž›ŽȱśȬŗǯ

Figure 5-1. Pulse Fuel Pump.
Carburetor
‘ŽœŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠȱŠ•‹›˜ȱę¡Žȱ–Š’—ȱ
“ŽȱŒŠ›‹ž›Ž˜›ǯȱŽŽȱ’ž›ŽȱśȬŘǯȱ‘ŽȱŒŠ›‹ž›Ž˜›œȱ ’••ȱ
have a low idle speed adjustment screw, and either
ę¡Žȱ’•Žǰȱ˜›ȱŠȱ•’–’Ž›ȱŒŠ™ȱ˜—ȱ‘Žȱ’•ŽȱžŽ•ȱŠ“žœ–Ž—ȱ
needle.
Figure 5-2. Carburetor.
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••ȱŸŽ—’•ŠŽǰȱž—˜ŒŒž™’Žȱ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ
̊–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’—ȱŒ˜—ŠŒȱ
 ’‘ȱ‘˜ȱ™Š›œȱ˜›ȱœ™Š›”œȱ›˜–ȱ’—’’˜—ǯȱ˜ȱ—˜ȱœŠ›ȱ‘Žȱ
Ž—’—Žȱ—ŽŠ›ȱœ™’••ŽȱžŽ•ǯȱŽŸŽ›ȱžœŽȱŠœ˜•’—ŽȱŠœȱŠȱŒ•ŽŠ—’—ȱ
ŠŽ—ǯ
Section 5
Fuel System and Governor
Troubleshooting – Fuel System
If engine troubles are experienced that appear to be
žŽ•ȱœ¢œŽ–ȱ›Ž•ŠŽǰȱŒ‘ŽŒ”ȱ‘Žȱ˜••˜ ’—ȱŠ›ŽŠœȱ‹Ž˜›Žȱ
adjusting or disassembling the carburetor.
ȱ Ȋȱ Š”Žȱœž›Žȱ‘ŽȱžŽ•ȱŠ—”ȱ’œȱꕕŽȱ ’‘ȱŒ•ŽŠ—ǰȱ›Žœ‘ȱ
gasoline.
ȱ Ȋȱ Š”Žȱœž›Žȱ‘ŽȱžŽ•ȱŒŠ™ȱŸŽ—ȱ’œȱ—˜ȱ‹•˜Œ”ŽȱŠ—ȱ
that it is operating properly.
ȱ Ȋȱ Š”Žȱœž›ŽȱžŽ•ȱ’œȱ›ŽŠŒ‘’—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱ‘’œȱ
’—Œ•žŽœȱŒ‘ŽŒ”’—ȱ‘ŽȱžŽ•ȱœ‘žȬ˜ěȱŸŠ•ŸŽǰȱžŽ•ȱ
Š—”ȱꕝŽ›ȱœŒ›ŽŽ—ǰȱ’—Ȭ•’—ŽȱžŽ•ȱꕝŽ›ǰȱžŽ•ȱ•’—ŽœǰȱŠ—ȱ
fuel pump (as equipped), for restrictions or faulty
components.
ȱ Ȋȱ Š”Žȱœž›Žȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽȱŠ—ȱŒŠ›‹ž›Ž˜›ȱŠ›Žȱ 5
œŽŒž›Ž•¢ȱŠœŽ—Žȱ˜ȱ‘ŽȱŽ—’—Žȱžœ’—ȱŠœ”Žœȱ’—ȱ
good condition.
ȱ Ȋȱ Š”Žȱœž›Žȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ȱ’œȱŒ•ŽŠ—ǰȱŠ—ȱŠ••ȱ
air cleaner components are fastened securely.
ȱ Ȋȱ Š”Žȱœž›Žȱ‘Žȱ’—’’˜—ȱœ¢œŽ–ǰȱ˜ŸŽ›—˜›ȱœ¢œŽ–ǰȱ
Ž¡‘Šžœȱœ¢œŽ–ǰȱŠ—ȱ‘›˜Ĵ•ŽȱŠ—ȱŒ‘˜”ŽȱŒ˜—›˜•œȱ
are operating properly.
ǰȱŠĞŽ›ȱŒ‘ŽŒ”’—ȱ‘Žȱ’Ž–œȱ•’œŽȱŠ‹˜ŸŽǰȱœŠ›’—ȱ
problems or conditions similar to those listed in the
following table exist, it may be necessary to adjust or
service the carburetor.
5.3
Section 5
Fuel System and Governor

Troubleshooting – Fuel System

Condition
1. Engine starts hard, runs roughly
or stalls at idle speed.
2. Engine runs rich. (Indicated
‹¢ȱ‹•ŠŒ”ǰȱœ˜˜¢ȱŽ¡‘Šžœȱœ–˜”Žǰȱ
–’œę›’—ǰȱ•˜œœȱ˜ȱœ™ŽŽȱŠ—ȱ™˜ Ž›ǰȱ ȱ ‹ǯȱ ˜ ȱ’•ŽȱžŽ•ȱ–’¡ž›Žȱ’œȱ’–™›˜™Ž›•¢ȱŠ“žœŽǯȱ“žœȱ•˜ ȱ’•Žȱ
governor hunting, or excessive
‘›˜Ĵ•Žȱ˜™Ž—’—Ǽǯ
ȱ řǯȱ —’—Žȱ›ž—œȱ•ŽŠ—ǯȱǻ—’ŒŠŽȱ‹¢ȱ
–’œę›’—ǰȱ•˜œœȱ˜ȱœ™ŽŽȱŠ—ȱ™˜ Ž›ǰȱ
governor hunting, or excessive
‘›˜Ĵ•Žȱ˜™Ž—’—Ǽǯȱ
ȱ Śǯȱ žŽ•ȱ•ŽŠ”œȱ›˜–ȱŒŠ›‹ž›Ž˜›ǯ
Carburetor Adjustment
NOTE: Carburetor adjustments should be made only
ŠĞŽ›ȱ‘ŽȱŽ—’—Žȱ‘Šœȱ Š›–Žȱž™ǯ
Possible Cause/Probable Remedy
ȱŗŠǯȱ ˜ ȱ’•ŽȱžŽ•ȱ–’¡ž›ŽȦœ™ŽŽȱ’–™›˜™Ž›•¢ȱŠ“žœŽǯȱ“žœȱ‘Žȱ•˜ ȱ
idle speed screw, then adjust the low idle fuel needle.
ȱ ‹ǯȱ –™›˜™Ž›ȱŒ‘˜”ŽȱŠ“žœ–Ž—ǯ
ȱ؊ǯȱ ‘˜”Žȱ™Š›’Š••¢ȱŒ•˜œŽȱž›’—ȱ˜™Ž›Š’˜—ǯȱ‘ŽŒ”ȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›Ȧ
•’—”ŠŽȱ˜ȱŽ—œž›ŽȱŒ‘˜”Žȱ’œȱ˜™Ž›Š’—ȱ™›˜™Ž›•¢ǯ
fuel needle.
ȱ Œǯȱ •˜Šȱ•ŽŸŽ•ȱ’œȱœŽȱ˜˜ȱ‘’‘ǯȱ’‘ȱžŽ•ȱ‹˜ •ȱ›Ž–˜ŸŽȱŠ—ȱŒŠ›‹ž›Ž˜›ȱ
’—ŸŽ›Žǰȱ‘ŽȱŽ¡™˜œŽȱœž›ŠŒŽȱ˜ȱ̘Šȱ–žœȱ‹Žȱ™Š›Š••Ž•ȱ ’‘ȱ‘Žȱ
‹˜ •ȱŠœ”Žȱœž›ŠŒŽȱ˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ǯ
d. Dirt under fuel inlet needle. Remove needle; clean needle and
seat and blow with compressed air.
e. Bowl vent or air bleeds plugged. Remove fuel bowl, low idle
fuel adjusting needle, and welch plugs. Clean vent, ports, and air
bleeds. Blow out all passages with compressed air.
ȱ ǯȱ žŽ•ȱ‹˜ •ȱŠœ”Žȱ•ŽŠ”œǯȱŽ–˜ŸŽȱžŽ•ȱ‹˜ •ȱŠ—ȱ›Ž™•ŠŒŽȱŠœ”Žǯ
ȱ ǯȱ ŽŠ”¢ǰȱŒ›ŠŒ”Žǰȱ˜›ȱŠ–ŠŽȱ̘Šǯȱž‹–Ž›Žȱ̘Šȱ˜ȱŒ‘ŽŒ”ȱ˜›ȱ
•ŽŠ”œǯ
ȱřŠǯȱ ˜ ȱ’•ŽȱžŽ•ȱ–’¡ž›Žȱ’œȱ’–™›˜™Ž›•¢ȱŠ“žœŽǯȱ“žœȱ•˜ ȱ’•Žȱ
fuel needle.
ȱ ‹ǯȱ •˜Šȱ•ŽŸŽ•ȱ’œȱœŽȱ˜˜ȱ•˜ ǯȱ’‘ȱžŽ•ȱ‹˜ •ȱ›Ž–˜ŸŽȱŠ—ȱŒŠ›‹ž›Ž˜›ȱ
’—ŸŽ›Žǰȱ‘ŽȱŽ¡™˜œŽȱœž›ŠŒŽȱ˜ȱ̘Šȱ–žœȱ‹Žȱ™Š›Š••Ž•ȱ ’‘ȱ‘Žȱ
‹˜ •ȱŠœ”Žȱœž›ŠŒŽȱ˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ǯ
c. Idle holes plugged; dirt in fuel delivery channels. Remove fuel
bowl, low idle fuel adjusting needle, and welch plugs. Clean
main fuel jet and all passages; blow out with compressed air.
ȱŚŠǯȱ •˜Šȱ•ŽŸŽ•ȱœŽȱ˜˜ȱ‘’‘ǯȱŽŽȱŽ–Ž¢ȱ،ǯ
b. Dirt under fuel inlet needle. See Remedy 2d.
c. Bowl vent plugged. Remove fuel bowl and clean bowl vent. Blow
out with compressed air.
ȱ ǯȱ •˜Šȱ’œȱŒ›ŠŒ”Žȱ˜›ȱŠ–ŠŽǯȱŽ™•ŠŒŽȱ̘Šǯ
ȱ Žǯȱ ˜ •ȱ›ŽŠ’—’—ȱœŒ›Ž ȱŠœ”ŽȱŠ–ŠŽǯȱŽ™•ŠŒŽȱŠœ”Žǯ
ȱ ǯȱ ˜ •ȱ›ŽŠ’—’—ȱœŒ›Ž ȱ•˜˜œŽǯȱ˜›šžŽȱœŒ›Ž ȱ˜ȱœ™ŽŒ’ęŒŠ’˜—œǯ

The carburetor is designed to deliver the correct Idle Speed (RPM)

žŽ•Ȭ˜ȬŠ’›ȱ–’¡ž›Žȱ˜ȱ‘ŽȱŽ—’—Žȱž—Ž›ȱŠ••ȱ˜™Ž›Š’—ȱ Adjustment Screw
conditions. The main fuel jet is calibrated at the
factory and is not adjustable*. The idle fuel adjustment Idle Fuel
needle is also set at the factory and normally does not Mixture Needle
need adjustment. If the engine is hard starting or does
not operate properly, however, it may be necessary to
adjust or service the carburetor.

ȘDZȱ —’—Žœȱ˜™Ž›Š’—ȱŠȱŠ•’žŽœȱŠ‹˜ŸŽȱ
Š™™›˜¡’–ŠŽ•¢ȱŗŞřŖȱ–ȱǻŜŖŖŖȱĞǯǼȱ–Š¢ȱ›Žšž’›Žȱ Figure 5-3. Fixed Main Jet Carburetor.
a special high altitude main jet. Refer to High
Altitude Operation later in this section.

5.4
 Section 5
Fuel System and Governor

Low Idle Mixture Adjustment* Low Idle Speed Setting

NOTE:ȱ —’—Žœȱ ’••ȱ‘ŠŸŽȱę¡Žȱ’•Žȱǻ—˜ȱŠ“žœ–Ž—ȱ
possible) or a limiter cap on the idle fuel
adjustment needle. Step 2 can only be
performed within the limits allowed by the
cap.
ȱ ŗǯȱ Š›ȱ‘ŽȱŽ—’—ŽȱŠ—ȱ›ž—ȱŠȱ‘Š•ȱ‘›˜Ĵ•Žȱ˜›ȱśȱ˜ȱŗŖȱ
minutes to warm up. The engine must be warm
before doing step 2.
ȱ ŗǯȱ Š›ȱ‘ŽȱŽ—’—ŽȱŠ—ȱ›ž—ȱŠȱ‘Š•ȱ‘›˜Ĵ•Žȱ˜›ȱśȱ˜ȱŗŖȱ
minutes to warm up. The engine must be warm
before doing step 2.
2. ˜ ȱ•Žȱ™ŽŽȱŽĴ’—DZȱ•ŠŒŽȱ‘Žȱ‘›˜Ĵ•Žȱ
control into the idle or slow position. Set the
low idle speed by turning the low idle speed
adjusting screw in or outǯȱ‘ŽŒ”ȱ‘Žȱœ™ŽŽȱžœ’—ȱ
a tachometer.

2. ˜ ȱ•ŽȱžŽ•ȱŽŽ•ŽȱŽĴ’—DZȱ•ŠŒŽȱ‘Žȱ‘›˜Ĵ•Žȱ DZȱ‘ŽȱŠŒžŠ•ȱ•˜ ȱ’•Žȱœ™ŽŽȱŽ™Ž—œȱ˜—ȱ

into the idle or slow position.
Turn the low idle fuel adjustment needle out
ǻŒ˜ž—Ž›Œ•˜Œ” ’œŽǼȱ›˜–ȱ‘Žȱ™›Ž•’–’—Š›¢ȱœŽĴ’—ȱ
until engine speed decreases (rich). Note the
position of the needle.
ȱ ȱ ˜ ȱž›—ȱ‘ŽȱŠ“žœ’—ȱ—ŽŽ•Žȱ’—ȱǻŒ•˜Œ” ’œŽǼǯȱ
The engine speed may increase, then it will
decrease as the needle is turned in (lean). Note
the position of the needle.
the application–refer to equipment
manufacturer’s recommendations. The
recommended low idle speed for basic
Ž—’—Žœȱ’œȱŗśŖŖȱǯȱ˜ȱŽ—œž›Žȱ‹Žœȱ›Žœž•œȱ
 ‘Ž—ȱœŽĴ’—ȱ‘Žȱ•˜ ȱ’•ŽȱžŽ•ȱ—ŽŽ•Žǰȱ‘Žȱ
•˜ ȱ’•Žȱœ™ŽŽȱ–žœȱ—˜ȱŽ¡ŒŽŽȱŗśŖŖȱȱ 5
ǻƹŝśȱǼǯ

Set the adjusting needle midway between the rich

Š—ȱ•ŽŠ—ȱœŽĴ’—œǯȱŽŽȱ’ž›ŽȱśȬŚǯ

Lean

Adjust to Midpoint

Rich

Figure 5-4. Optimum Low Idle Fuel Setting.

ȘDZȱȱ‘ŽȱŽ—’—Žȱ’œȱŽšž’™™Žȱ ’‘ȱŠȱ˜ŸŽ›—Žȱ’•Žȱ
Š“žœ–Ž—ȱǻŽŽȱ’ž›ŽȱśȬŘřǼǰȱ‘Žȱ˜ŸŽ›—˜›ȱ
will compensate for speed changes due to the
low idle mixture adjustment. Disable the
˜ŸŽ›—Žȱ’•ŽȱŒ˜—›˜•ȱ‹¢ȱ‹ŠŒ”’—ȱ˜žȱ‘Žȱ
˜ŸŽ›—Žȱ’•ŽȱŠ“žœ’—ȱœŒ›Ž ȱŠ—ȱœŽĴ’—ȱŠȱ
ę¡Žȱ’•Žȱœ™ŽŽȱžœ’—ȱ‘Žȱ’•Žȱœ™ŽŽȱœŒ›Ž ȱ
˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱŠ”Žȱ‘Žȱ•˜ ȱ’•Žȱ–’¡ž›Žȱ
adjustment and then reset the governed idle
speed at the adjusting screw.

5.5
Section 5
Fuel System and Governor

Disassembly

Throttle Lever and Shaft

Dust Seal

Throttle Plate Screw(s) Choke Lever and Shaft

Throttle Plate Choke Return Spring

Choke Plate
Low Idle Speed Adjusting
Screw and Spring

Fuel Inlet
Low Idle Fuel Adjusting
Needle
Needle and Spring with Float
Limiter Cap
Float Shaft

Bowl Gasket

Fuel Bowl

Bowl Retaining Screw Gasket

Fuel Shut-off Solenoid

or Bowl Retaining Screw

Figure 5-5. Carburetor - Exploded View.

ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‹˜ •ȱ›ŽŠ’—’—ȱœŒ›Ž ȱ˜›ȱžŽ•ȱœ‘žȬ˜ěȱ
œ˜•Ž—˜’ǰȱ›ŽŠ’—’—ȱœŒ›Ž ȱŠœ”ŽǰȱŠ—ȱžŽ•ȱ‹˜ •ǯ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‹˜ •ȱŠœ”Žǰȱ̘Šȱœ‘ŠĞǰȱ̘ŠǰȱŠ—ȱ
fuel inlet needle.
ȱ řǯȱ Do notȱŠĴŽ–™ȱ˜ȱ›Ž–˜ŸŽȱ‘Žȱ•˜ ȱ’•ŽȱžŽ•ȱ
adjustment needle if it has a limiter cap.
Further disassembly to remove the welch plugs,
–Š’—ȱžŽ•ȱ“Žǰȱ‘›˜Ĵ•Žȱ™•ŠŽȱŠ—ȱœ‘ŠĞǰȱŠ—ȱŒ‘˜”Žȱ
™•ŠŽȱŠ—ȱœ‘ŠĞȱ’œȱ›ŽŒ˜––Ž—Žȱ˜—•¢ȱ’ȱ‘ŽœŽȱ
parts are to be cleaned or replaced.
Welch Plug Removal
In order to clean the idle ports and bowl vent
thoroughly, remove the welch plugs covering these
areas.
Use SPX Tool No. KO-1018 and the following
™›˜ŒŽž›Žȱ˜ȱ›Ž–˜ŸŽȱ‘Žȱ Ž•Œ‘ȱ™•žœǯȱŽŽȱ’ž›ŽȱśȬŜǯ
1. Pierce the welch plug with the tip of the tool.
DZȱ ˜ȱ™›ŽŸŽ—ȱŠ–ŠŽȱ˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǰȱ˜ȱ
—˜ȱŠ••˜ ȱ‘Žȱ˜˜•ȱ˜ȱœ›’”Žȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ
body.

2. Pry out the welch plug with the tip of the tool.

5.6

Tool No. KO1018
Pry Out Plug
Do Not Allow
Tip to Strike
Carburetor Body Pierce Plug with Tip
Welch Plug
Figure 5-6. Removing Welch Plug.
Main Fuel Jet Removal
The main jet is pressed into the side of the tower
portion of the body. Removal is not recommended,
ž—•ŽœœȱŠȱ‘’‘ȬŠ•’žŽȱ”’ȱ’œȱ‹Ž’—ȱ’—œŠ••Žǰȱ’—ȱ ‘’Œ‘ȱ
case the removal instructions will be included in the
”’ǯ
Fuel Inlet Seat Removal
The fuel inlet seat is pressed into the carburetor body,
do notȱŠĴŽ–™ȱ˜ȱ›Ž–˜ŸŽȱ’ǯȱȱ—ŽŒŽœœŠ›¢ǰȱŒ•ŽŠ—ȱ’ȱ’—ȱ
place with aerosol carburetor cleaner.
Choke Shaft Removal
ȱ ŗǯȱ ŽŒŠžœŽȱ‘ŽȱŽŽœȱ˜ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱŠ›Žȱ‹ŽŸŽ•Žǰȱ
–Š›”ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱŠ—ȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ǰȱ˜ȱ
Ž—œž›ŽȱŒ˜››ŽŒȱ›ŽŠœœŽ–‹•¢ǯȱŽŽȱ’ž›ŽȱśȬŝǯ
ȱ ȱ •œ˜ȱ—˜Žȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱ™˜œ’’˜—ȱ’—ȱ‘Žȱ‹˜›Žǰȱ
Š—ȱ‘Žȱ™˜œ’’˜—ȱ˜ȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›ȱŠ—ȱŒ‘˜”Žȱ
ŽŽ™ȱœ™Š›”œǰȱ̊–ŽœǰȱŠ—ȱ˜‘Ž›ȱœ˜ž›ŒŽœȱ˜ȱ’—’’˜—ȱŠ Š¢ȱ
return spring.
Figure 5-7. Marking Choke Plate and Carburetor
Body.
Section 5
Fuel System and Governor
ȱ Řǯȱ ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱ’œȱ’—œŽ›Žȱ’—˜ȱŠȱœ•˜ȱ’—ȱ‘Žȱ
Œ‘˜”Žȱœ‘ŠĞǯȱ ›Šœ™ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱ ’‘ȱ™•’Ž›œǰȱ
Š—ȱ™ž••ȱ’ȱ˜žȱ˜ȱ‘Žȱœ•˜ǯȱŽŽȱ’ž›ŽȱśȬŞǯȱ
5
Figure 5-8. Removing Choke Plate.
ȱ řǯȱ Ž–˜ŸŽȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞȱŠ—ȱŒ‘˜”Žȱ›Žž›—ȱœ™›’—ǯ
Throttle Shaft Removal
Do notȱŠĴŽ–™ȱ˜ȱ›Ž–˜ŸŽȱ‘Žȱ‘›˜Ĵ•Žȱœ‘ŠĞǰȱŠœȱ›Ž™Š’›ȱ
”’œȱŠ›Žȱ—˜ȱŠŸŠ’•Š‹•Žǯȱ‘›˜Ĵ•Žȱœ‘ŠĞȱ ŽŠ›ȱ’œȱ—˜›–Š••¢ȱ
accompanied by corresponding wear to the carburetor
‹˜¢ǰȱ–Š”’—ȱ’ȱ’–™›ŠŒ’ŒŠ•ȱ˜ȱŠĴŽ–™ȱŠȱŒ˜œȬŽěŽŒ’ŸŽȱ
›Ž™Š’›ǯȱŽ™•ŠŒŽȱ‘ŽȱŽ—’›ŽȱŒŠ›‹ž›Ž˜›ȱ’ȱ‘Žȱ‘›˜Ĵ•Žȱ
œ‘ŠĞȱ’œȱ ˜›—ǯ
Cleaning
WARNING: Flammable Solvents!
Š›‹ž›Ž˜›ȱŒ•ŽŠ—Ž›œȱŠ—ȱœ˜•ŸŽ—œȱŠ›ŽȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•Žǯȱ
›˜–ȱ‘ŽȱŠ›ŽŠǯȱ˜••˜ ȱ‘ŽȱŒ•ŽŠ—Ž›ȱ–Š—žŠŒž›Ž›Ȃœȱ Š›—’—œȱ
Š—ȱ’—œ›žŒ’˜—œȱ˜—ȱ’œȱ™›˜™Ž›ȱŠ—ȱœŠŽȱžœŽǯȱŽŸŽ›ȱžœŽȱ
Šœ˜•’—ŽȱŠœȱŠȱŒ•ŽŠ—’—ȱŠŽ—ǯ
All parts should be cleaned thoroughly using a
Œ˜––Ž›Œ’Š•ȱŒŠ›‹ž›Ž˜›ȱŒ•ŽŠ—Ž›ǯȱŠ”Žȱœž›ŽȱŠ••ȱž–ȱ
deposits are removed from the following areas.
• Carburetor body and bore; especially the areas
 ‘Ž›Žȱ‘Žȱ‘›˜Ĵ•Žȱ™•ŠŽǰȱŒ‘˜”Žȱ™•ŠŽȱŠ—ȱœ‘ŠĞœȱ
are seated.
• Idle fuel and idle ports in carburetor bore, main
jet, bowl vent, and fuel inlet needle and seat.
Ȋȱ •˜ŠȱŠ—ȱ̘Šȱ‘’—Žǯ
• Fuel bowl.
5.7
Section 5
Fuel System and Governor
ȱ Ȋȱ ‘›˜Ĵ•Žȱ™•ŠŽǰȱŒ‘˜”Žȱ™•ŠŽǰȱ‘›˜Ĵ•Žȱœ‘ŠĞǰȱŠ—ȱ
Œ‘˜”Žȱœ‘ŠĞǯ
DZȱ ˜ȱ—˜ȱœž‹–Ž›Žȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ’—ȱ
Œ•ŽŠ—Ž›ȱ˜›ȱœ˜•ŸŽ—ȱ ‘Ž—ȱ™•Šœ’Œǰȱꋎ›ǰȱ
›ž‹‹Ž›ǰȱ˜Š–ȱœŽŠ•œȱ˜›ȱŠœ”ŽœȱŠ›Žȱ
installed. The cleaner may damage these
components.
Inspection
Carefully inspect all components and replace those
that are worn or damaged.
ȱ Ȋȱ —œ™ŽŒȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ȱ˜›ȱŒ›ŠŒ”œǰȱ‘˜•ŽœǰȱŠ—ȱ
other wear or damage.
Welch Plug Installation
Use SPX Tool No. KO1017 and install new plugs as
˜••˜ œDZ
1. Position the carburetor body with the welch plug
cavities to the top.
2. Place a new welch plug into the cavity with the
raised surface up.
ȱ řǯȱ œŽȱ‘ŽȱŽ—ȱ˜ȱ‘Žȱ˜˜•ȱ‘Šȱ’œȱŠ‹˜žȱ‘ŽȱœŠ–Žȱœ’£Žȱ
Šœȱ‘Žȱ™•žȱŠ—ȱ̊ĴŽ—ȱ‘Žȱ™•žǯȱDo not force the
plug below the surface of the cavity. See Figure
śȬşǯ

ȱ Ȋȱ —œ™ŽŒȱ‘Žȱ̘Šȱ˜›ȱŒ›ŠŒ”œǰȱ‘˜•ŽœǰȱŠ—ȱ–’œœ’—ȱ˜›ȱ
Š–ŠŽȱ̘ŠȱŠ‹œǯȱ‘ŽŒ”ȱ‘Žȱ̘Šȱ‘’—ŽȱŠ—ȱ™’—ȱ
for wear or damage.

• Inspect the fuel inlet needle and seat for wear or Tool No. KO1017
damage.

• Inspect the tip of the low idle fuel adjustment

needle for wear or grooves.
New Welch Plug
Carburetor Body
ȱ Ȋȱ —œ™ŽŒȱ‘Žȱ‘›˜Ĵ•ŽȱŠ—ȱŒ‘˜”Žȱœ‘ŠĞȱŠ—ȱ™•ŠŽȱ
assemblies for wear or excessive play.
Figure 5-9. Installing Welch Plugs.
Repair
• Š¢œȱžœŽȱ—Ž ȱŠœ”Žœȱ ‘Ž—ȱœŽ›Ÿ’Œ’—ȱ˜›ȱ ȱ Śǯȱ Ў›ȱ‘Žȱ™•žœȱŠ›Žȱ’—œŠ••ŽǰȱœŽŠ•ȱ‘Ž–ȱ ’‘ȱ
›Ž’—œŠ••’—ȱŒŠ›‹ž›Ž˜›œǯȱŽ™Š’›ȱ”’œȱŠ›ŽȱŠŸŠ’•Š‹•Žȱ Glyptal™ (or an equivalent sealant). Allow the
 ‘’Œ‘ȱ’—Œ•žŽȱ—Ž ȱŠœ”ŽœȱŠ—ȱ˜‘Ž›ȱŒ˜–™˜—Ž—œǯȱ sealant to dry.
Always refer to the Parts Manual for the engine being
œŽ›Ÿ’ŒŽȱ˜ȱŽ—œž›Žȱ‘ŽȱŒ˜››ŽŒȱ›Ž™Š’›ȱ”’œȱŠ›Žȱ˜›Ž›Žǯ DZȱ ȱŠȱŒ˜––Ž›Œ’Š•ȱœŽŠ•Š—ȱ’œȱ—˜ȱŠŸŠ’•Š‹•Žǰȱ
ꗐŽ›—Š’•ȱ™˜•’œ‘ȱŒŠ—ȱ‹ŽȱžœŽǯ
Reassembly
Carburetor Reassembly
Choke Shaft Installation 1. Install the low idle speed adjusting screw and
ȱ ŗǯȱ —œŠ••ȱ‘ŽȱŒ‘˜”Žȱ›Žž›—ȱœ™›’—ȱ˜ȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞǯ spring.

ȱ Řǯȱ —œŽ›ȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞȱ ’‘ȱ‘Žȱ›Žž›—ȱœ™›’—ȱ’—˜ȱ 2. If the low idle fuel adjusting needle contains

the carburetor body.
ȱ řǯȱ ˜ŠŽȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›ȱŠ™™›˜¡’–ŠŽ•¢ȱŗȦŘȱž›—ȱ
counterclockwiseǯȱŠ”Žȱœž›Žȱ‘ŽȱŒ‘˜”Žȱ›Žž›—ȱ
œ™›’—ȱ‘˜˜”œȱ˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‹˜¢ǯ
ȱ Śǯȱ ˜œ’’˜—ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱŠœȱ–Š›”Žȱž›’—ȱ
’œŠœœŽ–‹•¢ǯȱ—œŽ›ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽȱ’—˜ȱ‘Žȱœ•˜ȱ
’—ȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞǯȱŠ”Žȱœž›Žȱ‘ŽȱŒ‘˜”Žȱœ‘ŠĞȱ’œȱ
•˜Œ”Žȱ‹Ž ŽŽ—ȱ‘ŽȱŠ‹œȱ˜—ȱ‘ŽȱŒ‘˜”Žȱ™•ŠŽǯ
a limiter, adjust to the midpoint within the
adjustment range.
ȱȱřǯȱ —œŽ›ȱ‘ŽȱžŽ•ȱ’—•Žȱ—ŽŽ•Žȱ’—˜ȱ‘Žȱ̘Šǯȱ•’—ȱ‘Žȱ
—ŽŽ•Žȱ ’‘ȱ‘ŽȱœŽŠȱŠ—ȱ•˜ Ž›ȱ‘Žȱ̘Šȱ’—˜ȱ‘Žȱ
ŒŠ›‹ž›Ž˜›ȱ‹˜¢ǯȱŽŽȱ’ž›ŽȱśȬŗŖǯȱ—œŠ••ȱ‘Žȱ̘Šȱ
œ‘ŠĞǯ

