Kohler COMMAND CH18-745 User Manual

SERVICE MANUALHORIZONTAL CRANKSHAFTCOMMAND CH18-745

1.9Section 1Safety and General Information1CamshaftEnd Play (With Shim) ...

5B.41Section 5BEFI Fuel System5BCode: 51 "32 Pin" (MSE 1.1) Plastic-Cased ECU only.Source: Injector #1 circuit open, shorted toground, or sh

5B.42Section 5BEFI Fuel SystemCode: 56 "32 Pin" (MSE 1.1) Plastic-Cased ECU only.Source: Fuel pump relay circuit open, shortedto ground, or

5B.43Section 5BEFI Fuel System5BFigure 5B-44.*Operate for an appropriate period of time based upon original fault codes.

5B.44Section 5BEFI Fuel SystemFlow Chart Diagnostic AidsDiagnostic Aid #1 "SYSTEM POWER" (MIL does notilluminate when key is turned “on”)Pos

5B.45Section 5BEFI Fuel System5BDiagnostic Aid #4 “SPEED SENSOR” (MIL does notturn off during cranking). Indicates the ECU is notreceiving a signal fr

5B.46Section 5BEFI Fuel System

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

6.2Section 6Lubrication SystemNOTE: To prevent extensive engine wear or damage,always maintain the proper oil level in thecrankcase. Never operate the

6.3Section 6Lubrication System61. Clean the areas around the drain plug, oil filter, oilfill cap and dipstick.2. Remove one of the oil drain plugs. A

6.4Section 6Lubrication SystemFigure 6-7. Oil Coolers.Inspect and clean the oil cooler every 100 hours ofoperation (more frequently under severe condi

1.10Section 1Safety and General InformationClosure PlateClosure Plate Fastener Torque ... 2

6.5Section 6Lubrication System6To install the switch, follow these steps:1. Apply pipe sealant with Teflon® (Loctite® No.59241 or equivalent) to the t

6.6Section 6Lubrication System

7.1Section 7Retractable Starter7Section 7Retractable StarterWARNING: Spring Under Tension!Retractable starters contain a powerful, recoil spring that

7.2Section 7Retractable StarterFigure 7-3. Installing Rope.10. Tie a slipknot approximately 12 in. from the freeend of rope. Hold the pulley firmly an

7.3Section 7Retractable Starter7DisassemblyWARNING: Spring Under Tension!Do not remove the center screw from the starter untilthe spring tension is re

7.4Section 7Retractable Starter8. Note the position of the spring and keeperassembly in the pulley. See Figure 7-7.Remove the spring and keeper assemb

7.5Section 7Retractable Starter74. Place the brake washer in the recess in starterpulley; over the center shaft.5. Lubricate the brake spring sparingl

7.6Section 7Retractable Starter

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

1.11Section 1Safety and General Information1Cylinder HeadCylinder Head Fastener TorqueHex. Flange Nut - Torque in Two Stages...

8.3Section 8Electrical System and Components82. Keep the cables, terminals, and external surfacesof the battery clean. A build-up of corrosive acid or

8.4Section 8Electrical System and ComponentsThe SMART-SPARK™ ignition system used on somemodels is an advanced version of the CD ignitionsystem used o

8.5Section 8Electrical System and Components8Figure 8-4. Capacitive Discharge (Fixed Timing) Ignition System.Kill Switch or‘‘Off’’ Position ofKey Swit

8.6Section 8Electrical System and ComponentsFigure 8-6. Capacitive Discharge Ignition System with Spark Advance.PowerSourcePulseGeneratorResetCircuitB

8.7Section 8Electrical System and Components8The pulse generated by the input coil of the ignitionmodule (L1, Figure 8-5) is fed to the input of theco

8.8Section 8Electrical System and Componentsc. If neither side is firing, recheck position ofignition switch and check for shorted kill lead.Test Proc

8.9Section 8Electrical System and Components8Figure 8-9.3. Run the engine at idle and use the timing lightbeam to locate the line on the screen. Draw

8.10Section 8Electrical System and Components5. Check and/or adjust the ignition module airgap(s). An air gap of 0.28/0.33 mm(0.011/0.013 in.) must be

