KOHLER COURAGE Model SV725 24HP Engine Workshop Repair Manual

Service Manual SV710-SV740 SV810-SV840 2 Safety 3 Maintenance 5 Speciﬁcations 14 Tools and Aids 17 Troubleshooting 21 Air Cleaner/Intake 22 Fuel System 30 Governor System 31 Lubrication System 33 Electrical System 45 Starter System 51 Emission Compliant Systems 54 Disassembly/Inspection and Service 68 Reassembly 1 32 690 01 Rev. G KohlerEngines.com IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Downloaded from www.Manualslib.com manuals search engine

2 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. WARNING Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed. WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed. WARNING Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. Carburetor cleaners and solvents are extremely flammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. CAUTION Damaging Crankshaft and Flywheel can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing flywheel. KohlerEngines.com 32 690 01 Rev. G Downloaded from www.Manualslib.com manuals search engine

3 Maintenance 32 690 01 Rev. G KohlerEngines.com MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer. MAINTENANCE SCHEDULE Every 25 Hours¹ ● Service/replace precleaner. Air Cleaner/Intake ● Replace air cleaner element (if not equipped with precleaner). Air Cleaner/Intake Every 100 Hours¹ ● Replace air cleaner element (if equipped with precleaner). Air Cleaner/Intake ● Change oil and filter. Lubrication System ● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake Every 100 Hours ● Check that all fasteners are in place and components are properly secured. Reassembly ● Replace fuel filter. Every 200 Hours² ● Have valve clearance (lash) checked/adjusted. Reassembly Every 500 Hours ● Replace spark plugs and set gap. Electrical System ¹ Perform these procedures more frequently under severe, dusty, dirty conditions. ² Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). Downloaded from www.Manualslib.com manuals search engine

4 Maintenance KohlerEngines.com 32 690 01 Rev. G OIL RECOMMENDATIONS We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below. FUEL RECOMMENDATIONS WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. NOTE: E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not warrantable. Fuel must meet these requirements: ● Clean, fresh, unleaded gasoline. ● Octane rating of 87 (R+M)/2 or higher. ● Research Octane Number (RON) 90 octane minimum. ● Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable. ● Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved. ● Do not add oil to gasoline. ● Do not overfill fuel tank. ● Do not use gasoline older than 30 days. STORAGE If engine will be out of service for 2 months or more follow procedure below. 1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable). 2. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil. 3. Disconnect negative (-) battery cable. 4. Store engine in a clean, dry place. Downloaded from www.Manualslib.com manuals search engine

5 Speciﬁcations 32 690 01 Rev. G KohlerEngines.com Dimensions in millimeters. Inch equivalents shown in [ ]. Engine Dimensions Downloaded from www.Manualslib.com manuals search engine

6 Speciﬁcations KohlerEngines.com 32 690 01 Rev. G Dimensions in millimeters. Inch equivalents shown in [ ]. Engine Dimensions Downloaded from www.Manualslib.com manuals search engine

7 Specifications 32 690 01 Rev. G KohlerEngines.com GENERAL SPECIFICATIONS 3.6 SV710 SV810 SV715 SV720 SV820 SV725 SV730 SV830 SV735 SV740 SV840 Bore 83 mm (3.27 in.) Stroke 67 mm (2.64 in.) Displacement 725 cc (44 cu. in.) Oil Capacity (refill) 1.6-1.8 L (1.7-1.9 qt.) Maximum Angle of Operation (@ full oil level) 4 25° TORQUE SPECIFICATIONS 3,5 SV710 SV810 SV715 SV720 SV820 SV725 SV730 SV830 SV735 SV740 SV840 Blower Housing and Sheet Metal M4 HI-LO Screw 2.8 N·m (25 in. lb.) M5 Fasteners 6.2 N·m (55 in. lb.) into new hole 4.0 N·m (35 in. lb.) into used hole M6 Fasteners 10.7 N·m (95 in. lb.) into new hole 7.3 N·m (65 in. lb.) into used hole Carburetor Mounting Nut 6.2-7.3 N·m (55-65 in. lb.) Connecting Rod Cap Fastener (torque in increments) 11.3 N·m (100 in. lb.) Crankcase Breather Assembly Inner Cover Fastener Outer Cover Stud Outer Cover Hex Nut 10.7 N·m (95 in. lb.) into new hole 7.3 N·m (65 in. lb.) into used hole 6.2 N·m (55 in. lb.) into new hole 4.0 N·m (35 in. lb.) into used hole 1.3 N·m (11.5 in. lb.) Oil Drain Plug 13.6 N·m (10 ft. lb.) ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model . . . . . . . . . . . . . . . . . . . . . SV710 Courage Engine Vertical Shaft Numerical Designation Specification . . . . . . . . . . . . . . . SV710-0001 Serial . . . . . . . . . . . . . . . . . . . . . 4223500328 Year Manufactured Code Factory Code Code Year 42 2012 43 2013 44 2014 3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. 5 Lubricate threads with engine oil prior to assembly. 6 Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com. Downloaded from www.Manualslib.com manuals search engine