5.8

Figure 5-10. Installing Float and Fuel Inlet Needle.
ȱ Śǯȱ —œŠ••ȱ‘Žȱ‹˜ •ȱŠœ”ŽǰȱžŽ•ȱ‹˜ •ǰȱ‹˜ •ȱ›ŽŠ’—’—ȱ
œŒ›Ž ȱŠœ”ŽǰȱŠ—ȱ‹˜ •ȱ›ŽŠ’—’—ȱœŒ›Ž ȱ˜›ȱžŽ•ȱ
solenoid.
Torque the bowl retaining screw to 5.1-6.2 N·m
(45-55 in. lb.).
Fuel Shut-off Solenoid
Š—¢ȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠȱžŽ•ȱœ‘žȬ˜ěȱ
solenoid installed in place of the bowl retaining screw
˜ȱŽ•’–’—ŠŽȱ‹ŠŒ”ę›’—ȱ ‘Ž—ȱ‘ŽȱŽ—’—Žȱ’œȱœ‘žȱ˜ —ǯȱ
ȱ‹ŠŒ”ę›’—ȱ˜ŒŒž›œȱ˜—ȱŽ—’—ŽœȱŽšž’™™Žȱ ’‘ȱ‘’œȱ
solenoid, verify that the correct shutdown procedure
’œȱ‹Ž’—ȱžœŽǯȱ—ȱ˜›Ž›ȱ˜›ȱ‘Žȱœ˜•Ž—˜’ȱ˜ȱ‹ŽȱŽěŽŒ’ŸŽǰȱ
the engine must be running between half and full
‘›˜Ĵ•Žȱ ‘Ž—ȱ‘Žȱ”Ž¢ȱ’œȱž›—Žȱ˜ěǯȱŽ¡ǰȱŒ‘ŽŒ”ȱ‘Žȱ
‹ŠĴŽ›¢ȱ˜ȱŽ—œž›Žȱ‘Šȱ’ȱ’œȱ—˜ȱ’œŒ‘Š›Žȱ˜›ȱŠž•¢ǯȱȱ
–’—’–ž–ȱ˜ȱŝǯřȱŸ˜•œȱȱ’œȱ›Žšž’›Žȱ˜ȱŠŒ’ŸŠŽȱ‘Žȱ
œ˜•Ž—˜’ǯȱ•œ˜ȱŒ‘ŽŒ”ȱ˜ȱœŽŽȱ‘Šȱ‘Žȱ›˜ž—ȱ•ŽŠȱ›˜–ȱ
the carburetor body to the air cleaner base mounting
screw is properly connected.
ȱ‘ŽœŽȱŒ‘ŽŒ”ȱ˜žǰȱ‘Žȱœ˜•Ž—˜’ȱœ‘˜ž•ȱ‹Žȱ›Ž–˜ŸŽȱ˜›ȱ
‹Ž—Œ‘ȱŽœ’—ǯȱŽ–Ž–‹Ž›ȱ˜ȱœ‘žȱ˜ěȱ‘ŽȱžŽ•ȱœž™™•¢ȱ
and catch any fuel spilling from the carburetor as the
solenoid is removed.
Bench test the solenoid by grounding the solenoid
case and applying 12 volt DC to the spade terminal. If
the plunger does not retract, the solenoid is faulty and
–žœȱ‹Žȱ›Ž™•ŠŒŽǯȱ• Š¢œȱžœŽȱŠȱ—Ž ȱžŽ•ȱ‹˜ •ȱŠœ”Žȱ
whenever the solenoid is installed. Refer to the wiring
’Š›Š–ȱ’—ȱŽŒ’˜—ȱŝȱŠ—ȱŒ˜——ŽŒȱ‘ŽȱžŽ•ȱœ‘žȬ˜ěȱ
solenoid.
Section 5
Fuel System and Governor
Figure 5-11. Fuel Shut-Off Solenoid.
High Altitude Operation
‘Ž—ȱ˜™Ž›Š’—ȱ‘ŽȱŽ—’—ŽȱŠȱŠ•’žŽœȱ˜ȱŗŞřŖȱ–ȱ
5
ǻŜŖŖŖȱĞǯǼȱŠ—ȱŠ‹˜ŸŽǰȱ‘Žȱ–Š’—ȱžŽ•ȱ–’¡ž›ŽȱŽ—œȱ˜ȱŽȱ
˜ŸŽ›ȱ›’Œ‘ǯȱ—ȱ˜ŸŽ›Ȭ›’Œ‘ȱ–’¡ž›ŽȱŒŠ—ȱŒŠžœŽȱŒ˜—’’˜—œȱ
œžŒ‘ȱŠœȱ‹•ŠŒ”ǰȱœ˜˜¢ȱŽ¡‘Šžœȱœ–˜”Žǰȱ–’œę›’—ǰȱ•˜œœȱ
of speed and power, poor fuel economy, and poor or
slow governor response.
˜ȱŒ˜–™Ž—œŠŽȱ˜›ȱ‘ŽȱŽěŽŒœȱ˜ȱ‘’‘ȱŠ•’žŽǰȱŠȱœ™ŽŒ’Š•ȱ
high altitude main jet can be installed. High altitude
“ŽœȱŠ›Žȱœ˜•ȱ’—ȱ”’œȱ ‘’Œ‘ȱ’—Œ•žŽȱ‘Žȱ“ŽȱŠ—ȱ—ŽŒŽœœŠ›¢ȱ
Šœ”ŽœǯȱŽŽ›ȱ˜ȱ‘ŽȱŠ›œȱŠ—žŠ•ȱ˜›ȱ‘ŽȱŽ—’—Žȱ‹Ž’—ȱ
œŽ›Ÿ’ŒŽȱ˜›ȱ‘ŽȱŒ˜››ŽŒȱ”’ȱ—ž–‹Ž›ǯ
Unitized Throttle and Choke Control
˜–ŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠȱž—’’£Žȱ‘›˜Ĵ•Žȱ
Š—ȱŒ‘˜”ŽȱŒ˜—›˜•ǯȱ‘’œȱŠœœŽ–‹•¢ȱŒ˜—›˜•œȱ‘ŽȱŒ‘˜”Žȱ
Š—ȱŽ—’—Žȱœ™ŽŽȱ ’‘ȱŠȱœ’—•Žȱ•ŽŸŽ›ǯȱŽŽȱ’ž›ŽȱśȬŗŘǯ
Throttle Cable Adjustment
ȱ ŗǯȱ ˜˜œŽ—ȱ‘ŽȱŒ˜—›˜•ȱŒŠ‹•ŽȱŒ•Š–™ǯȱŽŽȱ’ž›ŽȱśȬŗŘǯ
Cable
Clamp
Figure 5-12. Speed Control Bracket with Unitized
Throttle/Choke Control.
5.9
Section 5
Fuel System and Governor
ȱ Řǯȱ •ŠŒŽȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ•ŽŸŽ›ȱ˜ȱ‘ŽȱŽšž’™–Ž—ȱ
into the fast or high speed position. The actuating
Š‹Ƹȱ˜ȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›ȱœ‘˜ž•ȱ‹Žȱ“žœȱ‹Ž•˜ ȱ‘Žȱ
Ž—ȱ˜ȱ‘ŽȱŒ‘˜”ŽȱŠ“žœ’—ȱœŒ›Ž ǯȱŽŽȱ’ž›ŽȱśȬŗřǯ
Choke
Adjustment
Screw
Figure 5-13. Adjusting Unitized Throttle/Choke
Control.
DZȱ ‘ŽȱŒ‘˜”Žȱ’œȱ™•ŠŒŽȱ˜—ȱ‹¢ȱ–˜Ÿ’—ȱ‘Žȱ
‘›˜Ĵ•ŽȱŒ˜—›˜•ȱœ•’‘•¢ȱ™Šœȱ‘ŽȱŠœȱ
™˜œ’’˜—ǯȱȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ˜Žœȱ—˜ȱ
‘ŠŸŽȱŠȱŽœ’—ŠŽȱŒ‘˜”Žȱ˜—ȱ™˜œ’’˜—ǰȱ‹Žȱ
œž›Žȱ˜ȱ•ŽŠŸŽȱœžĜŒ’Ž—ȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ
travel past the fast position. This will
Ž—Š‹•Žȱ‘ŽȱŒ‘˜”Žȱ˜ȱ‹Žȱ™•ŠŒŽȱ˜—ǯȱŽŽȱ
’ž›ŽȱśȬŗŚǯ
Cold Engine Warm Engine
Figure 5-14. Typical Throttle/Choke Controls.
ȱ řǯȱ Early Models: Early models use a single
alignment hole to set the engine RPM. Align
‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ ’‘ȱ‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ
œ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ‹¢ȱ’—œŽ›’—ȱŠȱ™Ž—Œ’•ȱ˜›ȱŜǯřśȱ
––ȱǻŗȦŚȱ’—ǯǼȱ›’••ȱ‹’ǯȱŽŽȱ’ž›ŽȱśȬŗśǯ
5.10
Alignment Hole
Figure 5-15. Alignment Hole in Speed Control
Bracket and Throttle Lever. (Early Models)
Later Models:ȱŠŽ›ȱ–˜Ž•œȱžœŽȱŠȱ—Ž ȱŒ˜—›˜•ȱ
ŠœœŽ–‹•¢ǰȱ’Ž—’ꮍȱ‹¢ȱ ˜ȱ˜™™˜œ’—ȱŠ•’—–Ž—ȱ
‘˜•ŽœȱǻŒ•˜œŽȱ˜ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ™’Ÿ˜Ǽǰȱ’—œŽŠȱ˜ȱ
˜—ŽǯȱŠœŽȱž™˜—ȱ‘Žȱ’—Ž—Žȱ‘’‘Ȭœ™ŽŽȱǻǼȱ
œŽĴ’—ǰȱ‘›˜Ĵ•ŽȱŒŠ‹•ŽȱŠ“žœ–Ž—ȱ–žœȱ‹Žȱ–ŠŽȱ
by matching the hole in the control lever with the
Œ˜››ŽŒȱŠ•’—–Ž—ȱ‘˜•ŽǯȱœŽȱ‘Žȱ•˜ Ž›ȱǻ•ŽĞȱœ’ŽǼȱ
‘˜•Žȱ˜›ȱ‘’‘Ȭœ™ŽŽȱœŽĴ’—œȱŠ‹˜ŸŽȱřŖŖŖȱǯȱœŽȱ
‘Žȱž™™Ž›ȱǻ›’‘ȱœ’ŽǼȱ‘˜•Žȱ˜›ȱ‘’‘Ȭœ™ŽŽȱœŽĴ’—œȱ
•˜ Ž›ȱ‘Š—ȱřŖŖŖȱǯȱ˜ŸŽȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜ȱ
align the hole in the lever with the correct hole in
‘ŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žǯȱ—œŽ›ȱŠȱ™Ž—Œ’•ȱ˜›ȱŠȱŜǯřśȱ––ȱ
ǻŗȦŚȱ’—ǯǼȱ›’••ȱ‹’ȱ˜ȱ‘˜•ȱ’—ȱ™˜œ’’˜—ǯȱŽŽȱ’ž›Žȱ
śȬŗŜǯ
ȱ Śǯȱ ž••ȱ˜—ȱ‘Žȱ˜žŽ›ȱœ‘’Ž•ȱ˜ȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ
ŒŠ‹•Žȱ˜ȱ›Ž–˜ŸŽȱŠ—¢ȱœ•ŠŒ”ǯȱ’‘Ž—ȱ‘ŽȱŒŠ‹•Žȱ
clamp securely.
Alignment Hole
for Less Than
Alignment Hole 3000 RPM
for 3000 RPM
and Higher
Figure 5-16. Alignment Holes in Speed Control
Bracket and Throttle Lever. (Later Models)

Starting an Engine Equipped with Unitized
Throttle and Choke Control
1. ˜›ȱŠȱ˜•ȱ˜›ȱŠ›–ȱ—’—ŽȱȮȱ•ŠŒŽȱ‘Žȱ‘›˜Ĵ•ŽȦ
Œ‘˜”ŽȱŒ˜—›˜•ȱ’—˜ȱ‘Žȱfast/choke on position.
‘’œȱ ’••ȱŠ•œ˜ȱ™•ŠŒŽȱ‘ŽȱŒ‘˜”Žȱ’—˜ȱ‘Žȱon
™˜œ’’˜—ǯȱŽŽȱ’ž›ŽȱśȬŗŝǯ
Figure 5-17. Throttle Position for Starting Engine.
ȱ Řǯȱ Š”Žȱœž›Žȱ‘ŽȱŽšž’™–Ž—ȱ’œȱ’—ȱ—Žž›Š•ǯ
ȱ řǯȱȱ Œ’ŸŠŽȱ‘ŽȱœŠ›Ž›ȱœ ’Œ‘ǯȱŽ•ŽŠœŽȱ‘Žȱœ ’Œ‘ȱŠœȱ
soon as the engine starts.
DZȱ ˜ȱ—˜ȱŒ›Š—”ȱ‘ŽȱŽ—’—ŽȱŒ˜—’—ž˜žœ•¢ȱ
for more than 10 seconds at a time.
If the engine does not start, allow a
ŜŖȱœŽŒ˜—ȱŒ˜˜•ȱ˜ —ȱ™Ž›’˜ȱ‹Ž ŽŽ—ȱ
œŠ›’—ȱŠĴŽ–™œǯȱŠ’•ž›Žȱ˜ȱ˜••˜ ȱ
these guidelines can burn out the starter
motor.
DZȱ ȱ‘ŽȱŽ—’—ŽȱŽŸŽ•˜™œȱœžĜŒ’Ž—ȱœ™ŽŽȱ
to disengage the starter but does not
”ŽŽ™ȱ›ž——’—ȱǻŠȱŠ•œŽȱœŠ›ǼǰȱŽ—’—Žȱ
rotation must be allowed to come to
ŠȱŒ˜–™•ŽŽȱœ˜™ȱ‹Ž˜›ŽȱŠĴŽ–™’—ȱ
to restart the engine. If the starter is
Ž—ŠŽȱ ‘’•Žȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ’œȱ›˜Š’—ǰȱ
‘ŽȱœŠ›Ž›ȱ™’—’˜—ȱŠ—ȱĚ¢ ‘ŽŽ•ȱ›’—ȱŽŠ›ȱ
may clash, resulting in damage to the
starter.
If the starter does not turn the engine over, shut the
œŠ›Ž›ȱ˜ěȱ’––Ž’ŠŽ•¢ǯȱDo notȱ–Š”Žȱž›‘Ž›ȱŠĴŽ–™œȱ
to start the engine until the condition is corrected. Do
—˜ȱ“ž–™ȱœŠ›ȱžœ’—ȱŠ—˜‘Ž›ȱ‹ŠĴŽ›¢ȱǻ›ŽŽ›ȱ˜ȱŠĴŽ›¢ǰȱ
ŽŒ’˜—ȱŝǼǯȱŽŽȱ¢˜ž›ȱ
˜‘•Ž›ȱ—’—ŽȱŽ›Ÿ’ŒŽȱŽŠ•Ž›ȱ˜›ȱ ŽŽȱ’ž›ŽȱśȬŗŞǯȱ‘ŽŒ”ȱ‘Žȱœ™ŽŽȱ ’‘ȱŠȱ
trouble analysis.
Section 5
Fuel System and Governor
ȱ Śǯȱ For Operation ȮȱЎ›ȱ‘ŽȱŽ—’—ŽȱœŠ›œǰȱ–˜ŸŽȱ
‘Žȱ‘›˜Ĵ•ŽȦŒ‘˜”ŽȱŒ˜—›˜•ȱ›˜–ȱ‘Žȱfast/choke
on position and set the desired engine operating
speed (between the slow and fast position).
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 high
speed (RPM) depends on the application. Refer to the
Žšž’™–Ž—ȱ–Š—žŠŒž›Ž›Ȃœȱ’—œ›žŒ’˜—œȱ˜›ȱœ™ŽŒ’ęŒȱ
information.
WARNING: Overspeed is Hazardous!
˜ȱ—˜ȱŠ–™Ž›ȱ ’‘ȱ‘Žȱ˜ŸŽ›—˜›ȱœŽĴ’—ǯȱŸŽ›ȱœ™ŽŽȱ’œȱ
‘Š£Š›˜žœȱŠ—ȱŒ˜ž•ȱŒŠžœŽȱ™Ž›œ˜—Š•ȱ’—“ž›¢ǯ
ȱ ŗǯȱ Š”Žȱœž›Žȱ‘Žȱ‘›˜Ĵ•ŽȱŒŠ‹•Žȱ’œȱŠ“žœŽȱ™›˜™Ž›•¢ȱ
ǻœŽŽȱȁ‘›˜Ĵ•ŽȱŠ‹•Žȱ“žœ–Ž—Ǽǯ 5
2. Start the engine and allow it to warm up. Place
‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ•ŽŸŽ›ȱ’—˜ȱ‘ŽȱŠœȱ˜›ȱ‘’‘ȱ
œ™ŽŽȱ™˜œ’’˜—ǯȱž›—ȱ‘ŽȱŒ‘˜”ŽȱŠ“žœ–Ž—ȱœŒ›Ž ȱ
ǻœŽŽȱ’ž›ŽȱśȬŗřǼȱ˜žȦŒ˜ž—Ž›Œ•˜Œ” ’œŽǰȱœ˜ȱ‘Ž›Žȱ’œȱ
Œ•ŽŠ›Š—ŒŽȱ›˜–ȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›ǰȱŠ—ȱ‘ŠȱŒ˜—ŠŒȱ
ŒŠ——˜ȱ˜ŒŒž›ȱž›’—ȱŽ™ȱŚǯȱŽŽȱ’ž›ŽȱśȬŗřǯ
ȱ řǯȱ Early Models: Early models use a single
alignment hole to set the engine RPM. Align
‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ ’‘ȱ‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ
œ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ‹¢ȱ’—œŽ›’—ȱŠȱ™Ž—Œ’•ȱ˜›ȱŜǯřśȱ
––ȱǻŗȦŚȱ’—ǯǼȱ›’••ȱ‹’ǯȱŽŽȱ’ž›ŽȱśȬŗśǯ
Later Models:ȱŠŽ›ȱ–˜Ž•œȱž’•’£ŽȱŠȱ—Ž ȱŽœ’—ȱ
Œ˜—›˜•ȱŠœœŽ–‹•¢ǰȱ’Ž—’ꮍȱ‹¢ȱ ˜ȱ˜™™˜œ’—ȱ
Š•’—–Ž—ȱ‘˜•ŽœȱǻŒ•˜œŽȱ˜ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ™’Ÿ˜Ǽǰȱ
instead of one. Based upon the intended high
œ™ŽŽȱǻǼȱœŽĴ’—ǰȱ‘›˜Ĵ•ŽȱŒŠ‹•ŽȱŠ“žœ–Ž—ȱ
must be made matching the hole in the control
lever with the appropriate alignment hole. Use
‘Žȱ•˜ Ž›ȱǻ•ŽĞȱœ’ŽǼȱ‘˜•Žȱ˜›ȱ‘’‘Ȭœ™ŽŽȱœŽĴ’—œȱ
řŖŖŖȱȱŠ—ȱŠ‹˜ŸŽǯȱœŽȱ‘Žȱž™™Ž›ȱǻ›’‘ȱœ’ŽǼȱ
‘˜•Žȱ˜›ȱ‘’‘Ȭœ™ŽŽȱœŽĴ’—œȱ•Žœœȱ‘Š—ȱřŖŖŖȱǯȱ
˜ŸŽȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜ȱŠ•’—ȱ‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ
lever with the appropriate hole in the control
‹›ŠŒ”Žǯȱ—œŽ›ȱŠȱ™Ž—Œ’•ȱ˜›ȱŠȱŜǯřśȱ––ȱǻŗȦŚȱ’—Ǽȱ›’••ȱ
‹’ȱ˜ȱ‘˜•ȱ’—ȱ™˜œ’’˜—ǯȱŽŽȱ’ž›ŽȱśȬŗŜǯ
ȱ Śǯȱ ˜˜œŽ—ȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ–˜ž—’—ȱ
œŒ›Ž œǯȱ•’Žȱ‘Žȱ‹›ŠŒ”Žȱ˜› Š›ȱ˜›ȱ‹ŠŒ” Š›ǰȱ
until the desired high speed (RPM) is reached.
tachometer.
5.11
Section 5
Fuel System and Governor
Figure 5-18. Adjusting High Speed (RPM).
˜ȱ’—Œ›ŽŠœŽȱ‘Žȱ‘’‘ȱœ™ŽŽȱǻǼ, move the
‹›ŠŒ”Žȱ˜ Š›ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯ
˜ȱŽŒ›ŽŠœŽȱ‘Žȱ‘’‘ȱœ™ŽŽȱǻǼ, move the
‹›ŠŒ”ŽȱŠ Š¢ȱ›˜–ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯ
ȱ śǯȱ ’‘Ž—ȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ–˜ž—’—ȱ
œŒ›Ž œǯȱŽŒ‘ŽŒ”ȱ‘Žȱœ™ŽŽȱ ’‘ȱŠȱŠŒ‘˜–ŽŽ›ȱŠ—ȱ
readjust if necessary.
ȱ ȱ ˜›šžŽȱ‘Žȱ–˜ž—’—ȱœŒ›Ž œȱŠœȱ˜••˜ œDZ
—˜ȱ—Ž ȱŠœȬŒŠœȱ‘˜•ŽȱȮ 11.0 N·m (95 in. lb.).
Into used hole – 7.5 N·m (65 in. lb.).
ȱ Ŝǯȱ “žœȱ‘ŽȱŒ‘˜”ŽȱǻœŽŽȱ‘˜”Žȱ“žœ–Ž—ȱ ‘’Œ‘ȱ
follows).
Choke Adjustment
This procedure must follow the High Speed
Adjustment just described. If not already completed,
™Ž›˜›–ȱ‘Šȱ˜™Ž›Š’˜—ȱꛜǯ
ȱ ŗǯȱ ž›—ȱ‘ŽȱŒ‘˜”ŽȱŠ“žœ’—ȱœŒ›Ž ȱout
ǻŒ˜ž—Ž›Œ•˜Œ” ’œŽǼǰȱž—’•ȱ’ȱ—˜ȱ•˜—Ž›ȱŒ˜—ŠŒœȱ‘Žȱ
Œ‘˜”Žȱ•ŽŸŽ›ǯȱ
ȱ Řǯȱ ‘Ž—ȱž›—ȱ’ȱ‹ŠŒ”ȱinȱǻŒ•˜Œ” ’œŽǼǰȱž—’•ȱ’ȱ“žœȱ
–Š”ŽœȱŒ˜—ŠŒǯ
ȱ řǯȱ ‘’•Žȱ˜‹œŽ›Ÿ’—ȱ‘ŽȱŒ‘˜”Žȱ•’—”ǰȱ–˜ŸŽȱ‘Žȱ‘›˜Ĵ•Žȱ
control lever to the low idle (slow) position, then
‹ŠŒ”ȱ˜ȱž••ȱ‘›˜Ĵ•ŽȱǻŠœǼǯȱ‘ŽȱŒ‘˜”Žȱ•’—”ȱœ‘˜ž•ȱ
—˜ȱ–˜ŸŽȱŠœȱ‘Žȱ‘›˜Ĵ•Žȱ–˜ŸŽœȱ‘›˜ž‘ȱ‘Žȱ
—˜›–Š•ȱ›Š—Žǯȱȱ’ȱ˜Žœǰȱ‹ŠŒ”ȱ‘ŽȱŠ“žœ’—ȱœŒ›Ž ȱ
out until it no longer moves.
5.12
ȱ Śǯȱ ˜ŸŽȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ•ŽŸŽ›ȱ˜ȱ‘ŽȱŒ‘˜”Žȱ
™˜œ’’˜—ǯȱ‘ŽŒ”ȱ’ȱ‘ŽȱŒ‘˜”Žȱ‘Šœȱž••¢ȱŒ•˜œŽȱ‹¢ȱ
™•ŠŒ’—ȱ¢˜ž›ȱꗐŽ›ȱ˜—ȱ‘Žȱ›’‘ȱœ’Žȱ˜ȱ‘Žȱ•˜ Ž›ȱ
Ž—ȱ˜ȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›ȦŒ‘˜”Žȱ•’—”ȱŠ—ȱŠ™™•¢’—ȱ
gentle pressure towards the carburetor. If the
Œ˜—›˜•œȱ‘ŠŸŽȱ‹ŽŽ—ȱ™›˜™Ž›•¢ȱœŽǰȱ‘Žȱ•’—”ȱœ‘˜ž•ȱ
not move.
Separate Throttle and Choke Control
˜–ŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱœŽ™Š›ŠŽȱ‘›˜Ĵ•ŽȱŠ—ȱ
Œ‘˜”ŽȱŒ˜—›˜•œǯȱ‘’œȱŠ••˜ œȱ¢˜žȱ˜ȱŠ“žœȱ‘ŽȱŒ‘˜”Žȱ
Š—ȱ‘›˜Ĵ•ŽȱŒ˜—›˜•œȱ’—’Ÿ’žŠ••¢ǯ
Install Separate Control Cables
Throttle Control Installation
ȱ ŗǯȱ ˜˜œŽ—ȱ‘Žȱ ˜ȱŒŠ‹•ŽȱŒ•Š–™ȱœŒ›Ž œȱ˜—ȱ‘Žȱœ™ŽŽȱ
Œ˜—›˜•ȱ‹›ŠŒ”ŽȱŠœœŽ–‹•¢ǯȱŽŽȱ’ž›ŽȱśȬŗşǯ
ȱ Řǯȱ ˜ŸŽȱ‘ŽȱŠ™™•’ŒŠ’˜—ȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ•ŽŸŽ›ȱ˜ȱ‘Žȱ
–Š¡’–ž–ȱž••ȱǻŠœǼȱ‘›˜Ĵ•Žȱ™˜œ’’˜—ǰȱŠ—ȱ‘Ž—ȱ
–˜ŸŽȱ’ȱ‹ŠŒ”ȱřȦŗŜȈȱ˜›ȱŚǯŝśȱ––ǯȱ—œŽ›ȱ‘ŽȱŒŠ‹•Žȱ
‹˜Ž—ȱ ’›Žȱ’—˜ȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ•ŽŸŽ›ȱ˜—ȱ‘Žȱ
control plate.
ȱ řǯȱ ˜œ’’˜—ȱ‘Žȱ‘›˜Ĵ•ŽȱŒŠ‹•Žȱž—Ž›ȱ‘ŽȱŒŠ‹•ŽȱŒ•Š–™ǯ
Choke
Cable Clamp
Throttle
Cable Clamp
Figure 5-19. Separate Choke and Throttle Cable
Controls.
Śǯȱȱ Early Models: Early models use a single
alignment hole to set the engine RPM. Align
‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ ’‘ȱ‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ
œ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ‹¢ȱ’—œŽ›’—ȱŠȱ™Ž—Œ’•ȱ˜›ȱŜǯřśȱ
––ȱǻŗȦŚȱ’—ǯǼȱ›’••ȱ‹’ǯȱŽŽȱ’ž›ŽȱśȬŘŖǯ

Alignment Hole
Figure 5-20. Alignment Hole in Speed Control
Bracket and Throttle Lever. (Early Models)
Later Models:ȱŠŽ›ȱ–˜Ž•œȱž’•’£ŽȱŠȱ—Ž ȱŽœ’—ȱ
Œ˜—›˜•ȱŠœœŽ–‹•¢ǰȱ’Ž—’ꮍȱ‹¢ȱ ˜ȱ˜™™˜œ’—ȱ
Š•’—–Ž—ȱ‘˜•ŽœȱǻŒ•˜œŽȱ˜ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ™’Ÿ˜Ǽǰȱ
instead of one. Based upon the intended high
œ™ŽŽȱǻǼȱœŽĴ’—ǰȱ‘›˜Ĵ•ŽȱŒŠ‹•ŽȱŠ“žœ–Ž—ȱ
must be made matching the hole in the control
lever with the appropriate alignment hole. Use
‘Žȱ•˜ Ž›ȱǻ•ŽĞȱœ’ŽǼȱ‘˜•Žȱ˜›ȱ‘’‘Ȭœ™ŽŽȱœŽĴ’—œȱ
řŖŖŖȱȱŠ—ȱŠ‹˜ŸŽǯȱœŽȱ‘Žȱž™™Ž›ȱǻ›’‘ȱœ’ŽǼȱ
‘˜•Žȱ˜›ȱ‘’‘Ȭœ™ŽŽȱœŽĴ’—œȱ•Žœœȱ‘Š—ȱřŖŖŖȱǯȱ
˜ŸŽȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜ȱŠ•’—ȱ‘Žȱ‘˜•Žȱ’—ȱ‘Žȱ
lever with the appropriate hole in the control
‹›ŠŒ”Žǯȱ—œŽ›ȱŠȱ™Ž—Œ’•ȱ˜›ȱŠȱŜǯřśȱ––ȱǻŗȦŚȱ’—ǯǼȱ›’••ȱ
‹’ȱ˜ȱ‘˜•ȱ’—ȱ™˜œ’’˜—ǯȱŽŽȱ’ž›ŽȱśȬŘŗǯ
ȱ śǯȱ ž••ȱ˜—ȱ‘Žȱ˜žŽ›ȱœ‘’Ž•ȱ˜ȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ
ŒŠ‹•Žȱ˜ȱ›Ž–˜ŸŽȱŠ—¢ȱœ•ŠŒ”ǯȱ’‘Ž—ȱ‘ŽȱŒŠ‹•Žȱ
clamp securely.
Alignment Hole
for Less Than
Alignment Hole
3000 RPM
for 3000 RPM
and Higher
Figure 5-21. Alignment Holes in Speed Control
Bracket and Throttle Lever. (Later Models)
Section 5
Fuel System and Governor
ȱ Ŝǯȱ ˜ŸŽȱ‘ŽȱŠ™™•’ŒŠ’˜—ȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜ȱ‘Žȱœ•˜ ȱ
™˜œ’’˜—ǰȱ‘Ž—ȱ˜ȱž••ȱ‘›˜Ĵ•Žǯȱ‘ŽŒ”ȱ‘ŽȱŽ—’—Žȱ
control to ensure it stops against the stop screw,
which means it is properly set.
Choke Control Installation
ȱ ŗǯȱ ˜——ŽŒȱ‘ŽȱŒ‘˜”ŽȱŒŠ‹•Žȱ‹˜Ž—ȱ ’›Žȱ˜ȱ‘ŽȱŽ—’—Žȱ
Œ‘˜”ŽȱŒ˜—›˜•ȱ•ŽŸŽ›ȱ˜—ȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ
assembly.
ȱ Řǯȱ ˜œ’’˜—ȱ‘ŽȱŒ‘˜”ŽȱŒŠ‹•Žȱž—Ž›ȱ‘ŽȱŒŠ‹•ŽȱŒ•Š–™ǯ
ȱ řǯȱ žœ‘Ȧ–˜ŸŽȱ‘ŽȱŒ‘˜”ŽȱŒ˜—›˜•ȱ˜ȱ‘Žȱ˜ě position
’—ȱ‘ŽȱŠ™™•’ŒŠ’˜—ȱ™Š—Ž•ȱž—’•ȱ’ȱ‹˜Ĵ˜–œǰȱ‘Ž—ȱ™ž••ȱ
’ȱ‹ŠŒ”ȱŠ™™›˜¡’–ŠŽ•¢ȱŗȦŗŜȱ’—ǯ
ȱ Śǯȱ žœ‘ȱ˜—ȱ‘ŽȱŒ‘˜”ŽȱŒŠ‹•ŽǰȱŠ‘ŽŠȱ˜ȱ‘ŽȱŒ•Š–™ȱ˜—ȱ
‘ŽȱŽ—’—ŽȱŒ˜—›˜•ȱ™•ŠŽǰȱž—’•ȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›ȱ 5
stops. Do not force. Then tighten the cable clamp
screw.
ȱ śǯȱ ˜ŸŽȱ‘ŽȱŒ‘˜”ŽȱŒ˜—›˜•ȱž—’•ȱ’ȱœ˜™œȱǻon
™˜œ’’˜—Ǽǯȱ‘ŽŒ”ȱ‘Šȱ‘ŽȱŒ‘˜”Žȱ•’—”ȱŒŠ——˜ȱ‹Žȱ
–˜ŸŽȱ˜ Š›œȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ‹¢ȱŠ™™•¢’—ȱꗐŽ›ȱ
™›Žœœž›Žȱ˜—ȱ‘Žȱ•˜ Ž›ȱ•’—”Ȧ•ŽŸŽ›ȱ‹Ž•˜ ȱ‘ŽȱŽ—’—Žȱ
Œ˜—›˜•ȱ™•ŠŽǯȱȱ‘ŽȱŒ‘˜”Žȱ•’—”ȱ–˜ŸŽœǰȱ›ŽŠ“žœȱ‹¢ȱ
˜••˜ ’—ȱœŽ™œȱřȱŠ—ȱŚǯ
ȱ Ŝǯȱ žœ‘Ȧ–˜ŸŽȱ‘ŽȱŒ‘˜”ŽȱŒ˜—›˜•ȱ’—Ȧ˜ —ȱž—’•ȱ’ȱ
‹˜Ĵ˜–œǯȱ‘ŽȱŒ‘˜”Žȱ•ŽŸŽ›ȱŠ—ȱ•’—”ȱœ‘˜ž•ȱ‹Žȱ˜ȱ
‘Žȱ›’‘ȱŠȱ‘ŽȱŽ—ȱ˜ȱ’œȱ›ŠŸŽ•ǰȱ ’‘ȱ•’—”ŠŽȱ›ŽŽȱ
œ˜ȱ‘ŽȱŽ—’—Žȱ˜Žœȱ—˜ȱ›ž—ȱ˜—ȱ™Š›’Š•ȱŒ‘˜”Žǯȱ
Starting an Engine Equipped with Separate
Control Cables
ŗǯȱ •ŠŒŽȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ–’ Š¢ȱ‹Ž ŽŽ—ȱ‘Žȱ
slow and fastȱ™˜œ’’˜—œǯȱ•ŠŒŽȱ‘ŽȱŒ‘˜”ŽȱŒ˜—›˜•ȱ
into the on position.
2. Start the engine.
ȱ řǯȱ ˜›ȱŠȱ˜•ȱ—’—ŽȱȮȱ ›ŠžŠ••¢ȱ›Žž›—ȱ‘ŽȱŒ‘˜”Žȱ
Œ˜—›˜•ȱ˜ȱ‘Žȱ˜ěȱ™˜œ’’˜—ȱŠĞŽ›ȱ‘ŽȱŽ—’—ŽȱœŠ›œȱ
and warms up.
The engine/equipment may be operated during
the warm up period, but it may be necessary
˜ȱ•ŽŠŸŽȱ‘ŽȱŒ‘˜”Žȱ™Š›’Š••¢ȱ˜—ȱž—’•ȱ‘ŽȱŽ—’—Žȱ
warms up.
ȱ Śǯȱ ˜›ȱŠȱŠ›–ȱ—’—ŽȱȮȱŽž›—ȱŒ‘˜”Žȱ˜ȱ˜ěȱ™˜œ’’˜—ȱ
as soon as engine starts.
5.13
Section 5
Fuel System and Governor
Changing the High Speed (RPM) on the Engines
with Separate Controls (Increase or Decrease
RPM)
ȱ ŗǯȱ ‘ŽŒ”ȱ‘Šȱ‘Žȱ˜ŸŽ›—˜›ȱœ™›’—ȱŠ—ȱ’—œŠ••Š’˜—ȱ
matches the intended high speed RPM operating
›Š—ŽǯȱŽŽ›ȱ˜ȱ’ž›ŽȱśȬŘŝȱ˜›ȱśȬŘŞǯ
ȱ Řǯȱ Š›ȱ‘ŽȱŽ—’—Žǰȱ–˜ŸŽȱ‘ŽȱŠ™™•’ŒŠ’˜—ȱ‘›˜Ĵ•Žȱ
•ŽŸŽ›ȱ˜ȱž••ȱ‘›˜Ĵ•ŽȦŠœǰȱŠ—ȱ•˜˜œŽ—ȱ‘Žȱ–˜ž—’—ȱ
œŒ›Ž œȱ˜ȱ‘Žȱ–Š’—ȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ˜ȱŠ••˜ ȱ
›Ž™˜œ’’˜—’—ǯȱŽŽȱ’ž›ŽȱśȬŘŘǯ
Figure 5-22. Adjusting High Speed (RPM).
ȱ řǯȱ To increase the RPM: Move the speed control
‹›ŠŒ”Žǰȱ˜ Š›œȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱTo decrease the
RPM:ȱ˜ŸŽȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”ŽǰȱŠ Š¢ȱ›˜–ȱ
‘ŽȱŒŠ›‹ž›Ž˜›ǯȱ‘ŽŒ”ȱ‘Žȱȱ ’‘ȱŠȱŠŒ‘˜–ŽŽ›ȱ
Š—ȱ’‘Ž—ȱœŒ›Ž œȱ ‘Ž—ȱŒ˜››ŽŒȱœŽĴ’—ȱ‘Šœȱ‹ŽŽ—ȱ
˜‹Š’—ŽǯȱŽŽȱ’ž›ŽȱśȬŗşǯ
ȱ Śǯȱ ˜ȱŽ—œž›Žȱ‘Šȱ‘Žȱȱ‘Šœȱ‹ŽŽ—ȱ˜‹Š’—Žǰȱ–˜ŸŽȱ
‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜ȱ•˜ ȱ’•ŽȦœ•˜ ȱ‘Ž—ȱ‹ŠŒ”ȱ˜ȱ
ž••ȱ‘›˜Ĵ•ŽȦŠœȱ™˜œ’’˜—ȱŠ—ȱŒ‘ŽŒ”ȱ‘Žȱȱ ’‘ȱ
a tachometer.
Setting the Low Idle RPM
1. Move the application control to slow position.
ȱ Řǯȱ œ’—ȱŠȱŠŒ‘˜–ŽŽ›ǰȱŒ‘ŽŒ”ȱ‘Žȱǯȱ‘Ž—ǰȱžœ’—ȱ
a screwdriver, turn the low idle speed screw (see
’ž›ŽȱśȬřǼȱ’— Š›ȱǻŒ•˜Œ” ’œŽǼȱ˜ȱ’—Œ›ŽŠœŽȱ‘Žȱ
ǰȱŠ—ȱ˜ž Š›ȱǻŒ˜ž—Ž›Œ•˜Œ” ’œŽǼȱ˜ȱ•˜ Ž›ȱ
the RPM.
Governed Idle Adjustment
A governed idle control system was supplied as
a option on early engines and is standard on later
model engines. The purpose of this system is to
maintain a desired idle speed regardless of ambient
conditions (temperature, parasitic load, etc.) that may
Œ‘Š—Žǯȱȱ‘Žȱ•ŠŽ›ȱ–˜Ž•œȱŒŠ—ȱ‹Žȱ’Ž—’ꮍȱ‹¢ȱ‘Žȱtwo
5.14
˜™™˜œ’—ȱŠ•’—–Ž—ȱ‘˜•ŽœǰȱǻŠ“ŠŒŽ—ȱ›˜–ȱ‘Žȱ‘›˜Ĵ•Žȱ
lever pivot) rather than one. Based upon the intended
‘’‘ȱœ™ŽŽȱǻǼȱœŽĴ’—ǰȱŒŠ‹•ŽȱŠ“žœ–Ž—ȱ–žœȱ‹Žȱ
made matching the hole in the control lever with the
appropriate alignment hole.
The system requires an additional procedure for
œŽĴ’—ȱ‘Žȱ’•Žȱœ™ŽŽǯȱȱœ™ŽŽȱŠ“žœ–Ž—œȱŠ›Žȱ
required proceed as follows.
ȱ ŗǯȱ Š”ŽȱŠ—¢ȱ—ŽŒŽœœŠ›¢ȱœ™ŽŽȱ˜›ȱŒ˜—›˜•ȱŠ“žœ–Ž—œȱ
following the appropriate instructions already
covered in this section.
ȱ Řǯȱ ˜ŸŽȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ȱ˜ȱ‘Žȱ’•Žȱ™˜œ’’˜—ǯȱ
Hold the governor lever away from the
ŒŠ›‹ž›Ž˜›ǰȱœ˜ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ’œȱ’‘ȱŠŠ’—œȱ‘Žȱ
’•Žȱœ™ŽŽȱŠ“žœ’—ȱœŒ›Ž ǯȱ‘ŽŒ”ȱ‘Žȱœ™ŽŽȱ ’‘ȱ
ŠȱŠŒ‘˜–ŽŽ›ȱŠ—ȱŠ“žœȱ’ȱ˜ȱŗśŖŖȬŗŝśŖȱǯȱ
ȱȱřǯȱ Ž•ŽŠœŽȱ‘Žȱ˜ŸŽ›—˜›ȱ•ŽŸŽ›ȱŠ—ȱŠ••˜ ȱ‘ŽȱŽ—’—Žȱ
˜ȱ›Žž›—ȱ˜ȱ‘Žȱ˜ŸŽ›—Žȱ’•Žȱœ™ŽŽǯȱ‘ŽŒ”ȱ
it with a tachometer against the equipment
manufacturers recommended idle speed. If
adjustment is necessary, use the governed idle
adjusting screw on the speed control assembly
ǻœŽŽȱ’ž›ŽȱśȬŘřǼǯȱž›—ȱ‘ŽȱœŒ›Ž ȱŒ•˜Œ” ’œŽȱ
to increase the governed idle speed and
Œ˜ž—Ž›Œ•˜Œ” ’œŽȱ˜ȱŽŒ›ŽŠœŽȱ’ǯ
Governed Idle
Adjusting Screw
Figure 5-23. Location of Governed Idle Adjusting
Screw.
Governor
These engines are equipped with a centrifugal
Ě¢ Ž’‘ȱ–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—ȱ’œȱ
›’ŸŽ—ȱ˜ěȱŠȱŽŠ›ȱ˜—ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱ

NOTE: Flyweights must be installed perpendicular
to the nylon gear as shown. Improper
’—œŠ••Š’˜—ȱ˜ȱ‘ŽȱĚ¢ Ž’‘œȱ–Š¢ȱŒŠžœŽȱ
Š–ŠŽȱ˜ȱ‘Žȱ˜ŸŽ›—˜›ȱŽŠ›ǯȱŽŽȱ’ž›ŽȱśȬŘŚǯ
Flyweights
Section 5
Fuel System and Governor
‘Žȱ˜ŸŽ›—Žȱœ™ŽŽȱœŽĴ’—ȱ’œȱŽŽ›–’—Žȱ‹¢ȱ‘Žȱ
™˜œ’’˜—ȱ˜ȱ‘Žȱ‘›˜Ĵ•ŽȱŒ˜—›˜•ǯȱȱŒŠ—ȱ‹ŽȱŸŠ›’Š‹•Žȱ˜›ȱ
constant, depending on the application.
Initial 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›ȱœŽĴ’—ǰȱ–Š”Žȱœž›Žȱ‘Žȱ‘›˜Ĵ•Žȱ•’—”ŠŽȱ
’œȱŒ˜——ŽŒŽȱ˜ȱ‘Žȱ˜ŸŽ›—˜›ȱŠ›–ȱŠ—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ
˜—ȱ‘ŽȱŒŠ›‹ž›Ž˜›ǯȱŽŽȱ’ž›ŽœȱśȬŘśȱŠ—ȱśȬŘŜǯ

1. Move the governor lever toward the carburetor

ǻ ’Žȱ˜™Ž—ȱ‘›˜Ĵ•ŽǼǯȱDo not apply excess force
̎¡’—ȱ˜›ȱ’œ˜›’—ȱ‘Žȱ‘›˜Ĵ•Žȱ•’—”ǯ

ȱ Řǯȱ ›Šœ™ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞȱ ’‘ȱ™•’Ž›œǰȱŠ—ȱž›—ȱ‘Žȱ
Nylon Gear œ‘ŠĞȱcounterclockwise as far as it will go, then
tighten the hex nut. Torque the hex nut to 5
7.0-8.5 N·m (60-75 in. lb.).
Figure 5-24. Governor Gear/Flyweight 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–˜ŸŽȱ˜ž Š›ǰȱ‘Ž¢ȱŒŠžœŽȱ‘Žȱ
regulating pin to move outward.

