Kohler Aegis TP-2509 User Manual

1KOHLER® AEGIS™ 17,20,23 HPSERVICE MANUALLIQUID-COOLEDVERTICAL CRANKSHAFT

1.8Section 1Safety and General InformationGeneral Specifications1Power (@ 3600 RPM, corrected to SAE J1995)LV560...

10.8Section 10Inspection and ReconditioningPistons and RingsInspectionScuffing and scoring of pistons and cylinder wallsoccurs when internal temperatu

10.9Section 10Inspection and Reconditioning10Replacement pistons are available in STD bore size,0.08 mm (0.03 in.), 0.25 mm (0.010 in.), and 0.50mm (0

10.10Section 10Inspection and ReconditioningInstall Piston RingsTo install piston rings, proceed as follows:NOTE: Rings must be installed correctly. R

10.11Section 10Inspection and Reconditioning10NOTE: The governor gear is held onto the shaft bysmall molded tabs in the gear. When the gearis removed

10.12Section 10Inspection and ReconditioningFigure 10-15. Installing Cross Shaft Oil Seal.Figure 10-16. Governor Shaft Seal Installation.2.0 mm (0.078

11.1Section 11Reassembly11Section 11ReassemblyLV560, LV625, LV675GeneralNOTE: Make sure the engine is assembled usingall specified torque values, tigh

11.2Section 11ReassemblyFigure 11-1. Installing Flywheel End Oil Seal inCrankcase.The camshaft seal should be installed to a depthof 1-1.5 mm (.039-.0

11.3Section 11Reassembly11Figure 11-5. Proper Piston Connecting RodOrientation.1. Stagger the piston rings in the grooves. The endgaps of the top two

11.4Section 11ReassemblyFigure 11-8. Assembly of Nylon Washer, Retainer,and Setting the End play.Install Camshaft1. Inspect the edges of the keyway in

11.5Section 11Reassembly11Determining Camshaft End Play1. Install the shim removed during disassembly ontothe camshaft.2. Position the camshaft end pl

1.9Section 1Safety and General Information1Carburetor and Intake ManifoldIntake Manifold Mounting Fasteners Torque ...

11.6Section 11Reassembly3. Install the O-Ring in groove as shown. See Figure11-14. Apply a 1.5 mm (1/16 in.) bead of sealantto the sealing surface of

11.7Section 11Reassembly11Figure 11-17. Applying Loctite to New Stud.2. Tighten two nuts together on the shorter threadedsection.3. Thread the end of

11.8Section 11ReassemblyAssemble Cylinder HeadsPrior to installation, lubricate all components withengine oil, paying particular attention to the lip

11.9Section 11Reassembly11Figure 11-24. Cylinder Head Torque Sequence.Figure 11-25. Torquing Cylinder Heads.6. Note the mark or tag identifying each p

11.10Section 11Reassembly9. Mount a dial indicator to touch the top of the valveretainer, of the valve to be set. See Figure 11-27.NOTE: At this time,

11.11Section 11Reassembly11Figure 11-30. Installing Shim(s).14. Reassemble the rocker arm and pivot assemblyto the head and seat the push rod. See Fig

11.12Section 11ReassemblyFigure 11-33. Depressing To Bottom Limit of LifterPlunger Travel.10. With the lifter still compressed, slowly tightenthe rock

11.13Section 11Reassembly11Figure 11-36. Installing Shim(s).Figure 11-37. Torquing Rocker Arm.15. Hold down the push rod end of the rocker arm(step 9)

11.14Section 11ReassemblyFigure 11-42. Installing Pipe Plug.Install Oil Fill/Dipstick Tube Assembly andLower Blower Housing1. Lubricate the O-Ring wit

11.15Section 11Reassembly11Figure 11-44. Tie Strap in Lower Blower Housing.3. Set the lower blower housing down into positionon the crankcase, and ali

1.10Section 1Safety and General InformationCrankshaft (Cont'd.)Connecting Rod JournalO.D. - New ...

