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SERVICE MANUAL
® ™
KOHLER AEGIS 17,20,23 HP
LIQUID-COOLED
VERTICAL CRANKSHAFT
1
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Contents 1 Section 1. Safety and General Information ............................................................................ 2 Section 2. Special Tools .......................................................................................................... 3 Section 3. Troubleshooting ..................................................................................................... 4 Section 4. Air Cleaner and Air Intake System ..........................................................
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Section 1 Safety and General Information LV560, LV625, LV675 1 Section 1 Safety and General Information Safety Precautions To insure safe operations 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, dea
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Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause fires and Explosive Fuel can cause fires and Carbon Monoxide can cause severe acid burns. severe burns. severe nausea, fainting or death. Charge battery only in a well Stop engine before filling fuel tank. Do not operate engine in closed or ventilated area. Keep sources of confined area. ignition away. Lethal Exhaust Gases! Explosive Gas! Explosive Fuel! Engine exhaust gases contain Batteries produce explosi
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Section 1 Safety and General Information Engine Identification Numbers When ordering parts, or in any communication 1 involving an engine, always give the Model, Specification and Serial Numbers, including letter suffixes if there are any. The engine identification numbers appear on a decal, or decals, affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2. Figure 1-1. Engine Identification Decal Location. A. Model No. L V 675 S Liquid Cooled Vers
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Section 1 Safety and General Information Refer to Section 6 - “Lubrication System” for detailed Oil Recommendations procedures on checking the oil, changing the oil and Using the proper type and weight of oil in the changing the oil filter. crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine Coolant Recommendations wear and failure. Use equal parts of ethylene glycol and water only. Dis
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Section 1 Safety and General Information Fuel Type Gasoline/Alcohol blends For best results, use only clean, fresh, unleaded Gasohol (up to 10% ethyl alcohol, 90% unleaded 1 gasoline with a pump sticker octane rating of 87 or gasoline by volume) is approved as a fuel for Kohler higher. In countries using the Research method, it engines. Other gasoline/alcohol blends are not should be 90 octane minimum. approved. Unleaded gasoline is recommended, as it leaves fewer Gasoline/Ether blends combustio
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Section 1 Safety and General Information Storage 4. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to If the engine will be out of service for two months or prevent deterioration. If you choose to use a more, use the following storage procedure: stabilizer, follow the manufacturer’s recommendations, and add the correct amount 1. Clean the exterior surfaces of the radiator and for the capacity of the fuel system. Fill the fuel engine. tank with clean
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Section 1 Safety and General Information 260.6 1 Cyl. #2 Cyl. #1 334.5 Fuel Pump 167.2 2x 89.8 Hose 2x 72.8 434.1 479.3 Over All Coolant Drain Plug Coolant Drain Plug 3/8 N.P.T Inch 3/8 N.P.T Inch 30º 30º 50.0 50.0 Exhaust Exhaust Port #1 Port #2 C 18.2 LOil Fill 35º 35º 104.0 140.0 Mounting Hole ‘‘A’’ 135.7 C 285.5 Oil Fill L Oil Fill & Dipstick 242.2 451.0 89.8 Starter Motor 45º 45º 153.0 15.7 Housing Oil Filter Removal Removal Oil Fill & Dipstick 4x ø 9.2 (.36) thru ø 135.0 Mounting Hole
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Section 1 Safety and General Information 1 General Specifications Power (@ 3600 RPM, corrected to SAE J1995) LV560 ............................................................................................. 12.7 kW (17 HP) LV625 ............................................................................................. 14.9 kW (20 HP) LV675 ............................................................................................. 17.1 kW (23 HP) Peak Torque LV560 (@ 2400 RPM) ............
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Section 1 Safety and General Information Carburetor and Intake Manifold Intake Manifold Mounting Fasteners Torque ......................................... 6.2 N·m (55 in. lb.) 1 Carburetor Mounting Fasteners Torque ................................................ 6.2 N·m (55 in. lb.) Connecting Rod Cap Fastener Torque (torque in increments) ........................................ 11.3 N·m (100 in. lb.) Connecting Rod-to-Crankpin Running Clearance New ...........................................