‘Žȱ›Žž•Š’—ȱ™’—ȱŒ˜—ŠŒœȱ‘ŽȱŠ‹ȱ˜—ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞǰȱ
ŒŠžœ’—ȱ‘Žȱœ‘ŠĞȱ˜ȱ›˜ŠŽǯȱ—ŽȱŽ—ȱ˜ȱ‘ŽȱŒ›˜œœȱœ‘ŠĞȱ
™›˜›žŽœȱ‘›˜ž‘ȱ‘Žȱœ’Žȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱ‘Žȱ
governor lever is clamped on the protruding end of
‘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‘ŠĞȱ
ŒŠžœŽœȱŒ˜››Žœ™˜—’—ȱ–˜ŸŽ–Ž—ȱ˜ȱ‘Žȱ‘›˜Ĵ•Žȱ™•ŠŽǯ

‘Ž—ȱ‘ŽȱŽ—’—Žȱ’œȱŠȱ›ŽœǰȱŠ—ȱ‘Žȱ‘›˜Ĵ•Žȱ’œȱ’—ȱ‘Žȱ Figure 5-25. Governor Adjustment.

fast position, the tension of the governor spring holds
‘Žȱ‘›˜Ĵ•Žȱ™•ŠŽȱ˜™Ž—ǯȱ‘Ž—ȱ‘ŽȱŽ—’—Žȱ’œȱ˜™Ž›Š’—ȱ
(the governor gear assembly is rotating), the force
Š™™•’Žȱ‹¢ȱ‘Žȱ›Žž•Š’—ȱ™’—ȱŠŠ’—œȱ‘ŽȱŒ›˜œœȱœ‘ŠĞȱ
Ž—œȱ˜ȱŒ•˜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.

‘Ž—ȱ•˜Šȱ’œȱŠ™™•’ŽȱŠ—ȱ‘ŽȱŽ—’—Žȱœ™ŽŽȱǻŠ—ȱ
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
rapidly, so a reduction in speed is hardly noticed. As
‘Žȱœ™ŽŽȱ›ŽŠŒ‘Žœȱ‘Žȱ˜ŸŽ›—ŽȱœŽĴ’—ǰȱ‘Žȱ˜ŸŽ›—˜›ȱ Figure 5-26. Tightening Governor Lever Nut.
spring tension and the force applied by the regulating
pin will again be in equilibrium. This maintains the
engine speed at a relatively constant level.

5.15
Section 5
Fuel System and Governor

Governor Sensitivity Adjustment ‘ŽȱŽœ’›Žȱ‘’‘ȱœ™ŽŽȱœŽĴ’—ȱǻǼȱ ’••ȱŽŽ›–’—Žȱ

Governor sensitivity is adjusted by repositioning the the governor spring position in the governor lever
governor spring in the holes in the governor lever. Š—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ǰȱŠœȱ Ž••ȱŠœȱ‘Žȱœ™›’—ȱžœŽǯȱŽŽȱ
If speed surging occurs with a change in load, the ’ž›ŽȱśȬŘŝȱŠ—ȱśȬŘŞǯ
governor is set too sensitive. If a big drop in speed
occurs when a normal load is applied, the governor
should be set for greater sensitivity.

Throttle Governor
Lever Lever

2
1
3 Single
Alignment
Hole
2 3

High Speed Governed Governed Throttle Lever White Green Black

RPM Idle RPM Lever Hole No. Hole No. Spring Spring Spring
3201-3400 2 2 X
3201-3400 2 2 X
3201-3400 1601-1800 2 2 X

Figure 5-27. Early Style Governor Spring Location Chart.

Single 1
Hole B
2
A
1 Alignment Hole
3
for Less Than
Alignment Hole 3000 RPM
2 for 3000 RPM
3
Throttle and Higher
Lever Governor Governor
Lever Lever
(Single Hole) (Multiple Hole)
High Speed Governed Governed Throttle Lever Red Alignment
RPM Idle RPM Lever Hole No. Hole No. Spring Hole
Less than 3000 RPM 2/Single Hole 2 X B
Less than 3000 RPM 2/Single Hole 2 X A
Figure 5-28. Later Style Governor Spring Location Chart.

5.16
 Section 6
Lubrication System

Section 6
Lubrication System

Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
RVIC
daily and changing oil regularly. Failure to use the SE

E
correct oil, or using dirty oil, causes premature engine

API

SJ
wear and failure. SAE
10W-30
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 6
of operation as shown in the following table.
Figure 6-2. Oil Container Logo.

RECOMMENDED SAE VISCOSITY GRADES

Check Oil Level
10W-30 The importance of checking and maintaining
** * the proper oil level in the crankcase cannot be
5W-20, 5W-30 overemphasized. Check oil BEFORE EACH USE as
Kohler 10W-30
follows:

°F -20 0 20 32 40 60 80 100 1. Make sure the engine is stopped, level, and is

°C -30 -20 -10 0 10 20 30 40
cool so the oil has had time to drain into the
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
* Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
sump.
up to 4°C (40°F)
** Synthetic oils will provide better starting in extreme cold below 2. To keep dirt, grass clippings, etc., out of the
-23°C (-10°F)
Ž—’—ŽǰȱŒ•ŽŠ—ȱ‘ŽȱŠ›ŽŠȱŠ›˜ž—ȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ
Figure 6-1. Viscosity Grades Table. dipstick before removing it.

NOTE: Using other than service class SG, SH, SJ or ȱ řǯȱ Ž–˜ŸŽȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”Dzȱ ’™Žȱ˜’•ȱ˜ěǯȱŽŽȱ
higher oil or extending oil change intervals Figure 6-3. Reinsert the dipstick into the tube and
longer than recommended can cause engine fully seat the dipstick in the tube. See Figure 6-4.
damage.

DZȱ ¢—‘Ž’Œȱ˜’•œȱ–ŽŽ’—ȱ‘Žȱ•’œŽȱŒ•Šœœ’ęŒŠ’˜—œȱ
may be used with oil changes performed
at the recommended intervals. However to
allow piston rings to properly seat, a new or
rebuilt engine should be operated for at least
50 hours using standard petroleum based oil
before switching to synthetic oil.

ȱ•˜˜ȱ˜›ȱœ¢–‹˜•ȱ˜—ȱ˜’•ȱŒ˜—Š’—Ž›œȱ’Ž—’ęŽœȱ‘Žȱȱ
service class and SAE viscosity grade. See Figure 6-2.

6.1
Section 6
Lubrication System
Figure 6-3. Removing Dipstick.
˜‘•Ž›ȱ˜’•ȱꕝŽ›.
Figure 6-4. Dipstick Seated.
4. Remove the dipstick and check the oil level. The
oil level should be up to, but not over the ‘‘F’’
mark on the dipstick. See Figure 6-5.
Operating
Range
Figure 6-5. Oil Level Dipstick.
ȱ śǯȱ ȱ‘Žȱ•ŽŸŽ•ȱ’œȱ•˜ ǰȱŠȱ˜’•ȱ˜ȱ‘Žȱ™›˜™Ž›ȱ¢™Žǰȱž™ȱ
to the ‘‘F’’ mark on the dipstick. Always check the
level with the dipstick before adding more oil.
6.2
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’’ mark or over the ‘‘F’’ mark on the
dipstick.
Change Oil and Oil Filter
‘Š—Žȱ‘Žȱ˜’•ȱŠ—ȱ˜’•ȱꕝŽ›ȱannually or every 100
hoursȱ˜ȱ˜™Ž›Š’˜—ǯȱ‘Š—Žȱ‘Žȱ˜’•ȱŠ—ȱ˜’•ȱꕝŽ›ȱ ‘’•Žȱ
‘ŽȱŽ—’—Žȱ’œȱœ’••ȱ Š›–ǯȱ‘Žȱ˜’•ȱ ’••ȱ̘ ȱ–˜›Žȱ›ŽŽ•¢ȱ
and carry away more impurities. Make sure the
Ž—’—Žȱ’œȱ•ŽŸŽ•ȱ ‘Ž—ȱꕕ’—ȱ˜›ȱŒ‘ŽŒ”’—ȱ˜’•ǯȱ‘Š—Žȱ
‘Žȱ˜’•ȱŠ—ȱꕝŽ›ȱŠœȱ˜••˜ œȱǻœŽŽȱ’ž›ŽȱŜȬŜǼǯȱAlways use
ŠȱŽ—ž’—Žȱ
Oil Filter
Oil Drain Plug
Figure 6-6. Oil Drain Plug, Oil Filter.
1. To keep dirt, grass clipping, etc., out of the
Ž—’—ŽǰȱŒ•ŽŠ—ȱ‘ŽȱŠ›ŽŠȱŠ›˜ž—ȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ
dipstick before removing it.
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ›Š’—ȱ™•žȱŠ—ȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ǯȱ
Be sure to allow ample time for complete
drainage.
ȱ řǯȱ Ž–˜ŸŽȱ‘Žȱ˜•ȱꕝŽ›ȱŠ—ȱ ’™Žȱ˜ěȱ‘Žȱ–˜ž—’—ȱ
pad.
4. Reinstall the oil drain plug and torque to 14 N·m
(125 in. lb.).
ȱ śǯȱ •ŠŒŽȱ‘Žȱ—Ž ȱ›Ž™•ŠŒŽ–Ž—ȱꕝŽ›ȱ’—ȱŠȱœ‘Š••˜ ȱ™Š—ȱ
 ’‘ȱ‘Žȱ˜™Ž—ȱŽ—ȱž™ǯȱ˜ž›ȱ—Ž ȱ˜’•ȱ˜ȱ‘Žȱ™›˜™Ž›ȱ
type, in through the threaded center hole. Stop
™˜ž›’—ȱ ‘Ž—ȱ‘Žȱ˜’•ȱ›ŽŠŒ‘Žœȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ
threads. Allow a minute or two for the oil to be
Š‹œ˜›‹Žȱ‹¢ȱ‘ŽȱꕝŽ›ȱ–ŠŽ›’Š•ǯ
ȱ Ŝǯȱ ™™•¢ȱŠȱ‘’—ȱꕖȱ˜ȱŒ•ŽŠ—ȱ˜’•ȱ˜ȱ‘Žȱ›ž‹‹Ž›ȱŠœ”Žȱ
˜—ȱ‘Žȱ—Ž ȱꕝŽ›ǯ
 Section 6
Lubrication System

ȱ ŝǯȱ —œŠ••ȱ‘Žȱ›Ž™•ŠŒŽ–Ž—ȱ˜’•ȱꕝŽ›ȱ˜ȱ‘Žȱ–˜ž—’—ȱ
™Šǯȱž›—ȱ‘Žȱ˜’•ȱꕝŽ›ȱŒ•˜Œ” ’œŽȱž—’•ȱ‘Žȱ›ž‹‹Ž›ȱ
Šœ”ŽȱŒ˜—ŠŒœȱ‘Žȱ™ŠǰȱŠ—ȱ‘Ž—ȱ’‘Ž—ȱ‘ŽȱꕝŽ›ȱ
an additional 3/4 to 1 turn.
.
8. Fill the crankcase with new oil of the proper type,
to the “F” mark on the dipstick.

ȱ şǯȱ Ž’—œŠ••ȱ‘Žȱ˜’•ȱꕕȱŒŠ™Ȧ’™œ’Œ”ȱŠ—ȱ™žœ‘ȱꛖ•¢ȱ
into place.

10. 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 Figure 6-7. Oil Pump on Intake Cam Shaft
over the “F” mark. (Gerotors Removed from Pump Housing).

NOTE: To prevent extensive engine wear or Oil Filter

damage, always maintain the proper oil
level in the crankcase. Never operate
the engine with the oil level below the
‘‘L’’ mark or over the ‘‘F’’ mark on the
dipstick.
Full-Pressure Lubrication System
‘ŽœŽȱŽ—’—ŽœȱŠ›ŽȱŽšž’™™Žȱ ’‘ȱŠȱž••Ȭ̘ ȱ˜’•ȱꕝŽ›ǯȱ
See Figure 6-8.
‘Žȱ˜’•ȱꕝŽ›ȱ‘Ž•™œȱ›Ž–˜ŸŽȱœ•žŽȱŠ—ȱ˜‘Ž›ȱ 6
Œ˜–‹žœ’˜—ȱ‹¢Ȭ™›˜žŒœȱ›˜–ȱ‘Žȱ˜’•ǯȱȱŠ•œ˜ȱŽ¡Ž—œȱ
the oil change interval and cools the oil.

Operation
This engine uses a full-pressure lubrication system
to deliver oil for internal lubrication. A cam driven,
‘’‘ȱŽĜŒ’Ž—Œ¢ȱ Ž›˜˜› oil pump located in the
™

Œ›Š—”ŒŠœŽȱ–Š’—Š’—œȱ™›˜™Ž›ȱ˜’•ȱ̘ ȱŠ—ȱ˜’•ȱ™›Žœœž›Žȱ
even at low speeds and high operating temperatures.
Oil is supplied from the pump via two circuits to the
Œ›Š—”œ‘ŠĞȱ–Š’—ȱ‹ŽŠ›’—œǰȱŒ›Š—”œ‘ŠĞǰȱŒ˜——ŽŒ’—ȱ
›˜ȱ‹ŽŠ›’—ȱœž›ŠŒŽœǰȱŒŠ–ȱŽŠ›œǰȱŠ—ȱŠ¡’œȱœ‘ŠĞœǯȱ—ȱ Oil Filter
integral pressure relief valve within the oil pump
limits the maximum pressure of the system.

For a cold engine at start up, the oil pressure can Figure 6-8. Oil Filter Location.
˜ȱž™ȱ˜ȱŘŖȬŘśȱ™œ’ǯȱ˜›ȱŠȱ Š›–ȱǻ—˜›–Š•ȱ˜™Ž›Š’—ȱ
Ž–™Ž›Šž›ŽǼȱŽ—’—ŽȱŠȱ’•Žȱœ™ŽŽǰȱ‘Žȱ˜’•ȱ™›Žœœž›ŽȱŒŠ—ȱ Oil Sentry ™

go down to 5 psi. Some engines are equipped with an optional Oil

Sentry ȱ˜’•ȱ™›Žœœž›Žȱ–˜—’˜›ǯȱȱ‘Žȱ˜’•ȱ™›Žœœž›ŽȱŽœȱ
™

Service low, Oil Sentry will either activate a low oil warning
™

The oil pump rotors typically require no servicing, if
normal maintenance is performed as outlined in
Section 1.
The closure plate must be removed for access to the
oil pump and the rotors. Refer to the Disassembly
Š—ȱŽŠœœŽ–‹•¢ǰȱŽŒ’˜—œȱǻŞȱŠ—ȱŗŖǼǰȱ˜›ȱ›Ž–˜ŸŠ•ȱŠ—ȱ
reinstallation procedures.
light or stop the engine, depending on the application.
Operation
The pressure switch is designed to break contact
as the oil pressure increases and make contact as
the oil pressure decreases. At oil pressure above
approximately 2 to 5 psi, the switch contacts open.
At oil pressures below approximately 2 to 5 psi, the
switch contacts close.

6.3
Section 6
Lubrication System
—ȱŸŽ‘’Œž•Š›ȱŠ™™•’ŒŠ’˜—œȱǻ•Š —ȱ›ŠŒ˜›œǰȱ–˜ Ž›œǰȱ
ŽŒǯǼǰȱ‘Žȱ™›Žœœž›Žȱœ ’Œ‘ȱŒŠ—ȱ‹ŽȱžœŽȱ˜ȱŠŒ’ŸŠŽȱŠȱ
•˜ ȱ˜’•ȱ Š›—’—ȱ•’‘ǯȱ—ȱœŠ’˜—Š›¢ȱ˜›ȱž—ŠĴŽ—Žȱ
applications, the pressure switch can be used to
ground the ignition module to stop the engine.
NOTE: Oil Sentry™ is not a substitute for checking
the oil level BEFORE EACH USE. Make sure
the oil level is maintained up to the ‘‘F’’ mark
on the dipstick. See Figure 6-5.
Installation
The pressure switch is installed into the center oil
Š••Ž¢ȱ˜ȱ‘ŽȱꕝŽ›ȱŠŠ™Ž›ȱŒŠœ’—ȱ˜—ȱ‘ŽȱŒ•˜œž›Žȱ™•ŠŽǯȱ
Based on the application an elbow adapter may also
be used. See Figure 6-9. On engines not equipped with
Oil Sentry™ǰȱ‘Žȱ˜’•ȱŠ••Ž¢ȱ’œȱœŽŠ•Žȱ ’‘ȱŠȱŗȦŞȈȱ™’™Žȱ
plug or completely sealed.
Oil Sentry™ (Behind
Oil Sentry™
Blower Housing)
(External)
Figure 6-9. Oil Sentry Pressure Switch Locations.
™
To install the Oil Sentry™ switch:
1. Remove and discard the pipe plug from the
ŒŽ—Ž›ȱ™ŠœœŠŽȱ˜ȱ˜’•ȱꕝŽ›ȱ–˜ž—’—ȱ™Šǯ
2. Apply ™’™ŽȱœŽŠ•Š—ȱ ’‘ȱŽĚ˜—®ȱǻ˜Œ’Ž® No.
śşŘŚŗȱ˜›ȱŽšž’ŸŠ•Ž—Ǽȱ˜ȱ‘Žȱ‘›ŽŠœȱ˜ȱ‘ŽȱşŖǚȱ
ŠŠ™Ž›ȱǻ’ȱžœŽǼǰȱŠ—ȱ‘Žȱ’•ȱŽ—›¢™ switch.
ȱȱřǯȱ —œŠ••ȱ‘ŽȱŠŠ™Ž›ȱǻ’ȱžœŽǼǰȱŠ—ȱŒŠ›Žž••¢ȱ’‘Ž—ȱ
it to the intended position. Do not over tighten or
damage the adapter.
ȱ Śǯȱ —œŠ••ȱ‘Žȱœ ’Œ‘ȱ’—˜ȱ‘ŽȱŠŠ™Ž›ȱ˜›ȱŒŽ—Ž›ȱ
passage. Torque the switch to 4.5-5.0 N·m
(40-45 in. lb.).
5. Connect the lead to the terminal on the Oil
Sentry™ switch.
6.4
Testing the Oil Sentry™ Switch
The Oil Sentry™ pressure monitor is a normally closed
œ ’Œ‘ǯȱȱ’œȱŒŠ•’‹›ŠŽȱ˜ȱ˜™Ž—ȱǻ‹›ŽŠ”ȱŒ˜—ŠŒǼȱ ’‘ȱ
’—Œ›ŽŠœ’—ȱ™›Žœœž›ŽȱŠ—ȱŒ•˜œŽȱǻ–Š”ŽȱŒ˜—ŠŒǼȱ ’‘ȱ
decreasing pressure within the range of 2.0/5.0 psi.
Compressed air, a pressure regulator, pressure gauge,
and a continuity tester are required to test the switch.
1. Connect the continuity tester across the blade
terminal and the metal case of the switch. With
0 psi pressure applied to the switch, the tester
should indicate continuity (switch closed).
2. Gradually increase the pressure to the switch. The
tester should indicate a change to no continuity
(switch open) as the pressure increases through
the range of 2.0/5.0 psi.
The switch should remain open as the pressure is
increased to 90 psi maximum.
3. Gradually decrease the pressure to the switch.
The tester should indicate a change to continuity
(switch closed) as the pressure decreases through
the range of 2.0/5.0 psi; approaching
0 psi.
ȱ ȱ ȱ‘Žȱœ ’Œ‘ȱ˜Žœȱ—˜ȱ˜™Ž›ŠŽȱŠœȱœ™ŽŒ’ꮍǰȱ
replace the switch.
Testing Oil Pressure
On some models the engine oil pressure can be tested
using an oil pressure tester. Follow the instructions
included with the tester. The pressure can be tested by
›Ž–˜Ÿ’—ȱ‘Žȱ˜’•ȱꕝŽ›ȱŠ—ȱ’—œŠ••’—ȱ‘ŽȱŽœŽ›ȱŠŠ™Ž›ȱ
on the mounting pad, or by removing the Oil Sentry™
™›Žœœž›Žȱœ ’Œ‘ȱǻ˜›ȱ™’™Žȱ™•žǼȱŠ—ȱ‘›ŽŠ’—ȱ‘ŽȱŽœŽ›ȱ
hose directly into the mounting hole. See Figure 6-10.
Locations
For Tester
Figure 6-10. Tester Locations (Some Models).
 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.

Š“˜›ȱŽ•ŽŒ›’ŒŠ•ȱœ¢œŽ–œȱŠ—ȱŒ˜–™˜—Ž—œȱŒ˜ŸŽ›Žȱ’—ȱ‘’œȱœŽŒ’˜—ȱ’—Œ•žŽȱ‘Žȱ’—’’˜—ȱœ¢œŽ–ǰȱ‹ŠĴŽ›¢ǰȱ‹ŠĴŽ›¢ȱ
charging systems, electric starter, and optional Oil Sentry™ oil level pressure switch.

WARNING: Electrical Shock

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

Spark Plug NOTE: Do not clean the spark plug in a machine

—’—Žȱ–’œę›Žȱ˜›ȱœŠ›’—ȱ™›˜‹•Ž–œȱŠ›Žȱ˜ĞŽ—ȱŒŠžœŽȱ using abrasive grit. Some grit could
by a spark plug that is in poor condition or has an remain in the spark plug and enter the
’–™›˜™Ž›ȱŠ™ȱœŽĴ’—ǯ engine, causing extensive wear and
damage.
The engine is equipped with the following spark plug:
3. Check the gap using a wire feeler gauge.
Type: Champion® RC12YC or Adjust the gap by carefully bending the ground
QC12YC (RFI Compliant) electrode. Gap plugs to 0.76 mm (0.030 in.). See
Gap
Thread Size:
0.76 mm (0.030 in.)
14 mm
Figure 7-1. 7
Reach: 19.1 mm (3/4 in.) Wire Gauge
Hex Size: 15.9 mm (5/8 in.)

Spark Plug Service Spark Plug

Every 2 years or 200 hours of operation, remove the
spark plug. Check its condition, and reset the gap
or replace with a new plug as necessary. Spark plug
replacement is recommended at 500 hours.

1. Before removing the spark plug, clean the area

around the base of the plug to keep dirt and
debris out of the engine. Due to the deep recess
around the spark plug, blowing out the cavity
 ’‘ȱŒ˜–™›ŽœœŽȱŠ’›ȱ’œȱžœžŠ••¢ȱ‘Žȱ–˜œȱŽěŽŒ’ŸŽȱ
method for cleaning. The spark plug is most
accessible when the blower housing is removed
for cleaning.
2. Remove the plug and check its condition. Replace
the plug if worn or reuse is questionable.
0.76 mm
(0.030 in. )
Ground
Electrode Gap
Figure 7-1. Servicing Spark Plug.
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to ŘŚȬřŖȱȉ–ȱǻŗŞȬŘŘȱĞǯȱ•‹ǯǼ.
5. Reconnect the spark plug lead and reinstall the
blower housing, if removed previously. Torque the
blower housing screws to ŝǯŝȱȉ–ȱǻŜŞǯřȱ’—ǯȱ•‹ǯǼ.

7.1
Section 7
Electrical System and Components
Inspection
Inspect the spark plug as soon as it is removed from
the cylinder head. The deposits on the tip are an
indication of the general condition of the piston rings,
valves, and carburetor.

Normal and fouled plugs are shown in the following

photos.

‘Š•”¢ȱ‘’ŽȱŽ™˜œ’œDZ Chalky white colored

deposits indicate overheating. This condition is
usually accompanied by excessive gap erosion. A
Œ•˜Žȱ›ŠœœȱœŒ›ŽŽ—ǰȱŒ•˜ŽȱŒ˜˜•’—ȱꗜǰȱŠ—ȱ•ŽŠ—ȱ
carburetion are some causes of overheating.

˜›–Š•DZ A plug taken from an engine operating under

normal conditions will have light tan or gray colored
deposits. If the center electrode is not worn, a plug in
this condition could be regapped and reused.

Š›‹˜—ȱ˜ž•ŽDZȱ˜Ğǰȱœ˜˜¢ǰȱ‹•ŠŒ”ȱŽ™˜œ’œȱ’—’ŒŠŽȱ
incomplete combustion. Incomplete combustion
is usually caused by over-rich carburetion, weak
ignition, or poor compression.

Worn: On a worn plug, the center electrode will be

rounded and the gap will be eroded .010" or more
than the correct gap. Replace a worn spark plug
immediately.

Žȱ˜ž•ŽDZ A wet plug is caused by excess fuel, or

oil in the combustion chamber. Excess fuel could be
caused by operating the engine with too much choke
˜›ȱŠȱ’›¢ȱŠ’›ȱꕝŽ›ǯȱ’•ȱ’—ȱ‘ŽȱŒ˜–‹žœ’˜—ȱŒ‘Š–‹Ž›ȱ’œȱ
usually caused by worn piston rings or valve guides.

7.2
 Section 7
Electrical System and Components

Electronic CD Ignition System

Spark Plug Boot

Spark Plug
Terminal (C)
Spark Plug
Air Gap
0.203/0.305 mm
(0.008-0.012 in.)
Ignition Module

Lamination (A) Kill Terminal (B)

Magnet

Flywheel

Kill Switch or Off

Position of Key Switch

Figure 7-2. Electronic CD Ignition System.

These engines are equipped with a dependable • A spark plug.

7
electronic, capacitive discharge (CD) ignition system.
The system consists of the following components: • A kill switch (or key switch), which grounds the
module to stop the engine.
ȱ Ȋȱ ȱ–Š—ŽȱŠœœŽ–‹•¢ȱ ‘’Œ‘ȱ’œȱ™Ž›–Š—Ž—•¢ȱŠĜ¡Žȱ
˜ȱ‘ŽȱĚ¢ ‘ŽŽ•ǯ

• An electronic, capacitive discharge ignition

module which mounts on the engine crankcase.

7.3
Section 7
Electrical System and Components
D1
SCS
L1
L2
Figure 7-3. Capacitive Discharge Ignition Module.
Operation
œȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›˜ŠŽœǰȱŠ—ȱ‘Žȱ–Š—Žȱ™ŠœœŽœȱ‘Žȱ
’—’’˜—ȱ–˜ž•Žǰȱ‘Žȱ–Š—Ž’Œȱꎕȱ’—žŒŽœȱŒž››Ž—ȱ
’—ȱ‘Žȱ’—™žȱŒ˜’•ȱǻŗǼǯȱ‘ŽȱŒž››Ž—ȱ™ž•œŽȱ’œȱ›ŽŒ’ꮍȱ
by a diode (D1) and charges a high-voltage capacitor
(C1). As the magnet completes its pass, it induces
current in a small triggering coil (L2), which turns
on the semiconductor switch (SCS). With the switch
on, the charged capacitor is directly connected to the
primary winding (P) of the transformer (T1). As the
capacitor discharges through the primary, the current
’—’’ŠŽœȱŠȱŠœȬ›’œ’—ȱ̞¡ȱꎕȱ’—ȱ‘Žȱ›Š—œ˜›–Ž›ȱŒ˜›Žǯȱ
‘Žȱ̞¡ȱꎕȱ’—žŒŽœȱŠȱ‘’‘ȱŸ˜•ŠŽȱ’—ȱ‘ŽȱœŽŒ˜—Š›¢ȱ
winding (S) of the transformer. The high voltage pulse
is delivered to the spark plug, where it arcs across the
electrode gap and ignites the fuel-air mixture in the
combustion chamber.
Troubleshooting and Testing CD Ignition
Systems
The CD ignition system is designed to be trouble
free for the life of the engine. Other than periodically
checking/replacing the spark plug, no maintenance
or timing adjustment is necessary or possible. The
ignition module automatically controls the timing
of the spark. Mechanical systems do occasionally
fail or break down, however, so the following
troubleshooting information is provided to help
systematically determine the cause of a reported
problem.
Ž™˜›Žȱ’—’’˜—ȱ™›˜‹•Ž–œȱŠ›Žȱ–˜œȱ˜ĞŽ—ȱžŽȱ˜ȱ
poor or loose connections. Before beginning the test
procedure check all external wiring, including ground
•ŽŠœȱ˜›ȱ ’›’—ȱ‘Š›—ŽœœȱŠ—ȱ›ŽŒ’ꎛȬ›Žž•Š˜›ȱǻ’ȱœ˜ȱ
equipped). Be certain all ignition-related wires are
connected, including the spark plug lead, and all
Ž›–’—Š•ȱŒ˜——ŽŒ’˜—œȱęȱœ—ž•¢ǯȱŠ”Žȱœž›Žȱ‘Žȱ’—’’˜—ȱ
switch is in the run position.
7.4
C1
T1
Spark
Plug
P S
NOTE: The CD ignition systems are sensitive to
excessive load on the kill lead. Customer
complaints of hard starting, low power, or
–’œę›Žȱž—Ž›ȱ•˜Šȱ–Š¢ȱ‹ŽȱžŽȱ˜ȱŽ¡ŒŽœœ’ŸŽȱ
draw on the kill circuit. Disconnect any
auxiliary kill wires or safety switches
connected to the kill circuit and operate the
engine to determine if the reported problem
is gone.
Preliminary Test
To be certain the reported problem is in the engine
ignition system, it should be isolated from the unit, as
follows.
1. Locate the plug connectors where the wiring
harnesses from the engine and unit are joined.
Separate the connectors and separate the white
kill lead from the engine connector. Rejoin the
connectors and position or insulate the kill
lead terminal, so it cannot touch ground. Try to
start the engine to verify whether the reported
problem is still present.
a. If the problem is gone, the electrical system
on the unit is suspect. Check the key switch,
wires, connections, safety interlocks, etc.
b. If the problem persists, continue with the
following troubleshooting procedure. Leave
the kill lead isolated until all testing is
completed.

Electrical System and Components
CD Ignition System Troubleshooting Guide
The following guide will help locate and correct ignition system problems.
Problem Test
1. Make sure the spark plug lead is connected
to the spark plug.
2. Check the condition of spark plug. Make
sure gap is set to 0.76 mm (0.030 in.).
3. a. Test for spark with ignition tester (See
Section 2).
Disconnect spark plug lead and connect it to
the post terminal of the tester. See Figure 7-4.
Connect the clip to a good ground, —˜ the
spark plug.
NOTE: To maintain engine speeds normally
obtained during cranking, do not
remove the engine spark plug.
b. Make sure the engine ignition switch,
kill switch, or key switch is in the ‘‘run’’
Engine position.
Will
Not c. Crank the engine (minimum speed 500
Start RPM), and observe the tester. Visible and
audible sparks should be produced.
4. Measure the resistance of module
secondary using an ohmmeter (see Figures
7-2 and 7-5):
Zero ohmmeter before testing. Connect
one ohmmeter lead to laminations (A).
Connect the other lead to the spark plug
terminal (C) of high-tension lead. With the
ohmmeter leads connected in this manner,
the resistance of secondary should be 7,900
˜ȱŗŞǰŚŖŖȱ˜‘–œ.
NOTE: This test cannot be performed
ž—•Žœœȱ–˜ž•Žȱ‘Šœȱ‹ŽŽ—ȱꛎȱŠȱ
least once.
Figure 7-4. Ignition Tester (See Section 2)
Figure 7-5. Testing CD Ignition Module Secondary.
Section 7
Conclusion
2. If plug is in good condition, check/adjust
gap and reinstall.
3. If visible and audible sparks are produced,
the ignition module is OK.
If visible and audible sparks are not
produced:
a. Make sure the engine ignition switch,
kill switch, or key switch is in the
‘‘run’’ position.
b. Check wires and terminals of ignition
module and other components for
accidental grounding and damaged
insulation.
c. If wires and terminals are OK, the
ignition module is probably faulty
and should be replaced. Test module
further using an ohmmeter (Test 4).
4. If the resistance is •˜ ȱ˜›ȱŖȱ˜‘–œ, the
module secondary is shorted. Replace the
module.*
If the resistance is ‘’‘ȱ˜›ȱ’—ę—’¢ȱ˜‘–œ,
7
the module secondary is open. Replace the
module.*
ȱ‘Žȱ›Žœ’œŠ—ŒŽȱ’œȱ ’‘’—ȱ‘Žȱœ™ŽŒ’ꮍȱ
range, the module secondary is OK.
*Refer to the Disassembly and Reassembly
Sections for complete ignition module
removal and installation procedures.
7.5
Section 7
Electrical System and Components

Battery Battery Test

ȱŗŘȱŸ˜•ȱ‹ŠĴŽ›¢ȱ ’‘ȱŠȱ–’—’–ž–ȱŒž››Ž—ȱ›Š’—ȱ Žœȱ‘Žȱ‹ŠĴŽ›¢ȱŸ˜•ŠŽȱ‹¢ȱŒ˜——ŽŒ’—ȱŠȱȱŸ˜•–ŽŽ›ȱ
of 250 cold cranking amps is recommended. The ŠŒ›˜œœȱ‘Žȱ‹ŠĴŽ›¢ȱŽ›–’—Š•œȱŠ—ȱŒ›Š—”’—ȱ‘ŽȱŽ—’—Žǯȱ
actual cold cranking amp requirement depends on ȱ‘Žȱ‹ŠĴŽ›¢ȱ›˜™œȱ‹Ž•˜ ȱşȱŸ˜•œȱ ‘’•ŽȱŒ›Š—”’—ǰȱ‘Žȱ
engine size, application and starting temperatures. ‹ŠĴŽ›¢ȱ’œȱ’œŒ‘Š›Žȱ˜›ȱŠž•¢ǯȱŽŽ›ȱ˜ȱ’ž›ŽȱŝȬŜǯ
As temperatures decrease, cranking requirements
’—Œ›ŽŠœŽȱ‹žȱ‹ŠĴŽ›¢ȱŒŠ™ŠŒ’¢ȱœ‘›’—”œǯȱŽŽ›ȱ˜ȱ‘Žȱ
operating instructions of the equipment this engine
™˜ Ž›œȱ˜›ȱœ™ŽŒ’ęŒȱ‹ŠĴŽ›¢ȱ›Žšž’›Ž–Ž—œǯ
DC
ȱ‘Žȱ‹ŠĴŽ›¢ȱŒ‘Š›Žȱ’œȱ—˜ȱœžĜŒ’Ž—ȱ˜ȱŒ›Š—”ȱ‘Žȱ Voltmeter
Ž—’—Žǰȱ›ŽŒ‘Š›Žȱ‘Žȱ‹ŠĴŽ›¢ǯȱ˜ȱ—˜ȱjump start using
Š—˜‘Ž›ȱ‹ŠĴŽ›¢ǯ
Battery

Battery Charging

WARNING: Explosive Gases!