11.16Section 11ReassemblyFigure 11-48. Torquing Thermostat Housing Screws.4. Check that the gasket surfaces of the intakemanifold and cylinder heads a

11.17Section 11Reassembly11from the crankshaft. Orient the parts as shown inFigure 11-54 while tightening. Torque the six intakemanifold mounting scre

11.18Section 11ReassemblyFigure 11-59. Installing O-Ring in Crankcase forWater Pump.NOTE: A mark or dot of paint applied to top ofpulley indicating th

11.19Section 11Reassembly11Figure 11-62. Installing Ferrule and Hex. Cap ontoFitting.2) Insert the plain end of the transfer tubethrough the hex. cap

11.20Section 11ReassemblyNOTE: When installation is complete, the tangsof the two hose clamps must be downtoward the crankcase, away from theflywheel

11.21Section 11Reassembly11Figure 11-70. By-pass Hose Installation.Install Stator and Rectifier-Regulator1. Position the stator onto the mounting boss

11.22Section 11Reassembly3. Place the small sleeve spacer onto the stud, inthe center of the intake manifold. If the stud wasremoved from the manifold

11.23Section 11Reassembly118. Lift the by-pass hose and secure it within themetal clip under the main support bracket. SeeFigure 11-78.Figure 11-78. S

11.24Section 11ReassemblyInstall Ignition Modules and Flywheel1. Route the spark plug leads of the ignitionmodules, out through the corresponding cuto

11.25Section 11Reassembly113. Lower the flywheel down into position oncrankshaft and make sure the ring gear sectionis below the legs of the ignition

1.11Section 1Safety and General Information1IgnitionSpark Plug Type (Champion® or equivalent) ... RC14YC (Kohler

11.26Section 11Reassembly7. Rotate the flywheel back and forth checking forclearance between the magnet and ignitionmodules. Make sure the magnet does

11.27Section 11Reassembly11Figure 11-93. Attaching Linkages onto Carburetor.Checking Valve Train1. Rotate engine to check for free operation of theval

11.28Section 11Reassembly3. Install the carburetor as an assembly, onto thecarburetor studs. See Figure 11-94. Carefully liftup on the lower blower ho

11.29Section 11Reassembly11Install Throttle Controls1. Connect the choke linkage from the carburetor into the choke actuator lever on the speed contro

11.30Section 11ReassemblyInstall Air Cleaner Base1. Install a new air cleaner base gasket onto thecarburetor studs.2. Install the air cleaner base ont

11.31Section 11Reassembly11Figure 11-102. Rechecking Governor LinkageAdjustment.4. After adjustment is correct, reinstall the blackbushing and linkage

11.32Section 11Reassembly1. Use equal parts of ethylene glycol (anti-freeze)and water only. Distilled or deionized water isrecommended, especially in

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044FOR SALES AND SERVICE INFORMATIONIN U.S. AND CANADA, CALL1-800-544-2444LITHO IN U.S.A.FORM NO.: TP

1.12Section 1Safety and General Information²Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.Piston, Pi

1.13Section 1Safety and General Information1Valves and Valve Lifters (Cont'd.)Intake Valve Guide I.D.New...

1.14Section 1Safety and General InformationEnglish Fastener Torque Recommendations for Standard ApplicationsGrade 2 or 5Fasteners IntoAluminumSize8-32

2.1Section 2Special Tools2LV560, LV625, LV675Section 2Special ToolsThese quality tools are designed to help you perform specific disassembly, repair,

2.2Section 2Special ToolsSpecial Tools You Can MakeFlywheel Holding ToolFlywheel removal and reinstallation becomes a ‘‘snap’’using a handy holding to

3.1Section 3Troubleshooting3Section 3TroubleshootingTroubleshooting GuideWhen troubles occur, be sure to check the simplecauses which, at first, may s

ContentsSection 1. Safety and General Information ...Section 2. Special Tools

3.2Section 3TroubleshootingEngine Overheats (cont'd.)7. Radiator cap faulty or loose.8. Lean fuel mixture.9. Water pump belt failed/off.10. Water

3.3Section 3Troubleshooting3NOTE: It is good practice to drain oil at a locationaway from the workbench. Be sure toallow ample time for complete drain

3.4Section 3TroubleshootingLeakdown Test Instructions1. Run engine 3-5 minutes to warm it up.2. Remove spark plugs, dipstick, and air filter fromengin

4.1Section 4Air Cleaner and Air Intake System4Section 4Air Cleaner and Air Intake SystemLV560, LV625, LV675Air Intake SystemGeneralAll intake air, for

4.2Section 4Air Cleaner and Air Intake SystemFigure 4-4. Cleaning Separated Screen Assembly.Always reinstall the upper blower assembly after it hasbee

4.3Section 4Air Cleaner and Air Intake System42. Remove the precleaner from the paper element.See Figure 4-7.Figure 4-7. Removing Precleaner from Pape

4.4Section 4Air Cleaner and Air Intake System4. Disconnect the breather hose from the aircleaner base.Figure 4-9. Base Plate Removal on Standard Type.