8 Specifications KohlerEngines.com 32 690 01 Rev. G TORQUE SPECIFICATIONS 3,5 SV710 SV810 SV715 SV720 SV820 SV725 SV730 SV830 SV735 SV740 SV840 Cylinder Head Head Bolt Fastener (torque in 2 increments) first to 22.6 N·m (200 in. lb.) finally to 41.8 N·m (370 in. lb.) Rocker Arm Screw 11.3 N·m (100 in. lb.) Rocker Arm Stud (AVT) 11.3 N·m (100 in. lb.) Rocker Arm/Valve Adjustment Jam Nut 7.3 N·m (65 in. lb.) Rocker Arm/Valve Adjustment Setscrew (AVT) 7.9 N·m (70 in. lb.) Flywheel Retaining Screw 74.5 N·m (55 ft. lb.) Fuel Pump Screw 2.3 N·m (20 in. lb.) Governor Lever Nut 6.8 N·m (60 in. lb.) Ignition Spark Plug 27 N·m (20 ft. lb.) Module Fastener 4.0-6.2 N·m (35-55 in. lb.) Rectifier-Regulator Fastener 4.0 N·m (35 in. lb.) Intake Manifold Mounting Fastener (torque in 2 increments) first to 7.4 N·m (66 in. lb.) finally to 9.9 N·m (88 in. lb.) Muffler M8 Hex Nuts 24.4 N·m (216 in. lb.) 5/16-18 Capscrew 16.9 N·m (150 in. lb.) Bracket Screw 9.9 N·m (88 in. lb.) Oil Filter Nipple (Style A Oil Pan only) 33.9 N·m (300 in. lb.) Oil Pan Fastener 24.4 N·m (216 in. lb.) Oil Pump Oil Pump Style A Screw (torque in 2 increments) 11.2 N·m (11 in. lb.) into new hole 7.3 N·m (65 in. lb.) into used holes Oil Pump Style B Screw (no torque sequence) 9.0 N·m (80 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly. Downloaded from www.Manualslib.com manuals search engine