ŠĴŽ›’Žœȱ™›˜žŒŽȱŽ¡™•˜œ’ŸŽȱ‘¢›˜Ž—ȱŠœȱ ‘’•Žȱ‹Ž’—ȱ
Œ‘Š›Žǯȱ˜ȱ™›ŽŸŽ—ȱŠȱꛎȱ˜›ȱŽ¡™•˜œ’˜—ǰȱŒ‘Š›Žȱ‹ŠĴŽ›’Žœȱ˜—•¢ȱ
’—ȱ Ž••ȱŸŽ—’•ŠŽȱŠ›ŽŠœǯȱ ŽŽ™ȱœ™Š›”œǰȱ˜™Ž—ȱ̊–ŽœǰȱŠ—ȱ˜‘Ž›ȱ Figure 7-6. Checking Battery Voltage.
œ˜ž›ŒŽœȱ˜ȱ’—’’˜—ȱŠ Š¢ȱ›˜–ȱ‘Žȱ‹ŠĴŽ›¢ȱŠȱŠ••ȱ’–Žœǯȱ ŽŽ™ȱ
‹ŠĴŽ›’Žœȱ˜žȱ˜ȱ‘Žȱ›ŽŠŒ‘ȱ˜ȱŒ‘’•›Ž—ǯȱŽ–˜ŸŽȱŠ••ȱ“Ž Ž•›¢ȱ Electrical Systems Wiring Diagrams and
 ‘Ž—ȱœŽ›Ÿ’Œ’—ȱ‹ŠĴŽ›’Žœǯ Battery Charging Systems
Most engines are equipped with either a 9 or 15 amp,
Ž˜›Žȱ’œŒ˜——ŽŒ’—ȱ‘Žȱ—ŽŠ’ŸŽȱǻȬǼȱ›˜ž—ȱŒŠ‹•Žǰȱ–Š”Žȱ ›Žž•ŠŽȱ‹ŠĴŽ›¢ȱŒ‘Š›’—ȱœ¢œŽ–ǯȱ˜–Žȱ‘ŠŸŽȱŠȱřȱ
œž›ŽȱŠ••ȱœ ’Œ‘ŽœȱŠ›ŽȱǯȱȱǰȱŠȱœ™Š›”ȱ ’••ȱ˜ŒŒž›ȱŠȱ‘Žȱ Š–™ǰȱ›Žž•ŠŽȱœ¢œŽ–ȱ ’‘ȱŠȱŝŖȱ ŠĴȱ•’‘’—ȱŒ’›Œž’ǯ
›˜ž—ȱŒŠ‹•ŽȱŽ›–’—Š•ǰȱ ‘’Œ‘ȱŒ˜ž•ȱŒŠžœŽȱŠ—ȱŽ¡™•˜œ’˜—ȱ’ȱ
‘¢›˜Ž—ȱŠœȱ˜›ȱŠœ˜•’—ŽȱŸŠ™˜›œȱŠ›Žȱ™›ŽœŽ—ǯ Refer to the following wiring diagrams and
troubleshooting guides to test and service the system.
Battery Maintenance
Žž•Š›ȱ–Š’—Ž—Š—ŒŽȱ ’••ȱŽ—œž›Žȱ‘Žȱ‹ŠĴŽ›¢ȱ ’••ȱ NOTE: Observe the following guidelines to
accept and hold a charge. prevent damage to the electrical system and
components.
1. Regularly check the level of electrolyte. Add
distilled water as necessary to maintain the ȱ ŗǯȱ Š”Žȱœž›Žȱ‘Žȱ‹ŠĴŽ›¢ȱ™˜•Š›’¢ȱ’œȱŒ˜››ŽŒǯȱȱ
recommended level. negative (-) ground system is used.

DZȱ ˜ȱ—˜ȱ˜ŸŽ›ę••ȱ‘Žȱ‹ŠĴŽ›¢ǯȱ˜˜›ȱ ȱ Řǯȱ ’œŒ˜——ŽŒȱ‘Žȱ‹ŠĴŽ›¢ȱŒŠ‹•Žœȱǻ—ŽŠ’ŸŽȱǻȬǼȱŒŠ‹•Žȱ

performance or early failure due to loss ꛜǼǰȱ‹Ž˜›Žȱ˜’—ȱŽ•ŽŒ›’Œȱ Ž•’—ȱ˜—ȱ‘Žȱ
of electrolyte will result. equipment powered by the engine.

2. Keep the cables, terminals, and external surfaces
˜ȱ‘Žȱ‹ŠĴŽ›¢ȱŒ•ŽŠ—ǯȱȱ‹ž’•Ȭž™ȱ˜ȱŒ˜››˜œ’ŸŽȱ
acid or grime on the external surfaces can self-
’œŒ‘Š›Žȱ‘Žȱ‹ŠĴŽ›¢ǯȱŽ•Ȭ’œŒ‘Š›’—ȱ‘Š™™Ž—œȱ
rapidly when moisture is present.
3. Prevent the stator leads from touching or
shorting while the engine is running. This could
damage the stator.

3. Wash the cables, terminals, and external surfaces

with a baking soda and water solution. Rinse
thoroughly with clear water.

NOTE: Do not allow the baking soda solution to

Ž—Ž›ȱ‘ŽȱŒŽ••œȱ˜ȱ‘Žȱ‹ŠĴŽ›¢ǰȱŠœȱ‘’œȱ ’••ȱ
destroy the electrolyte.

7.6
 Section 7
Electrical System and Components

3 Amp
Charging
Stator

Lighting
Lead (Yellow)
Diode
Lighting Stator

Charging
Lead (Black)
Figure 7-7. 3 Amp/70 Watt Stator.

Optional Oil SentryTM

Switch (Indicator Light)
White

Ground-To-
Kill Lead Ignition
Module
AC
A R B+

M S AC Stator Spark
Regulator- Plug
Flywheel
B 5HFWL¿HU 7
Key Switch Violet

Optional (Red)
Oil SentryTM
Shutdown Green

Optional Engine Optional Fuel

Fuse Connector Solenoid

Optional Oil
Starter Sentry™ Switch
Solenoid (Shutdown or
Indicator)
Battery Bendix
Starter

Figure 7-8. 3 amp Regulated Battery Charging System/70 Watt Lighting.

7.7
Section 7
Electrical System and Components
Troubleshooting Guide 3 Amp Battery Charging System With 70 Watt Lighting Stator
NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine
›ž——’—ȱŠȱž••ȱ‘›˜Ĵ•ŽȱȬȱ—˜ȱ•˜ŠǯȱŠĴŽ›¢ȱ–žœȱ‹Žȱž••¢ȱŒ‘Š›Žǯ
Problem Test
ȱ ŗǯȱ ’‘ȱŽ—’—Žȱ›ž——’—ȱ’—ȱ‘ŽȱŠœȱœŽĴ’—ǰȱ
–ŽŠœž›ŽȱŸ˜•ŠŽȱŠŒ›˜œœȱ‹ŠĴŽ›¢ȱŽ›–’—Š•œȱ
using a DC voltmeter.
ȱ Řǯȱ Ž–˜ŸŽȱŒ˜——ŽŒ˜›ȱ›˜–ȱ›ŽŒ’ꎛȬ›Žž•Š˜›ǯȱ 2. If voltage is ŘŖȱŸ˜•œȱ˜›ȱ–˜›Ž, stator
With engine running in the fast position,
measure AC voltage across stator leads
using an AC voltmeter.
3. With charging lead disconnected from
‹ŠĴŽ›¢ȱŠ—ȱŽ—’—Žȱœ˜™™Žǰȱ–ŽŠœž›Žȱ
resistance from charging lead to ground
No using an ohmmeter. Note reading.
Charge
To Reverse the leads and measure resistance
Battery again.
In one direction, the resistance should
‹Žȱ’—ę—’¢ȱ˜‘–œȱǻ˜™Ž—ȱŒ’›Œž’Ǽǯȱ’‘ȱ‘Žȱ
leads reversed, some resistance should be
measured (about midscale on Rx1 range).
4. Cut the sleeving on the charging lead to
expose the diode connections.
Measure the resistance from the stator side
of diode to ground using an ohmmeter.
1. Make sure lights are not burned out.
2. Disconnect the lighting lead from the
wiring harness.
ȱ ȱ ’‘ȱŽ—’—Žȱ›ž——’—ȱŠȱ’—ȱ‘ŽȱŠœȱœŽĴ’—ǰȱ
No measure voltage from lighting lead to
Lights ground using an AC voltmeter.
3. With engine stopped, measure the
resistance of stator from lighting lead to
ground using an ohmmeter.
7.8
Conclusion
1. If voltage is –˜›Žȱ‘Š—ȱŗŘǯśȱŸ˜•œ, charging
system is OK.
If voltage is ŗŘǯśȱŸ˜•œȱ˜›ȱ•Žœœ, the stator or
diode are probably faulty. Test the stator
and diode (Test 2, 3, and 4).
winding is OK.
If voltage is •Žœœȱ‘Š—ȱŘŖȱŸ˜•œ, test stator
using an ohmmeter (Tests 3 and 4).
3. If resistance is •˜  in both directions, the
diode is shorted. Replace the diode.
If resistance is high in both directions, the
diode or stator winding is open. (Use
Test 4).
4. If resistance is approximately 0.5 ohms,
stator winding is OK, diode is open.
Replace diode.
If resistance is 0 ohms, stator winding is
shorted. Replace stator.
If resistance is ’—ę—’¢ȱ˜‘–œ, stator
winding or lead is open. Replace stator.
1. Replace burned out lights.
2. If voltage is ŗřȱŸ˜•œȱ˜›ȱ–˜›Ž, stator is OK.
Check for loose connections or shorts in
wiring harness.
If voltage is •Žœœȱ‘Š—ȱŗřȱŸ˜•œ, test stator
using an ohmmeter (Test 3).
3. If resistance is approximately 0.2 ohms,
stator is OK.
If resistance is 0 ohms, stator is shorted.
Replace stator.
If resistance is ’—ę—’¢ȱ˜‘–œ, stator or
lighting lead is open. Replace stator.

Electrical System and Components
Troubleshooting Guide 3 Amp/70 Watt Braking Stator
NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine
›ž——’—ȱŠȱž••ȱ‘›˜Ĵ•ŽȱȬȱ—˜ȱ•˜ŠǯȱŠĴŽ›¢ȱ–žœȱ‹Žȱž••¢ȱŒ‘Š›Žǯ
Problem Test
ȱ ŗǯȱ ’‘ȱŽ—’—Žȱ›ž——’—ȱ’—ȱ‘ŽȱŠœȱœŽĴ’—ǰȱ
–ŽŠœž›ŽȱŸ˜•ŠŽȱŠŒ›˜œœȱ‹ŠĴŽ›¢ȱ
terminals using a DC voltmeter.
ȱ Řǯȱ Ž–˜ŸŽȱŒ˜——ŽŒ˜›ȱ›˜–ȱ›ŽŒ’ꎛȬ›Žž•Š˜›ǯȱ 2. If voltage is śȱŸ˜•œȱ˜›ȱ–˜›Ž, stator winding
With engine running in the fast position,
measure AC voltage across stator leads
using an AC voltmeter.
3. With charging lead disconnected from
‹ŠĴŽ›¢ȱŠ—ȱŽ—’—Žȱœ˜™™Žǰȱ–ŽŠœž›Žȱ
No resistance from charging lead to ground
Charge using an ohmmeter. Note reading.
To
Battery Reverse the leads and measure resistance
again.
In one direction, the resistance should
‹Žȱ’—ę—’¢ȱ˜‘–œȱǻ˜™Ž—ȱŒ’›Œž’Ǽǯȱ’‘ȱ‘Žȱ
leads reversed, some resistance should be
measured (about midscale on Rx1 range).
4. Disconnect the lighting lead (yellow) from
the wiring harness.
Measure the resistance from the lighting
lead to ground using an ohmmeter.
1. Make sure lights are not burned out.
2. Disconnect the lighting lead (yellow) from
the wiring harness.
ȱ ȱ ’‘ȱŽ—’—Žȱ›ž——’—ȱ’—ȱ‘ŽȱŠœȱœŽĴ’—ǰȱ
No measure voltage from lighting lead to
Lights ground using an AC voltmeter.
3. With engine stopped, measure the
resistance of stator from lighting lead to
ground using an ohmmeter.
Section 7
Conclusion
1. If voltage is –˜›Žȱ‘Š—ȱŗŘǯśȱŸ˜•œ, charging
system is OK.
If voltage is ŗŘǯśȱŸ˜•œȱ˜›ȱ•Žœœ, the stator or
diode are probably faulty. Test the stator and
diode (Test 2, 3, and 4).
is OK.
If voltage isȱ•Žœœȱ‘Š—ȱśȱŸ˜•œ, test stator
using an ohmmeter (Tests 3 and 4).
3. If resistance is •˜ ȱin both directions, the
diode is shorted. Replace the diode.
If resistance is high in both directions, the
diode or stator winding is open.
(Use Test 4.)
7
4. If resistance is approximately 0.15 ohms,
stator winding is OK, diode is open. Replace
diode.
If resistance is 0 ohms, stator winding is
shorted. Replace stator.
If resistance is ’—ę—’¢ȱ˜‘–œ, stator winding
or lead is open. Replace stator.
1. Replace burned out lights.
2. If voltage is ŗřȱŸ˜•œȱ˜›ȱ–˜›Ž, stator is OK.
Check for loose connections or shorts in
wiring harness.
If voltage is •Žœœȱ‘Š—ȱŗřȱŸ˜•œ, test stator
using an ohmmeter (Test 3).
3. If resistance is approximately 0.15 ohms,
stator is OK.
If resistance is 0 ohms, stator is shorted.
Replace stator.
If resistance is ’—ę—’¢ȱ˜‘–œ, stator or
lighting lead is open. Replace stator.
7.9
Section 7
Electrical System and Components
Troubleshooting Guide 3 amp/70 Watt Braking Stator (Continued)
Problem Test Conclusion
1. Make sure lights are not burned out. 1. Replace burned out lights.
2. Disconnect the braking lead (green) from 2. If voltage is řśȱŸ˜•œȱ˜›ȱ–˜›Ž, stator
the wiring harness. is OK. Circuitry on unit that grounds
No braking lead is shorted.
Lights ȱ ȱ ’‘ȱŽ—’—Žȱ›ž——’—ȱ’—ȱ‘ŽȱŠœȱœŽĴ’—ǰȱ
Or measure voltage from braking lead to If voltage is •Žœœȱ‘Š—ȱřśȱŸ˜•œ, test stator
Battery ground using an AC voltmeter. using an ohmmeter (Test 3).
Charging 3. With the engine stopped, measure the 3. If resistance is approximately
(Braking resistance from braking lead to ground 0.2-0.4 ohms, stator is OK.
System using an ohmmeter.
Test) If resistance is 0 ohms, stator is shorted.
Replace stator.

If resistance is ’—ę—’¢ȱ˜‘–œ, stator or

lighting lead is open. Replace stator.

7.10
 Section 7
Electrical System and Components
Battery Charging System 9 or 15 amp

Ground-to-Kill Lead
White

A R
Ignition
M S
AC Module
B+
B
AC Stator
Key Switch 5HFWL¿HU
Flywheel Spark
Regulator Plug
Violet
Red

Green

Engine Green
Optional Connector Optional
Fuse Fuel
Solenoid

Optional Oil Sentry™

Indicator Light Optional Oil Sentry™
_ Switch (Shutdown)
+
Battery
Optional Oil Sentry™
7
Switch (Indicator)
Bendix Starter
Starter Solenoid

Figure 7-9. Regulated Battery Charging System, 9 or 15 amp.

7.11
Section 7
Electrical System and Components

5HFWL¿HU5HJXODWRU

AC

AC B+

9 or 15 Amp Stator

)LJXUHRUDPS6WDWRUDQG5HFWL¿HU5HJXODWRU

DC Volt Meter

5HFWL¿HU5HJXODWRU

AC
B+
AC

Flywheel Stator
(-)

Ammeter
Battery

Figure 7-11. Proper Connection to Test 9 or 15 amp Charging System.

7.12
 Section 7
Electrical System and Components

Troubleshooting Guide 9 or 15 amp Regulated Battery Charging System

NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine
›ž——’—ȱŠȱž••ȱ‘›˜Ĵ•ŽȱȬȱ—˜ȱ•˜Šǯȱ‘Žȱ‹ŠĴŽ›¢ȱ–žœȱ‹Žȱž••¢ȱŒ‘Š›Žǯ

Problem Test Conclusion

ȱ ŗǯȱ ›ŠŒŽȱƸȱ•ŽŠȱ›˜–ȱ›ŽŒ’ꎛȬ›Žž•Š˜›ȱ˜ȱ 1. If voltage is 13.8-14.7 and charge rate increases

key switch, or other accessible connection. when load is applied, the charging system is
Disconnect it from switch or connection.  ȱŠ—ȱ‹ŠĴŽ›¢ȱ Šœȱž••¢ȱŒ‘Š›Žǯ
Connect an ammeter from loose end of B+
•ŽŠȱ˜ȱ™˜œ’’ŸŽȱŽ›–’—Š•ȱ˜ȱ‹ŠĴŽ›¢ǯȱ˜——ŽŒȱ If voltage is less than 13.8 or charge rate does
DC voltmeter from loose end of B+ lead to not increase when load is applied, test stator
—ŽŠ’ŸŽȱŽ›–’—Š•ȱ˜ȱ‹ŠĴŽ›¢ǯȱŽŽȱ’ž›ŽȱŝȬŗŗǯȱ (Tests 2 and 3).
With engine running in the fast position, read
voltage on voltmeter.

If voltage is 13.8 volts or more, place a

–’—’–ž–ȱ•˜Šȱ˜ȱśȱŠ–™œȘȱ˜—ȱ‹ŠĴŽ›¢ȱ˜ȱ
reduce voltage. Observe ammeter.

ȘDZȱ ž›—ȱ˜—ȱ•’‘œǰȱ’ȱŜŖȱ ŠĴœȱ˜›ȱ–˜›Žǯȱ
›ȱ™•ŠŒŽȱŠȱŘǯśȱ˜‘–ǰȱŗŖŖȱ ŠĴȱ›Žœ’œ˜›ȱ
ŠŒ›˜œœȱ‹ŠĴŽ›¢ȱŽ›–’—Š•œǯ
No ȱ Řǯȱ Ž–˜ŸŽȱŒ˜——ŽŒ˜›ȱ›˜–ȱ›ŽŒ’ꎛȬ›Žž•Š˜›ǯȱ
Charge With engine running in the fast position,
To measure AC voltage across stator leads using
řŘŘŗǯ
Battery an AC voltmeter.
3a. With engine stopped, measure the resistance
across stator leads using an ohmmeter.
2. If voltage is ŘŞȱŸ˜•œȱ˜›ȱ–˜›Ž, stator is OK.
ŽŒ’ꎛȬ›Žž•Š˜›ȱ’œȱ™›˜‹Š‹•¢ȱŠž•¢ǯȱŽ›’¢ȱ
 ’‘ȱŽŒ’ꎛȬ›Žž•Š˜›ȱŽœŽ›ȱ
If voltage is •Žœœȱ‘Š—ȱŘŞȱŸ˜•œ, stator is probably
faulty and should be replaced. Test stator
further using an ohmmeter (Test 3).
7
3a. If resistance is 0.1/0.2 ohms, the stator is OK.
If the resistance is ’—ę—’¢ȱ˜‘–œ, stator is open.
Replace stator.

3b. With the engine stopped, measure the
resistance from each stator lead to ground
using an ohmmeter.
3b. If the resistance is ’—ę—’¢ȱ˜‘–œ (no continuity),
the stator is OK (not shorted to ground).
If resistance (or continuity) is measured, the
stator is shorted to ground. Replace stator.

1. Perform same test as step 1 above. 1. If the voltage is ŗŚǯŝȱŸ˜•œȱ˜›ȱ•Žœœ the charging
Battery œ¢œŽ–ȱ’œȱ ǯȱ‘Žȱ‹ŠĴŽ›¢ȱ’œȱž—Š‹•Žȱ˜ȱ‘˜•ȱŠȱ
Continuously Œ‘Š›ŽǯȱŽ›Ÿ’ŒŽȱ‹ŠĴŽ›¢ȱ˜›ȱ›Ž™•ŠŒŽȱŠœȱ—ŽŒŽœœŠ›¢ǯ
Charges At
High Rate If voltage is –˜›Žȱ‘Š—ȱŗŚǯŝȱŸ˜•œ, the
ȱ ȱ ›ŽŒ’ꎛȬ›Žž•Š˜›ȱ’œȱŠž•¢ǯȱŽ™•ŠŒŽȱ
ȱ ȱ ›ŽŒ’ꎛȬ›Žž•Š˜›ǯ

7.13
Section 7
Electrical System and Components

Electric Starters DZȱ ȱ‘ŽȱŽ—’—ŽȱŽŸŽ•˜™œȱœžĜŒ’Ž—ȱœ™ŽŽȱ˜ȱ

These engines use inertia drive starting motors.
Operation
When power is applied to the starter, the armature
rotates. As the armature rotates, the drive pinion
–˜ŸŽœȱ˜žȱ˜—ȱ‘Žȱœ™•’—Žȱ›’ŸŽȱœ‘ŠĞȱŠ—ȱ’—˜ȱ–Žœ‘ȱ
 ’‘ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›’—ȱŽŠ›ǯȱ‘Ž—ȱ‘Žȱ™’—’˜—ȱ›ŽŠŒ‘Žœȱ
‘ŽȱŽ—ȱ˜ȱ‘Žȱ›’ŸŽȱœ‘ŠĞǰȱ’ȱ›˜ŠŽœȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŠ—ȱ
cranks the engine.
‘Ž—ȱ‘ŽȱŽ—’—ŽȱœŠ›œǰȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›˜ŠŽœȱŠœŽ›ȱ
than the starter armature and drive pinion. This
moves the drive pinion out of mesh with the ring
gear and into the retracted position. When power is
removed from the starter, the armature stops rotating
and the drive pinion is held in the retracted position
‹¢ȱ‘ŽȱŠ—’Ȭ›’Ğȱœ™›’—ǯ
disengage the inertia drive starter but does
not keep running (a false start), the engine
rotation must be allowed to come to a
Œ˜–™•ŽŽȱœ˜™ȱ‹Ž˜›ŽȱŠĴŽ–™’—ȱ˜ȱ›ŽœŠ›ȱ
the engine. If the starter is engaged while the
Ě¢ ‘ŽŽ•ȱ’œȱ›˜Š’—ǰȱ‘ŽȱœŠ›Ž›ȱ™’—’˜—ȱŠ—ȱ
Ě¢ ‘ŽŽ•ȱ›’—ȱŽŠ›ȱ–Š¢ȱŒ•Šœ‘ǰȱ›Žœž•’—ȱ’—ȱ
damage to the starter.
NOTE: If the starter does not crank the engine, shut
˜ěȱ‘ŽȱœŠ›Ž›ȱ’––Ž’ŠŽ•¢ǯȱ˜ȱ—˜ȱ–Š”Žȱ
ž›‘Ž›ȱŠĴŽ–™œȱ˜ȱœŠ›ȱ‘ŽȱŽ—’—Žȱž—’•ȱ‘Žȱ
condition is corrected.
NOTE: Do not drop the starter or strike the starter
frame or end cap. Doing so can damage the
starter.

Starting Motor Precautions

NOTE: Do not crank the engine continuously for
more than 10 seconds at a time. If the engine
does not start, allow a 60-second cool-down
™Ž›’˜ȱ‹Ž ŽŽ—ȱœŠ›’—ȱŠĴŽ–™œǯȱŠ’•ž›Žȱ
to follow these guidelines can burn out the
starter motor.

7URXEOHVKRRWLQJ*XLGH6WDUWLQJ'LI¿FXOWLHV
Problem Possible Fault Correction
ȱ ŗǯȱ ‘ŽŒ”ȱ‘Žȱœ™ŽŒ’ęŒȱ›ŠŸ’¢ȱ˜ȱ‹ŠĴŽ›¢ǯȱȱ•˜ ǰȱ›ŽŒ‘Š›Žȱ˜›ȱ›Ž™•ŠŒŽȱ
Battery ‹ŠĴŽ›¢ȱŠœȱ—ŽŒŽœœŠ›¢ǯ

Wiring 1. Clean corroded connections and tighten loose connections.

Starter
2. Replace wires in poor condition.
Does Not
Energize 1. Bypass the switch or solenoid with a jumper wire. If starter cranks
Starter Switch
or Solenoid normally, replace the faulty components.

ȱ ŗǯȱ ‘ŽŒ”ȱ‘Žȱœ™ŽŒ’ęŒȱ›ŠŸ’¢ȱ˜ȱ‹ŠĴŽ›¢ǯȱȱ•˜ ǰȱ›ŽŒ‘Š›Žȱ˜›ȱ›Ž™•ŠŒŽȱ

Battery ‹ŠĴŽ›¢ȱŠœȱ—ŽŒŽœœŠ›¢ǯ
ȱ Řǯȱ ŠĴŽ›¢ȱ˜˜ȱœ–Š••ǰȱ–žœȱ‹ŽȱŠȱ•ŽŠœȱŘśŖȱŒ˜•ȬŒ›Š—”’—ȱŠ–™œǯ

1. Check for excessively dirty or worn brushes and commutator.

Brushes Clean commutator using a coarse cloth (not emery cloth).
Starter
Energizes 2. Replace brushes if excessively or unevenly worn.
But Turns
1. Make sure the clutch or transmission is disengaged or placed in
Slowly
neutral. This is especially important on equipment with
Transmission
hydrostatic drive. The transmission must be exactly in neutral to
or
prevent resistance which could keep the engine from starting.
Engine
2. Check for seized engine components such as the bearings,
connecting rod, and piston.

7.14
 Section 7
Electrical System and Components

Starter Removal and Installation

Refer to the Disassembly and Reassembly Sections for
starter removal and installation procedures.

Starter Drive Service

Every ‘›ŽŽȱ¢ŽŠ›œȱ˜›ȱŗśŖȱ‘˜ž›œ of operation, clean and
•ž‹›’ŒŠŽȱ‘Žȱœ™•’—Žœȱ˜—ȱ‘ŽȱœŠ›Ž›ȱ›’ŸŽȱœ‘ŠĞǯȱȱ‘Žȱ
drive pinion is worn, or has chipped or broken teeth,
it must be replaced. See Figure 7-12.

It is not necessary to completely disassemble the

starter to service the drive components.

Figure 7-13. Assembling Inner Half of Tool Around

The Armature Shaft and Retaining Ring.

Spring Retaining 4. Thread the center screw into the removal tool
Retainer Ring until you feel resistance. Use a wrench (1 1/8" or
adjustable) to hold the base of the removal tool.
Use another wrench or socket (1/2" or 13 mm) to
turn the center screw clockwise (see Figure 7-14).
The resistance against the center screw will tell
you when the retaining ring has popped out of
Anti-
‘Žȱ›˜˜ŸŽȱ’—ȱ‘ŽȱŠ›–Šž›Žȱœ‘ŠĞǯ
Drift
Spring
Drive
Pinion 7

Drive Nut (Collar)

Figure 7-12. Drive Components.

1. Disassemble the retaining ring, use tool (See

Section 2).

2 Referring to Figure 7-12, grasp the spring retainer
and push it toward the starter, compressing the
Š—’Ȭ›’Ğȱœ™›’—ȱŠ—ȱŽ¡™˜œ’—ȱ‘Žȱ›ŽŠ’—’—ȱ›’—ǯ
3. Holding the spring retainer in the retracted
position, assemble the inner halves of the removal
˜˜•ȱŠ›˜ž—ȱ‘ŽȱŠ›–Šž›Žȱœ‘ŠĞȱ ’‘ȱ‘Žȱ›ŽŠ’—’—ȱ
ring in the inner groove (see Figure
7-13). Slide the collar over the inner halves to
hold them in position.
Figure 7-14. Holding Tool and Turning Center
Screw (Clockwise) to Remove Retaining Ring.
5. Remove the drive components, and drive nut
ǻŒ˜••Š›Ǽȱ›˜–ȱ‘ŽȱŠ›–Šž›Žȱœ‘ŠĞǰȱ™Š¢’—ȱŠĴŽ—’˜—ȱ
to the sequence. If the splines are dirty, clean
them with solvent.
ȱ Ŝǯȱ ‘Žȱœ™•’—Žœȱœ‘˜ž•ȱ‘ŠŸŽȱŠȱ•’‘ȱꕖȱ˜ȱ•ž‹›’ŒŠ—ǯȱ
Relubricate as necessary with Kohler bendix
starter lubricant (See Section 2). Reinstall or
replace the drive components, assembling them
in the same sequence as they were removed.

7.15
Section 7
Electrical System and Components
Retaining Ring Installation 3. Remove the thru bolts and recessed hex nuts.
1. Position the retaining ring in the groove in one of
the inner halves. Assemble the other half over the ȱ Śǯȱ Ž–˜ŸŽȱ‘ŽȱŒ˜––žŠ˜›ȱŽ—ȱŒŠ™ȱŠ—ȱ•’Ğȱ˜žȱ
top and slide on the outer collar. the brush carrier assembly with the brushes and
springs.
2. Be certain the drive components are installed in
Œ˜››ŽŒȱœŽšžŽ—ŒŽȱ˜—˜ȱ‘ŽȱŠ›–Šž›Žȱœ‘ŠĞǯ 5. Remove the drive end cap, then pull the armature
with the thrust washer and wave washer (as
ȱ řǯȱ •’™ȱ‘Žȱ˜˜•ȱ˜ŸŽ›ȱ‘ŽȱŽ—ȱ˜ȱ‘ŽȱŠ›–Šž›Žȱœ‘ŠĞǰȱœ˜ȱ equipped) out of the starter frame.
the retaining ring inside is resting on the end of
‘Žȱœ‘ŠĞǯȱ
˜•ȱ‘Žȱ˜˜•ȱ ’‘ȱ˜—Žȱ‘Š—ǰȱŽ¡Ž›’—ȱ
Retaining Ring
slight pressure toward the starter. Tap the top
of the tool with a hammer until you feel the Retainer
retaining ring snap into the groove. Disassemble
Anti-Drift Spring
and remove the tool.
Pinion
4. Squeeze the retaining ring with pliers to
compress it into the groove. Drive Nut (Collar)
5. Assemble the inner halves with the larger cavity Hex Flange Nuts
around the spring retainer (see Figure 7-15). Slide Drive End Cap
the collar over them and thread the center screw
in until resistance is felt. Thrust Washer

Wave Washer

Armature

Frame Assembly
Figure 7-15. Assembling Larger Inner Half Around
Spring Retainer.

6. Hold the base of the tool with a 1 1/8" wrench

and turn the center screw clockwise with a 1/2" Brush Carrier Assembly
or 13 mm wrench to draw the spring retainer up
around the retaining ring. Stop turning when the
resistance increases. Disassemble and remove the
tool. Commutator End Cap

Starter Disassembly Insulating Washer

1. Remove the drive components following the
instructions for servicing the drive. Hex Flange Nut
Thru Bolts
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žȱŠ—ȱ’—œž•Š’—ȱ Šœ‘Ž›ȱ
from the positive (+) brush lead stud.
Figure 7-16. Inertia Drive Electric Starter.

7.16

Brush Replacement
ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žȱŠ—ȱ’—œž•Š’—ȱ Šœ‘Ž›ȱ
from the positive (+) brush lead stud.
Section 7
Electrical System and Components
2. Insert the armature into the starter frame. The
magnets will hold it in place. See Figure 7-19.

2. Remove the thru bolts and captured hex nuts.

3. Remove the commutator end cap, then pull the

brush carrier assembly out of the frame. See
Figure 7-17.

Figure 7-19. Armature Installed in Starter Frame.

3. Align the holes with the spaces between the

magnets and install the drive end cap onto the
front of the frame.

4. If the brush assembly is not being replaced,

Figure 7-17. Removing Brush Carrier Assembly.
position the springs and brushes within their
pockets in the carrier; move them to the retracted
Commutator Service
position, and install carton staples to retain them.
Clean the commutator with a coarse, lint free cloth. Do
See Figure 7-20. Replacement brushes come
not use emery cloth.
pre-assembled in the carrier housing, retained 7
with two carton staples.
If the commutator is badly worn or grooved, turn it
down on a lathe or replace the armature.

Starter Reassembly
1. Place the wave washer, followed by the thrust
 Šœ‘Ž›ȱ˜—˜ȱ‘Žȱ›’ŸŽȱœ‘ŠĞȱ˜ȱ‘ŽȱŠ›–Šž›ŽǯȱŽŽȱ
Figure 7-18.

Figure 7-20. Brush Carrier Assembly with Staples.

Figure 7-18. Washers Installed on Armature.

7.17
Section 7
Electrical System and Components
5. Hold the brush holder assembly with the positive
brush lead stud up. Align the molded sections
with the corresponding cutouts in the starter
frame and slide the brush carrier assembly into
place. The commutator will push the carton
staples out as the brush assembly is inserted. See
Figure 7-21.
ȱ Şǯȱ —œŠ••ȱ‘Žȱ’—œž•Š’—ȱ Šœ‘Ž›ȱŠ—ȱ‘Ž¡ȱ̊—Žȱ—žȱ
onto the positive (+) brush lead stud. Make sure
the stud is centered and does not touch the metal
Ž—ȱŒŠ™ǯȱ˜›šžŽȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žȱ˜ȱ
ŘǯŘȬŚǯśȱȉ–ȱǻŘŖȬŚŖȱ’—ǯȱ•‹ǯǼ.
DZȱ Ў›ȱ’—œŠ••Š’˜—ȱŠ—ȱŒ˜——ŽŒ’˜—ȱ˜ȱ‘Žȱ
starter lead, torque the outer nut to
ŗǯŜȬŘǯŞȱȉ–ȱǻŗŘȬŘśȱ’—ǯȱ•‹ǯǼǰȱ˜ȱ—˜ȱȱ ȱ
˜ŸŽ›ȱ˜›šžŽ.