5.1Section 5Fuel System and Governor5Section 5Fuel System and GovernorDescriptionWARNING: Explosive Fuel!Gasoline is extremely flammable and its vapor

5.2Section 5Fuel System and GovernorFuel System TestsWhen the engine starts hard, or turns over but will not start, it is possible that the problem is

5.3Section 5Fuel System and Governor52. Remove the hex. flange screws (securing pumpto blower housing) and fuel pump.3. Remove the vacuum line that co

1.1Section 1Safety and General Information1Section 1Safety and General InformationSafety PrecautionsTo insure safe operations please read the followin

5.4Section 5Fuel System and GovernorSlow Circuit: (Figure 5-2) At low speeds the engine operates only on the slow circuit. As a metered amount of airi

5.5Section 5Fuel System and Governor5Main Circuit: (Figure 5-3) At high speeds the engine operates mostly on the main circuit. As a metered amountof a

5.6Section 5Fuel System and GovernorTroubleshooting ChecklistWhen the engine starts hard, runs roughly or stalls atlow idle speed, check the following

5.7Section 5Fuel System and Governor5Fuel Shut-off SolenoidCarburetors are equipped with a fuel shut-off solenoid,which also contains the main jet. Th

5.8Section 5Fuel System and GovernorFloat ReplacementIf symptoms described in the carburetortroubleshooting guide indicate float level problems,remove

5.9Section 5Fuel System and Governor5Figure 5-6. Carburetor - Exploded View.Inspection/RepairTo clean vent ports, internal circuits etc., use a goodco

5.10Section 5Fuel System and GovernorOverhaul Kit Contains: Reassembly ProcedureReassembly is essentially the reverse of thedisassembly procedure. Use

5.11Section 5Fuel System and Governor5Figure 5-7. Governor Controls and Linkage (External).AdjustmentsGeneralThe governed speed setting is determined

5.12Section 5Fuel System and GovernorThrottle Control CableChoke Control CableKill SwitchAdjusting ScrewDual Control High IdleLever Stop Screw"Do

6.1Section 6Lubrication System6Section 6Lubrication SystemGeneralThis engine uses a full pressure lubrication system.This system delivers oil under pr

1.2Section 1Safety and General InformationCarbon Monoxide can causesevere nausea, fainting or death.Do not operate engine in closed orconfined area.WA

6.2Section 6Lubrication SystemFigure 6-3. Oil Level Marks on Dipstick.NOTE: To prevent extensive engine wear ordamage, always maintain the proper oill

6.3Section 6Lubrication System63. Before removing the oil filter, clean thesurrounding area to keep dirt and debris out of theengine. Remove the old f

6.4Section 6Lubrication SystemTo install the switch, follow these steps:1. Apply Loctite® No. 592 Pipe Sealant withTeflon® (or equivalent) to the thre

7.1Section 7 Cooling System7Section 7Cooling SystemWARNING: Explosive release of fluids from pressurized cooling system can cause serious burns!When i

7.2Section 7Cooling SystemCoolant RecommendationsUse equal parts of ethylene glycol (anti-freeze) andwater only. Distilled or deionized water isrecomm

7.3Section 7 Cooling System7Figure 7-4. Coolant Levels on Reservoir.NOTE: Do not operate the engine without coolant inthe system. Do not remove the ra

7.4Section 7Cooling SystemFigure 7-8. Removing Overflow Reservoir.7. Reinstall the reservoir, inserting the two lowermolded protrusions into the mount

7.5Section 7 Cooling System7Hoses and TubesHoses and tubes are used to connect the componentswithin the cooling system. To guard against coolantloss a

7.6Section 7Cooling SystemHigh Temperature SensorA high temperature sensor may be mounted in theintake manifold and is used to activate a warning ligh

7.7Section 7 Cooling System7Figure 7-12. Adapter Installed onto the Tester.2. Pressurize the tester to 15 psi.3. Observe the indicated pressure. It sh

