Kohler Courage SV735

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Speciﬁ cations

KohlerEngines.com 32 690 01 Rev. G

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions

Main Page

Contents1
Safety Precautions2
Maintenance Instructions3
Maintenance Schedule3
Repairs/Service Parts3
Maintenance4
Oil Recommendations4
Storage4
Fuel Recommendations4
Engine Dimensions5
Specifications5
Engine Identification Numbers7
General Specifications7
Torque Specifications7
Crankcase7
Intake Manifold8
Oil Filter8
Oil Pan8
Oil Pump8
Oil Sentry9
Solenoid (Starter)9
Speed Control Bracket9
Starter Assembly9
Clearance Specifications9
Clearance Specifications10
Crankshaft10
Cylinder Bore10
Cylinder Head10
Piston, Piston Rings, and Piston Pin11
Piston-To-Piston Pin Running Clearance11
Valves and Valve Tappets12
General Torque Values13
English Fastener Torque Recommendations for Standard Applications13
Metric Fastener Torque Recommendations for Standard Applications13
Tools and Aids14
Separate Tool Suppliers14
Flywheel Holding Tool16
Rocker Arm/Crankshaft Tool16
Troubleshooting Guide17
Engine Cranks but will Not Start17
Engine will Not Crank17
Engine Runs but Misses17
Engine Loses Power18
Engine Uses Excessive Amount of Oil18
Oil Leaks from Oil Seals, Gaskets18
External Engine Inspection18
Crankcase Vacuum Test19
To Test Crankcase Vacuum with Manometer19
To Test Crankcase Vacuum with Vacuum/Pressure Gauge19
Compression Test20
Cylinder Leakdown Test20
Air Cleaner21
Air Cleaner Components21
Paper Element21
Air Cleaner Base21
Breather Tube21
Air Cooling21
Performance22
Fuel Pump Replacement22
Fuel System Tests22
Carburetor23
Keihin One-Barrel Carburetor Components23
Nikki One-Barrel Carburetor Components23
Walbro One-Barrel Carburetor Components24
Troubleshooting Checklist24
Troubleshooting-Carburetor Related Causes25
Fuel Shut-Off Solenoid25
Carburetor Circuits25
Float25
Slow and MID-Range26
Low Idle Fuel Adjustment26
Optimum Low Idle Fuel Setting26
Carburetor Adjustments26
Carburetor Servicing27
High Altitude Operation27
Unitized Throttle and Choke Control28
Governor/Throttle Control Connections28
Throttle Cable Adjustment29
Starting an Engine Equipped with Unitized Throttle and Choke Control29
Governor System30
Governor Components30
Governor Adjustments30
Lubrication System31
Lubrication Components31
Check Oil Level31
Change Oil and Filter31
Installation32
Spark Plugs33
Spark Plug Component and Details33
Wet Fouled33
Service33
Electrical System33
Carbon Fouled34
Electronic Ignition Systems34
Overheated34
Battery Size Recommendations34
Fixed Ignition System35
Wiring Diagram-Electronic CD Fixed Ignition Timing System Diagram35
Digital Spark Advance Ignition (DSAI) Ignition System36
Wiring Diagram-Digital Spark Advance Ignition (DSAI) System36
Digital Spark Advance Module (DSAM) Ignition System37
Wiring Diagram-Digital Spark Advance Module (DSAM) Ignition System37
Electronic Ignition Systems Tests38
Test for Spark38
Test Timing Advance (DSAI and DSAM Only)39
Test Ignition Modules and Connections (DSAI Only)39
Test Ignition Modules and Connections (DSAM Only)39
Test DSAM41
To Test DSAM Using Spark Advance Module (SAM)42
Electrical System43
Battery Charging System43
12/15/25 Amp Regulated Charging System43
12/15/25 Amp Battery Charging Systems44
Troubleshooting-Starting Difficulties45
Starter System45
Inertia Drive Electric Starters46