8.11Section 8Electrical System and Components8terminal of the ground lead or the groundscrew/bolt. Check the voltage with the keyswitch in both the “S

8.12Section 8Electrical System and ComponentsFigure 8-12.2. Check the SAM part number, stamped on the sideof the housing, and determine if you have an

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.MufflerMuf

8.13Section 8Electrical System and Components8Battery Charging SystemGeneralMost engines are equipped with a 15 or 20 ampregulated charging system. So

8.14Section 8Electrical System and Components15/20/25 amp Regulated Charging SystemFigure 8-14. Wiring Diagram - 15/20/25 amp Regulated Battery Chargi

8.15Section 8Electrical System and Components8Figure 8-17. 25 amp Stator and Rectifier-Regulators.Ground-To-Kill Lead (White)DiodeKeySwitchOptionalOil

8.16Section 8Electrical System and ComponentsFigure 8-19. 3 amp/70 Watt Stator.StatorThe stator is mounted on the crankcase behind theflywheel. Follow

8.17Section 8Electrical System and Components83. Plug the tester into a 110 volt AC outlet supplyand turn on the power switch. See Figure 8-22.The ‘‘P

8.18Section 8Electrical System and Components6. Press the ‘‘TEST’’ button until a ‘‘click’’ is heardand then release. See Figure 8-23. Momentarilyone

8.19Section 8Electrical System and Components8Figure 8-28.3. Plug the tester into a 110 volt AC outlet and turnon the power switch. The ‘‘POWER’’ ligh

8.20Section 8Electrical System and ComponentsProblem Test Conclusion1. Trace B+ lead from rectifier-regulator to keyswitch, or other accessible connec

8.21Section 8Electrical System and Components8Troubleshooting Guide3 amp Battery Charging System with 70 Watt Lighting StatorNOTE: Zero ohmmeters on e

8.22Section 8Electrical System and ComponentsElectric Starting MotorsSome engines in this series use inertia drive startingmotors while most use solen

1.13Section 1Safety and General Information1Piston, Piston Rings, and Piston Pin cont.Piston Thrust Face-to-Cylinder Bore² Running ClearanceNew - CH18

8.23Section 8Electrical System and Components8Operation - Inertia Drive StartersWhen power is applied to the starter, the armaturerotates. As the arma

8.24Section 8Electrical System and Components3. Again referring to Figure 8-31, grasp the springretainer and push it toward the starter,compressing th

8.25Section 8Electrical System and Components8Retaining Ring Installation1. Position the retaining ring in the groove in one ofthe inner halves. Assem

8.26Section 8Electrical System and ComponentsNOTE: Use a brush holder tool to keep thebrushes in the pockets. A brush holdertool can easily be made fr

8.27Section 8Electrical System and Components8Figure 8-38. Style ‘‘B’’ Commutator End Cap withBrushes.6. Install the thru bolts and tighten securely.7

8.28Section 8Electrical System and ComponentsStarter Disassembly1. Disconnect the lead wire from the solenoid.2. Remove the hex. nuts securing the sol

8.29Section 8Electrical System and Components8Figure 8-41. Removing Solenoid Screws.3. If the solenoid was mounted with Phillips headscrews, separate

8.30Section 8Electrical System and ComponentsFigure 8-44. Removing Thru Bolts.5. Remove the commutator end plate assembly,containing the brush holder,

8.31Section 8Electrical System and Components8Figure 8-50. Removing Retaining Ring.12. Remove the drive pinion assembly from thearmature.13. Clean the

8.32Section 8Electrical System and ComponentsFigure 8-52. Checking Brushes.Armature1. Clean and inspect the commutator (outersurface). The mica insula

1.14Section 1Safety and General InformationValves and Valve Lifters cont.Exhaust Valve Guide I.D.New...