1.3Section 1Safety and General Information1L V 675 SA. Model No.Liquid CooledVertical CrankshaftDisplacement/Size (cc)Version CodeS = Electric StartFi

7.8Section 7Cooling System

8.1Section 8Electrical System and Components8Section 8Electrical System and ComponentsThis section covers the operation, service and repair ofthe elec

8.2Section 8Electrical System and ComponentsNormal: A plug taken from an engine operating undernormal conditions will have light tan or gray coloredde

8.3Section 8Electrical System and Components8Overheated: Chalky, white deposits indicate very highcombustion temperatures. This condition is usuallyac

8.4Section 8Electrical System and ComponentsElectronic CD Ignition SystemsOperation of CD Ignition SystemsCapacitive Discharge with Fixed TimingThis s

8.5Section 8Electrical System and Components8Figure 8-5. Capacitive Discharge Ignition Module.Operation: As the flywheel rotates, the magnetgrouping p

8.6Section 8Electrical System and ComponentsTest1. If one side is not firing, check all wiring,connections, and terminations on that side. Ifwiring is

8.7Section 8Electrical System and Components8BatteryBattery (R)_+Starter (L/R)Run (R)Ignition Kill (W)Accessory (Y)Key SwitchGround (B)GroundStarterBa

8.8Section 8Electrical System and ComponentsLighting Lead(Yellow)Charging Lead(Black)DiodeLighting Stator3 Amp Charging StatorFigure 8-9. 3 amp/70 Wat

8.9Section 8Electrical System and Components8StatorThe stator is mounted on the crankcase behind theflywheel. Should the stator have to be replaced, f

1.4Section 1Safety and General InformationOil RecommendationsUsing the proper type and weight of oil in thecrankcase is extremely important. So is che

8.10Section 8Electrical System and ComponentsTroubleshooting Guide15/20/25 amp Battery Charging SystemsIf it is difficult to keep the battery charged,

8.11Section 8Electrical System and Components8Troubleshooting Guide3 amp Battery Charging System with 70 Watt Lighting StatorNOTE: Zero ohmmeters on e

8.12Section 8Electrical System and ComponentsSolenoid Shift Electric StartersThe following subsection covers the solenoid shiftstyle electric starters

8.13Section 8Electrical System and Components8Delco-Remy StartersFigure 8-13. Removing Solenoid Screws.Figure 8-14. Solenoid Removed from Starter.3. L

8.14Section 8Electrical System and ComponentsFigure 8-21. Retaining Ring Detail.5. Remove the commutator end plate assembly,containing the brush holde

8.15Section 8Electrical System and Components8LeverSolenoidCE FrameBoltRingStopDriveArmatureWasher11. Remove the retainer from the armature shaft.Save

8.16Section 8Electrical System and ComponentsInspectionDrive Pinion Check and inspect the following areas:a. The pinion teeth for abnormal wear ordam

8.17Section 8Electrical System and Components82. Remove the two screws securing the brush holderassembly to the end cap (plate). Note theorientation f

8.18Section 8Electrical System and Components4. Apply a small amount of oil to the bearing in thedrive end cap, and install the armature with thedrive

8.19Section 8Electrical System and Components810. Starter reassembly when replacing the Brushes/Brush Holder Assembly:a. Hold the starter assembly ver

1.5Section 1Safety and General Information1Fuel TypeFor best results, use only clean, fresh, unleadedgasoline with a pump sticker octane rating of 87

8.20Section 8Electrical System and Components11. Install the end cap onto armature and frame,aligning the thin raised rib in the end cap with thecorre

8.21Section 8Electrical System and Components8Starter AssemblyFigure 8-44. Nippendenso Solenoid Shift Starter.Operation – Solenoid Shift StarterWhen p

8.22Section 8Electrical System and Components8. The outward travel of the drive pinion is controlledby a snap ring, installed in a groove in thearmatu

9.1Section 9Disassembly9Section 9DisassemblyWARNING: Accidental Starts!19. Remove water pump and transfer tube.20. Remove by-pass hose and wiring harn

9.2Section 9DisassemblyShut Off Fuel SupplyDrain Oil From Crankcase andRemove Oil Filter1. Remove the dipstick and one of the oil drainplugs. See Figu

9.3Section 9Disassembly9Figure 9-6. Separating Screen from Housing.Remove Muffler1. Remove the muffler or exhaust system andattaching hardware from th