ȱ şǯȱ ž‹›’ŒŠŽȱ‘Žȱ›’ŸŽȱœ‘ŠĞȱ ’‘ȱ ˜‘•Ž›ȱ‹Ž—’¡ȱ

starter drive lubricant (See Section 2). Install
the drive components following the instructions
for servicing the drive. The completed starter is
shown in Figure 7-23.

Figure 7-21. Installing Brush Carrier Using Staples.

6. Position the commutator end cap over the brush

assembly, aligning the holes for the stud terminal
and the thru bolts.

7. Install the thru bolts and hex nuts. Torque to

3.3-3.9 N·m. ǻřŖȬřśȱ’—ǯȱ•‹ǯǼ. See Figure 7-22.

Figure 7-23. Assembled Starter.

Figure 7-22. Torquing Thru Bolts.

7.18
 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
Žšž’™–Ž—ǰȱ’œŠ‹•Žȱ‘ŽȱŽ—’—ŽȱŠœȱ˜••˜ œDZȱŗǼȱ’œŒ˜——ŽŒȱ‘Žȱœ™Š›”ȱ™•žȱ•ŽŠǯȱŘǼȱ’œŒ˜——ŽŒȱ—ŽŠ’ŸŽȱǻȬǼȱ‹ŠĴŽ›¢ȱ
ŒŠ‹•Žȱ›˜–ȱ‹ŠĴŽ›¢ǯ

The following sequence is suggested for complete ŗŞǯȱ Ž–˜ŸŽȱŒ›Š—”œ‘ŠĞȱŠ—ȱ‹Š•Š—ŒŽȱ Ž’‘ȱŠœœŽ–‹•¢ǯ

engine disassembly. This procedure can be varied to 19. Remove balance weight assembly from
accommodate options or special equipment. Œ›Š—”œ‘ŠĞǯ
ŘŖȱ Ž–˜ŸŽȱ˜ŸŽ›—˜›ȱŒ›˜œœȱœ‘ŠĞǯȱ
Clean all parts thoroughly as the engine is Řŗǯȱ Ž–˜ŸŽȱȱŠ—ȱĚ¢ ‘ŽŽ•ȱœ’Žȱ˜’•ȱœŽŠ•œǯ
disassembled. Only clean parts can be accurately
inspected and gauged for wear or damage. There Drain Oil from Crankcase and Remove Oil
are many commercially available cleaners that will Filter
quickly remove grease, oil, and grime from engine ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ˜’•ȱ›Š’—ȱ™•žȱŠ—ȱ˜’•ȱꕕȱŒŠ™Ȧ
parts. When such a cleaner is used, follow the ’™œ’Œ”ǯȱŽŽȱ’ž›ŽȱŞȬŗǯȱ
manufacturer’s instructions and safety precautions
carefully. 2. Allow ample time for the oil to drain from the
crankcase.
Make sure all traces of the cleaner are removed before
the engine is reassembled and placed into operation. ȱ řǯȱ Ž–˜ŸŽȱŠ—ȱ’œŒŠ›ȱ‘Žȱ˜’•ȱꕝŽ›ǯ
Even small amounts of these cleaners can quickly
break down the lubricating properties of engine oil. 8
Typical Disassembly Sequence
ȱ ŗǯȱ ›Š’—ȱ˜’•ȱ›˜–ȱ‘ŽȱŒ›Š—”ŒŠœŽȱŠ—ȱ›Ž–˜ŸŽȱ˜’•ȱꕝŽ›ǯ Oil Fill Cap/
2. Remove blower housing. Dipstick
3. Disconnect spark plug lead.
ȱ Śǯȱ Ž–˜ŸŽȱ–žĝŽ›ǯ
ȱ śǯȱ Ž–˜ŸŽȱ›ŽŒ’ꎛȬ›Žž•Š˜›ǯȱ
Oil Filter
6. Remove electric starter.
7. Remove air cleaner.
8. Remove external governor components, Oil Drain
carburetor and fuel pump. Plug
9. Remove ignition module.
ŗŖǯȱ Ž–˜ŸŽȱ›ŠœœȱœŒ›ŽŽ—ǰȱŠ—ǰȱŠ—ȱĚ¢ ‘ŽŽ•ǯ
11. Remove stator.
12. Remove valve cover and cylinder head. Figure 8-1. Oil Drain Location, Oil Filter, and Oil
13. Remove closure plate and wiring harness. Fill Cap/Dipstick.
ŗŚǯȱ Ž–˜ŸŽȱŒŠ–ȱŽŠ›œǰȱŒŠ–ȱœ‘ŠĞœǰȱŠ—ȱ˜’•ȱ™ž–™ǯ
15. Remove connecting rod and piston.
16. Remove piston from connecting rod.
17. Remove piston rings.

8.1
Section 8
Disassembly
Remove Oil Sentry™ Pressure Switch
(On Models So Equipped)
1. Disconnect the lead from the Oil Sentry™
pressure switch.
2. Remove the pressure switch from the center
passage or adapter elbow in the closure plate. See
’ž›ŽȱŞȬŘǯ
Figure 8-2. Removing Oil Sentry™ Switch.
Remove Blower Housing
1. Remove the four shoulder screws securing the
blower housing to the closure plate. See Figure
ŞȬřǯȱ
ȱ Řǯȱ ’Ğȱ‘Žȱ‹•˜ Ž›ȱ‘˜žœ’—ȱŠ—ȱœŽ™Š›ŠŽȱ‘Žȱœ™Š›”ȱ
plug lead from the corresponding slot.
Figure 8-3. Removing Blower Housing Screws.
Disconnect Spark Plug Lead
1. Carefully pull on the boot section and disconnect
the spark plug lead.
8.2
5HPRYH0XIÀHU
ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žœȱ˜›ȱśȦŗŜȬŗŞȱŒŠ™œŒ›Ž œȱ
ŠĴŠŒ‘’—ȱ‘Žȱ–žĝŽ›ȱ˜›ȱŽ¡‘Šžœȱœ¢œŽ–ȱ˜ȱ‘Žȱ
Ž—’—ŽǯȱŽ–˜ŸŽȱŠ—¢ȱŠĴŠŒ‘Žȱ‹›ŠŒ”ŽœǯȱŽŽȱ’ž›Žȱ
ŞȬŚǯȱ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ–žĝŽ›ȱŠ—ȱŠœ”Žȱ›˜–ȱ‘ŽȱŽ¡‘Šžœȱ
port.
Figure 8-4. Removing Exhaust Flange Nuts (Stud
Design).
5HPRYH5HFWL¿HU5HJXODWRU
ȱ ŗǯȱ —™•žȱ‘ŽȱŒ˜——ŽŒ˜›ȱ›˜–ȱ‘Žȱ›ŽŒ’ꎛȬ›Žž•Š˜›ǯ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ›ŽŒ’ꎛȬ
›Žž•Š˜›ȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱŽ–˜ŸŽȱ‘Žȱ›ŽŒ’ꎛȬ
›Žž•Š˜›ǯȱŽŽȱ’ž›ŽȱŞȬśǯ
)LJXUH5HPRYLQJ5HFWL¿HU5HJXODWRU
Remove Electric Starter
1. Disconnect the starter lead from the terminal
stud.
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—Žȱ—žœȱœŽŒž›’—ȱ‘Žȱ
starter to the closure plate. Remove the starter.
ŽŽȱ’ž›ŽȱŞȬŜǯȱ

Figure 8-6. Removing Electric Starter.
Remove Air Cleaner
1. Loosen the two knobs and remove the air cleaner
Œ˜ŸŽ›ǯȱŽŽȱ’ž›ŽȱŞȬŝǯ
Figure 8-7. Removing Air Cleaner Cover.
2. Remove the precleaner (if so equipped), and the
air cleaner element with the formed rubber seal.
ŽŽȱ’ž›ŽȱŞȬŞǯ
Figure 8-8. Air Cleaner Components.
Section 8
Disassembly
ȱ řǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—Žȱ—žœǰȱ˜›ȱœ’—•Žȱ—žȱ
and long mounting screw securing the air cleaner
‹ŠœŽǯȱŽŽȱ’ž›ŽȱŞȬşǯ
Figure 8-9. Removing Air Cleaner Base Fasteners.
4. Disconnect the breather hose from the valve
cover and remove the air cleaner base and gasket.
ŽŽȱ’ž›ŽȱŞȬŗŖǯ
8
Figure 8-10. Removing Air Cleaner Base and
Breather Hose.
Remove External Governor Components,
Carburetor, and Fuel Pump
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••ȱŸŽ—’•ŠŽǰȱž—˜ŒŒž™’Žȱ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱ
̊–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
engine near spilled fuel. Never use gasoline as a cleaning
agent.
8.3
Section 8
Disassembly
ȱ ŗǯȱ ‘žȱ˜ěȱ‘ŽȱžŽ•ȱœž™™•¢ǯȱ’œŒ˜——ŽŒȱ‘ŽȱžŽ•ȱ•’—Žȱ
›˜–ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱ’—•ŽȱęĴ’—ǯȱŽŽȱ’ž›ŽȱŞȬŗŗǯȱ
If a fuel pump is used, disconnect the pulse line
›˜–ȱ‘ŽȱęĴ’—ȱ˜—ȱ‘ŽȱŒ•˜œž›Žȱ™•ŠŽǯȱŽŽȱ’ž›Žȱ
ŞȬŗŘǯ

)LJXUH5HPRYLQJ+HDW'HÀHFWRU6FUHZDQG
Ground Lead.

3. If the carburetor uses a fuel solenoid, carefully

cut the plastic tie strap and disconnect the fuel
solenoid lead from the wiring harness. See Figure
Figure 8-11. Disconnecting Fuel Line from ŞȬŗŚǯ
Carburetor.

Figure 8-14. Disconnecting Fuel Solenoid Lead.

Figure 8-12. Disconnecting Pulse Line from Fitting.
4. Slide the carburetor outward and disconnect the
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ‘ŽŠȱŽĚŽŒ˜›ȱ–˜ž—’—ȱœŒ›Ž ȱŠ—ȱ ‘›˜Ĵ•ŽȱŠ—ȱŒ‘˜”Žȱ•’—”ŠŽœǯȱŽŽȱ’ž›ŽȱŞȬŗśǯ
special washer, which also secures the ground
•ŽŠȱ˜›ȱ‘ŽȱžŽ•ȱœ‘žȬ˜ěȱœ˜•Ž—˜’ǰȱ’ȱœ˜ȱŽšž’™™Žǯȱ
ŽŽȱ’ž›ŽȱŞȬŗřǯ

Figure 8-15. Removing Carburetor.

8.4
 Section 8
Disassembly
5. Mark the mounted position of the speed control
‹›ŠŒ”Žȱ’—ȱ‘Žȱœ•˜ĴŽȱ‘˜•ŽœȱŠ—ȱ›Ž–˜ŸŽȱ‘Žȱ ˜ȱ
screws securing the speed control bracket to the
closure plate. Note or mark the governor spring
hole for correct installation later. Unhook the
governor spring, then remove the control bracket
ǻ ’‘ȱžŽ•ȱ™ž–™ȱŠĴŠŒ‘Žǰȱ’ȱŽšž’™™ŽǼȱŠ—ȱ
•’—”ŠŽœȱ›˜–ȱ‘ŽȱŽ—’—ŽǯȱŽŽȱ’ž›ŽœȱŞȬŗŜȱŠ—ȱ
ŞȬŗŝǯ

Figure 8-18. Removing Governor Lever.

7. Remove the carburetor gasket, then carefully

›Ž–˜ŸŽȱ‘Žȱ‘ŽŠȱŽĚŽŒ˜›ȱŠ—ȱŠœ”Žȱ›˜–ȱ‘Žȱ
’—Š”Žȱœžǯȱ‘Žȱ‘ŽŠȱŽĚŽŒ˜›ȱ’œȱ–ŠŽȱ›˜–ȱ
Šȱ™•Šœ’Œȱ‘Šȱ’œȱšž’Žȱ‹›’Ĵ•Žǯȱ˜ȱ—˜ȱ™›¢ȱ˜—ȱ
‘ŽȱŒ˜›—Ž›œǰȱ˜›ȱ¢˜žȱ›’œ”ȱŒ›ŠŒ”’—Ȧ‹›ŽŠ”’—ȱ‘Žȱ
ŽĚŽŒ˜›ǯȱȱ™›¢’—ȱ’œȱ—ŽŒŽœœŠ›¢ȱ˜ȱ•˜˜œŽ—ȱ‘Žȱ
ŽĚŽŒ˜›ǰȱŒŠ›Žž••¢ȱ™›¢ȱ—ŽŠ›ȱ‘Žȱ’—Š”Žȱœžȱ˜—•¢ǯȱ
ŽŽȱ’ž›ŽȱŞȬŗşǯȱŽ–˜ŸŽȱ‘Žȱ–˜ž—’—ȱœžȱ›˜–ȱ
the cylinder only if required.
Figure 8-16. Removing Speed Control Bracket
from Closure Plate.

)LJXUH5HPRYLQJ+HDW'HÀHFWRU
Figure 8-17. Disconnecting Governor Spring.

ȱ Ŝǯȱ ˜˜œŽ—ȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žȱŠ—ȱ›Ž–˜ŸŽȱ‘Žȱ
˜ŸŽ›—˜›ȱ•ŽŸŽ›Șȱ›˜–ȱ‘Žȱ˜ŸŽ›—˜›ȱŒ›˜œœȱœ‘ŠĞǯȱ
ŽŽȱ’ž›ŽȱŞȬŗŞǯ

*NOTE: It is recommended that a new governor lever

be installed whenever removal is performed.

8.5
Section 8
Disassembly
8. Remove the insert from the intake port (some
–˜Ž•œǼǰȱ’ȱœŽ™Š›ŠŽȱ›˜–ȱ‘Žȱ‘ŽŠȱŽĚŽŒ˜›ǯȱŽŽȱ
’ž›ŽȱŞȬŘŖǯ

Insert Figure 8-22. Removing Ignition Module.

Remove Grass Screen, Fan, and Flywheel

1. Unsnap the grass screen from the cooling fan. See
Figure 8-20. Removing Insert (Some Models). ’ž›ŽȱŞȬŘřǯ

Remove Ignition Module

1. Disconnect the kill lead from the ignition module.

ȱ Řǯȱ ˜ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ–Š—ŽȱŠ Š¢ȱ›˜–ȱ‘Žȱ
module.

3. Remove the RFI sheathed spark plug lead with

from retaining clip, if so equipped. See Figure
ŞȬŘŗǯ

Figure 8-23. Removing Grass Screen.

DZȱ • Š¢œȱžœŽȱŠȱĚ¢ ‘ŽŽ•ȱœ›Š™ȱ ›Ž—Œ‘ȱ˜›ȱ
Ě¢ ‘ŽŽ•ȱ‘˜•’—ȱ˜˜•ȱǻœŽŽȱŽŒ’˜—ȱŘǼȱ˜ȱ‘˜•ȱ
‘ŽȱĚ¢ ‘ŽŽ•ȱ ‘Ž—ȱ•˜˜œŽ—’—ȱ˜›ȱ’‘Ž—’—ȱ
‘ŽȱĚ¢ ‘ŽŽ•ȱŠ—ȱŠ—ȱ›ŽŠ’—’—ȱŠœŽ—Ž›œǯȱ˜ȱ
not use any type of bar or wedge between
‘Žȱꗜȱ˜ȱ‘ŽȱŒ˜˜•’—ȱŠ—ǰȱŠœȱ‘ŽȱꗜȱŒ˜ž•ȱ
become cracked or damaged.

Figure 8-21. Removing Lead from Clip (RFI
Suppression Equipped Units.
ȱ Śǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱŠ—ȱ‘Žȱ
’—’’˜—ȱ–˜ž•ŽǯȱŽŽȱ’ž›ŽȱŞȬŘŘǯ
2. Remove the retaining screw, washer and the fan
–˜ž—’—ȱ™•ŠŽǰȱœŽŒž›’—ȱ‘ŽȱŠ—ȱŠ—ȱĚ¢ ‘ŽŽ•ȱ˜ȱ
‘ŽȱŒ›Š—”œ‘ŠĞǯȱŽŽȱ’ž›ŽȱŞȬ24.

8.6
 Section 8
Disassembly

Figure 8-24. Removing Fan and Flywheel Mounting

Figure 8-26. Removing Stator.
Hardware.

ȱ řǯȱ Š›Žž••¢ȱ•’Ğȱ‘ŽȱŒ˜˜•’—ȱŠ—ȱ˜ȱ’œŽ—ŠŽȱ‘Žȱ ˜ȱ Remove the Valve Cover and Cylinder Head

›’ŸŽȱ™’—œȱŠ—ȱ›Ž–˜ŸŽȱ’ȱ›˜–ȱ‘ŽȱĚ¢ ‘ŽŽ•ǯ 1. Remove the seven screws securing the valve cover
Š—ȱŠ—¢ȱŠĴŠŒ‘Žȱ‹›ŠŒ”ŽœǯȱŽŽȱ’ž›ŽȱŞȬŘŝǯ
Śǯȱ Ž–˜ŸŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ›˜–ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱžœ’—ȱŠȱ
™ž••Ž›ǯȱŽŽȱ’ž›ŽȱŞȬŘśǯ

NOTE: Always use a puller to remove the

Ě¢ ‘ŽŽ•ȱ›˜–ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱ˜ȱ—˜ȱ
œ›’”Žȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ˜›ȱĚ¢ ‘ŽŽ•ǰȱŠœȱ‘Ž¢ȱ
could be cracked or damaged.

8
Figure 8-27. Removing Valve Cover Screws.

2. Remove the valve cover and gasket from the

Œ¢•’—Ž›ȱ‘ŽŠǯȱŽŽȱ’ž›ŽȱŞȬŘŞǯ

Figure 8-25. Removing Flywheel Using Puller.

ȱ śǯȱ Ž–˜ŸŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ”Ž¢ȱ›˜–ȱ‘ŽȱŒ›Š—”ȱœ‘ŠĞǯ

Remove the Stator

1. Remove the two screws securing the stator to the
Œ•˜œž›Žȱ™•ŠŽȱ‹˜œœŽœǯȱŽŽȱ’ž›ŽȱŞȬŘŜǯ

NOTE: To disconnect the B+ or stator leads from

the wiring harness connector, insert a
œ–Š••ȱœŒ›Ž ›’ŸŽ›ǰȱ˜›ȱœ’–’•Š›ȱ—Š››˜ ȱ̊ȱ
blade, and bend down the locking tang
of the terminal(s). Gently pull the lead(s) Figure 8-28. Valve Cover and Gasket Details.
out of the connector.

8.7
Section 8
Disassembly
3. Loosen the inner set screws (T15 TORX) and
‹ŠŒ”ȱ˜ěȱ‘Žȱ›˜Œ”Ž›ȱŠ›–ȱŠ“žœ’—ȱ—žœǯȱŽ–˜ŸŽȱ
the push rods and mark them, so they can be
›Ž’—œŠ••Žȱ’—ȱ‘ŽȱœŠ–Žȱ•˜ŒŠ’˜—ǯȱŽŽȱ’ž›ŽȱŞȬŘşǯ

Figure 8-31. Removing Cylinder Head and Gasket.

6. Remove the drain back check ball (some models)

from the keyhole slot in the crankcase. See Figure
ŞȬřŘǯȱȱ˜Ž•œȱ ’‘˜žȱŠȱŒ‘ŽŒ”ȱ‹Š••ȱ‘ŠŸŽȱŠ—ȱ
Figure 8-29. Loosening Adjustment Set Screw and internal drain back tube in the crankcase.
Nut.

ȱ Śǯȱ Ž–˜ŸŽȱ‘Žȱœ’¡ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ
cylinder head. Note the thick washer used on the
screw closest to the exhaust port. See Figure
ŞȬřŖǯ

Figure 8-32. Removing Drain Back Check Ball

Washer from Crankcase (Some Models).

Figure 8-30. Removing Cylinder Head Bolts and

Washer.

5. Remove the cylinder head and head gasket. See

’ž›ŽȱŞȬřŗǯ

8.8

Disassemble Cylinder Head
NOTE: Before disassembly, mark all valve train
components that will be reused, to assure
they are reassembled on the same side.
ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱœ™Š›”ȱ™•žǯȱŽŽȱ’ž›ŽȱŞȬ33.
Figure 8-33. Removing Spark Plug.
ȱ Řǯȱ Ž–˜ŸŽȱ‘ŽȱŠ“žœ–Ž—ȱ—žœǰȱ™’Ÿ˜œȱŠ—ȱ›˜Œ”Ž›ȱ
arms from the pivot studs.
3. Remove the rocker arm pivot studs and push rod
ž’Žȱ™•ŠŽœǯȱŽŽȱ’ž›ŽȱŞȬřŚǯ
Figure 8-34. Disassembling Rocker Arm
Components.
4. Remove the valves.
a. Compress the valve springs using a valve
spring compressor and remove the keepers.
ŽŽȱ’ž›ŽȱŞȬřśǯ
b. Remove the compressor; then remove the
valve spring caps, valve springs, and valves.
Section 8
Disassembly
Figure 8-35. Removing Valves with Spring
Compressor.
Remove Closure Plate
ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ˜ž›ŽŽ—ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ
the closure plate to the crankcase. See Figure
ȱ ȱ ŞȬ36. Note the location and position of any
ŠĴŠŒ‘ŽȱŒ•’™œȱ˜›ȱŒ•Š–™œǯ
Figure 8-36. Removing Closure Plate Screws.
2. A gasket is used between the closure plate and
crankcase. If necessary, carefully tap on the
‹˜œœŽœȱ˜›ȱ‘ŽȱœŠ›Ž›ȱ˜›ȱ˜’•ȱꕝŽ›ȱ ’‘ȱŠȱœ˜ĞȬ
faced mallet to loosen. Do not pry on the gasket
surfaces of the crankcase or oil pan, as this can
cause damage resulting in leaks.
8.9
Section 8
Disassembly
3. Remove the closure plate assembly and gasket.
ŽŽȱ’ž›ŽȱŞȬřŝǯ
4. If the wiring harness needs to be separated from
the closure plate, pry open the clamps and pull
out through the slot.
Figure 8-37. Closure Plate and Gasket Removed
from Crankcase.
Disassemble Closure Plate
1. Remove the governor gear and regulating pin
assembly. Gently pry upward using the blades of
 ˜ȱœ–Š••ȱœŒ›Ž ›’ŸŽ›œǯȱŽŽȱ’ž›ŽȱŞȬ38.
DZȱ ‘Žȱ˜ŸŽ›—˜›ȱŽŠ›ȱ’œȱ‘Ž•ȱ˜—˜ȱ‘Žȱœ‘ŠĞȱ‹¢ȱ
small molded tabs in the gear. When the
gear is removed these tabs are destroyed
and the gear must be replaced. Governor
gear removal is required for closure plate
disassembly and cleaning of the oil passages.
Figure 8-38. Removing Governor Gear.
8.10
2. Remove the six screws securing the oil passage
cover to the closure plate. Remove the cover and
Šœ”ŽǯȱŽŽȱ’ž›ŽȱŞȬřşǯ
Figure 8-39. Removing Oil Passage Cover and
Gasket.
Remove Cam Gears, Cam Shafts, and Oil
Pump
1. Remove the thrust washer(s) and cam gears from
‘ŽȱŒŠ–ȱœ‘ŠĞœǯȱŠŽ›ȱ–˜Ž•œȱ ’••ȱ‘ŠŸŽȱŠȱ‘›žœȱ
 Šœ‘Ž›ȱ˜—ȱ‘ŽȱŽ¡‘Šžœȱœ’Žȱ˜—•¢ǯȱŽŽȱ’ž›ŽȱŞȬŚŖǯ
NOTE: The ACR weight and spring normally
captured by the thrust washer and
installation of closure plate, will fall out if the
exhaust cam gear is turned upside down.
Thrust Washer
(Intake Side) Early
Models Only
Figure 8-40. Removing Cam Gears.
 Section 8
Disassembly
2. Remove the screws securing the cam levers to the
Œ›Š—”ŒŠœŽǯȱŽŽȱ’ž›ŽȱŞȬŚŗǯȱŠ›”ȱ‘ŽȱŒŠ–ȱ•ŽŸŽ›œȱ
for proper reassembly.

NOTE: Cam Gear assemblies may contain either two

or four rivets. The four rivet design is shown
’—ȱꐞ›Žœǯ

Drain Back Tube

Figure 8-43. Removing Drain Back Tube (Some

Models).
NOTE: Engine Serial No. 332740003 and Lower, use
a rubber outlet between the oil pump outlet
and lower main bearing area. Some models
use an open seal with an internal passage to
feed oil to the lower bearing. Some models
use a closedȱ˜›ȱœ˜•’ȱœŽŠ•ǰȱŠ—ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ
Figure 8-41. Removing Cam Levers. ’œȱŒ›˜œœŽȬ›’••Žȱ˜ȱŽŽȱ˜’•ȱ˜ȱ‘Žȱ•˜ Ž›ȱ
‹ŽŠ›’—ǯȱȱŽŽȱ’ž›ŽȱŞȬŚŚǯ
ȱ řǯȱ ž••ȱ‘ŽȱŽ¡‘Šžœȱœ’ŽȱŒŠ–ȱœ‘ŠĞȱŠ—ȱœ•˜ĴŽȱ‘›žœȱ
 Šœ‘Ž›ǰȱ˜žȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱŽŽȱ’ž›ŽȱŞȬŚŘ. Engine Serial No. 332740003 and Higher, the
outlet of the oil pump is closed and no rubber
œŽŠ•ȱ’œȱžœŽǯȱȱŽŽȱ’ž›ŽȱŞȬŚśǯ

Open Seal Closed Seal

Figure 8-44. Outlet Seal Styles (Some Models).

Open Outlet Style

Figure 8-42. Removing Exhaust Side Cam Shaft Closed Outlet Style
(Requires Seal)
and Slotted Thrust Washer.

4. If the engine contains an internal drain back

tube, unhook it from the oil pump and pull it
out of the crankcase passage. Check for cracks,
‹›’Ĵ•Ž—Žœœȱ˜›ȱŠ–ŠŽǯȱŽ™•ŠŒŽȱ’ȱšžŽœ’˜—Š‹•Žȱ’—ȱ
Š—¢ȱ Š¢ǯȱȱŽŽȱ’ž›ŽȱŞȬŚřǯ
Figure 8-45. Pump Outlet Styles.

8.11
Section 8
Disassembly
5. Remove the two screws securing the oil pump
Š—ȱ’—Š”Žȱœ’ŽȱŒŠ–ȱœ‘ŠĞȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱȱ
a drain back tube is used, it may be unhooked
and removed separately or together with oil
™ž–™ǯȱŠ›Žž••¢ȱ™ž••ȱž™ Š›ȱ˜—ȱ‘ŽȱŒŠ–ȱœ‘ŠĞȱ˜ȱ
remove the assembly from the crankcase cavity.
A small rubber oil pump outlet seal on the outlet
of the oil pump may become dislodged during
removal. Do notȱ•˜œŽȱ’ǯȱŽŽȱ’ž›ŽœȱŞȬŚŚȱŠ—ȱŞȬŚŜǯ
Remove Connecting Rod and Piston
ȱ ŗǯȱ ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱœ˜ȱ‘Žȱ›˜ȱ“˜ž›—Š•ȱ’œȱ’—ȱ‘Žȱ
9 o’clock position.
NOTE: If a carbon ridge is present at the top of the
bore, use a ridge reamer to remove it before
ŠĴŽ–™’—ȱ˜ȱ›Ž–˜ŸŽȱ‘Žȱ™’œ˜—ǯ
ȱ Řǯȱ Ž–˜ŸŽȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱŠ—ȱ‘Žȱ
Œ˜——ŽŒ’—ȱ›˜ȱŒŠ™ǯȱŽŽȱ’ž›ŽœȱŞȬŚŞǯ

Outlet Seal
(Some Models)

Figure 8-46. Intake Cam Shaft and Oil Pump

Assembly.
Figure 8-48. Removing Connecting Rod Cap.
6. If necessary, the oil pump can be separated from
the intake side ŒŠ–ȱœ‘ŠĞǯȱ›˜Ÿ’ŽȱŠ™™›˜™›’ŠŽȱ 3. Carefully push the connecting rod and the piston
œž™™˜›ȱ˜›ȱ‘Žȱœ‘ŠĞǰȱŠ—ȱ›’ŸŽȱ˜žȱ‘Žȱ•˜ Ž›ȱ Š Š¢ȱ›˜–ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ—ȱ˜žȱ˜ȱ‘ŽȱŒ¢•’—Ž›ȱ
pin. The oil pump assembly can then be removed ‹˜›ŽǯȱŽŽȱ’ž›ŽȱŞȬŚşǯ
from the ŒŠ–ȱœ‘ŠĞǯȱŽŽȱ’ž›ŽȱŞȬ47.

Figure 8-49. Removing Piston and Connecting

Figure 8-47. Separating Oil Pump Assembly from Rod.
Intake Side Cam Shaft.

8.12

Remove Piston from Connecting Rod
1. Remove the wrist pin retainer and wrist pin.
Separate the piston from the connecting rod. See
’ž›ŽȱŞȬśŖǯ
Figure 8-50. Separating Piston from Connecting
Rod.
Remove Piston Rings
1. Remove the top and center compression rings
žœ’—ȱŠȱ›’—ȱŽ¡™Š—Ž›ǯȱŽŽȱ’ž›ŽȱŞȬ51.
2. Remove the oil control ring rails, then remove the
spacer.
Figure 8-51. Removing Piston Rings.
Section 8
Disassembly
Remove Crankshaft and Balance Weight
Assembly
ŗǯȱ Š›Žž••¢ȱ›Ž–˜ŸŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ—ȱ‹Š•Š—ŒŽȱ
weight assembly from the crankcase. See Figure
ŞȬśŘǯȱ—ȱŽ—’—ŽœȱŠĞŽ›ȱSerial No. 3618005223,
ŒŠ›Žž••¢ȱ•’Ğȱ‘Žȱ•˜ Ž›ȱŒ˜—›˜•ȱ•’—”ȱǻ˜›ȱ‹Š•Š—ŒŽȱ
 Ž’‘Ǽǰȱ˜ěȱ‘Žȱ‹˜œœȱ˜ȱŒ›Š—”ŒŠœŽȱŠœȱ‘Žȱ
Œ›Š—”œ‘ŠĞȱ’œȱ›Ž–˜ŸŽǯȱŽŽȱ’ž›ŽȱŞȬśřǯ
Figure 8-52. Removing Crankshaft and Balance
Weight Assembly (Before Serial No. 3618005213).
Figure 8-53. Removing Crankshaft and Link (After
Serial No. 3618005223).
8.13
Section 8
Disassembly

Balance Weight Disassembly

If necessary, the balance weight assembly can be
œŽ™Š›ŠŽȱ›˜–ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱ’œŠœœŽ–‹•Žȱ˜—•¢ȱ’ȱ
required.

ȱ ŗǯȱ Ž–˜ŸŽȱ‘ŽȱŒ›Š—”ȱŽŠ›ȱ›˜–ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ—ȱ
carefully remove the key from the keyway. See
’ž›ŽȱŞȬśŚǯ

Figure 8-55. Removing Balance Weight Screw

(Guide Shoe Design Before Serial No. 3618005213).

Figure 8-54. Removing Crank Gear Key.

2. Remove the guide shoe from the guide pin on

‘ŽȱĚ¢ ‘ŽŽ•ȱœ’Žȱ˜ȱ‘ŽȱŠœœŽ–‹•¢ȱǻBefore Serial
No. 3618005213)ǯȱŽŽȱ’ž›ŽȱŞȬśśǯȱŽ–˜ŸŽȱ‘Žȱ
link from the guide pin on the PTO side of the
assembly (Ў›ȱŽ›’Š•ȱ˜ǯȱřŜŗŞŖŖśŘŘřǼ. See
’ž›ŽȱŞȬśŜǯȱ

Figure 8-56. Removing Balance Weight Screw and

ȱ řǯȱ Ž–˜ŸŽȱ‘Žȱ•˜—ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ȱœŽŒž›’—ȱ Guide Pin (Control Link Design After Serial No.
the two balance weight halves together on the 3618005223).
Œ›Š—”œ‘ŠĞǯȱ˜Žȱ‘Žȱ˜›’Ž—Š’˜—ȱ˜ȱŠ••ȱ™Š›œǯȱ‘Žȱ
ž’Žȱ™’—ȱ’œȱ˜—ȱĚ¢ ‘ŽŽ•ȱœ’Žȱ˜›ȱ‘Žȱ‹Š•Š—ŒŽȱ
weight design with the closure plate side guide
shoe. The guide pin is on PTO side for the
balance weight design with the lower control
link. Hold the guide pin with wrench or torx bit
socket as required. Do not hold or damage the
outside diameter (O.D.) of the guide pin. See
’ž›ŽȱŞȬśśȱ˜›ȱŞȬśŜǯ

8.14
 Section 8
Disassembly
4. Mark the weights for proper reassembly and
ŒŠ›Žž••¢ȱœ•’Žȱ‘Žȱ‹Š•Š—ŒŽȱ Ž’‘œȱ˜ěȱ‘Žȱ
Œ›Š—”œ‘ŠĞȱŽŒŒŽ—›’ŒœǯȱŽŽȱ’ž›ŽœȱŞȬśŝȱŠ—ȱŞȬśŞǯ

Figure 8-59. Removing Hitch Pin and Washer.

ȱ Řǯȱ •’Žȱ‘Žȱœ‘ŠĞȱ’— Š›ȱŠ—ȱ›Ž–˜ŸŽȱ’ȱ‘›˜ž‘ȱ‘Žȱ
inside of the crankcase. Be careful not to lose the
Figure 8-57. Disassembled Balance Weight (Guide œ–Š••ȱ Šœ‘Ž›ȱ’—ȱ‘Žȱ’—œ’Žȱ™˜›’˜—ȱ˜ȱ‘Žȱœ‘ŠĞǯȱ
Shoe Design Before Serial No. 3618005213). ŽŽȱ’ž›ŽȱŞȬŜŖǯ

8
Figure 8-60. Removing Governor Cross Shaft.

Figure 8-58. Disassembled Balance Weight Remove PTO and Flywheel Side Oil Seals
(Control Link Design After Serial No. 3618005223). ȱ ŗǯȱ œŽȱŠȱœŽŠ•ȱ™ž••Ž›ȱ˜ȱ›Ž–˜ŸŽȱ‘ŽȱȱŠ—ȱĚ¢ ‘ŽŽ•ȱ
œ’Žȱ˜’•ȱœŽŠ•œǯȱŽŽȱ’ž›ŽȱŞȬŜŗǯ
Remove Governor Cross Shaft
1. Remove the hitch pin and washer located on the
˜žœ’Žȱ˜ȱ‘Žȱ˜ŸŽ›—˜›ȱŒ›˜œœȱœ‘ŠĞǯȱŽŽȱ’ž›Žȱ
ŞȬśşǯ

Figure 8-61. Removing Seal with a Seal Puller.

8.15
 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 External Governor, Section 5
Ignition, Charging and Electric Starter, 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 that results 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.

Refer to A Guide to Engine Rebuilding (TP-2150) for additional information. Measurement Guide (TP-2159-A)
and Engine Inspection Data Record (TP-2435) are also available; use these to record inspection results.
Automatic Compression Release (ACR)
This engine is equipped with an Automatic When the engine is stopped, the spring returns the
Compression Release (ACR) mechanism. The ACR Ě¢ Ž’‘ȦŒ˜—›˜•ȱ™’—ȱŠœœŽ–‹•¢ȱ˜ȱ‘ŽȱŒ˜–™›Žœœ’˜—ȱ
lowers compression at cranking speeds to make release position, ready for the next start.
starting easier.