8.33Section 8Electrical System and Components8Figure 8-56. Service Brush Kit.5. Perform Steps 10-13 in the “Starter Reassembly”sequence. Installation

8.34Section 8Electrical System and ComponentsFigure 8-58. Installing Thrust Washer.4. Apply a small amount of oil to the bearing in thedrive end cap,

8.35Section 8Electrical System and Components8Figure 8-62. Installing Thrust Washer.10. Starter reassembly when replacing the Brushes/Brush Holder Ass

8.36Section 8Electrical System and ComponentsFigure 8-66. Installing Brush Holder Assemblyusing Tool with Extension.11. Install the end cap onto the a

9.1Section 9Disassembly9Section 9DisassemblyWARNING: Accidental Starts!Disabling engine. Accidental starting can cause severe injury or death. Before

9.2Section 9DisassemblyFigure 9-2. Removing Dipstick from Tube.Figure 9-3. Removing Oil Fill Cap from Cover.Figure 9-6. Removing Oil Filter Adapter Ni

9.3Section 9Disassembly9Figure 9-7. Removing Oil Cooler.4. An oil cooler is standard equipment on somemodels and an option on others. It may be a cast

9.4Section 9DisassemblyFigure 9-11. Removing Tube from Breather Cover.6. Remove the rubber breather tube from thebreather cover. See Figure 9-11.Remov

9.5Section 9Disassembly9Figure 9-15. Removing Screws Holding Fuel Pump(Metal Bodied Pump Shown).4. Note or mark the orientation of the fuel pump,then

9.6Section 9DisassemblyFigure 9-19. Rear Air Cleaner Bracket (SomeModels).2. Mark the spring hole locations and disconnect thespring from the governor

1.15Section 1Safety and General Information1English Fastener Torque Recommendations for Standard ApplicationsGrade 2 or 5Fasteners IntoAluminumSize8-3

9.7Section 9Disassembly93. Remove the carburetor, throttle linkage andgovernor lever as an assembly. See Figure 9-24.Figure 9-26. Removing Electric St

9.8Section 9DisassemblyFigure 9-29. Removing the Spark Advance Module(Applicable Models).4. Remove the three (each side) hex. flange screwssecuring th

9.9Section 9Disassembly9Figure 9-34. Removing Fasteners Holding Baffleand Breather Cover.2. Remove both inner baffles. See Figure 9-35.Figure 9-35. Re

9.10Section 9Disassembly7. Remove the hex. flange screw, breather reedretainer and breather reed. See Figure 9-39.Figure 9-39. Removing Breather Reed.

9.11Section 9Disassembly9Figure 9-41. Disconnecting Leads from IgnitionModules.2. Rotate the flywheel so the magnet is away fromthe modules.3. Remove

9.12Section 9DisassemblyFigure 9-46. Removing Cylinder Head Fasteners.2. Mark the position of the push rods as either intakeor exhaust and cylinder 1

9.13Section 9Disassembly9Figure 9-48. Removing Hydraulic Lifter.Figure 9-47. Removing Cylinder Head Assembly.4. Remove the lifters from the lifter bor

9.14Section 9DisassemblyFigure 9-53. Valve Train Components.Figure 9-51. Removing Rocker Arms.2. Compress the valve springs using a valve springcompre

9.15Section 9Disassembly9Figure 9-55. Removing Plastic Type Grass Screen.2. Remove the four hex. flange screws and fan. SeeFigure 9-56.Figure 9-56. Re

9.16Section 9DisassemblyFigure 9-63. Breaking Seal on Top Splitting Tab.Governor Gear AssemblyThe governor gear assembly is located inside theclosure

1.16Section 1Safety and General Information

9.17Section 9Disassembly9Figure 9-65. Removing Connecting Rod Bolts.NOTE: If a carbon ridge is present at the top ofeither cylinder bore, use a ridge

9.18Section 9DisassemblyFigure 9-68. Removing Crankshaft.Remove Governor Cross Shaft1. Remove the hitch pin and plain washer, or theretainer and nylon

10.1Section 10Inspection and Reconditioning10Section 10Inspection and ReconditioningThis section covers the operation, inspection, andrepair/reconditi

10.2Section 10Inspection and ReconditioningInspect the crankshaft bearing surfaces for scoring,grooving, etc. Some engines have bearing inserts inthe

10.3Section 10Inspection and Reconditioning10Check the cylinder bore wall for scoring. In severecases, unburned fuel can cause scuffing and scoringof

10.4Section 10Inspection and ReconditioningThe final cleaning operation should always be athorough scrubbing with a brush and hot, soapy water.Use a s