9.4Section 9Disassembly2. Disconnect the fuel lines at the inlet of thecarburetor, and the in-line fuel filter. See Figure 9-11.Figure 9-11. Removing

9.5Section 9Disassembly9Figure 9-17. Loosening Governor Lever Clamp Nut.3. Remove the four hex. flange screws securing thethrottle control bracket to

9.6Section 9Disassembly4. Remove the throttle control bracket, governorlever, and governor spring as an assembly. SeeFigure 9-19.Figure 9-19. Removing

9.7Section 9Disassembly9Figure 9-23. Location of Four Screws SecuringBlocking Plates.Remove Overflow Reservoir1. Remove the reservoir cap from the res

1.6Section 1Safety and General InformationStorageIf the engine will be out of service for two months ormore, use the following storage procedure:1. Cl

9.8Section 9DisassemblyFigure 9-27. Removing Ignition Module.4. Repeat the procedure for the other ignition module.Remove Flywheel1. Use a flywheel ho

9.9Section 9Disassembly9Figure 9-31. Removing Center Mounting Nut.2. Cut the metal tie strap from around the lowerhose/tube assembly, secured to the

9.10Section 9DisassemblyFigure 9-36. Lower Hose Removed.6. Lift the entire cooling system, with the radiators,hoses, and supporting brackets attached,

9.11Section 9Disassembly9Figure 9-40. Removing B+ Charging Lead fromConnector.4. Remove the stator and rectifier-regulator.Remove Cam Pulley and Coola

9.12Section 9DisassemblyFigure 9-44. Removing Hex. Cap Section.3. Remove the six screws securing the water pumpto the crankcase. See Figure 9-45.Figur

9.13Section 9Disassembly9Figure 9-48. Removing No. 1 Side Intake ManifoldScrews with the Ground Leads.3. Disconnect the wire leads from the Oil Sentry

9.14Section 9DisassemblyFigure 9-52. Removing Remaining Intake ManifoldScrews.2. Separate the intake manifold from the cylinderheads and remove it, by

9.15Section 9Disassembly9Figure 9-56. Removing Dipstick Tube Assembly.Remove Oil Sentry™ (If So Equipped)1. Remove the Oil Sentry™ switch, from the br

9.16Section 9DisassemblyFigure 9-63. Removing the Valve Cover.Remove Cylinder Heads and HydraulicLifters1. Rotate the crankshaft until the valves of o

9.17Section 9Disassembly9Figure 9-65. Removing Hex. Flange Nuts andWashers from Studs.5. Carefully remove the cylinder heads, and headgaskets. See Fig

1.7Section 1Safety and General Information1Figure 1-4. Typical Engine Dimensions.260.6Cyl. #118.2Oil Fill &DipstickMounting Hole ‘‘A’’285.5 O

9.18Section 9DisassemblyFigure 9-72. Removing Oil Pan Fasteners.2. Locate the splitting tab cast into the perimeter ofthe oil pan. Insert the drive en

9.19Section 9Disassembly9Oil Pump AssemblyThe oil pump is mounted in the oil pan. If service isrequired, refer to the service procedures under ‘‘OilPu

9.20Section 9Disassembly2. Carefully remove the connecting rod and pistonassembly from the cylinder bore. See Figure 9-78.NOTE: The cylinders are numb

10.1Section 10Inspection and Reconditioning10Section 10Inspection and ReconditioningThis section covers the operation, inspection, and repair/recondit

10.2Section 10Inspection and ReconditioningInspect the crankpin for score marks or metallic pickup. Slight score marks can be cleaned with crocuscloth

10.3Section 10Inspection and Reconditioning10CrankcaseThese engines contain a cast-iron cylinder liner thatmay be reconditioned as follows:Inspection

10.4Section 10Inspection and Reconditioning2. Use an inside micrometer, telescoping gauge,or bore gauge and measure the cylinder bore.Take the measure

10.5Section 10Inspection and Reconditioning10ABCDEFGHSeat AngleInsert O.D.Guide DepthGuide I.D.Valve Head DiameterValve Face AngleValve Margin (Min.)V

10.6Section 10Inspection and ReconditioningLeakage: A poor grind on face or seat of valve will allowleakage resulting in a burned valve on one side on

10.7Section 10Inspection and Reconditioning10Valve GuidesIf a valve guide is worn beyond specifications, it will notguide the valve in a straight line