Operation
The ACR mechanism consists of an actuating spring Control Pin
9
Š—ȱŠȱ™’Ÿ˜’—ȱĚ¢ Ž’‘ȦŒ˜—›˜•ȱ™’—ȱŠœœŽ–‹•¢ǰȱ Lower Section
located in the exhaust side cam gear. A thrust washer
and mounting of the closure plate hold the ACR in
position. See Figure 9-1. At cranking speeds (700 RPM Cam Lobe
˜›ȱ•˜ Ž›Ǽǰȱ‘Žȱœ™›’—ȱ‘˜•œȱ‘ŽȱĚ¢ Ž’‘ȱ’—ȱŠ—ȱ‘Žȱ
rounded surface of the control pin protrudes above Flyweight
the exhaust cam lobe. This pushes the exhaust valve
˜ěȱ’œȱœŽŠȱž›’—ȱ‘Žȱꛜȱ™Š›ȱ˜ȱ‘ŽȱŒ˜–™›Žœœ’˜—ȱ Cam Gear
œ›˜”Žǯȱ‘ŽȱŒ˜–™›Žœœ’˜—ȱ’œȱ›ŽžŒŽȱ˜ȱŠ—ȱŽěŽŒ’ŸŽȱ
Spring
ratio of about 2:1 during cranking.

Ў›ȱœŠ›’—ǰȱ ‘Ž—ȱŽ—’—Žȱœ™ŽŽȱŽ¡ŒŽŽœȱŝŖŖȱǰȱ
Thrust Washer
ŒŽ—›’žŠ•ȱ˜›ŒŽȱ˜ŸŽ›Œ˜–Žœȱ‘Žȱ˜›ŒŽȱ˜ȱ‘ŽȱĚ¢ Ž’‘ȱ
œ™›’—ǯȱ‘ŽȱĚ¢ Ž’‘ȱ–˜ŸŽœȱ˜ž Š›ǰȱ›˜Š’—ȱ‘Žȱ
Œ˜—›˜•ȱ™’—ȱ˜ȱŽ¡™˜œŽȱ‘Žȱ̊ȱœž›ŠŒŽǰȱ ‘’Œ‘ȱ’œȱ•˜ Ž›ȱ
than the cam lobe. The control pin no longer has any
ŽěŽŒȱ˜—ȱ‘ŽȱŽ¡‘ŠžœȱŸŠ•ŸŽǰȱŠ—ȱ‘ŽȱŽ—’—Žȱ˜™Ž›ŠŽœȱŠȱ
Figure 9-1. ACR Details.
full power.

9.1
Section 9
Inspection and Reconditioning
%HQH¿WV
Reducing the compression at cranking speeds results
’—ȱœŽŸŽ›Š•ȱ’–™˜›Š—ȱ‹Ž—Žęœǯ
ȱ ŗǯȱ ‘ŽȱœŠ›Ž›ȱŠ—ȱ‹ŠĴŽ›¢ȱŒŠ—ȱ‹Žȱœ–Š••Ž›ǰȱ–˜›Žȱ
practical for the applications in which these
engines are used.
2. ACR eliminates kickback during starting, so a
spark retard/advance mechanism is no longer
required.
ȱ řǯȱ ‘ŽȱŒ‘˜”ŽȱŒ˜—›˜•ȱœŽĴ’—ȱ’œȱ•ŽœœȱŒ›’’ŒŠ•ȱ ’‘ȱǯȱ
—ȱ‘ŽȱŽŸŽ—ȱ˜ȱ̘˜’—ǰȱŽ¡ŒŽœœȱžŽ•ȱ’œȱ‹•˜ —ȱ˜žȱ
the opened exhaust valve and does not hamper
starting.
4. Engines with ACR start much faster in cold
weather.
5. Engines with ACR can be started with spark
plugs that are worn or fouled. Engines without
ACR would be less likely to start with the same
plugs.
Cam Gears
Inspection and Service
Inspect the gear teeth and cam lobes of the intake and
exhaust cam gears. If the lobes exhibit excessive wear,
or the teeth are worn, chipped or broken, replacement
of the cam gear(s) will be necessary.
Crankshaft and Crank Gear
Inspection and Service
˜—’—ȱ’œȱ‹Žœȱ
Inspect the teeth of the crank gear. If the teeth
are badly worn, chipped, or some are missing,
replacement of the crank gear will be necessary.
Ž–˜ŸŽȱ‘ŽȱŽŠ›ȱ‹¢ȱ™ž••’—ȱ’ȱ˜ěȱ‘Žȱ”Ž¢ȱŠ—ȱ
Œ›Š—”œ‘ŠĞǯ
—œ™ŽŒȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ‹ŽŠ›’—ȱ“˜ž›—Š•ȱœž›ŠŒŽœȱ˜›ȱ
wear, scoring, grooving, etc. If they show signs of
Š–ŠŽȱ˜›ȱŠ›Žȱ˜žȱ˜ȱ›ž——’—ȱŒ•ŽŠ›Š—ŒŽȱœ™ŽŒ’ęŒŠ’˜—œǰȱ
‘ŽȱŒ›Š—”œ‘ŠĞȱ–žœȱ‹Žȱ›Ž™•ŠŒŽǯȱ
—œ™ŽŒȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ”Ž¢ Š¢œǯȱȱ ˜›—ȱ˜›ȱŒ‘’™™Žǰȱ
›Ž™•ŠŒŽ–Ž—ȱ˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ ’••ȱ‹Žȱ—ŽŒŽœœŠ›¢ǯ
9.2
Inspect the crankpin for wear, score marks or
aluminum transfer. Slight score marks can be cleaned
with crocus cloth soaked in oil. If wear limits are
exceeded (see Section 1), it will be necessary to replace
‘ŽȱŒ›Š—”œ‘ŠĞǯȱ
Crankcase
Inspection and Service
Check all gasket surfaces to make sure they are free of
gasket fragments and deep scratches or nicks.
Check the cylinder wall for scoring. In severe cases,
unburned fuel can wash the necessary lubricating
˜’•ȱ˜ěȱ‘Žȱ™’œ˜—ȱŠ—ȱŒ¢•’—Ž›ȱ Š••ǯȱ‘Žȱ™’œ˜—ȱ›’—œȱ
make metal to metal contact with the wall, causing
œŒžĜ—ȱŠ—ȱœŒ˜›’—ǯȱŒ˜›’—ȱ˜ȱ‘ŽȱŒ¢•’—Ž›ȱ Š••ȱŒŠ—ȱ
also be caused by localized hot spots from blocked
Œ˜˜•’—ȱꗜȱ˜›ȱ›˜–ȱ’—ŠŽšžŠŽȱ˜›ȱŒ˜—Š–’—ŠŽȱ
lubrication.
If the cylinder bore is scored, worn, tapered, or out-
of-round, resizing may be possible. Use an inside
micrometer or telescoping gauge to determine the
amount of wear (refer to Section 1). If wear exceeds
the published limits, a 0.08 mm (0.003 in.) oversize
piston is available. If the cylinder will not clean
up at 0.08 mm (0.003 in.) oversize, a short block or
replacement engine will need to be considered.
Honing
While most commercially available cylinder hones
can be used with either portable drills or drill presses,
the use of a low speed drill press is preferred as it
facilitates more accurate alignment of the bore in
›Ž•Š’˜—ȱ˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŒ˜ž—Ž›ȱ‹˜›Žǯȱ
accomplished at a drill speed of about 250 RPM and
60 strokesȱ™Ž›ȱ–’—žŽǯȱЎ›ȱ’—œŠ••’—ȱŒ˜Š›œŽȱœ˜—Žœȱ’—ȱ
hone, proceed as follows:
ȱ ŗǯȱ ˜ Ž›ȱ‘Žȱ‘˜—Žȱ’—˜ȱ‘Žȱ‹˜›ŽȱŠ—ǰȱŠĞŽ›ȱŒŽ—Ž›’—ǰȱ
adjust it so that the stones are in contact with
‘ŽȱŒ¢•’—Ž›ȱ Š••ǯȱœŽȱ˜ȱŠȱŒ˜––Ž›Œ’Š•ȱŒžĴ’—Ȭ
cooling agent is recommended.
2. With the lower edge of each stone positioned
even with the lowest edge of the bore, start the
drill and honing process. Move the hone up and
down while resizing to prevent the formation of
ŒžĴ’—ȱ›’Žœǯȱ‘ŽŒ”ȱ‘Žȱœ’£Žȱ›ŽšžŽ—•¢ǯȱŠ”Žȱ
sure the bore is cool when measuring.

3. When the bore is within 0.064 mm (0.0025 in.)
of desired size, remove the coarse stones and
replace with burnishing stones. Continue with
the burnishing stones until within 0.013 mm
(0.0005 in.)ȱ˜ȱŽœ’›Žȱœ’£ŽȱŠ—ȱ‘Ž—ȱžœŽȱꗒœ‘ȱ
œ˜—ŽœȱǻŘŘŖȬŘŞŖȱ›’ǼȱŠ—ȱ™˜•’œ‘ȱ˜ȱꗊ•ȱœ’£Žǯȱȱ
crosshatch should be observed if honing is done
correctly. The crosshatch should intersect at
Š™™›˜¡’–ŠŽ•¢ȱŘřȬřřǚȱ˜ěȱ‘Žȱ‘˜›’£˜—Š•ǯȱ˜˜ȱ̊ȱ
an angle could cause the rings to skip and wear
excessively, too steep an angle will result in high
oil consumption (refer to Figure 9-2).
Figure 9-2. Cylinder Bore Crosshatch after Honing.
ȱ Śǯȱ Ў›ȱ‘˜—’—ǰȱŒ‘ŽŒ”ȱ‘Žȱ‹˜›Žȱ˜›ȱ›˜ž——ŽœœǰȱŠ™Ž›ǰȱ
and size. Use an inside micrometer, telescoping
gauge, or bore gauge to take measurements.
The measurements should be taken at three
locations in the cylinder – at the top, middle,
Š—ȱ‹˜Ĵ˜–ǯȱ ˜ȱ–ŽŠœž›Ž–Ž—œȱœ‘˜ž•ȱ‹ŽȱŠ”Ž—ȱ
(perpendicular to each other) at each of the three
locations.
Clean Cylinder Bore after Honing
Proper cleaning of the cylinder walls following honing
’œȱŒ›’’ŒŠ•ǯȱ ›’ȱ•ŽĞȱ’—ȱ‘ŽȱŒ¢•’—Ž›ȱ‹˜›ŽȱŒŠ—ȱŽœ›˜¢ȱ
Š—ȱŽ—’—Žȱ’—ȱ•Žœœȱ‘Š—ȱ˜—Žȱ‘˜ž›ȱ˜ȱ˜™Ž›Š’˜—ȱŠĞŽ›ȱŠȱ
rebuild.
‘Žȱꗊ•ȱŒ•ŽŠ—’—ȱ˜™Ž›Š’˜—ȱœ‘˜ž•ȱŠ• Š¢œȱ‹ŽȱŠȱ
thorough scrubbing with a brush and hot, soapy
water. Use a strong detergent that is capable of
breaking down the machining oil while maintaining
a good level of suds. If the suds break down during
cleaning, discard the dirty water and start again
with more hot water and detergent. Following the
scrubbing, rinse the cylinder with very hot, clear
water, dry it completely, and apply a light coating of
engine oil to prevent rusting.
Section 9
Inspection and Reconditioning
Measuring Piston-to-Bore Clearance
Before installing the piston into the cylinder bore, it
is necessary that the clearance be accurately checked.
‘’œȱœŽ™ȱ’œȱ˜ĞŽ—ȱ˜ŸŽ›•˜˜”ŽǰȱŠ—ȱ’ȱ‘ŽȱŒ•ŽŠ›Š—ŒŽœȱŠ›Žȱ
—˜ȱ ’‘’—ȱœ™ŽŒ’ęŒŠ’˜—œǰȱŽ—’—ŽȱŠ’•ž›Žȱ ’••ȱžœžŠ••¢ȱ
result.
NOTE: Do not use a feeler gauge to measure piston-
to-bore clearance – it will yield inaccurate
measurements. Always use a micrometer.
Use the following procedure to accurately measure
the piston-to-bore clearance:
1. Use a micrometer and measure the diameter of
the piston perpendicular to the piston pin, up
8 mm (0.314 in.)ȱ›˜–ȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ™’œ˜—ȱ
skirt as indicated in Figure 9-3.
Measure 8 mm (0.314 in.) Above the Bottom of
Piston Skirt at Right Angles to Piston Pin.
8 mm (0.314 in.)
Figure 9-3. Measuring Piston Diameter.
2. Use an inside micrometer, telescoping gauge, or
bore gauge and measure the cylinder bore. Take
the measurement approximately 63.5 mm 9
(2.5 in.) below the top of the bore and
perpendicular to the piston pin.
3. Piston-to-bore clearance is the piston diameter
subtracted from the bore diameter (step 2 minus
step 1).
Balance Weight Assembly
The balance weight assembly counterbalances
‘ŽȱŒ›Š—”œ‘ŠĞȱ Ž’‘œȱŠ—ȱ’—Ž›—Š•ȱ˜›ŒŽœȱž›’—ȱ
operation to minimize vibration. Several key areas of
the balance weight must be checked before installation
and use. Additionally, the mating components
ǻŒ›Š—”œ‘ŠĞȱŽŒŒŽ—›’ŒœȱŠ—ȱŒ•˜œž›Žȱ™•ŠŽȱž’ŽȱŒ‘Š——Ž•Ǽȱ
must also be inspected for wear or damage.
Use the following procedure to check the balance
weight and matching components.
9.3
Section 9
Inspection and Reconditioning
Balance Weight-to-Eccentric Clearance
Before the balance weight assembly is reassembled to
‘ŽȱŒ›Š—”œ‘ŠĞǰȱ‘Žȱ›ž——’—ȱŒ•ŽŠ›Š—ŒŽȱ˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ
eccentrics must be accurately checked. Failure
to maintain the required clearances will result in
vibration or engine failure.
NOTE: Do not use a feeler gauge to measure balance
weight-to-eccentric clearance.
Measuring Balance Weight to Crankshaft
Eccentric Ring(s) Clearance
1. Use an inside micrometer, telescoping gauge,
or bore gauge and measure the inside diameter
of the balance weight bearing surface. Take two
measurements 90° to each other on each weight.
See Figure 9-4.
Figure 9-4. Measuring Balance Weight Bearing
Surface.
2. Then use an outside micrometer and measure
ŠŒ›˜œœȱŽŠŒ‘ȱŽŒŒŽ—›’Œȱ˜—ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯȱŠ’—ȱ
take two measurements 90° to each other. See
Figure 9-5.
Figure 9-5. Measuring Crankshaft Eccentric.
9.4
3. The running clearance is the eccentric
diameter subtracted from the balance weight
bearing diameter (step 1 minus step 2). If
the measurements are outside the maximum
 ŽŠ›ȱ•’–’œȱ•’œŽȱ’—ȱŽŒ’˜—ȱŗǰȱ‘ŽȱŠěŽŒŽȱ
component(s) must be replaced.
Measuring Balance Weight Guide Pin and Guide
Shoe-to-Closure Plate Guide Channel Running
Clearance
1. Use an outside micrometer and measure the
outside width of the balance weight guide shoe.
See Figure 9-6.
Figure 9-6. Measuring Balance Weight Guide Shoe.
2. Use an inside micrometer, telescoping gauge or
similar tool and measure the width of the guide
channel in the closure plate. See Figure 9-7.
Record these dimensions.
Figure 9-7. Measuring Guide Channel in Closure
Plate.
 Section 9
Inspection and Reconditioning

3. Use an outside micrometer again and measure Flywheel

the O.D. of the balance weight guide pin. See
Figure 9-8.
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
‘ŽȱĚ¢ ‘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

Inspect the ring gear for cracks or damage. Ring gears

Š›Žȱ—˜ȱŠŸŠ’•Š‹•ŽȱœŽ™Š›ŠŽ•¢ǯȱŽ™•ŠŒŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ’ȱ‘Žȱ
ring gear is damaged.

Figure 9-8. Measuring Guide Pin O.D.

4. Use a split ball gauge or dial calipers and

measure the I.D. of the corresponding hole in
the guide shoe. See Figure 9-9. Record these
dimensions.

Figure 9-9. Measuring Guide Shoe Hole I.D.

If any of the measurements taken are outside the

–Š¡’–ž–ȱ ŽŠ›ȱ•’–’œȱ•’œŽȱ’—ȱŽŒ’˜—ȱŗǰȱ‘ŽȱŠěŽŒŽȱ
component(s) must be replaced.

9.5
Section 9
Inspection and Reconditioning

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‘ŽŒ”ȱ‘Žȱ
›ž——’—ȱŒ•ŽŠ›Š—ŒŽȱ‹Ž ŽŽ—ȱ‘ŽȱŸŠ•ŸŽȱœŽ–œȱŠ—ȱž’ŽœǯȱŽŽȱ’ž›ŽȱşȬŗŖȱ˜›ȱŸŠ•ŸŽȱŽŠ’•œȱŠ—ȱœ™ŽŒ’ęŒŠ’˜—œǯ

Exhaust Valve E E Intake Valve

A
D A
D
F F

G G

B B
C C

Dimension Intake Exhaust

A Seat Angle 89° 89°
B Guide Depth 10.20 mm 6.2 mm
C Guide I.D. 6.038/6.058 mm 6.038/6.058 mm
D Š•ŸŽȱ
ŽŠȱ’Š–ŽŽ› 37.625/37.375 mm 32.125/32.375 mm
E Valve Face Angle 45° 45°
F Valve Margin (Min.) 1.5 mm 1.5 mm
G Valve Stem Diameter 5.982/6.000 mm 5.970/5.988 mm
Figure 9-10. Valve Details.

9.6
 Section 9
Inspection and Reconditioning

Š›ȱœŠ›’—ǰȱ˜›ȱ•˜œœȱ˜ȱ™˜ Ž›ȱŠŒŒ˜–™Š—’Žȱ‹¢ȱ‘’‘ȱžŽ•ȱŒ˜—œž–™’˜—ǰȱ–Š¢ȱ‹Žȱœ¢–™˜–œȱ˜ȱŠž•¢ȱŸŠ•ŸŽœǯȱ
•‘˜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
defects such as warped head, excessive corrosion, or worn stem end. Replace valves found to be in bad condition.
A normal valve and valves in bad condition are shown in the accompanying illustrations.

Normal:ȱŸŽ—ȱŠĞŽ›ȱ•˜—ȱ‘˜ž›œȱ˜ȱ˜™Ž›Š’˜—ȱŠȱŸŠ•ŸŽȱ Leakage: A poor grind on a valve face or seat will

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

9.7
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.
9.8
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
normal operating temperatures. Replace corroded
valves.
Overheating: An exhaust valve subject to overheating
will have a dark discoloration in the area above the
valve guide. Worn guides and faulty valve springs
may cause this condition. Also check for clogged air
’—Š”ŽǰȱŠ—ȱ‹•˜Œ”Žȱꗜȱ ‘Ž—ȱ‘’œȱŒ˜—’’˜—ȱ’œȱ—˜Žǯ

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,
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
clearance exceeds 0.038/0.076 mm (0.0015/0.0030 in.) or
the exhaust clearance exceeds 0.050/0.088 mm
(0.0020/0.0035 in.), determine whether the valve stem
or guide is responsible for the excessive clearance.
Maximum (I.D.) wear on the intake valve guide is
6.135 mm (0.2415 in.) while 6.160 mm (0.2425 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
Š›Ž—ŽȱœŽŽ•ȱŠ••˜¢ȱ’—Š”ŽȱŠ—ȱŽ¡‘ŠžœȱŸŠ•ŸŽȱ
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.
Recondition the valve seat inserts following the
’—œ›žŒ’˜—œȱ™›˜Ÿ’Žȱ ’‘ȱ‘ŽȱŸŠ•ŸŽȱœŽŠȱŒžĴŽ›ȱ‹Ž’—ȱ
žœŽǯȱȱ¢™’ŒŠ•ȱŒžĴŽ›ȱ’œȱœ‘˜ —ȱ’—ȱ’ž›ŽȱşȬŗŗǯȱ‘Žȱꗊ•ȱ
Œžȱœ‘˜ž•ȱ‹Žȱ–ŠŽȱ ’‘ȱŠ—ȱŞşǚȱŒžĴŽ›ȱŠœȱœ™ŽŒ’ꮍȱ˜›ȱ
the valve seat angle in Figure 9-10. With the proper 45°
valve face angle, and the valve seat cut properly (44.5°
as measured from centerline when cut 89°) 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.
’‘ȱ˜’•ȱ
Section 9
Inspection and Reconditioning
Valve Seat Cutter
Pilot
Figure 9-11. Typical Valve Seat Cutter.
Lapping Valves
Reground or new valves must be lapped in, to provide
a good seal. Use a hand valve grinder with suction
Œž™ȱ˜›ȱꗊ•ȱ•Š™™’—ǯȱ’‘•¢ȱŒ˜ŠȱŸŠ•ŸŽȱŠŒŽȱ ’‘ȱꗎȱ
grade of grinding compound, then rotate valve on seat
with grinder. Continue grinding until smooth surface
is obtained on seat and on valve face. Thoroughly
clean cylinder head in soap and hot water to remove
Š••ȱ›ŠŒŽœȱ˜ȱ›’—’—ȱŒ˜–™˜ž—ǯȱЎ›ȱ›¢’—ȱŒ¢•’—Ž›ȱ
head, apply a light coating of engine oil to prevent
rusting.
Pistons and Rings
Inspection
ŒžĜ—ȱŠ—ȱœŒ˜›’—ȱ˜ȱ™’œ˜—œȱŠ—ȱŒ¢•’—Ž›ȱ Š••œȱ
occurs when internal temperatures approach the
welding point of the piston. Temperatures high
enough to do this are created by friction, which is
žœžŠ••¢ȱŠĴ›’‹žŽȱ˜ȱ’–™›˜™Ž›ȱ•ž‹›’ŒŠ’˜—ǰȱŠ—Ȧ˜›ȱ
overheating of the engine. 9
˜›–Š••¢ǰȱŸŽ›¢ȱ•’Ĵ•Žȱ ŽŠ›ȱŠ”Žœȱ™•ŠŒŽȱ’—ȱ‘Žȱ™’œ˜—ȱ
boss-piston pin area. If the original piston and
Œ˜——ŽŒ’—ȱ›˜ȱŒŠ—ȱ‹Žȱ›ŽžœŽȱŠĞŽ›ȱ—Ž ȱ›’—œȱŠ›Žȱ
installed, the original pin can also be reused, but new
piston pin retainers are required. The piston pin is part
of the piston assembly; if the pin boss or the pin are
worn or damaged, a new piston assembly is required.
Ring failure is usually indicated by excessive oil
consumption and blue exhaust smoke. When rings
fail, oil is allowed to enter the combustion chamber
 ‘Ž›Žȱ’ȱ’œȱ‹ž›—ŽȱŠ•˜—ȱ ’‘ȱ‘ŽȱžŽ•ǯȱ
consumption can also occur when the piston ring
end gap is incorrect because the ring cannot properly
conform to the cylinder wall under this condition. Oil
control is also lost when ring gaps are not staggered
during installation.
9.9
Section 9
Inspection and Reconditioning
When cylinder temperatures get too high, lacquer and Replacement pistons are available in STD and 0.08
varnish collect on pistons causing rings to stick which mm (0.003 in.) oversize, which include new rings and
results in rapid wear. A worn ring usually takes on a piston pins. Service replacement piston ring sets are
shiny or bright appearance. also available separately. Always use new piston rings
when installing pistons. Never reuse old rings.
Scratches on rings and pistons are caused by abrasive
material such as carbon, dirt, or pieces of hard metal. The cylinder bore must be deglazed before service
ring sets are used.
Detonation damage occurs when a portion of the fuel
charge ignites spontaneously from heat and pressure
œ‘˜›•¢ȱŠĞŽ›ȱ’—’’˜—ǯȱ‘’œȱŒ›ŽŠŽœȱ ˜ȱ̊–Žȱ›˜—œȱ
that meet and explode to create extreme hammering
™›Žœœž›Žœȱ˜—ȱŠȱœ™ŽŒ’ęŒȱŠ›ŽŠȱ˜ȱ‘Žȱ™’œ˜—ǯȱŽ˜—Š’˜—ȱ
generally occurs from using low octane fuels.

Preignition or ignition of the fuel charge before the

timed spark can cause damage similar to detonation.
›Ž’—’’˜—ȱŠ–ŠŽȱ’œȱ˜ĞŽ—ȱ–˜›ŽȱœŽŸŽ›Žȱ‘Š—ȱ
detonation damage. Preignition is caused by a hot
spot in the combustion chamber from sources such
Šœȱ•˜ ’—ȱŒŠ›‹˜—ȱŽ™˜œ’œǰȱ‹•˜Œ”Žȱꗜǰȱ’–™›˜™Ž›•¢ȱ
seated valve, or wrong spark plug. See Figure 9-12 for
some common types of piston and ring damage.

Stuck, Broken Rings Abrasive Scratched Rings

Overheated or Deteriorated Oil Scored Piston and Rings

Figure 9-12. Common Types of Piston and Ring Damage.

9.10
 Section 9
Inspection and Reconditioning

Some important points to remember when servicing

piston rings:

1. If the cylinder bore is within the wear limits (refer

to Section 1) and the old piston is within wear
•’–’œǰȱ›ŽŽȱ˜ȱœŒ˜›Žȱ˜›ȱœŒžěȱ–Š›”œǰȱ‘Žȱ˜•ȱ™’œ˜—ȱ
may be reused.

2. Remove old rings and clean up grooves. Never

reuse old rings.

3. Before installing the rings on the piston, place

each of the top two rings in its running area in the
cylinder bore and check the end gap (see Figure
şȬŗřǼǯȱ˜–™Š›Žȱ˜ȱ‘Žȱ•’œŽȱœ™ŽŒ’ęŒŠ’˜—œǯ
Top and Middle Compression Ring End Gap
New Bore
Top Ring..................... 0.15/0.40 mm (0.006/0.016 in.)
Middle Ring............... 0.30/0.55 mm (0.012/0.022 in.)
Max. Used Bore.........0.77 mm (0.030 in.)
Figure 9-14. Measuring Piston Ring Side
Clearance.
Install Piston Rings
To install piston rings, proceed as follows:
NOTE: Rings must be installed correctly. Ring
installation instructions are usually included
with new ring sets. Follow instructions
carefully. Use a piston ring expander to
’—œŠ••ȱ›’—œǯȱ—œŠ••ȱ‘Žȱ‹˜Ĵ˜–ȱǻ˜’•ȱŒ˜—›˜•Ǽȱ
›’—ȱꛜȱŠ—ȱ‘Žȱ˜™ȱŒ˜–™›Žœœ’˜—ȱ›’—ȱ•Šœǯȱ
Refer to Figure 9-15.

Piston Ring

End Gap

,GHQWL¿FDWLRQ
Mark
Figure 9-13. Measuring Piston Ring End Gap. 9
ȱ Śǯȱ Ў›ȱ’—œŠ••’—ȱ‘Žȱ—Ž ȱŒ˜–™›Žœœ’˜—ȱǻ˜™ȱŠ—ȱ
middle) rings on the piston, check piston-to-ring Piston
side clearance. The maximum recommended side
clearance for each ring is 0.04 mm (0.0016 in.). If Top Compression
‘Žȱœ’ŽȱŒ•ŽŠ›Š—ŒŽȱ’œȱ›ŽŠŽ›ȱ‘Š—ȱœ™ŽŒ’ꮍǰȱŠȱ—Ž ȱ Ring
piston must be used. Refer to Figure 9-14.
Center Compression
Top Compression Ring-to-Groove Ring
Side Clearance ................................0.04 mm (0.0016 in.)
Rails
Middle Compression Ring-to-Groove
Side Clearance ............................... 0.04 mm (0.0016 in.)
Expander
Oil Control Ring
(Three Piece)
Figure 9-15. Piston Ring Installation.

9.11
Section 9
Inspection and Reconditioning
ȱ ŗǯȱ ’•ȱ˜—›˜•ȱ’—ȱǻ˜Ĵ˜–ȱ ›˜˜ŸŽǼDZȱ—œŠ••ȱ‘Žȱ
Oil Passages
expander and then the rails. Make sure the ends
of the expander are not overlapped.

2. Compression Ring (Center Groove): Install the

center ring using a piston ring installation tool.
Š”Žȱœž›Žȱ‘Žȱ’Ž—’ęŒŠ’˜—ȱ–Š›”ȱ’œȱž™ȱ ‘Ž—ȱ‘Žȱ
ring is installed.

3. Compression Ring (Top Groove): Install the top

ring using a piston ring installation tool. Make
œž›Žȱ‘Žȱ’Ž—’ęŒŠ’˜—ȱ–Š›”ȱ’œȱž™ȱ ‘Ž—ȱ‘Žȱ›’—ȱ
is installed.

Figure 9-16. Oil Passages in Closure Plate.

Connecting Rods

Inspection and Service

Check the bearing area (big end) for score marks and
excessive wear (measure running and side clearances;
refer to Section 1. Service replacement connecting rods
are available in STD crankpin size.

Oil Pump Assembly and Pressure Relief

Valve
Oil Passages
Inspection and Service
The closure plate must be removed to inspect and
service the oil pump. Refer to the Disassembly and
Reassembly Sections (8 and 10) for removal and
reinstallation procedures. Check the oil pump and
gears for cracks, damage, wear, and smooth rotation. Figure 9-17. Oil Passages in Passage Cover.
Replace the pump if any binding is noted or reuse is
questionable in any way. Use a new passage cover gasket and install the passage
cover onto the closure plate. Reinstall the six mounting
A pressure relief valve is built into the oil pump to screws and torque to 4.0 N·m (35 in. lb.), following the
limit maximum pressure. It is not serviceable. If a sequence in Figure 9-18.
problem exists with the pressure relief valve, the oil
pump assembly should be replaced.

Closure Plate and Passage Cover 4

2
5
1
Inspection and Service
If disassembly was performed, inspect and ensure the
oil passages in the closure plate and the passage cover
are completely clean and not obstructed in any way.
See Figures 9-16 and 9-17. Check straightness of the
6
™ŠœœŠŽȱŒ˜ŸŽ›ȱ’ȱ›Žšž’›ŽǰȱŠŠ’—œȱŠȱ̊ȱœž›ŠŒŽǯ
3

Figure 9-18. Torque Sequence for Passage Cover.

9.12

Governor Gear and Shaft
Inspection
Inspect the governor gear teeth. Look for any evidence
of worn, chipped, or cracked teeth. If one or more of
these problems is noted, replace the governor gear.
‘ŽȱŽŠ›ȱ’œȱ‘Ž•ȱ˜—ȱ‘Žȱ˜ŸŽ›—˜›ȱœ‘ŠĞȱ‹¢ȱ–˜•ŽȱŠ‹œǰȱ
which are damaged when the gear is removed. Never
›ŽžœŽȱ‘ŽȱŽŠ›ȱ˜—ŒŽȱ’ȱ‘Šœȱ‹ŽŽ—ȱ™ž••Žȱ›˜–ȱ‘Žȱœ‘ŠĞǯȱ
Ž™•ŠŒŽȱ‘Žȱ˜ŸŽ›—˜›ȱœ‘ŠĞȱ˜—•¢ȱ’ȱ’ȱ’œȱŠ–ŠŽȱ˜›ȱ
worn.
Procedure to Remove Governor Shaft:
ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‹•˜ Ž›ȱ‘˜žœ’—ǰȱĚ¢ ‘ŽŽ•ǰȱŠ—ȱ
cooling fan.
ȱ Řǯȱ Ž–˜ŸŽȱ‘ŽȱœŠ˜›ȱŠ—ȱŒ›Š—”œ‘ŠĞȱ”Ž¢ǯ
3. Remove the closure plate screws and closure
plate.
4. Rotate engine to top dead center aligning timing
–Š›”œȱ˜—ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ—ȱŒŠ–ȱŽŠ›œǯ
5. Remove the governor gear assembly and
regulating pin from the closure plate with two
small screwdrivers.
ȱ Ŝǯȱ ˜ŒŠŽȱ‘Žȱ˜ŸŽ›—˜›ȱ™’—ȱ›˜–ȱĚ¢ ‘ŽŽ•ȱœ’Žǯȱ’‘ȱ
a small punch, drive the pin out of the closure
plate. This could also be done with a press. DO
NOT remove the governor pin with a vise grip or
pliers, you may damage the closure plate.
7. Remove any old gasket material from the mating
surfaces of the crankcase and closure plate. Use
an aerosol gasket remover to help loosen any old
gasket material. Do not scrape the surfaces, as
any scratches, nicks, or burrs can result in leaks.
Section 9
Inspection and Reconditioning
Procedure to Install Governor Shaft:
1. Install new pin by pressing or lightly tapping it
into the closure plate. It must be installed so that
it protrudes 44.50 mm (1.750 in.), plus or minus
0.101 mm (0.004 in.) above the crankcase boss.
See Figure 9-19.
Governor Gear
Shaft
44.50 mm
(1.750 in.)*
*To Gasket Surface - Before Oil Passage
Cover Plate and Gasket are Assembled
Figure 9-19. Governor Shaft Press Depth.
2. Install the new governor regulating pin and
governor gear assembly.
3. Make sure governor gear assembly rotates freely.
4. Check that timing marks are still aligned.
5. Install a new closure plate gasket and install the
closure plate. Refer to Section 10, Reassembly for
™›˜™Ž›ȱ˜›šžŽȱœŽšžŽ—ŒŽȱŠ—ȱœ™ŽŒ’ęŒŠ’˜—ǯ
6. Complete engine reassembly following
Reassembly procedures.
9
7. When engine reassembly is completed,
reset initial governor adjustment according
to procedure in Section 5, Fuel System and
Governor.
9.13
 Section 10
Reassembly

Section 10
Reassembly

The following sequence is suggested for complete 13. Assemble cylinder head.
engine reassembly. This procedure assumes that all 14. Install cylinder head.
components are new or have been reconditioned, and 15. Install rocker arms and push rods.
all component subassembly work has been completed. 16. Install valve cover.
This procedure may be varied to accommodate 17. Install stator and wiring harness.
options or special equipment. ŗŞǯȱ —œŠ••ȱĚ¢ ‘ŽŽ•ȱŠ—ȱŠ—ǯ
19. Install electric starter.
NOTE: Make sure the engine is assembled using 20. Install ignition module.
Š••ȱœ™ŽŒ’ꮍȱ˜›šžŽȱŸŠ•žŽœǰȱ’‘Ž—’—ȱ 21. Install spark plug.
sequences, and clearances. Failure to observe ŘŘǯȱ —œŠ••ȱ‘ŽŠȱŽĚŽŒ˜›ǰȱŒŠ›‹ž›Ž˜›ǰȱ•’—”ŠŽǰȱŠ—ȱŠ’›ȱ
œ™ŽŒ’ęŒŠ’˜—œȱŒ˜ž•ȱŒŠžœŽȱœŽŸŽ›ŽȱŽ—’—Žȱ ŽŠ›ȱ cleaner base.
or damage. 23. Install and adjust governor lever, mounting speed
control bracket.
NOTE: Always use new gaskets. ŘŚǯȱ —œŠ••ȱžŽ•ȱ™ž–™ȱǻœ˜–Žȱ–˜Ž•œǼǯ
Řśǯȱ —œŠ••ȱ›ŽŒ’ꎛȬ›Žž•Š˜›ǯ
NOTE: Make sure all components have been ŘŜǯȱ —œŠ••ȱ‹•˜ Ž›ȱ‘˜žœ’—ȱŠ—ȱĚ¢ ‘ŽŽ•ȱœŒ›ŽŽ—ǯ
properly cleaned BEFORE reassembly. 27. Install Oil Sentry™ switch or pipe plug.
28. Install air cleaner element, precleaner and air
NOTE: Apply a small amount of oil to the threads cleaner cover.
of critical fasteners before assembly, unless a Řşǯȱ —œŠ••ȱ–žĝŽ›ǯ
ŽŠ•Š—ȱ˜›ȱ˜Œ’Žțȱ’œȱœ™ŽŒ’ꮍȱ˜›ȱ™›ŽŠ™™•’Žǯ
Install PTO Side Oil Seal
Typical Reassembly Sequence 1. Use a seal driver and install to a depth of 5.5 mm
The following sequence is suggested for complete (0.216 in.)ȱ’—˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱŽŽȱ’ž›ŽœȱŗŖȬŗȱ
engine reassembly. This procedure assumes that all Š—ȱŗŖȬŘǯ
components are new or have been reconditioned, and
all component subassembly work has been completed.
The sequence may vary to accommodate options or
special equipment. Detailed procedures follow:
10
1. Install PTO side oil seal.
ȱ Řǯȱ —œŠ••ȱ˜ŸŽ›—˜›ȱŒ›˜œœȱœ‘ŠĞǯȱ
ȱ řǯȱ —œŠ••ȱ˜’•ȱ™ž–™ȱŠ—ȱ’—Š”ŽȱŒŠ–ȱœ‘ŠĞȱŠœœŽ–‹•¢ǯ
ȱ Śǯȱ —œŠ••ȱŒ›Š—”œ‘ŠĞȱŠ—ȱ‹Š•Š—ŒŽȱ Ž’‘ǯ
5. Install piston rings.
6. Install piston to connecting rod.
ȱ ŝǯȱ —œŠ••ȱ™’œ˜—ȱŠ—ȱ›˜ȱ˜ȱŒ›Š—”œ‘ŠĞǯ
8. Install cam levers.
ȱ şǯȱ —œŠ••ȱŽ¡‘ŠžœȱŒŠ–ȱœ‘ŠĞǰȱŒŠ–ȱŽŠ›ȱŠ—ȱǯ
10. Install intake cam gear.
ŗŗǯȱ —œŠ••ȱ˜’•ȱœŽŠ•ȱ’—˜ȱŒ•˜œž›Žȱ™•ŠŽȱǻĚ¢ ‘ŽŽ•ȱœ’ŽǼǯ Figure 10-1. Installing PTO Side Oil Seal.
12. Install closure plate gasket, closure plate and
wiring harness.