10.5Section 10Inspection and Reconditioning10EXHAUSTVALVEEGFHDDCABABAFEGHINTAKE VALVEEXHAUSTINSERTINTAKEINSERTABCDEFGHSeat AngleInsert O.D.Guide Depth

10.6Section 10Inspection and ReconditioningNormal: Even after long hours of operation a valvecan be reconditioned and reused if the face andmargin are

10.7Section 10Inspection and Reconditioning10Excessive Combustion Temperatures: The whitedeposits seen here indicate very high combustiontemperatures,

10.8Section 10Inspection and ReconditioningValve GuidesIf a valve guide is worn beyond specifications, it will notguide the valve in a straight line.

2.1Section 2Special Tools2Section 2Special ToolsCH18-745Certain quality tools are designed to help you perform specific disassembly, repair, and reass

10.9Section 10Inspection and Reconditioning10Ring failure is usually indicated by excessive oilconsumption and blue exhaust smoke. When ringsfail, oil

10.10Section 10Inspection and ReconditioningPiston RingPiston RingExpanderReplacement pistons are available in STD bore size,and in 0.25 mm (0.010 in.

10.11Section 10Inspection and Reconditioning10Figure 10-12. Piston Ring Installation.1. Oil Control Ring (Bottom Groove): Install theexpander and then

10.12Section 10Inspection and ReconditioningFigure 10-13. Removing Governor Gear.2. Remove the locking tab thrust washer locatedunder the governor gea

10.13Section 10Inspection and Reconditioning103. Install the rotor.4. Install the oil pump body to the closure plate andsecure with the two hex. flang

10.14Section 10Inspection and Reconditioning

11.1Section 11Reassembly11Section 11ReassemblyGeneralNOTE: Make sure the engine is assembled using allspecified torque values, tightening sequencesand

11.2Section 11ReassemblyFigure 11-2. Installing Oil Seal.Install Governor Cross Shaft1. Lubricate the governor cross shaft bearingsurfaces in the cran

11.3Section 11Reassembly11Figure 11-9. Installing Piston Assembly Using RingCompressor Tool.5. Install the inner rod cap to the connecting rodusing th

11.4Section 11ReassemblyFigure 11-10. Connecting Rod Bolts.Figure 11-12. Apply Camshaft Lubricant to CamLobes.2. Position the timing mark of the crank

2.2Section 2Special ToolsFigure 2-1. Tool Catalog and Price List.Special Tools You Can MakeFlywheel Holding ToolFlywheel removal and reinstallation be

11.5Section 11Reassembly11Figure 11-14. Checking Camshaft End Play.3. Apply pressure on the camshaft end playchecking tool (pushing camshaft towardcra

11.6Section 11ReassemblyRemove the closure plate. If end play requiresadjustment, remove the original spacer and install theappropriate size shim spac

11.7Section 11Reassembly11Figure 11-19. Closure Plate Sealant Pattern.4. Make sure the end of the governor cross shaft islying against the bottom of c

11.8Section 11ReassemblyInstall FlywheelWARNING: Damaging Crankshaft andFlywheel Can Cause Personal Injury!Using improper procedures to install the fl

11.9Section 11Reassembly11Figure 11-29. Installing and Torquing FlywheelFastener.Install Flywheel Fan1. Install the fan onto the flywheel using the fo

11.10Section 11ReassemblyInstall Supports for the Metal Grass Screen1. If a metal grass screen is used, with threadedindividual supports, install a sp

11.11Section 11Reassembly11Figure 11-36. Match Numbers on Cylinder Barrel andHead.Figure 11-38. Valve Components.IntakeValveSealValveKeepersRetainerSp

11.12Section 11ReassemblyFigure 11-41. Torquing Cylinder Head Fasteners.Figure 11-42. Cylinder Head Fastener TorqueSequence.Heads secured with mountin

11.13Section 11Reassembly11Figure 11-43. Installing New Mounting Studs toSpecified Height.4. Check that the dowel pins are in place and installa new c

11.14Section 11Reassembly5. Repeat the above steps for the remainingcylinder. Do not interchange parts from thecylinder heads.Figure 11-47. Using Span

1.1Section 1Safety and General Information1Section 1Safety and General InformationCH18-745Safety PrecautionsTo ensure safe operation please read the f

