Kohler KT19 - Service Manual

Identifies engine model, specification, and serial numbers for parts and communication.

Important safety warnings and cautions for engine operation and maintenance.

Guidance on oil type, viscosity, changes, and checking procedures.

Information on gasoline types, alcohol/ether blends, storage, and handling.

Recommended intervals for engine maintenance tasks like oil changes and inspections.

Procedures for cleaning, inspecting, and replacing air cleaner elements.

Instructions for keeping cooling fins and external surfaces clean for efficient cooling.

Technical data including general specs, torque settings, and fitted part tolerances.

Specific torque values for various engine components.

Measurement specifications for engine components like bearings, pins, and clearance.

General torque specifications for fasteners into cast iron, steel, and aluminum.

Information on special or fabricated tools required for service procedures.

Instructions for constructing a U-tube manometer for measuring crankcase vacuum.

Lists common engine issues like hard starting, rough running, overheating, and power loss.

Procedures for checking the engine's external condition before disassembly.

Outlines fundamental tests like crankcase vacuum and compression for diagnosis.

Details on the assembly, disassembly, and maintenance of air cleaner types.

Information on the specific design and servicing of fabricated breather hoses.

Disassembly and assembly instructions for the square type air cleaner.

Disassembly and assembly instructions for the round type air cleaner.

Details on the anti-icing system for carburetors during cold weather.

Instructions for washing and oiling precleaner elements for extended paper element life.

Procedures for carburetor adjustments, cleaning, and reconditioning.

Explanation of governor operation, adjustments, and sensitivity settings.

Instructions for the disassembly and assembly of the throttle control system.

Procedures for the disassembly and assembly of the choke control system.

Information on fuel pump function, checks, and installation of non-metallic pumps.

Details on the function and adjustment of automatic chokes and shutdown controls.

Troubleshooting guide for automatic choke problems and service procedures.

Procedure for testing the engine shutdown control solenoid and plunger.

Details on the full-pressure lubrication system used in Series II engines.

Explanation of the pressurized spray lubrication system for other KT models.

Information on the oil pump's location, function, and service without splitting the crankcase.

Procedures for servicing oil pump components and the pressure relief valve.

Overview of the battery ignition system components and operational testing.

Information on spark plug inspection, replacement, gap setting, and deposit analysis.

Details on condenser function, testing, and its effect on breaker points.

Information on breaker point condition, adjustment, and their impact on engine timing.

Explanation of ignition coil function, primary/secondary resistance checks, and terminal connections.

Guidance on battery maintenance, checks, polarity, and preventing damage.

Procedures for safely removing and installing high tension leads to prevent damage.

Procedures for setting engine ignition timing using static or timing light methods.

Information on 3 amp and 15 amp alternator charging systems and their components.

Specific service procedures and troubleshooting for the 3 amp alternator system.

Guide for testing the 3 amp system for battery charging and lighting issues.

Overview of the 15 amp alternator system components and precautions.

Guide for testing the 15 amp system for battery charging and load issues.

Explanation of starter motor operation, components, and general service.

Troubleshooting common starter motor problems like failure to energize or slow cranking.

Procedures for replacing starter brushes and servicing the commutator.

Instructions for inspecting and replacing the starter drive pinion.

Warning regarding flywheel ring gear replacement and when to replace the flywheel.

Steps for removing external parts like the air cleaner, linkages, and manifolds.

Procedures for removing the flywheel, including warnings and inspection.

Inspecting the flywheel for cracks, keyway damage, and ring gear condition.

Methods for marking crankcase halves and cylinder heads for proper reassembly.

Steps for removing cylinder heads, barrels, valves, and pistons for inspection.

Checking cylinder head flatness and cleaning carbon deposits.

Procedures for inspecting cylinder walls for scoring, wear, and honing.

Detailed steps for honing the cylinder bore to prepare for pistons and rings.

Inspecting valves, guides, seats, and springs for wear or damage.

Information on replacing valve guides if they exceed wear tolerances.

Procedures for replacing intake and exhaust valve seat inserts if damaged.

Guidelines for replacing intake valve stem seals, if equipped.

Information on valve spring types and proper installation orientation.

Inspecting pistons and rings for scuffing, scoring, and wear.

Procedures for replacing piston rings and selecting correct sizes.

Steps for removing the closure plate and splitting the crankcase halves.

Instructions for removing and measuring the oil pressure relief valve spring.

Procedures for removing the camshaft bore plug, including marking for reassembly.

Specific procedures for disassembling Posi-Lock connecting rods from the crankshaft.

Inspecting camshaft and crankshaft gear teeth, bearings, and keyways.

Inspecting connecting rod bearing areas for wear and checking clearances.

Steps for removing the governor gear and cross shaft assembly.

Specific instructions for removing the governor cross shaft in generator applications.

Inspecting the governor gear teeth for wear or damage.

Procedures for removing and inspecting the oil pump components.

Instructions for removing the center oil pickup tube and housing.

Installing the governor cross shaft and L-bracket in generator applications.

Installing the oil pickup tube, housing, and spring clip correctly.

Instructions for installing the oil pump drive gear, shaft, and rotors.

Procedures for installing connecting rods onto the crankshaft, noting design differences.

Installing crankshaft bearings, thrust washers, and connecting rods onto the crankshaft.

Instructions for assembling roller thrust bearings and flat thrust washers on the crankshaft.

Procedures for installing tappets and assembling the camshaft with timing marks.

Steps for preparing sealing surfaces and applying sealant to crankcase halves.

List of recommended commercially available sealants for crankcase assemblies.

Installing the camshaft bore plug with an O-ring to seal the bore.

Sequence and torque values for tightening crankcase fasteners.

Instructions for installing the camshaft bore cup plug using crankcase sealer.

Procedures for applying sealant and installing the front crankshaft oil seal.

Steps for installing pistons, cylinder barrels, and the closure plate assembly.

Instructions for installing the rear crankshaft oil seal into the closure plate.

Procedures for installing valve stems, seals, springs, keepers, and cylinder heads.

Instructions for assembling breather components and installing the valve cover.

Procedures for installing the fuel pump, including non-metallic types.

Critical steps and warnings for installing the flywheel onto the crankshaft.

Instructions for attaching cylinder head baffles and blower housing components.

Mounting instructions for the ignition switch and starter solenoid on Series II engines.

Information on attaching and adjusting the grass deflector to the blower housing.

Instructions for mounting the rectifier-regulator to the blower housing.

Instructions for installing and adjusting breaker points.

Procedures for assembling the carburetor, intake, and exhaust manifolds.

Instructions for assembling governor linkage, breather hose, and fuel line connections.

Procedures for mounting and connecting the ignition coil and condenser.

Instructions for installing the air cleaner assembly to the carburetor.