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Section 1 Safety and General Information Crankshaft (Cont'd.) Connecting Rod Journal O.D. - New ..................................................................................... 35.955/35.973 mm (1.4156/1.4163 in.) O.D. - Max. Wear Limit .................................................................. 35.94 mm (1.415 in.) Max. Taper ..................................................................................... 0.018 mm (0.0007 in.) Max. Out-of-Round .................................
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Section 1 Safety and General Information Ignition ® Spark Plug Type (Champion or equivalent) ......................................... RC14YC (Kohler Part No. 66 132 01-S) 1 Spark Plug Gap .................................................................................... 0.76 mm (0.030 in.) Spark Plug Torque ................................................................................ 24.4-29.8 N·m (18-22 ft. lb.) Ignition Module Air Gap .....................................................
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Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin (Cont'd.) Top and Middle Compression Ring End Gap LV560 New Bore Top Ring .................................................................................. 0.180/0.380 mm (0.0071/0.0150 in.) Middle Ring ............................................................................. 0.180/0.440 mm (0.0071/0.0173 in.) Used Bore (Max.) ........................................................................ 0.76 mm (0.029
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Section 1 Safety and General Information Valves and Valve Lifters (Cont'd.) Intake Valve Guide I.D. 1 New ................................................................................................ 7.038/7.058 mm (0.2771/0.2779 in.) Max. Wear Limit ............................................................................. 7.134 mm (0.2809 in.) Intake Valve Stem Diameter New ................................................................................................ 6.982/7.000 mm (0.
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Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Grade 2 or 5 Assembled Into Cast Iron or Steel Fasteners Into Aluminum Grade 2 Grade 5 Grade 8 Size 8-32 2.3 (20) 2.8 (25) --------- 2.3 (20) 10-24 3.6 (32) 4.5 (40) --------- 3.6 (32) 10-32 3.6 (32) 4.5 (40) --------- --------- 1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70) 1/4-28 9.6 (85) 15.8 (140) 22.6 (200) -
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Section 2 Special Tools LV560, LV625, LV675 Section 2 Special Tools 2 These quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. By using tools designed for the job, you can service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Camshaft End play Plate ................................................................................. KO1031* Flywhe
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Section 2 Special Tools Special Tools You Can Make RTV Silicone Sealant RTV (Room Temperature Vulcanizing) silicone sealant Flywheel Holding Tool is used as a gasket between the crankcase and oil Flywheel removal and reinstallation becomes a ‘‘snap’’ pan. using a handy holding tool you can make out of a piece of an old ‘‘junk’’ flywheel ring gear as shown in Only oxime-based, oil resistant RTV sealants, such as ® Figure 2-2. Using an abrasive cut-off wheel, cut out a those listed below, are app
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Section 3 LV560, L Troubleshooting V625, LV675 Section 3 Troubleshooting 3 Troubleshooting Guide 6. Faulty spark plugs. 7. Low compression. When troubles occur, be sure to check the simple 8. Weak spark. causes which, at first, may seem too obvious to be 9. Fuel pump malfunction causing lack of fuel. considered. For example, a starting problem could be 10. Engine overheated-cooling system problem. caused by an empty fuel tank. Engine Will Not Crank Some common causes of engine troubles are liste
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Section 3 Troubleshooting Engine Overheats (cont'd.) • Check for buildup of dirt and debris on the 7. Radiator cap faulty or loose. radiators, crankcase, cooling fins, grass screen, 8. Lean fuel mixture. blower housing and other external surfaces. Dirt 9. Water pump belt failed/off. or debris on these areas are causes of higher 10. Water pump malfunction. operating temperatures and overheating. Engine Knocks Check for obvious fuel, oil, and coolant leaks, or 1. Excessive engine load. damaged c