2.3Section 2Special Tools2Figure 2-5. Loctite® 5900 Aerosol Dispenser.Camshaft Break-in LubricantCamshaft lubricant, Kohler Part No. 25 357 14-S(Valsp

11.15Section 11Reassembly11Figure 11-50. Setting Ignition Module Air Gap.6. Torque the screws to 4.0 N·m (35 in. lb.).7. Repeat steps 4 through 6 for

11.16Section 11ReassemblyFigure 11-56. Installing Breather Reed Assembly.4. Insert the breather filter into position in thecrankcase. Make sure no fil

11.17Section 11Reassembly11Figure 11-58. Installing Screws (Locations 3 and 4).7. Install the inner baffles using the two remaininghex. flange screws

11.18Section 11ReassemblyFigure 11-65. Tighten Baffle Mounting Screws.6. The metal grass screen can now be attached tothe supports.Figure 11-64. Tight

11.19Section 11Reassembly11Figure 11-67. Breather Cover Fastener TorqueSequence. Reconnect Rectifier-Regulator1. Install the rectifier-regulator in th

11.20Section 11ReassemblyFigure 11-71. Reinstalling SAM Module.Install Electric Starter Motor1. Install the starter motor using the two hex. flangescr

11.21Section 11Reassembly11Figure 11-74. Reinstalled Fuel Pump.Install CarburetorWARNING: Explosive Fuel!Gasoline may be present in the carburetor and

11.22Section 11ReassemblyFigure 11-78. Adjusting Governor Lever.4. Insert a nail into the hole on the cross shaft androtate the shaft counterclockwise

11.23Section 11Reassembly11Figure 11-82. Connecting Spring to GovernorLever.3. Connect the governor spring from the maincontrol bracket to the appropr

11.24Section 11ReassemblyCH26,CH745 EFI EnginesGovernor ShaftConfiguration High Idle WOTIntendedMaximum RPMSpring Color Hole No.CH20-740 EnginesAccele

2.4Section 2Special Tools

11.25Section 11Reassembly11Figure 11-83. Throttle/Choke Control Bracket Detail.Install Oil Sentry™ (If So Equipped)1. Apply pipe sealant with Teflon®

11.26Section 11ReassemblyInstall Valve CoversThree valve cover designs have been used. Theearliest type used a gasket and RTV sealant betweenthe cover

11.27Section 11Reassembly11Figure 11-87. Connecting Fuel Inlet Line.2. Position a new gasket and the air cleaner basewhile carefully pulling the loose

11.28Section 11ReassemblyFigure 11-92. Torquing Oil Filter Nipple.Install Oil Cooler1. Reinstall the oil cooler on the engine (if equipped).Install a

11.29Section 11Reassembly11Figure 11-96. Reinstall the Dipstick in Tube.6. Make sure the O-Ring is in place then reinstall theoil fill cap on the valv

11.30Section 11Reassembly

12.1Section 12Clutch12Section 12ClutchCH18-745ClutchGeneralSome engines are equipped with a “wet” disc type clutch. See Figure 12-1 for exploded view

12.2Section 12ClutchServiceOn this type, an oil “splash” type lubrication system isused. The proper oil level must be maintained toprovide efficient l

LITHO IN U.S.A.FORM NO.: TP-2428-BISSUED: 4/92REVISED: 6/04MAILED: 7/04ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044FOR SALES AND SERVICE INFOR

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

3.2Section 3TroubleshootingEngine Will Not Idle1. Dirt or water in the fuel system.2. Stale fuel and/or gum in carburetor.3. Faulty spark plugs.4. Fue

3.3Section 3Troubleshooting3• Check the condition of the oil. Drain the oil into acontainer - the oil should flow freely. Check formetal chips and oth

3.4Section 3TroubleshootingCompression TestSome of these engines are equipped with an automaticcompression release (ACR) mechanism. Because ofthe ACR

3.5Section 3Troubleshooting3Leakdown Test ResultsAir escaping from crankcase breather ...Defective rin

3.6Section 3Troubleshooting

4.1Section 4Air Cleaner and Air Intake System4Section 4Air Cleaner and Air Intake SystemAir CleanersGeneralMost engines are equipped with a replaceabl

