Kohler Courage SV710 Manual de usuario

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

132 690 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.

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

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).

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.

Speciﬁcations

32 690 01 Rev. G KohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions

Speciﬁcations

KohlerEngines.com 32 690 01 Rev. G

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions

Speciﬁcations

32 690 01 Rev. G KohlerEngines.com

GENERAL SPECIFICATIONS3.6 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)425°

TORQUE SPECIFICATIONS3,5 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.

4Exceeding maximum angle of operation may cause engine damage from insufﬁcient lubrication.

5Lubricate threads with engine oil prior to assembly.

6Any 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.

Speciﬁcations

KohlerEngines.com 32 690 01 Rev. G

TORQUE SPECIFICATIONS3,5 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.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

32 690 01 Rev. G KohlerEngines.com

TORQUE SPECIFICATIONS3,5 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 SPECIFICATIONS3SV710

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.

Speciﬁcations

KohlerEngines.com 32 690 01 Rev. G

CLEARANCE SPECIFICATIONS3SV710

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.

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