9 Speciﬁcations 32 690 01 Rev. G KohlerEngines.com TORQUE SPECIFICATIONS 3,5 SV710 SV810 SV715 SV720 SV820 SV725 SV730 SV830 SV735 SV740 SV840 Oil Sentry ™ Pressure Switch 4.5 N·m (40 in. lb.) Solenoid (Starter) Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.) Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.) Speed Control Bracket Fastener 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Starter Assembly Thru Bolt Inertia Drive Solenoid Shift 4.5-5.7 N·m (40-50 in. lb.) 5.6-9.0 N·m (49-79 in. lb.) Mounting Screw 15.3 N·m (135 in. lb.) Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.) Stator Mounting Screw 6.2 N·m (55 in. lb.) Valve Cover Fastener 6.2 N·m (55 in. lb.) CLEARANCE SPECIFICATIONS 3 SV710 SV810 SV715 SV720 SV820 SV725 SV730 SV830 SV735 SV740 SV840 Camshaft End Play (with shim) 0.076/0.127 mm (0.0030/0.0050 in.) Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.) Bore I.D. New Max. Wear Limit 20.000/20.025 mm (0.7874/0.7884 in.) 20.038 mm (0.7889 in.) Bearing Surface O.D. New Max. Wear Limit 19.962/19.975 mm (0.7859/0.7864 in.) 19.959 mm (0.7858 in.) Connecting Rod Connecting Rod-to-Crankpin Running Clearance New Max. Wear Limit 0.030/0.055 mm (0.0012/0.0022 in.) 0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.) Connecting Rod-to-Piston Pin Running Clearance 0.015/0.028 mm (0.0006/0.0011 in.) Piston Pin End I.D. New Max. Wear Limit 17.015/17.023 mm (0.6699/0.6702 in.) 17.036 mm (0.6707 in.) Crankcase Governor Cross Shaft Bore I.D. New Max. Wear Limit 8.025/8.075 mm (0.3159/0.3179 in.) 8.088 mm (0.3184 in.) 3 Values are in Metric units. Values in parentheses are English equivalents. Downloaded from www.Manualslib.com manuals search engine

10 Speciﬁcations KohlerEngines.com 32 690 01 Rev. G CLEARANCE SPECIFICATIONS 3 SV710 SV810 SV715 SV720 SV820 SV725 SV730 SV830 SV735 SV740 SV840 Crankshaft End Play (free) 0.070/0.590 mm (0.0028/0.0230 in.) Bore (in crankcase) New Max. Wear Limit 40.965/41.003 mm (1.6128/1.6143 in.) 41.016 mm (1.6148 in.) Bore (in oil pan) New 40.974/40.987 mm (1.6131/1.6136 in.) Crankshaft Bore (in oil pan)-to-Crankshaft Running Clearance New 0.039/0.074 mm (0.0015/0.0029 in.) Flywheel End Main Bearing Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round 40.913/40.935 mm (1.6107/1.6116 in.) 40.84 mm (1.608 in.) 0.022 mm (0.0009 in.) 0.025 mm (0.0010 in.) Oil Pan End Main Bearing Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round 40.913/40.935 mm (1.6107/1.6116 in.) 40.84 mm (1.608 in.) 0.022 mm (0.0009 in.) 0.025 mm (0.0010 in.) Connecting Rod Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round 35.955/35.973 mm (1.4156/1.4163 in.) 35.94 mm (1.415 in.) 0.018 mm (0.0007 in.) 0.025 mm (0.0010 in.) T.I.R. PTO End, Crank in Engine Entire Crank, in V-Blocks 0.279 mm (0.0110 in.) 0.20 mm (0.0079 in.) Cylinder Bore Bore I.D. New Max. Wear Limit Max. Out-of-Round Max. Taper 83.031/83.006 mm (3.2689/3.2679 in.) 83.069 mm (3.2704 in.) 0.12 mm (0.0047 in.) 0.05 mm (0.0020 in.) Cylinder Head Max. Out-of-Flatness 0.076 mm (0.003 in.) Governor Governor Cross Shaft-to-Crankcase Running Clearance 0.025/0.126 mm (0.0009/0.0049 in.) Cross Shaft O.D. New Max. Wear Limit 7.949/8.000 mm (0.3129/0.3149 in.) 7.936 mm (0.3124 in.) Governor Gear Shaft-to-Governor Running Clearance 0.015/0.140 mm (0.0006/0.0055 in.) Gear Shaft O.D. New Max. Wear Limit 5.990/6.000 mm (0.2358/0.2362 in.) 5.977 mm (0.2353 in.) Ignition Spark Plug Gap 0.76 mm (0.030 in.) Module Air Gap (Fixed or DSAM Ignition System Only) 0.28/0.33 mm (0.011/0.013 in.) 3 Values are in Metric units. Values in parentheses are English equivalents. Downloaded from www.Manualslib.com manuals search engine

KOHLER COURAGE Model SV725 24HP Engine Workshop Repair Manual

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