4.2Section 4Air Cleaner and Air Intake System3. Wash the precleaner in warm water withdetergent. Rinse the precleaner thoroughly untilall traces of de

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

4.3Section 4Air Cleaner and Air Intake System45. Check the seal for any damage or deterioration.Replace as necessary. See Figure 4-7.6. Reinstall the

4.4Section 4Air Cleaner and Air Intake SystemFigure 4-9. Bracket Retaining Screw.Air Cleaner Element Cover and Seal - Make sureelement cover is not be

4.5Section 4Air Cleaner and Air Intake System4Figure 4-12. Heavy-Duty Air Cleaner.To ServiceEvery 250 hours of operation (more often underextremely du

4.6Section 4Air Cleaner and Air Intake SystemFigure 4-14. Adapters for Heavy-Duty Air Cleaners.Air Intake/Cooling SystemTo ensure proper cooling, make

5.1Section 5Fuel System and Governor5Section 5Fuel System and GovernorDescriptionThe Command horizontal twins use three differenttypes of fuel systems

5.2Section 5Fuel System and GovernorGasoline/Ether blendsMethyl Tertiary Butyl Ether (MTBE) and unleadedgasoline blends (up to a maximum of 15% MTBE b

5.3Section 5Fuel System and Governor5NOTE: On most models, the pulse line isconnected to a fitting on the crankcase,while on early models, it is conne

5.4Section 5Fuel System and GovernorCarburetorGeneralThese engines are equipped with fixed main jetcarburetors manufactured by Keihin to Kohlerspecifi

5.5Section 5Fuel System and Governor5Troubleshooting ChecklistWhen the engine starts hard, runs roughly or stalls atlow idle speed, check the followin

5.6Section 5Fuel System and GovernorFigure 5-4. Pre-Compliance Carburetor with LowIdle Adjustment.1. With the engine stopped, turn the low idle fuelad

1.3Section 1Safety and General Information1A. Model No.Version CodeS = Electric StartC H 18 SEngine Identification NumbersWhen ordering parts, or in a

5.7Section 5Fuel System and Governor5Figure 5-6. Carburetor Detail.5. Hold the carburetor upper body so that the floatassembly hangs vertically and re

5.8Section 5Fuel System and Governor7. In order to clean the ‘‘off-idle’’ vent ports and bowlvent thoroughly, use a good carburetor solvent(like Gumou

5.9Section 5Fuel System and Governor51. Carburetor Upper Body (Choke)2. Self-relieving Choke3. Body Gasket (Formed Rubber)4. Slow Speed Jet5. Inlet Ne

5.10Section 5Fuel System and GovernorReassemblyReassemble the carburetor using the following steps.See Figure 5-9.1. Assemble the fuel inlet needle to

5.11Section 5Fuel System and Governor5GeneralThe governed speed setting is determined by theposition of the throttle control. It can be variable orcon

5.12Section 5Fuel System and GovernorFigure 5-13. Electronic Governor Assembly.Digital Linear Actuator (DLA)Energizing the bi-directional digital line

5.13Section 5Fuel System and Governor5Governor Control Unit (GCU) senses engine speed bypulse voltage inputs from the ignition modules. TheGCU regulat

5.14Section 5Fuel System and Governor

5A.1Section 5ALPG Fuel Systems5ASection 5ALPG Fuel SystemsCH18-740Figure 5A-1.Vacuum LineVaporizerLock-Off/FilterAssemblyLPG RegulatorFuel LineWARNING

5A.2Section 5ALPG Fuel SystemsOperationIn a liquid withdrawal system, the Liquefied PetroleumGas (LPG) is released from the bottom of the supplytank u

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

5A.3Section 5ALPG Fuel Systems5AEngine stalls during operation1. No fuel.2. Faulty lock-off or blocked filter.3. Improper governor setting.4. Damaged

5A.4Section 5ALPG Fuel SystemsHigh Altitude OperationThe standard carburetor calibrations will provideproper operation up to altitudes of 1500 m (5000

5A.5Section 5ALPG Fuel Systems5A4. Inspect the overall condition of the fuelenrichment hose attached to the carburetor. Itmust be free of cracks, dete