10.1
Section 10
Reassembly

Hitch Pin

Oil Seal
Thick Washer

Figure 10-4. Securing Governor Shaft.

Seal Depth
5.5 mm (0.216 in.)
Install Oil Pump Assembly and Intake
Cam Shaft
Figure 10-2. PTO Seal Depth Details.
Install Governor Cross Shaft
1. Place the thin thrust washer onto the governor
Œ›˜œœȱœ‘ŠĞȱŠœȱŠ›ȱŠœȱ’ȱ ’••ȱ˜ǯȱ
ȱ Řǯȱȱ ’‘•¢ȱ•ž‹›’ŒŠŽȱ‘Žȱœ‘ŠĞȱ ’‘ȱ˜’•ǰȱŠ—ȱ’—œŠ••ȱ’ȱ
›˜–ȱ’—œ’Žȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱŽŽȱ’ž›ŽȱŗŖȬřǯ
Thin Washer
1. If the oil pump assembly was removed from the
’—Š”ŽȱŒŠ–ȱœ‘ŠĞǰȱ›ŽŠœœŽ–‹•Žȱ’ȱ˜—˜ȱ‘Žȱœ‘ŠĞǯȱ‘Žȱȱ
™›Žœœȱęȱ˜ȱ‘Žȱ›’ŸŽȱ™’—œȱ’—ȱ‘Žȱ‘˜•Žœȱ–Š¢ȱ‹Žȱ˜—Žȱ
of two designs. One style of tube has drive pin
‘˜•Žœȱ–ŠŒ‘’—Žȱ˜ȱ‹ŽȱŠȱŒ•ŽŠ›Š—ŒŽȱǻœ•’™Ǽȱęȱ˜—ȱ˜—Žȱ
œ’ŽȱŠ—ȱŠȱ™›Žœœȱęȱ˜—ȱ‘Žȱ˜‘Ž›ȱŠŒŒŽ™’—ȱsmooth
style drive pins. Later design tubes have holes
uniformly machined and use knurled style drive
™’—œǯȱž™™˜›ȱ‘ŽȱŒŠ–ȱœ‘ŠĞȱǻŒ•ŽŠ›Š—ŒŽȱ‘˜•ŽœȱȈž™Ȉǰȱ
 ‘Ž—ȱŠ™™•’ŒŠ‹•ŽǼǰȱŠ—ȱ’—œŠ••ȱ‘Žȱœ‘˜›Ž›ȱ2.5 mm
(0.098 in.) diameter pin in the outer hole, closest
˜ȱ‘Žȱ‹˜Ĵ˜–ȱŽ—ǯȱŽŽȱ’ž›ŽœȱŗŖȬśȱŠ—ȱŗŖȬŜǯȱ
Ž—Ž›ȱ‘Žȱ™’—ȱ’—ȱ‘Žȱœ‘ŠĞǯ

Intake
Cam
Oil Pump Shaft

Governor
Shaft

Pin In
Figure 10-3. Installing Governor Cross Shaft. Outermost
Hole
ȱ řǯȱ •’Žȱ‘Žȱ‘’Œ”ȱ‘›žœȱ Šœ‘Ž›ȱ˜—˜ȱ‘Žȱœ‘ŠĞȱ›˜–ȱ
the outside as far as it will go. Secure by inserting
the hitch pin in the machined groove. See Figure
ŗŖȬŚǯ Figure 10-5. Installing Oil Pump and Lower Drive
Pin on Intake Cam Shaft.

10.2
 Section 10
Reassembly
drilled for lower bearing lubrication. Both styles
˜ȱ˜ž•ŽȱœŽŠ•œȱŠ›Žȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŗŖȬşǯȱȱŠȱ—Ž ȱ
6 5 seal is to be ordered, be sure it is the same style
as the one that was taken out. Lightly lubricate
the ends of the oil pump outlet seal with oil and
1 install in into the outlet of the oil pump. See
2 4
’ž›ŽȱŗŖȬŗŖǯ

Figure 10-6. Assembled Intake Cam Shaft Details. Open Seal Closed Seal

ȱ ȱ ŗǯȱ —Š”ŽȱŠ–ȱ‘ŠĞ Figure 10-8. Pump Outlet Seals.

2. 3 mm Diameter Pin
3. Oil Pump Assembly Open Outlet Style
4. 2.5 mm Diameter Pin (Requires Seal) Closed Outlet Style
5. #1 Hole Location
6. #2 Hole Location

2. If it was removed, install and center the longer,

3 mm diameter drive pin into the upper hole (See
’ž›ŽȱŗŖȬŜǼǯ

3. Lightly grease the gerotor gears and install into Figure 10-9. Oil Pump Outlet Styles.
‘Žȱ˜’•ȱ™ž–™ǰȱ ’‘ȱ‘Žȱœ‘˜›ȱ›’ŸŽȱ™’—ȱęĴŽȱ’—˜ȱ
‘Žȱœ•˜ȱ˜ȱ‘Žȱ’——Ž›ȱŽŠ›ǯȱŽŽȱ’ž›ŽȱŗŖȬŝǯ

Pump Outlet Seal 10

Figure 10-10. Installing Oil Pump Outlet Seal.

Figure 10-7. Gerotor Gears Installed in Oil Pump.

4. Determine if the outlet of the oil pump is open or

closedǯȱŽŽȱ’ž›ŽȱŗŖȬşǯȱȱ‘Žȱopen style pumps
require the use of a rubber seal between the
pump outlet and lower main bearing area. See
’ž›ŽȱŗŖȬŞǯȱ˜–Žȱ–˜Ž•œȱžœŽȱŠ—ȱopen style seal
with an internal passage to feed oil to the lower
bearing. Some models use a closed seal without
Š—ȱ˜’•ȱ™ŠœœŠŽǰȱŠ—ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ’œȱŒ›˜œœŽȬ

10.3
Section 10
Reassembly
ȱ śǯȱ —œŠ••ȱ‘Žȱ’—Š”ŽȱŒŠ–ȱœ‘ŠĞȱ˜ —ȱ’—˜ȱ‘Žȱ 6. If the engine uses a drain back tube, insert the
crankcase boss. Seat the rubber oil pump outlet ›˜ž—ȱ̊—ŽȱŽ—ȱ’—˜ȱ‘Žȱ‘˜•Žȱ—ŽŠ›ȱ‹ŠœŽȱ˜ȱ
seal into the machined pocket. If an open style cylinder and clip it onto the oil pump body. See
outlet seal is used, check to make sure the small ’ž›ŽȱŗŖȬŗřǯ
feed hole is open and aligned with the lower
main bearing oil feed hole. Use a 3/32” allen
 ›Ž—Œ‘ǰȱ˜›ȱŠȱ•’‘ȱ ’‘ȱŠȱ–’››˜›ǯȱŽŽȱ’ž›ŽȱŗŖȬŗŗǯȱ Drain Back Tube
Push the steel sleeves in the pump housing down
ž—’•ȱ‹˜Ĵ˜–ŽȱŠŠ’—œȱ‘Žȱ–˜ž—’—ȱœž›ŠŒŽǯȱ
Install the two M5 mounting screws. Hold the
pump outlet against the main bearing area and
torque the screws to 6.2 N·m (55 in. lb.) into new
as case holes or 4.0 N·m (35 in. lb.) into used
‘˜•ŽœǯȱŽŽȱ’ž›ŽȱŗŖȬŗŘǯ

Oil Pump
3/32" Allen Wrench

Figure 10-13. Installing Drain Back Tube (Some

Models).

Install Crankshaft and Balance Weight

ȱ ŗǯȱ œœŽ–‹•Žȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ‹Š•Š—ŒŽȱ Ž’‘ȱ’ȱ
›Ž–˜ŸŽȱ›˜–ȱ‘ŽȱŒ›Š—”œ‘ŠĞǯ

ȱ ȱ Šǯȱ ž‹›’ŒŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŽŒŒŽ—›’ŒœȱŠ—ȱ‘Žȱȱ
balance weight bearing surfaces with oil.

b. Install the two balance weight halves onto the

Figure 10-11. Checking Outlet Seal Passage ȱ Œ›Š—”œ‘ŠĞȱŽŒŒŽ—›’ŒœȱŠœȱ–Š›”Žȱ˜›ȱ˜›’’—Š••¢ȱȱ
Opening (Open Style). installed.

Engines Serial No. 361805213 and Below:

c. Align the weights and install the balance
Intake Tube weight screw, through the mounting holes,
from the PTO side. Thread it into the guide
ȱ ™’—ȱ˜žœ’Žȱ‘Žȱ Ž’‘ȱ˜—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱœ’Žǯȱȱ
Hold the guide pin with a wrench or Torx bit,
and torque the screw to 11.3 N·m (100 in. lb.).
ȱ ŽŽȱ’ž›ŽȱŗŖȬŗŚǯȱ˜ȱ—˜ȱ‘˜•ǰȱ˜›ȱŠ–ŠŽȱ‘Žȱȱ
ȱ ˜žœ’Žȱ’Š–ŽŽ›ȱǻǯǯǼȱ˜ȱ‘Žȱž’Žȱ™’—ǯ
Oil Pump

Oil Passage Seal

Figure 10-12. Torquing Oil Pump Mounting
Screws.

10.4
 Section 10
Reassembly

ȱ Řǯȱ Š›Žž••¢ȱ’—œŠ••ȱŒ›Š—”ȱŽŠ›ȱ”Ž¢ȱ’—ȱ”Ž¢ Š¢ǯȱȱ ȱ
ŽŽȱ’ž›ŽȱŗŖȬŗŜǯ

PTO Side
Crank Gear Key

Guide Pin

Figure 10-14. Assembling Balance Weight to

Crankshaft (Guide Shoe Design).
Figure 10-16. Installing Crank Gear Key.
Engines Serial No. 3618005223 and Above:
c. Align the weights and insert the balance Engines Serial No. 3618005213 and below:
weight screw, through the mounting holes ȱ řǯȱ Š›Žž••¢ȱ’—œŠ••ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ’—˜ȱŒ›Š—”ŒŠœŽǰȱ
ȱ ›˜–ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱœ’Žǯȱ‘›ŽŠȱ’ȱ’—˜ȱ‘Žȱȱ through the PTO seal, and seat fully into place.
guide pin outside the weight on the PTO side. ˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱœ˜ȱ‘Šȱ‘Žȱ“˜ž›—Š•ȱ˜›ȱ‘Žȱ
Hold the guide pin with a wrench or Torx bit, connecting rod is away from the cylinder. See
and torque the screw to 11.3 N·m (100 in. lb.). ’ž›ŽœȱŗŖȬŗŝǯ
ȱ ŽŽȱ’ž›ŽȱŗŖȬŗśǯȱ˜ȱ—˜ȱ‘˜•ǰȱ˜›ȱŠ–ŠŽȱ‘Žȱȱ
ȱ ˜žœ’Žȱ’Š–ŽŽ›ȱǻǯǯǼȱ˜ȱ‘Žȱž’Žȱ™’—ǯȱȱ
ȱ ™™•¢ȱ›ŽŠœŽȱ˜ȱ‘Žȱ’——Ž›ȱ’Š–ŽŽ›ȱǻǯǯǼȱ˜ȱ
each hole in control link and install one end
over the guide pin.

Figure 10-17. Installing Crankshaft Assembly

(Before Serial No. 3618005213). 10
4. Install the balance weight guide shoe onto
the guide pin with the solid end toward the
Œ›Š—”œ‘ŠĞǯȱŽŽȱ’ž›ŽȱŗŖȬŗŞǯ
Figure 10-15. Assembling Balance Weight to
Crankshaft (Control Link Design).

10.5
Section 10
Reassembly

Control
Link

Guide
Pin

Figure 10-18. Installed Guide Shoe Figure 10-20. Installed Control Link on Crankcase
(Above Serial No. 3618005223). Guide Pin (Above Serial No. 3618005223).
3. Make sure pivot pin on boss in lower section
of crankcase is clean and free of any nicks, or Install Piston Rings
surface irregularities. Apply a small amount of NOTE: For detailed piston inspection procedures
grease to O.D. and piston ring installation refer to Section 9
Inspection and Reconditioning.
4. Apply a small amount of grease to O.D. of guide
pin on PTO side of counterweight and install Install Piston to Connecting Rod
‘ŽȱŒ˜—›˜•ȱ•’—”ǯȱŠ›Žž••¢ȱ’—œŠ••ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ 1. Assemble the piston, connecting rod, piston pin,
 ’‘ȱ•’—”ȱǻ‘˜•ȱ’—ȱ™˜œ’’˜—ȱŠœȱ›Žšž’›ŽǼǰȱ‘›˜ž‘ȱ Š—ȱ™’œ˜—ȱ™’—ȱ›ŽŠ’—Ž›œǯȱŽŽȱ’ž›ŽȱŗŖȬŘŗǯ
the PTO seal. Slightly rotate the counterweight
assembly and guide the outer end of link over
the stationary guide pin in crankcase. Seat link
Š—ȱŒ›Š—”œ‘ŠĞȱž••¢ȱ’—˜ȱ™•ŠŒŽǰȱdo not force
Ž’‘Ž›ȱ™Š›ȱ’—˜ȱ™˜œ’’˜—ǯȱŽŽȱ’ž›ŽœȱŗŖȬŗşȱŠ—ȱ
ŗŖȬŘŖǯ

Figure 10-21. Assembled Piston and Connecting

Rod.

Control
Link

Figure 10-19. Installing Crankshaft Assembly with

Control Link (Above Serial No. 3618005223).

10.6
 Section 10
Reassembly

Install Piston and Connecting Rod

NOTE: Proper orientation of the piston/connecting Soft End
rod inside the engine is extremely important. of Handle
Improper orientation can cause extensive
wear or damage. Ring Compressor

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.

ȱ Řǯȱ ˜–™›Žœœȱ‘Žȱ™’œ˜—ȱ›’—œȱžœ’—ȱŠȱ™’œ˜—ȱ›’—ȱ
compressor. Orient the FLY mark on the piston
˜ Š›ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱœ’Žȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱŽŽȱ
’ž›ŽȱŗŖȬŘŘǯȱ•ŠŒŽȱ‘Žȱ›’—ȱŒ˜–™›Žœœ˜›ȱ˜—ȱ‘Žȱ Figure 10-23. Installing Piston and Connecting
top surface of the crankcase and make certain it Rod.
is seated down around the entire circumference.
3. Guide the connecting rod down and rotate the
œŽȱŠȱœ˜Ğǰȱ›ž‹‹Ž›ȱ›’™ȱ‘Š––Ž›ȱ‘Š—•ŽȱŠ—ȱŠ™ȱ
Œ›Š—”œ‘ŠĞȱ˜ȱ–ŠŽȱ‘Žȱ“˜ž›—Š•œǯȱ—œŠ••ȱ‘Žȱ›˜ȱ
the piston/connecting rod into the bore. See
cap.
’ž›ŽȱŗŖȬŘřǯȱ‘ŽȱꛜȱŠ™ȱœ‘˜ž•ȱ‹Žȱ›Š‘Ž›ȱꛖǰȱ
so the oil ring moves from the compressor into
ȱ Śǯȱ —œŠ••ȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱŠ—ȱ˜›šžŽȱ’—ȱŘȱ
the bore in one smooth, quick motion. Otherwise
’—Œ›Ž–Ž—œǰȱꛜȱ˜ȱ5.5 N·m (50 in. lb.)ǰȱꗊ••¢ȱ˜ȱ
the oil ring rails may spring out and jam between
11.5 N·m (100 in. lb.)ǯȱŽŽȱ’ž›ŽȱŗŖȬŘŚǯ
the ring compressor and the top of the bore.

Figure 10-24. Torquing Connecting Rod Screws.

10
Figure 10-22. Direction Arrow on Piston.

10.7
Section 10
Reassembly

Install Cam Levers 2. Apply a dab of grease to the formed groove in

1. Install the two cam levers as shown in Figure
ŗŖȬŘśǯȱ‘Žȱ’–™•Žȱ˜›ȱœŽŠ’—ȱ‘Žȱ™žœ‘ȱ›˜ȱ–žœȱ
face up. Secure each cam lever using an M6 hex
̊—ŽȱœŒ›Ž ǯȱ˜›šžŽȱ‘ŽȱœŒ›Ž œȱ˜ȱ
7.5 N·m (65 in. lb.). Lubricate the dimple and
‹˜Ĵ˜–ȱœ’Žȱ˜ȱ‘ŽȱŒŠ–ȱ•ŽŸŽ›ȱ ’‘ȱ•’‘ȱ›ŽŠœŽȱ˜›ȱ
oil.
the thrust washer. Slide the washer onto the
ŒŠ–ȱœ‘ŠĞȱœ˜ȱ‘Žȱœ‘˜›ȱ›’ŸŽȱ™’—ȱ’œȱœŽŠŽȱ’—ȱ
the groove. The grease will hold the washer in
position. Pivot the exhaust cam lever toward
‘Žȱ™žœ‘ȱ›˜ȱ‹˜›Žǰȱ‘Ž—ȱ’—œŽ›ȱ‘ŽȱŒŠ–ȱœ‘ŠĞȱ’—˜ȱ
the counterbore of the crankcase. Make sure the
pin stays in the groove of the thrust washer. See
’ž›ŽȱŗŖȬŘŝǯ

Intake Cam
Follower Dimple

Exhaust
Cam
Follower
Figure 10-25. Installing Cam Levers.

Install the Exhaust Cam Shaft and Cam

Gear
1. If the drive pins were removed from the exhaust Exhaust Lever
ŒŠ–ȱœ‘ŠĞǰȱ˜••˜ ȱ‘ŽȱœŠ–Žȱ™›˜ŒŽž›ŽȱžœŽȱŽŠ›•’Ž›ȱ
˜›ȱ‘Žȱ’—Š”ŽȱŒŠ–ȱœ‘ŠĞȱŠ—ȱ›Ž’—œŠ••ȱ‘Ž–ǯȱŽŽȱ
’ž›ŽȱŗŖȬŘśǯ

Exhaust Cam
Shaft

4
6 5
Figure 10-27. Exhaust Cam Shaft Installation.

3. Lubricate the cam surfaces of the cam gears with

1 3 light grease or oil.
2

ȱ Śǯȱ œœŽ–‹•ŽȱŠ—ȱ’—œŠ••ȱ‘ŽȱȱǻŠž˜–Š’Œȱ
Œ˜–™›Žœœ’˜—ȱ›Ž•ŽŠœŽǼȱ’—˜ȱ‘ŽȱŽ¡‘ŠžœȱŒŠ–ȱŽŠ›ȱ’ȱ
removed for servicing.
Figure 10-26. Drive Pin Locations for Exhaust Cam
Shaft. ȱ ȱ Šǯȱ —œŠ••ȱ‘Žȱœ™›’—ȱ˜—˜ȱ‘Žȱȱ Ž’‘ȱ ’‘ȱȱ
loop around post, and the formed upper leg
ȱ ȱ ŗǯȱ ¡‘ŠžœȱŠ–ȱ‘ŠĞ hooked behind the upper section. See Figure
2. 3 mm Diameter Pin ȱ ŗŖȬŘŞǯ
3. 2.5 mm Diameter Pin
4. 1.86 mm ȱ ȱ ‹ǯȱȱ —œŠ••ȱ‘ŽȱȱŠœœŽ–‹•¢ȱ’—˜ȱ‘˜•Žȱ˜ȱŽ¡‘Šžœȱȱ
5. #1 Hole Location cam gear and hook the long leg behind the
6. #2 Hole Location ȱ —˜Œ‘ŽȱŠ‹ǯȱŽŽȱ’ž›ŽȱŗŖȬŘşǯ

10.8

Figure 10-28. Spring Installed on ACR Weight.
Figure 10-29. Hooking ACR Spring onto Exhaust
Cam Gear.
ȱ śǯȱ ’Ğȱ‘ŽȱŽ¡‘ŠžœȱŒŠ–ȱ•ŽŸŽ›ȱŠ—ȱ’—œŠ••ȱ‘ŽȱŽ¡‘Šžœȱ
ŒŠ–ȱŽŠ›ȱ ’‘ȱŠœœŽ–‹•Žȱȱ˜—˜ȱ‘ŽȱŒŠ–ȱ
œ‘ŠĞǰȱŽ—Š’—ȱ‘Žȱœ•˜ȱ ’‘ȱ‘Žȱž™™Ž›ȱ›’ŸŽȱ™’—ǯȱ
˜ŠŽȱ‘ŽȱŽŠ›ȱŠ—ȱœ‘ŠĞȱœ˜ȱ‘ŽȱEX timing mark
on the cam gear is in the 8 o’clock position. Install
‘Žȱ‘›žœȱ Šœ‘Ž›ȱ˜—˜ȱ‘ŽȱŒŠ–ȱœ‘ŠĞǯȱŽŽȱ
ȱ ȱ ’ž›ŽȱŗŖȬřŖǯ
Figure 10-30. Installing Exhaust Cam Gear.
Section 10
Reassembly
Install Intake Cam on Cam Shaft
ȱ ŗǯȱ ’Ğȱ‘Žȱ’—Š”ŽȱŒŠ–ȱ•ŽŸŽ›ȱŠ—ȱ’—œŠ••ȱ‘Žȱ’—Š”Žȱ
ŒŠ–ȱŽŠ›ȱ˜—˜ȱ‘Žȱ’—Š”ŽȱŒŠ–ȱœ‘ŠĞǰȱŽ—Š’—ȱ‘Žȱ
slot with the upper drive pin. Rotate the gear and
œ‘ŠĞȱœ˜ȱ‘ŽȱIN timing mark on the cam gear is in
the 4 o’clock position. Early Models Only: Install
‘Žȱ‘›žœȱ Šœ‘Ž›ȱǻ’ȱžœŽȱ˜›’’—Š••¢Ǽǰȱ˜—˜ȱ‘Žȱ
ŒŠ–ȱœ‘ŠĞǯȱŽŽȱ’ž›ŽȱŗŖȬřŗǯ
Thrust Washer
(Intake Side)
Used on
Early Models
Only
Figure 10-31. Installing Intake Cam Gear and
Thrust Washer.
ȱ DZȱŠ–ȱ ŽŠ›ȱŠœœŽ–‹•’Žœȱ–Š¢ȱŒ˜—Š’—ȱȱ
either two or four rivets. The four
ȱ ȱ›’ŸŽȱŽœ’—ȱ’œȱœ‘˜ —ȱ’—ȱꐞ›Žœǯ
Install Crank Gear
ȱ ŗǯȱ ›’Ž—ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱœ˜ȱ‘Žȱ”Ž¢ȱ’œȱ’—ȱ‘Žȱ
12 o’clock position. Hold the crank gear with
the timing marks visible and slide it onto the
Œ›Š—”œ‘ŠĞȱŠ—ȱ”Ž¢ǰȱœ˜ȱ‘Žȱ’–’—ȱ–Š›”œȱ˜—ȱ‘Žȱ
crank gear align with the timing marks on the
ŒŠ–ȱŽŠ›œǯȱŽŽȱ’ž›ŽȱŗŖȬřŘǯ
10
Figure 10-32. Installing Crank Gear.
10.9
Section 10
Reassembly

Install Flywheel Side Oil Seal

1. Lubricate the outside diameter and lip of the
Guide Channel
Ě¢ ‘ŽŽ•ȱŽ—ȱ˜’•ȱœŽŠ•ǯȱž™™˜›ȱ‘ŽȱŒ•˜œž›Žȱ™•ŠŽȱ
and install the oil seal. Using a seal driver, drive
the seal to a depth of 5 mm (0.196 in.) in the seal
‹˜›ŽǯȱŽŽȱ’ž›ŽȱŗŖȬřřǯ

Guide Shoe
(Some Models)

Figure 10-34. Aligning and Installing Closure Plate

(Guide Shoe Design Figure 10-14).

ȱ řǯȱ —œŠ••ȱ‘Žȱ˜ž›ŽŽ—ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ
Figure 10-33. Installing Flywheel Side Oil Seal.
Install Closure Plate Gasket, Closure
Plate, and Wiring Harness
NOTE: The special gasket used between the closure
™•ŠŽȱŠ—ȱŒ›Š—”ŒŠœŽȱŒ˜—›˜•œȱŒ›Š—”œ‘ŠĞȱ
endplay, no shimming is required. Do not
use RTV sealant in place of the gasket.
the closure plate to the crankcase, with any
clamps for the wiring harness and the sheathed
RFI suppression spark plug lead (#5 location, if so
Žšž’™™ŽǼǰȱ™˜œ’’˜—ŽȱŠœȱœ‘˜ —ȱ’—ȱ’ž›Žȱ
ŗŖȬřśǯȱȱ‘Žȱ ’›’—ȱ‘Š›—Žœœȱ ŠœȱœŽ™Š›ŠŽȱ›˜–ȱ
the closure plate, route the harness through the
Œ•Š–™œȱŠ—ȱ‘Žȱœ•˜ȱ’—ȱ‘ŽȱŒ•˜œž›Žȱ™•ŠŽǯȱ•˜œŽȱ‘Žȱ
clamps to retain the harness.

1. Make sure the sealing surfaces of crankcase and

closure plate are clean, dry, and free of any nicks
or burrs. Install a new closure plate gasket onto
the crankcase.

NOTE: Engines with Guide Shoe Design

Balance Weight: Apply grease to the
˜žœ’Žȱ̊ȱœž›ŠŒŽœȱ˜ȱ‘Žȱ‹Š•Š—ŒŽȱ
weight guide shoe. Position the guide
shoe so the solid end is toward the
Œ›Š—”œ‘ŠĞǯȱŽŽȱ’ž›ŽȱŗŖȬřřǯȱ ŽŽ™ȱ‘Žȱ
guide shoe stays in this position during Figure 10-35. Closure Plate Installed.
the next step.
4. Torque the closure plate fasteners to
2. Ensure the gasket, cover plate, and governor gear 24.5 N·m (216 in. lb.) using the sequence shown
assembly, have been properly assembled to the ’—ȱ’ž›ŽȱŗŖȬřŜǯ
Œ•˜œž›Žȱ™•ŠŽȱǻ›ŽŽ›ȱ˜ȱŽŒ’˜—ȱşǼǯȱŠ›ȱ‘ŽȱŒ•˜œž›Žȱ
plate onto the crankcase. Be sure the guide shoe
ǻŠ™™•’ŒŠ‹•Žȱ–˜Ž•œǼǰȱ’œȱŠ•’—Žȱ ’‘ȱ‘Žȱž’Žȱ
Œ‘Š——Ž•ȱ’—ȱ‘ŽȱŒ•˜œž›Žȱ™•ŠŽǰȱŠ—ȱ‘ŽȱŒŠ–ȱœ‘ŠĞœȱ
Š—ȱ˜ŸŽ›—˜›ȱŽŠ›ȱœ‘ŠĞȱŠ›ŽȱŠ•’—Žȱ ’‘ȱ‘Ž’›ȱ
–Š’—ȱ‹ŽŠ›’—ȱœž›ŠŒŽœǯȱŽŽȱ’ž›ŽȱŗŖȬřŚǯȱœȱ
‘ŽȱŒ•˜œž›Žȱ™•ŠŽȱ’œȱ•˜ Ž›Žȱ’—˜ȱꗊ•ȱ™˜œ’’˜—ǰȱ
›˜ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱœ•’‘•¢ȱ˜ȱ‘Ž•™ȱŽ—ŠŽȱ‘Žȱ
governor gear.

10.10
 Section 10
Reassembly
DZȱ ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ‘Šœȱ—˜ȱ‹ŽŽ—ȱž›—Žȱ
14 5
12 1 3 since the installation of the crank gear,
7 ž›—ȱ’ȱ˜—ŽȱǻŗǼȱŒ˜–™•ŽŽȱ›ŽŸ˜•ž’˜—ǯȱ‘’œȱ
will set the piston at top dead center
ǻǼȱ˜ȱ‘ŽȱŒ˜–™›Žœœ’˜—ȱœ›˜”Žǰȱ˜›ȱ
proper valve lash adjustment later.
10 9
2. If the engine uses a drain back check ball, install
8 it into the keyhole slot in the top of the crankcase.
11 ŽŽȱ’ž›ŽȱŗŖȬřŞǯ
13

6 4 2

Figure 10-36. Closure Plate Fastener Torque

Sequence.

Assemble Cylinder Head

Prior to assembly, lubricate all the components with
engine oil, including the tips of the valve stems and
valve guides. Using a valve spring compressor, install
the following items in the order listed. See Figure
ŗŖȬřŝǯ
Figure 10-38. Installing Drain Back Check Ball.
• Intake and exhaust valves
(Some Models)
• Valve spring caps
• Valve springs
3. Install a new cylinder head gasket. See Figure
• Valve spring retainers
ŗŖȬřşǯ
• Valve spring keepers

10

Figure 10-39. Installing Head Gasket.

Figure 10-37. Assembling Cylinder Head.
4. Install the cylinder head and start the six hex
̊—ŽȱœŒ›Ž œǯȱ—œŠ••ȱ‘Žȱ‘’Œ”ȱ Šœ‘Ž›ȱ˜—ȱ‘Žȱ
Install Cylinder Head screw closest to the exhaust port. See
NOTE: Do not reuse cylinder head screws or gasket,
ȱ ȱ ’ž›ŽȱŗŖȬřşǯ
always replace with new parts.

ȱ ŗǯȱ ‘ŽŒ”ȱ˜ȱ–Š”Žȱœž›Žȱ‘Ž›ŽȱŠ›Žȱ—˜ȱ—’Œ”œȱ˜›ȱ‹ž››œȱ
on the sealing surfaces of the cylinder head or
crankcase.

10.11
Section 10
Reassembly

Washer
(Position 6)

Figure 10-42. Installing Guide Plates and Rocker

Figure 10-40. Installing Cylinder Head Fasteners. Arm Pivot Studs.

6. Using the torque sequence shown in Figure 2. Apply grease to the contact surfaces of the rocker
ŗŖȬŚŗǰȱ˜›šžŽȱ‘ŽȱŒ¢•’—Ž›ȱ‘ŽŠȱœŒ›Ž œȱ’—ȱ ˜ȱ arms and adjusting nuts and install them onto
stages; initially to 20.5 N·m (180 in. lb.), and the pivot studs.
ꗊ••¢ȱ˜ȱ41.0 N·m (360 in. lb.).
NOTE: If being reused, push rods should
always be installed in their original
3 1 5 position.

3. Note the mark or tag identifying the push rod

as either intake or exhaust. Apply grease to the
ends of the push rods. Insert the push rods into
the push rod bores and seat the lower end into
the dimpled recess of the cam levers. It may be
—ŽŒŽœœŠ›¢ȱ˜ȱ•’Ğȱ˜›ȱœ‘’Ğȱ‘Žȱ•˜ Ž›ȱŽ—ȱ˜ȱ‘Žȱ
push rod slightly, and feel that the rod seats
into the recess. Once seated, hold it in place as
6 you position the rocker arm. The push rod must
4
stay in the recess while the rocker arms are
2 ™˜œ’’˜—ŽȱŠ—ȱŠ“žœŽǯȱŽŽȱ’ž›ŽȱŗŖȬŚřǯ
Figure 10-41. Cylinder Head Fastener Torque
Sequence.

Install Rocker Arms and Push Rods

NOTE: Installation and seating of the push rods into
the cam lever recesses during this sequence is
critical. Position the engine with the cylinder
head up if possible, to aid with proper
installation of the push rods and rocker arms,
and adjusting the valve lash.

1. Position the push rod guide plates on the cylinder

head with the extruded edges down over the
push rod bores. Secure by installing the rocker
arm pivot studs. Torque the studs to 13.5 N·m
(120 in. lb.)ǯȱŽŽȱ’ž›ŽȱŗŖȬŚŘǯ Figure 10-43. Installing Push Rods and Rocker
Arm Assemblies.

10.12

ȱ Śǯȱ ’‘ȱ‘ŽȱŽ—’—ŽȱŠȱȱ˜ȱ‘ŽȱŒ˜–™›Žœœ’˜—ȱ
œ›˜”Žǰȱ’—œŽ›ȱ‘ŽȱŒ˜››ŽŒȱœ’£Žȱ̊ȱŽŽ•Ž›ȱŠžŽȱ
ǻœŽŽȱ‹Ž•˜ Ǽȱ‹Ž ŽŽ—ȱ‘ŽȱŠ™™›˜™›’ŠŽȱŸŠ•ŸŽȱœŽ–ȱ
and rocker arm. Tighten the adjustment nut
with a wrench until a slight drag is felt on the
feeler gauge. Hold the nut in that position and
˜›šžŽȱ‘ŽȱœŽȱœŒ›Ž ȱǻŗśȱ˜›¡ȱ›’ŸŽǼȱ˜ȱ5.5 N·m
(50 in. lb.). To prevent damage to the nut, torque
the Torx screw only. Perform the adjustment
™›˜ŒŽž›Žȱ˜—ȱ‘Žȱ˜‘Ž›ȱŸŠ•ŸŽǯȱŽŽȱ’ž›ŽœȱŗŖȬŚŚȱ
Š—ȱŗŖȬŚśǯ
ȱ ȱ Š•ŸŽȱ•ŽŠ›Š—ŒŽȱ™ŽŒ’ęŒŠ’˜—œDZ
Intake Valve 0.127 mm (0.005 in.)
Exhaust Valve 0.178 mm (0.007 in.)
Figure 10-44. Adjusting Valve Clearance (Lash).
Figure 10-45. Locking Adjustment Nut Set Screw.
Section 10
Reassembly
Install Valve Cover
1. Make sure the sealing surfaces of the valve cover
and cylinder head are clean, and free of any nicks
or burrs.
2. Install a new valve cover gasket, followed by the
valve cover. Position any brackets that mount
on the valve cover and start the seven mounting
screws.
3. Torque the valve cover screws to 11.0 N·m
(95 in. lb.) ’—˜ȱ—Ž ǰȱŠœȬŒŠœȱ‘˜•Žœǰ or 7.5 N·m
(65 in. lb.) into used holes, using the sequence
œ‘˜ —ȱ’—ȱ’ž›ŽȱŗŖȬŚŜǯ
6 7
3 1
4 5
2
Figure 10-46. Valve Cover Fastener Torque
Sequence.
10
10.13
Section 10
Reassembly

Install Stator and Wiring Harness

Install Stator
1. Position the stator onto the mounting bosses so
that the leads lay in the channel and recess of the
Œ•˜œž›Žȱ™•ŠŽǯȱŽŽȱ’ž›ŽȱŗŖȬŚŝǯȱ‘Ž¢ȱ ’••ȱ‹ŽŒ˜–Žȱ
captured when the blower housing is installed.
If a clamp was used to retain the leads, remove
‘ŽȱœŒ›Ž ȱ’—ȱ‘Žȱ˜ǯȱŗřǰȱŽŽȱ’ž›ŽȱŗŖȬřŜǰȱ•˜ŒŠ’˜—ȱ
and install the clamp. Hold the clamp in position
and torque the screw to 24.5 N·m (216 in. lb.)

