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Kohler Courage SV730

Kohler Courage SV730
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Service Manual
SV710-SV740
SV810-SV840
2 Safety
3 Maintenance
5 Speci cations
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.

Table of Contents

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Kohler Courage SV730 Specifications

General IconGeneral
Compression Ratio8.5:1
Cooling SystemAir-cooled
Fuel SystemCarburetor
Ignition SystemElectronic
StarterElectric
Engine Type4-cycle, overhead valve (OHV)
Displacement725 cc
Oil Capacity2.0 U.S. quarts
LubricationFull Pressure
Weight85 lbs
Bore3.27 in. (83 mm)
Stroke2.64 inches

Summary

Safety

Safety Precautions

General warnings and definitions for hazards.

Maintenance

Maintenance Schedule

Routine checks and replacements based on operating hours.

Oil Recommendations

Recommended oil types and viscosity based on temperature.

Fuel Recommendations

Guidelines for using clean, fresh, unleaded gasoline.

Specifications

Engine Dimensions

Detailed measurements of engine components in mm and inches.

General Specifications

Bore, stroke, displacement, and oil capacity details.

Torque Specifications

Recommended torque values for various fasteners.

Clearance Specifications

Tolerances for engine part measurements.

Tools and Aids

Tools for Service

List of specialized tools and their part numbers for engine repair.

Aids for Service

Lubricants and sealants recommended for engine maintenance.

Troubleshooting

Troubleshooting Guide

Common engine problems and their potential causes.

Crankcase Vacuum Test

Procedure to test for proper crankcase vacuum.

Cylinder Leakdown Test

Method to determine internal engine leaks.

Air CleanerIntake System

Air Cleaner Components

Identification and service of air cleaner parts.

Air Cleaner Base

Procedures for removing and reinstalling the air cleaner base.

Fuel System

Fuel Pump Replacement

Steps to replace the engine's fuel pump.

Fuel System Tests

Diagnostic tests for fuel system issues.

Carburetor Servicing

Steps for cleaning and servicing carburetor components.

Unitized Throttle and Choke Control

How the single-lever throttle/choke system works.

Governor System

Governor Components

Diagram and identification of governor system parts.

Initial Adjustment Procedure

Procedure for initial governor arm adjustment.

Lubrication System

Check Oil Level

Procedure for verifying engine oil level.

Change Oil and Filter

Steps for performing an oil and filter change.

Oil Sentry (if equipped)

Function and testing of the low oil sensor.

Electrical System

Spark Plugs

Inspection, service, and specifications for spark plugs.

Electronic Ignition Systems

Overview of different ignition system types.

Battery

Recommendations and maintenance for the starting battery.

Test for Spark

Procedure for testing ignition spark output.

Test DSAM

Procedure for testing the Digital Spark Advance Module.

Battery Charging System

Testing procedures for the charging system.

Starter System

Troubleshooting Starting Difficulties

Common issues and solutions for starting problems.

Inertia Drive Electric Starters

Components and service for inertia drive starters.

Solenoid Shift Starters

Components and service for solenoid shift starters.

Solenoid Tests

Procedures for testing starter solenoid function.

Emission Compliant Systems

Carbon Canister System

Operation and maintenance of the evaporative emission control system.

Secondary Air Induction System

Operation and maintenance of the SAI emission system.

DisassemblyInspection and Service

External Engine Components

Overview of external engine parts for disassembly.

Disconnect Spark Plug Leads

Safe procedure for disconnecting spark plug wires.

Drain Oil From Crankcase and Remove Oil Filter

Steps for draining oil and removing the oil filter.

Remove Blower Housing and Outer Baffles

Procedures for removing blower housing components.

Remove Air Cleaner and Carburetor

Steps to remove air cleaner and carburetor assembly.

Remove Cylinder Heads

Procedures for removing cylinder heads.

Valve Guides

How to check and service valve guides.

Honing

Process for resizing cylinder bores using honing.

Measuring Piston-to-Bore Clearance

Procedure to accurately measure piston-to-bore clearance.

Install New Piston Rings

Correct procedure for installing new piston rings.

Reassembly

Install Crankshaft

Steps for installing the crankshaft into the crankcase.

Install Connecting Rods with Pistons and Rings

Procedure for installing rod/piston assemblies.

Install Valve Tappets and Camshaft

Steps for installing valve tappets and camshaft.

Determining Camshaft End Play

How to check and adjust camshaft end play.

Install Flywheel and Fan

Steps for installing the flywheel and fan assembly.

Install Ignition Modules

Procedures for installing ignition modules.

Assemble and Install Cylinder Heads

Steps for assembling and installing cylinder heads.

Adjust Valve Clearance

How to adjust valve clearance on rocker arms.

Install Valve Covers

Procedures for installing plastic and steel valve covers.

Install Oil Filter and Fill Crankcase with Oil

How to install oil filter and fill crankcase with oil.

Prepare Engine for Operation

Final checks before starting the engine.

Testing Engine

Recommended procedure for initial engine testing.

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