5A.6Section 5ALPG Fuel SystemsLPG Carburetor - ReassemblyImpco Carburetor1. Slide the venturi into the carburetor body, aligningthe position mark made

5A.7Section 5ALPG Fuel Systems5A3. Insert a 0.025 mm (0.001 in.) feeler gaugebetween the side of the stop collar and thecarburetor housing, then check

5A.8Section 5ALPG Fuel Systems2. Manually move the governor lever, with the throttlelinkage connected, toward the carburetor as far asit will go. Hold

5A.9Section 5ALPG Fuel Systems5AVaporizer AssemblyThe outer surface of the vaporizer should be kept freeof dirt and debris accumulation, which will ca

5A.10Section 5ALPG Fuel SystemsImpco (Beam) Regulator (See Figure 5A-20)LPG vapor enters at point (A), then passes intoprimary area (B) at point (28),

5A.11Section 5ALPG Fuel Systems5ANikki Regulator Primary Chamber(See Figure 5A-21)The primary chamber reduces the high pressure fuelflow from the tank

5A.12Section 5ALPG Fuel SystemsRegulator Drain PlugPreventative MaintenanceThe regulator is preset at the factory and generallyrequires no further adj

1.5Section 1Safety and General Information1Periodic Maintenance InstructionsWARNING: Accidental Starts!Disabling engine. Accidental starting can cause

5B.1Section 5BEFI Fuel System5BCH26, CH745Section 5BElectronic Fuel Injection (EFI)Fuel SystemContents Page(s)DescriptionInitial Starting/Priming Proc

5B.2Section 5BEFI Fuel SystemWARNING: Explosive Fuel!Gasoline is extremely flammable and its vapors canexplode if ignited. Store gasoline only in appr

5B.3Section 5BEFI Fuel System5BEFI Fuel System ComponentsGeneralThe Electronic Fuel Injection (EFI) system is acomplete engine fuel and ignition manag

5B.4Section 5BEFI Fuel SystemImportant Service Notes!• Cleanliness is essential and must be maintainedat all times when servicing or working on the EF

5B.5Section 5BEFI Fuel System5BThree different styles of ECU’s have been utilized inEFI production. The first style is easily identified by itsmetal c

5B.6Section 5BEFI Fuel SystemGeneralThe engine speed sensor is essential to engineoperation; constantly monitoring the rotational speed(RPM) of the cr

5B.7Section 5BEFI Fuel System5BMounted on the throttle body/intake manifold andoperated directly off the end of the throttle shaft, theTPS works like

5B.8Section 5BEFI Fuel SystemIf the resistance values in steps 3, 4, and 5 arewithin specifications, go to step 6.If the resistance values are not wit

5B.9Section 5BEFI Fuel System5Bb. If light stays on or blinking ceases prematurely,the procedure was unsuccessful and must berepeated. Possible causes

5B.10Section 5BEFI Fuel SystemFigure 5B-10. Engine (Oil) Temperature Sensor.GeneralThe engine (oil) temperature sensor (Figure 5B-10) isused by the sy

1.6Section 1Safety and General InformationFigure 1-4. Typical Engine Dimensions CH Series with Standard Flat Air Cleaner.Dimensions in millimeters.Inc

5B.11Section 5BEFI Fuel System5BFigure 5B-12. Cutaway of Oxygen Sensor.The oxygen sensor can function only after beingheated by exhaust temperatures t

5B.12Section 5BEFI Fuel System1. Oxygen sensor must be hot (minimum of 400°C,725°F). Run engine for about 5 minutes. With theengine running, disconnec

5B.13Section 5BEFI Fuel System5Ba. If there is no continuity displayed in either ofthe tests, check the harness circuit for breaksor damage, and the c

5B.14Section 5BEFI Fuel SystemFigure 5B-17. Style 2 Fuel Injector.GeneralThe fuel injectors mount into the intake manifold, andthe fuel rail attaches

5B.15Section 5BEFI Fuel System5BWhen the key switch is on and the relay is closed, thefuel rail is pressurized, and voltage is present at theinjector.