ȱ Řǯȱ —œŠ••ȱ‘Žȱ ˜ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱ˜ȱœŽŒž›Žȱ‘Žȱ
stator and torque to 6.0 N·m (55 in. lb.), into new,
ŠœȬŒŠœȱ‘˜•Žœǰȱ˜›ȱ4.0 N·m (35 in. lb.), into used
holes.
Figure 10-48. Installing B+ Lead into Connector.
Install Pipe Plug or Fitting and Pulse Line
for Fuel Pump
1. Apply ™’™ŽȱœŽŠ•Š—ȱ ’‘ȱŽĚ˜—® (Loctite® No.
śşŘŚŗȱ˜›ȱŽšž’ŸŠ•Ž—Ǽǰȱ˜ȱ‘ŽȱŗȦŞȄȱ™’™Žȱ™•žȱ˜›ȱşŖǚȱ
ęĴ’—ȱǻŠœȱŽšž’™™ŽǼǯȱ—œŠ••ȱŠ—ȱ’‘Ž—ȱ’—˜ȱ‘Žȱ
tapped vacuum port of the closure plate. Torque
the plug to 4.5-5.0 N·m (40-45 in. lb.). Turn the
˜ž•Žȱ˜ȱŠȱęĴ’—ȱ˜ȱ‘ŽȱŞȱ˜ȂŒ•˜Œ”ȱ™˜œ’’˜—ǯ

Channel ȱ Řǯȱ ȱŠȱęĴ’—ȱ’œȱžœŽǰȱŒ˜——ŽŒȱ‘ŽȱžŽ•ȱ™ž–™ȱ™ž•œŽȱ

•’—ŽȱŠ—ȱœŽŒž›Žȱ ’‘ȱ‘ŽȱŒ•Š–™ǯȱŽŽȱ’ž›ŽȱŗŖȬŚşǯ
Recess

Figure 10-47. Installing Stator.

Install Wiring Harness

ȱ ŗǯȱ ‘ŽŒ”ȱ‘Šȱ‘Žȱ•˜Œ”’—ȱŠ—ȱ˜—ȱ‘ŽȱŽ›–’—Š•ȱ˜ȱ‘Žȱ
violet B+ wiring harness lead is angled upward.
Insert the terminal into the center location of the
›ŽŒ’ꎛȬ›Žž•Š˜›ȱ™•žȱŒ˜——ŽŒ˜›ȱž—’•ȱ’ȱ•˜Œ”œȱ
’—˜ȱ™•ŠŒŽǯȱȱ—˜ȱŠ•›ŽŠ¢ȱ’—œŽ›Žǰȱ‘Žȱ ˜ȱȱ
leads from the stator go in the outer locations.
ŽŽȱ’ž›ŽȱŗŖȬŚŞǯ

Figure 10-49. Connecting Pulse Line to Fitting.

10.14
 Section 10
Reassembly

Install Fan and Flywheel

WARNING: Damaging Crankshaft and

Flywheel can Cause Personal Injury!
œ’—ȱ’–™›˜™Ž›ȱ™›˜ŒŽž›Žœȱ˜ȱ’—œŠ••ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŒŠ—ȱ
Œ›ŠŒ”ȱ˜›ȱŠ–ŠŽȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ—Ȧ˜›ȱĚ¢ ‘ŽŽ•ǯȱ‘’œȱ—˜ȱ
˜—•¢ȱŒŠžœŽœȱŽ¡Ž—œ’ŸŽȱŽ—’—ŽȱŠ–ŠŽǰȱ‹žȱŒŠ—ȱŠ•œ˜ȱŒŠžœŽȱ
™Ž›œ˜—Š•ȱ’—“ž›¢ǰȱœ’—ŒŽȱ‹›˜”Ž—ȱ›Š–Ž—œȱŒ˜ž•ȱ‹Žȱ‘›˜ —ȱ
›˜–ȱ‘ŽȱŽ—’—Žǯȱ• Š¢œȱ˜‹œŽ›ŸŽȱŠ—ȱžœŽȱ‘Žȱ˜••˜ ’—ȱ
™›ŽŒŠž’˜—œȱŠ—ȱ™›˜ŒŽž›Žœȱ ‘Ž—ȱ’—œŠ••’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ǯ

DZȱ Ž˜›Žȱ’—œŠ••’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ–Š”Žȱœž›Žȱ‘Žȱ
Œ›Š—”œ‘ŠĞȱŠ™Ž›ȱŠ—ȱĚ¢ ‘ŽŽ•ȱ‘ž‹ȱŠ›ŽȱŒ•ŽŠ—ǰȱ
dry and completely free of lubricants. The
Figure 10-50. Installing Fan and Mounting
™›ŽœŽ—ŒŽȱ˜ȱ•ž‹›’ŒŠ—œȱŒŠ—ȱŒŠžœŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ
Hardware to Flywheel.
to be over stressed and damaged when the
–˜ž—’—ȱœŒ›Ž ȱ’œȱ˜›šžŽȱ˜ȱœ™ŽŒ’ęŒŠ’˜—ǯ
ȱ śǯȱ œŽȱŠȱĚ¢ ‘ŽŽ•ȱœ›Š™ȱ ›Ž—Œ‘ȱ˜›ȱ‘˜•’—ȱ˜˜•ȱ
˜ȱ‘˜•ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŠ—ȱ˜›šžŽȱ‘Žȱ‘Ž¡ȱ̊—Žȱ
DZȱ Š”Žȱœž›Žȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ”Ž¢ȱ’œȱ’—œŠ••Žȱ
screw. For an M10 screw, torque to 66.5 N·m
™›˜™Ž›•¢ȱ’—ȱ‘Žȱ”Ž¢ Š¢ǯȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŒŠ—ȱ
ȱ ȱ ǻŚşȱĞǯȱ•‹ǯǼ. For an M12 screw, torque to 88.0 N·m
become cracked or damaged if the key is not
ǻŜśȱĞǯȱ•‹ǯǼǯȱŽŽȱ’ž›ŽȱŗŖȬśŗǯ
properly installed.

DZȱ • Š¢œȱžœŽȱŠȱĚ¢ ‘ŽŽ•ȱœ›Š™ȱ ›Ž—Œ‘ȱ˜›ȱ
Ě¢ ‘ŽŽ•ȱ‘˜•’—ȱ˜˜•ȱ˜ȱ‘˜•ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ
 ‘Ž—ȱ’‘Ž—’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŠœŽ—Ž›ǯȱ˜ȱ
not use any type of bar or wedge between the
Œ˜˜•’—ȱꗜȱ˜›ȱĚ¢ ‘ŽŽ•ȱ›’—ȱŽŠ›ǰȱŠœȱ‘ŽœŽȱ
parts could become cracked or damaged.

ŗǯȱ —œŠ••ȱ‘ŽȱŠ™™›˜™›’ŠŽȱ”Ž¢ȱ’—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ
”Ž¢ Š¢ǯȱȱŠœŽȱ˜—ȱŒ›Š—”œ‘ŠĞȱ”Ž¢ Š¢ȱœ¢•ŽǰȱžœŽȱ
Ž’‘Ž›ȱŠȱ ˜˜›žěȱ˜›ȱœ›Š’‘ȱ”Ž¢ǯȱŠ”Žȱœž›Žȱ”Ž¢ȱ
is fully seated.

ȱ Řǯȱ —œŠ••ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ˜—˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱŠ•’—’—ȱ
‘Žȱ”Ž¢ Š¢ȱ ’‘ȱ‘Žȱ”Ž¢ǯȱŽȱŒŠ›Žž•ȱ—˜ȱ˜ȱœ‘’Ğȱ˜›ȱ Figure 10-51. Torquing Flywheel.
unseat the key.

ȱ řǯȱ ˜œ’’˜—ȱ‘ŽȱŠ—ȱ˜—˜ȱ‘ŽȱĚ¢ ‘ŽŽ•ǰȱœ˜ȱ‘Žȱ•˜ŒŠ’—ȱ 10
pins drop into the corresponding recesses.

4. Install the fan mounting plate onto the fan,

aligning the four cutouts, followed by the heavy
̊ȱ Šœ‘Ž›ȱŠ—ȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ǯȱŽŽȱ
ȱ ȱ ’ž›ŽȱŗŖȬśŖǯ

10.15
Section 10
Reassembly
Install Electric Starter
1. Install the electric starter to the closure plate
Š—ȱœŽŒž›Žȱ ’‘ȱ‘Žȱ ˜ȱǛŗŖȬŘŚȱ‘Ž¡ȱ—žœǯȱŠ”Žȱ
sure the wires are clear of any moving parts and
torque the hex nuts to 3.6 N·m (32 in. lb.). See
’ž›ŽȱŗŖȬśŘǯ
Figure 10-52. Installing Electric Starter.
Install Ignition Module
ȱ ŗǯȱ ˜ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱœ˜ȱ‘Žȱ–Š—Žȱ’œȱŠ Š¢ȱ
from the ignition module bosses. Using the hex
̊—ŽȱœŒ›Ž œǰȱ’—œŠ••ȱ‘Žȱ’—’’˜—ȱ–˜ž•Žȱ˜ȱ‘Žȱ
crankcase bosses with the kill terminal up. Move
‘Žȱ–˜ž•ŽȱŠœȱŠ›ȱ›˜–ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŠœȱ™˜œœ’‹•Žǯȱ
’‘Ž—ȱ‘Žȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž œȱœžĜŒ’Ž—•¢ȱ˜ȱ”ŽŽ™ȱ
‘Žȱ–˜ž•Žȱ’—ȱ™˜œ’’˜—ǯȱŽŽȱ’ž›ŽȱŗŖȬśřǯ
Figure 10-53. Installing Ignition Module.
10.16
ȱ Řǯȱ ˜ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ˜ȱŠ•’—ȱ‘Žȱ–Š—Žȱ ’‘ȱ‘Žȱ
ignition module.
3. Insert a 0.25 mm (0.010 in.) ̊ȱŽŽ•Ž›ȱŠžŽȱ
between the magnet and ignition module. See
’ž›ŽȱŗŖȬśŚǯȱ˜˜œŽ—ȱ‘ŽȱœŒ›Ž œȱœ˜ȱ‘Žȱ–Š—Žȱ
pulls the module against the feeler gauge.
Figure 10-54. Setting Air Gap.
4. Torque the two screws to 6.0 N·m (55 in. lb.), into
—Ž ǰȱŠœȬŒŠœȱ‘˜•Žœǰȱ˜›ȱ4.0 N·m (35 in. lb.), into
used holes.
ȱ śǯȱ ˜ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ‹ŠŒ”ȱŠ—ȱ˜›‘ȱŒ‘ŽŒ”’—ȱ
for clearance between the magnet and ignition
module. Make sure the magnet does not strike
the module. Recheck the air gap with a feeler
gauge and readjust if necessary. Final Air Gap:
0.203/0.305 mm (0.008/0.012 in.).
ȱ Ŝǯȱ ˜——ŽŒȱ‘Žȱ”’••ȱ•ŽŠȱ˜ȱ‘ŽȱŠ‹ȱŽ›–’—Š•ȱ˜—ȱ‘Žȱ
ignition module.
7. If equipped with a sheathed RFI suppression
spark plug lead, place the lead in retaining clip so
braided wires will be in direct contact with clip
 ‘Ž—ȱŒ•˜œŽǯȱŠ›Žž••¢ȱŒ•˜œŽȱ‘ŽȱŒ•’™ȱ ’‘ȱŠȱ™•’Ž›œȱ
until a 0.127 mm (0.005 in.) gap exists between
the ends. Do notȱ™’—Œ‘ȱ˜›ȱ̊ĴŽ—ȱ‘ŽȱŒ•’™ǯȱŽŽȱ
’ž›ŽȱŗŖȬśśǯ
 Section 10
Reassembly

Stud

Insert
(Some Models)
Figure 10-55. Tightening Clip around Sheathing. Figure 10-57. Mounting Stud and Installing Insert
(Some Models).
Install New Spark Plug
ȱ ŗǯȱ œŽȱŠȱ—Ž ȱ‘Š–™’˜—® ŗŘȱ˜›ȱŗŘȱǻ˜›ȱ 2. Make sure all the gasket surfaces are clean and
Žšž’ŸŠ•Ž—Ǽȱœ™Š›”ȱ™•žǯ free of any nicks or damage.

2. Set the gap to 0.76 mm (0.030 in.).
3. Install the spark plug and torque it to 24-30 N·m
ǻŗŞȬŘŘȱĞǯȱ•‹ǯǼǯȱŽŽȱ’ž›ŽȱŗŖȬśŜǯ
3. Install a new intake gasket onto the carburetor
œžǰȱ‘Ž—ȱ’—œŠ••ȱ‘Žȱ‘ŽŠȱŽĚŽŒ˜›ǯȱ‘ŽȱŒž›ŸŽȱ
section should be down, toward the engine. If the
ŽĚŽŒ˜›ȱŒ˜—Š’—œȱŠȱ–˜•Žȱ™›˜›ž’—ȱ™˜’—ǰȱ
it should be towards the back inserted into the
intake port. Be sure the protruding point goes
through the large hole in the gasket, to keep it
Š•’—ŽǯȱŽŽȱ’ž›ŽȱŗŖȬśŞǯ

Figure 10-56. Installing Spark Plug.

10
ȱ Śǯȱ ˜——ŽŒȱ‘Žȱœ™Š›”ȱ™•žȱ•ŽŠǯ

,QVWDOO+HDW'HÀHFWRU&DUEXUHWRU/LQNDJH Figure 10-58. Installing Intake Gasket and Heat

and Air Cleaner Base 'HÀHFWRU
1. If the carburetor mounting stud was removed,
reinstall it in the outer cylinder location (closest
˜ȱ‘ŽŠǼǯȱœŽȱŠ—ȱśȱ˜›¡® socket or two hex
̊—Žȱ—žœȱ’‘Ž—Žȱ˜Ž‘Ž›ǰȱŠ—ȱž›—ȱ‘Žȱœžȱ
’—ȱž—’•ȱ’‘ǯȱŽŽȱ’ž›ŽȱŗŖȬśŝǯ

10.17
Section 10
Reassembly
4. Models with one screw and one mounting stud
only: Insert a 3/16” diameter rod, approximately
4” long, into the open mounting hole in the heat
ŽĚŽŒ˜›ȱ˜ȱœŽ›ŸŽȱŠœȱŠȱŽ–™˜›Š›¢ȱŠ•’—–Ž—ȱ™’—ǯȱ
ŽŽȱ’ž›ŽȱŗŖȬśşǯȱŽȱŒŠ›Žž•ȱ—˜ȱ˜ȱ˜›ŒŽȱ‘Žȱ›˜ȱ˜›ȱ
damage the threads.
7. If the carburetor has a fuel solenoid, fasten the
ground lead to the crankcase boss, with the
toothed washer between the eyelet terminal and
‘Žȱ‹˜œœǯȱŽŽȱ’ž›ŽȱŗŖȬŜŗǯȱ˜›šžŽȱ‘ŽȱœŒ›Ž ȱ˜ȱ
8.0 N·m (70 in. lb.)ǯȱ˜——ŽŒȱ‘Žȱœ˜•Ž—˜’ȱ™˜ Ž›ȱ
lead to the wiring harness and secure with a tie
œ›Š™ǯȱŽŽȱ’ž›ŽȱŗŖȬŜŘǯ

Ground Lead
Temporary Alignment Pin

Figure 10-59. Inserting Alignment Pin. Figure 10-61. Securing Ground Lead.

5. Install a new carburetor gasket onto the

–˜ž—’—ȱœžǻœǼȱŠ—Ȧ˜›ȱŠ•’—–Ž—ȱ™’—ǯȱ

ȱ Ŝǯȱ ĴŠŒ‘ȱ‘ŽȱŒ‘˜”ŽȱŠ—ȱ‘›˜Ĵ•Žȱ•’—”ŠŽœȱ˜ȱ‘Žȱ
carburetor and install the carburetor assembly.
ŽŽȱ’ž›ŽȱŗŖȬŜŖǯȱȱ‘Žȱ˜ŸŽ›—˜›ȱ•ŽŸŽ›ȱ Šœȱ—˜ȱ
’œŒ˜——ŽŒŽǰȱœ•’Žȱ’ȱ˜—˜ȱ‘Žȱ˜ŸŽ›—˜›ȱœ‘ŠĞȱ
with the lever up.

Throttle Linkage
Figure 10-62. Fuel Solenoid Lead Secured with Tie
Strap.
Choke Linkage
ȱ Şǯȱ ˜——ŽŒȱ‘ŽȱžŽ•ȱ•’—Žȱ˜ȱ‘ŽȱŒŠ›‹ž›Ž˜›ȱŠ—ȱœŽŒž›Žȱ
 ’‘ȱŠȱ‘˜œŽȱŒ•Š–™ǯȱŽŽȱ’ž›ŽȱŗŖȬŜřǯ

Figure 10-60. Installing Carburetor Assembly with

Linkages.

Figure 10-63. Connecting Fuel Line to Carburetor.

10.18
 Section 10
Reassembly
9. Install the air cleaner base.

ȱ Šǯȱ —œŠ••ȱŠȱ—Ž ȱŠ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽȱŠœ”Žǯȱ‘ŽŒ”ȱ
that the two metal spacers are in the air
cleaner base mounting holes and install
‘Žȱ‹ŠœŽȱ˜—˜ȱ‘ŽȱœžǻœǼǰȱŠ—ȱ˜›ȱŠ•’—–Ž—ȱ
pin. Make sure the upper mounting tab is
positioned above the closure plate boss. See
’ž›ŽȱŗŖȬŜŚǯȱ—œŠ••ȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žǻœǼȱŠ—ȱ
ꗐŽ›ȱ’‘Ž—ȱŽŽȱ’ž›ŽȱŗŖȬŜśǯ

Figure 10-66. Installing Mounting Screw. (Models

with one stud and one screw).

ȱ Œǯȱ ˜›šžŽȱ‘Žȱ—žǻœǼȱ˜ȱ5.5 N·m (48 in. lb.).

Torque the screw to 8.0 N·m (70 in. lb.) into
a new hole, or 5.5 N·m (48 in. lb.) into a
used hole, do not over tighten. See Figure
ŗŖȬŜŝǯȱ‘ŽȱŜȱœŒ›Ž ȱ˜›ȱ‘Žȱž™™Ž›ȱŠ‹ȱ ’••ȱ
be installed when the blower housing is
Tab on Top of Closure Plate
mounted.

Figure 10-64. Air Cleaner Base Upper Mounting

Tab Details.

Figure 10-67. Torquing Air Cleaner Fasteners.

10
ȱŗŖǯȱ ĴŠŒ‘ȱ‘Žȱ‹›ŽŠ‘Ž›ȱ‘˜œŽȱ˜ȱ‘ŽȱŸŠ•ŸŽȱŒ˜ŸŽ›ȱŠ—ȱ
Figure 10-65. Installing Air Cleaner Base. air cleaner base.

b. Models with one screw and one mounting

stud only: Apply hand pressure to keep the
™Š›œȱ›˜–ȱœ‘’Ğ’—ǰȱ‘Ž—ȱŒŠ›Žž••¢ȱ›Ž–˜ŸŽȱ
the alignment pin and install DRY the long
M6 thread forming screw – DO NOT OIL.
ŽŽȱ’ž›ŽȱŗŖȬŜŜǯȱ‘ŽŒ”ȱ˜ȱ–Š”Žȱœž›ŽȱŠ••ȱ
gaskets are still in proper position.

10.19
Section 10
Reassembly
Install and Adjust Governor Lever
1. Install the governor lever* onto the governor
œ‘ŠĞȱ ’‘ȱ‘Žȱ•ŽŸŽ›ȱœŽŒ’˜—ȱž™ǯȱ˜——ŽŒȱ‘Žȱ
‘›˜Ĵ•Žȱ•’—”ŠŽȱžœ’—ȱ‘Žȱ‹•ŠŒ”ȱ•’—”ŠŽȱ‹žœ‘’—ǯȱ
ŽŽȱ’ž›ŽȱŗŖȬŜŞǯ
*NOTE: It is recommended that a new governor lever
be installed whenever removal is performed.
Figure 10-68. Governor Lever Installed on Shaft.
2. Move the governor lever toward the carburetor,
˜ȱ‘Žȱ•’–’ȱ˜ȱ’œȱ›ŠŸŽ•ȱǻ ’ŽȬ˜™Ž—ȱ‘›˜Ĵ•ŽǼȱŠ—ȱ
hold in this position. Do not apply excessive
™›Žœœž›Žǰȱ̎¡’—ȱ˜›ȱ’œ˜›’—ȱ‘Žȱ•’—”ŠŽǯȱ ›Šœ™ȱ
‘ŽȱŒ›˜œœȱœ‘ŠĞȱ ’‘ȱŠȱ™•’Ž›œǰȱŠ—ȱž›—ȱ‘Žȱœ‘ŠĞȱ
counterclockwise as far as it will go. See Figure
ŗŖȬŜşǯȱ˜›šžŽȱ‘Žȱ‘Ž¡ȱ—žȱ˜ȱ7.0-8.5 N·m
(60-75 in. lb.).
Rotate
Counter
Clockwise
Figure 10-69. Adjusting Governor and Linkage.
10.20
Mounting Speed Control Bracket
ȱ ŗǯȱ ĴŠŒ‘ȱ‘Žȱ˜ŸŽ›—˜›ȱœ™›’—ȱ˜ȱ‘Žȱ˜ŸŽ›—˜›ȱ•ŽŸŽ›ȱ
Š—ȱ‘Žȱ‘›˜Ĵ•Žȱ•ŽŸŽ›ȱ˜ȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žǰȱ
in the original holes. If the holes were not marked
during disassembly, refer to the charts in
ȱ ȱ ŽŒ’˜—ȱśǯȱ˜——ŽŒȱ‘ŽȱŒ‘˜”Žȱ•’—”ŠŽȱ›˜–ȱ‘Žȱ
carburetor to the actuating lever of the speed
Œ˜—›˜•ȱ‹›ŠŒ”ŽǯȱŽŽȱ’ž›ŽȱŗŖȬŝŖǯ
Governor
Spring
Choke Linkage
Figure 10-70. Connecting Choke Linkage and
Governor Spring.
ȱ Řǯȱ ĴŠŒ‘ȱ‘Žȱœ™ŽŽȱŒ˜—›˜•ȱ‹›ŠŒ”Žȱ˜ȱ‘Žȱ
mounting locations on the engine with the M6
screws. Position the bracket as marked during
disassembly. Torque the screws to 11.0 N·m
(95 in. lb.)ȱ’—˜ȱ—Ž ǰȱŠœȬŒŠœȱ‘˜•Žœȱ˜›ȱ7.5 N·m
(65 in. lb.)ȱ’—˜ȱžœŽȱ‘˜•ŽœǯȱŽŽȱ’ž›ŽȱŗŖȬŝŗǯ
Figure 10-71. Attaching Speed Control Bracket.
 Section 10
Reassembly

Install Fuel Pump (If Equipped) ȱ Řǯȱ ĴŠŒ‘ȱ‘ŽȱŒ˜——ŽŒ˜›ȱ˜ȱ‘Žȱ›ŽŒ’ꎛȬ›Žž•Š˜›ȱ

ŗǯȱ ĴŠŒ‘ȱ‘ŽȱžŽ•ȱ™ž–™ȱ–˜ž—’—ȱ‹›ŠŒ”Žȱ˜ȱ‘Žȱ terminals.
speed control bracket with the two M5 screws.
Torque the screws to 6.5 N·m (55 in. lb.) into new
ŠœȬŒŠœȱ‘˜•Žœǰȱ˜›ȱ4.0 N·m (35 in. lb.) into used
‘˜•ŽœǯȱŽŽȱ’ž›ŽȱŗŖȬŝŘǯ

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Install Blower Housing and Flywheel

Screen
Figure 10-72. Fuel Pump Mounting Bracket. 1. Position the blower housing on the engine and
route the spark plug lead through the underside
ȱ Řǯȱ ĴŠŒ‘ȱ‘ŽȱžŽ•ȱ™ž–™ȱ˜ȱ‘Žȱ‹›ŠŒ”Žȱœ˜ȱ‘Žȱ™ž•œŽȱ œ•˜ǯȱŽŽȱ’ž›ŽȱŗŖȬŝśǯ
ęĴ’—ȱ’œȱ˜›’Ž—Žȱ’—ȱ‘Žȱ˜ž›ȱ˜ȂŒ•˜Œ”ȱ™˜œ’’˜—ǯȱ
Secure with the two M6 screws. Torque the
screws to 9.5 N·m (84 in. lb.)ȱ’—˜ȱ—Ž ǰȱŠœȬŒŠœȱ
holes or 5.9 N·m (52 in. lb.) into used holes. Do
not over tighten.

ȱ řǯȱ ˜——ŽŒȱ‘Žȱ™ž•œŽȱŠ—ȱžŽ•ȱ•’—Žœȱ˜ȱ‘ŽȱžŽ•ȱ™ž–™ȱ
Š—ȱœŽŒž›Žȱ ’‘ȱŒ•Š–™œǯȱŽŽȱ’ž›ŽȱŗŖȬŝřǯ

Figure 10-75. Installing Blower Housing.

10
ȱ Řǯȱ ‘ŽŒ”ȱ‘Šȱ‘ŽȱœŠ˜›ȱ•ŽŠœȱŠ›Žȱ ’‘’—ȱ‘Žȱ—˜Œ‘ȱ
of the blower housing. Align the mounting
locations, then install the four M6 shouldered
–˜ž—’—ȱœŒ›Ž œǯȱȱŠȱ̊ȱ Šœ‘Ž›ȱ ŠœȱžœŽȱž—Ž›ȱ
the head on one screw, install the screw in the
Figure 10-73. Installed Fuel Pump. •˜ŒŠ’˜—ȱŒ•˜œŽœȱ˜ȱ˜’•ȱꕕȦ’™œ’Œ”ǯȱ˜›šžŽȱ‘Žȱ
screws to 11.6 N·m (99 in. lb.)ȱ’—˜ȱ—Ž ǰȱŠœȬŒŠœȱ
holes, or 7.7 N·m (68 in. lb.), into used holes. See
,QVWDOO5HFWL¿HU5HJXODWRU
’ž›ŽȱŗŖȬŝŜǯ
ȱ ŗǯȱ œ’—ȱ‘Žȱ ˜ȱŜȱœŒ›Ž œǰȱ–˜ž—ȱ‘Žȱ›ŽŒ’ꎛȬ
regulator onto the crankcase bosses, with the
Œ˜˜•’—ȱꗜȱ˜žǯȱŽŽȱ’ž›ŽȱŗŖȬŝŚǯȱ˜›šžŽȱ‘Žȱ
screws to 6.0 N·m (55 in. lb.)ȱ’—˜ȱ—Ž ȱŠœȬŒŠœȱ
holes, or 4.0 N·m (35 in. lb.) into used holes.

10.21
Section 10
Reassembly

Center Passage

Notch

Figure 10-76. Installing Blower Housing Screws. Figure 10-78. Installing Pipe Plug or Adapter.

3. Snap the grass screen onto the cooling fan. See

’ž›ŽȱŗŖȬŝŝǯ

Oil Sentry™
Switch

Figure 10-79. Installed Oil Sentry™ Switch.

Figure 10-77. Installing Grass Screen.

Install Oil Sentry™ or Pipe Plug

1. Apply ™’™ŽȱœŽŠ•Š—ȱ ’‘ȱŽĚ˜—® (Loctite® No.
śşŘŚŗȱ˜›ȱŽšž’ŸŠ•Ž—Ǽǰȱ˜ȱ‘Žȱ‘›ŽŠœȱ˜ȱ‘ŽȱŗȦŞȄȱ
pipe plug or adapter. Install and tighten into the
™˜›ȱ˜—ȱ‘ŽȱŒ•˜œž›Žȱ™•ŠŽǯȱŽŽȱ’ž›ŽȱŗŖȬŝŞǯȱ˜›šžŽȱ
pipe plug to 4.5-5.0 N·m (40-45 in. lb.). If a switch
was installed, apply sealant to the threads of the
Oil Sentry™ switch and install into the adapter or
center passage. Torque the switch to 4.5-5.0 N·m
(40-45 in. lb.)ǯȱ˜——ŽŒȱ‘Žȱ›ŽŽ—ȱ ’›’—ȱ‘Š›—Žœœȱ
lead to the terminal on the switch. See Figure
ȱ ȱ ŗŖȬŝşǯ

10.22

Install Air Cleaner Element, Precleaner,
and Air Cleaner Cover
1. Install the air cleaner element with the pleated
side “out.” Seat the rubber seal onto all the edges
˜ȱ‘ŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱ‹ŠœŽǯȱŽŽȱ’ž›ŽȱŗŖȬŞŖǯ
Figure 10-80. Installing Air Cleaner Element.
ȱ Řǯȱ —œŠ••ȱ‘Žȱ™›ŽŒ•ŽŠ—Ž›ȱǻ’ȱœ˜ȱŽšž’™™ŽǼǰȱ’—˜ȱ‘Žȱ
upper section of the air cleaner cover. See Figure
ŗŖȬŞŗǯ
Figure 10-81. Installing Precleaner.
3. Install the air cleaner cover and secure with the
 ˜ȱ›ŽŠ’—’—ȱ”—˜‹œǯȱŽŽȱ’ž›ŽȱŗŖȬŞŘǯ
Section 10
Reassembly
Figure 10-82. Installing Air Cleaner Cover.
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ȱ ŗǯȱ —œŠ••ȱ‘ŽȱŠœ”Žǰȱ–žĝŽ›ǰȱŠ—ȱ‘Ž¡ȱ̊—Žȱ—žœȱ
on the exhaust port studs. Leave the nuts slightly
loose.
ȱ Řǯȱ ȱŠ—ȱŠž¡’•’Š›¢ȱ–žĝŽ›ȱ‹›ŠŒ”Žȱ’œȱžœŽǰȱ’—œŠ••ȱ‘Žȱ
Ŝȱ‘Ž¡ȱ̊—ŽȱœŒ›Ž ǻœǼȱ’—˜ȱ‘Žȱ‹›ŠŒ”Žǯ
ȱ řǯȱ ˜›šžŽȱ‘Žȱ‘Ž¡ȱ̊—Žȱ—žœȱ˜ȱ24.4 N·m
(216 in. lb.)ǯȱŽŽȱ’ž›ŽȱŗŖȬŞřǯȱ˜›šžŽȱ‘ŽȱœŒ›Ž œȱ
to 7.5 N·m (65 in. lb.).
10
Figure 10-83. Torquing Exhaust Flange Nuts.
10.23
Section 10
Reassembly
Install Drain Plug, Oil Filter, and Oil
1. Install the oil drain plug and torque to 14 N·m
(125 in. lb.).
ȱ Řǯȱ •ŠŒŽȱŠȱ—Ž ȱ›Ž™•ŠŒŽ–Ž—ȱꕝŽ›ȱ’—ȱŠȱœ‘Š••˜ ȱ™Š—ȱ
with the open end up. Pour new oil of the proper
type, in through the threaded center hole. Stop
™˜ž›’—ȱ ‘Ž—ȱ‘Žȱ˜’•ȱ›ŽŠŒ‘Žœȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ
threads. Allow a minute or two for the oil to be
Š‹œ˜›‹Žȱ‹¢ȱ‘ŽȱꕝŽ›ȱ–ŠŽ›’Š•ǯȱ
ȱ řǯȱ ™™•¢ȱŠȱ‘’—ȱꕖȱ˜ȱŒ•ŽŠ—ȱ˜’•ȱ˜ȱ‘Žȱ›ž‹‹Ž›ȱ
Šœ”Žȱ˜—ȱ‘Žȱ—Ž ȱꕝŽ›ǯȱ‘›ŽŠȱ‘ŽȱꕝŽ›ȱ˜—˜ȱ
the engine until the rubber gasket contacts the
œž›ŠŒŽǰȱ‘Ž—ȱ’‘Ž—ȱ‘ŽȱꕝŽ›ȱŠ—ȱŠ’’˜—Š•ȱ
3/4 to 1 turnǯȱŽŽȱ’ž›ŽȱŗŖȬŞŚǯȱ’••ȱ‘ŽȱŒ›Š—”ŒŠœŽȱ
with new oil of the proper type, to the “F” mark
on the dipstick.
Figure 10-84. Installing Oil Filter.
10.24
Prepare the Engine for Operation
The engine is now completely reassembled. Before
starting or operating the engine, be sure the following
have been done.
1. All hardware is tightened securely.
2. The oil drain plug, Oil Sentry™ pressure switch
ǻ’ȱœ˜ȱŽšž’™™ŽǼǰȱŠ—ȱŠȱ—Ž ȱ˜’•ȱꕝŽ›ȱŠ›Žȱ’—œŠ••Žǯ
ȱ řǯȱ ‘ŽȱŒ›Š—”ŒŠœŽȱ’œȱꕕŽȱ ’‘ȱ‘ŽȱŒ˜››ŽŒȱŠ–˜ž—ǰȱ
weight, and type of oil.
Testing the Engine
It is recommended that the engine be operated on a
test stand or bench prior to installation in the piece of
equipment.
1. Set the engine up on a test stand. Install an oil
pressure gauge. Start the engine and check to be
certain that oil pressure (5 psiȱ˜›ȱ–˜›ŽǼȱ’œȱ™›ŽœŽ—ǯ
ȱ Řǯȱ ž—ȱ‘ŽȱŽ—’—Žȱ˜›ȱśȬŗŖȱ–’—žŽœȱ‹Ž ŽŽ—ȱ’•ŽȱŠ—ȱ
–’Ȭ›Š—Žǯȱ“žœȱ‘Žȱ‘›˜Ĵ•ŽȱŠ—ȱŒ‘˜”ŽȱŒ˜—›˜•œȱ
Š—ȱ‘Žȱ‘’‘Ȭœ™ŽŽȱœŽĴ’—ȱŠœȱ—ŽŒŽœœŠ›¢ǯȱŠ”Žȱ
sure the maximum engine speed does not exceed
3300 RPM. Adjust the carburetor idle fuel needle
and/or idle speed screw as necessary. Refer to
Section 5, Fuel System and Governor.
 FORM NO.: TP-2548-A
ISSUED: 9/03
REVISED: 10/07
LITHO IN U.S.A.

FOR SALES AND SERVICE INFORMATION

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

KohlerEngines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044