Inertia Drive Electric Starter Components46
Drive Service46
Retaining Ring Installation46
Starter Disassembly47
End Cap/Brush Replacement47
Commutator Service47
Solenoid Shift Starter Components47
Starter System48
Inspection48
Drive Pinion48
Brush Replacement48
Starter Reassembly49
Solenoid Tests50
To Test Solenoid Hold-In Coil50
To Test Solenoid Pull-In Coil/Plunger50
Emission Compliant Systems51
Evaporative Emission Compliant System51
Carbon Canister System51
Secondary Emission Compliant System52
Twin Secondary Air Induction System52
Single Secondary Air Induction System52
Remove Inlet Screen53
Inlet Components53
Disassembly/Inspection and Service54
External Engine Components54
Disconnect Spark Plug Leads55
Drain Oil from Crankcase and Remove Oil Filter55
Remove Blower Housing and Outer Bafﬂ es55
Remove Throttle Controls55
Remove Air Cleaner and Carburetor56
Remove Ignition Modules56
Remove Intake Manifold and Rectiﬁ Er-Regulator56
Remove Electric Starter Motor56
Cylinder Head Components57
Remove Spark Plugs57
Remove Valve Covers and Cylinder Heads57
Remove Cylinder Heads57
Disassemble Cylinder Heads58
Inspection and Service58
Valve Details58
Exhaust Insert58
Lapping Valves59
Valve Guides59
Intake Valve Stem Seal59
Valve Seat Inserts59
Flywheel/Ignition/Breather Components60
Remove Debris Screen, Fan, and Flywheel60
Remove Backing Plate and Stator60
Remove Outer Breather Assembly60
Crankshaft/Governor Gear/Oil Pump Components61
Remove Oil Pan Assembly62
Governor Assembly62
Oil Pump Assembly (Style A)62
Governor Shaft Component and Details62
Oil Pump Assembly (Style B)63
Remove Camshaft and Valve Tappets63
Camshaft Inspection and Service63
Remove Governor Cross Shaft63
Connecting Rods/Piston/Breather Components64
Piston and Rings64
Piston and Rings Components and Details64
Remove Connecting Rods with Pistons and Rings64
Piston Style B65
Install New Piston Rings65
Piston Style a65
Remove Crankshaft66
Remove Inner Breather Assembly66
Remove Flywheel and PTO End Oil Seals66
Honing66
Clean Cylinder Bore after Honing67
Measuring Piston-To-Bore Clearance Piston Detail67
Install Flywheel End Oil Seal68
Install Breather Filter and Inner Cover68
Install Governor Cross Shaft68
Install Crankshaft70
Install Connecting Rods with Pistons and Rings70
Install Valve Tappets and Camshaft70
Oil Pump Assembly70
Install Oil Seal in Oil Pan71
Install Oil Pan Assembly71
Oil Seal Component and Detail71
Sealant Pattern71
Install Breather Reed and Outer Cover72
Breather Cover Sealant72
Install Stator and Backing Plate72
Install Flywheel and Fan73
Install Ignition Modules73
DSAI Ignition System73
Fixed or DSAM Ignition System73
Assemble and Install Cylinder Heads74
Assemble Cylinder Heads74
Adjust Valve Clearance75
Adjusters Retaining Push Rods75
Install Cylinder Heads75
Install Rocker Arms75
Install Valve Covers76
Stamped Steel Valve Cover Torque Sequence76
Install Spark Plugs76
Stamped Steel Valve Cover RTV Sealant76
Install Intake Manifold78
Install Carburetor78
Install External Governor Controls78
Install Rectiﬁ Er-Regulator78
Throttle and Choke Components79
Install Throttle and Choke Controls79
Governor Lever Hole Position79
Install Air Cleaner Element79
Install Blower Housing80
Install Fuel Pump80
Install Muffler80
Install Oil Filter and Fill Crankcase with Oil80

Kohler Courage SV735 - Page 6

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