5B.16Section 5BEFI Fuel SystemFigure 5B-21. Injector Inspection Points.1. Engine must be cool. Depressurize fuel systemthrough test valve in fuel rail

5B.17Section 5BEFI Fuel System5B8. Thoroughly clean the area around and includingthe throttle body/manifold and the injectors.9. Disconnect the thrott

5B.18Section 5BEFI Fuel System4. If the secondary resistance is not withinthe specified range, unscrew the sparkplug lead nut from the coil secondaryt

5B.19Section 5BEFI Fuel System5BFigure 5B-24. “24 Pin” (MSE 1.0) Plastic-CasedECU Connector.Fuel ComponentsFuel PumpFigure 5B-25. “32 Pin” (MSE 1.1) P

5B.20Section 5BEFI Fuel System1. Connect the black hose of Kohler pressure tester(SPX Part No. KO3217-4), to the test valve in thefuel rail. Route the

1.7Section 1Safety and General Information1Figure 1-5. Typical Engine Dimensions CH EFI Series with Heavy-Duty Air Cleaner.Dimensions in millimeters.I

5B.21Section 5BEFI Fuel System5BFigure 5B-29. Fuel Pressure Regulator Details.ServiceDepending on the application, the regulator may belocated in the

5B.22Section 5BEFI Fuel System8. Reconnect the negative (-) battery cable.9. Recheck regulated system pressure at fuel railtest valve.Fuel FilterEFI e

5B.23Section 5BEFI Fuel System5Bgradually increase to the established setting asoperation continues. Do not attempt to circumvent thiswarm up period,

5B.24Section 5BEFI Fuel SystemFigure 5B-37. Throttle Linkage/Governor LeverConnection.2. Check if the engine has a high-speed throttle stopscrew insta

5B.25Section 5BEFI Fuel System5BFigure 5B-39. Inserting Feeler Gauge (EnginesWithout Stop Screw).b. On engines with a stop screw, pivot the throttlesh

5B.26Section 5BEFI Fuel System4. Verify that the governor has been set correctly.With the linkage still retained in the “Full Throttle”position (Step

5B.27Section 5BEFI Fuel System5BElectrical SystemThe EFI system is a 12 VDC negative ground system,designed to operate down to a minimum of 7.0 volts.

5B.28Section 5BEFI Fuel SystemPin #1234567891011121314151617181920212223242526272829303132333435ComponentIgnition Coil #1Not usedEngine Speed SensorEC

1.8Section 1Safety and General InformationGeneral Specifications¹Power (@ 3600 RPM, corrected to SAE J1995)CH18...

5B.31Section 5BEFI Fuel System5B“24 Pin” (MSE 1.0) Plastic-Cased ECU SystemsPin #123456789101112131415161718192021222324Function1Permanent Battery Vol

5B.32Section 5BEFI Fuel System“32 Pin” (MSE 1.1) Plastic-Cased ECU SystemsPin #1234567891011121314151617181920212223242526272829303132FunctionPermanen

5B.34Section 5BEFI Fuel SystemFuel SystemWARNING: Fuel System Under Pressure!The fuel system operates under high pressure. Systempressure must be reli

5B.35Section 5BEFI Fuel System5BLong PauseShort PausesCode 3232Code 6116Long PauseLight remains on at end of transmission1. Diagnostic display initiat

5B.36Section 5BEFI Fuel SystemknilBedoC2DBOedoC-PelbacilppA"niP23":ot)1.1ESM(-tsyS/UCEylnOmenoitpircseDeruliaFronoitcennoC"niP53")

5B.37Section 5BEFI Fuel System5BCode: 21Source: Engine Speed SensorExplanation: ECU receiving inconsistent toothcount signals from speed sensor.Expect

5B.38Section 5BEFI Fuel System3. Engine Wiring Harness Related“32 Pin” (MSE 1.1) Plastic-Cased ECU:a. Pin circuits 4, 8, and/or 18 damaged (wiring,con

5B.39Section 5BEFI Fuel System5BCode: 32Source: Oxygen SensorExplanation: No change in the sensor output signal.Expected EngineResponse: “Open loop” o

5B.40Section 5BEFI Fuel System3. System Relateda. Engine is operating above the 176°C (350°F)temperature sensor limit.Code: 43 and 44 "32 Pin&quo