Kohler KT735 - User Manual

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132 690 03 Rev. I KohlerEngines.com

Service Manual

2 Safety

3 Maintenance

5 Speciﬁ cations

21 Tools and Aids

24 Troubleshooting

28 Air Cleaner/Intake

30 Fuel System

49 Governor System

50 Lubrication System

52 Electrical System

59 Starter System

63 Emission Compliant Systems

66 Disassembly/Inspection and Service

79 Reassembly

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.

KT610-KT620, KT715-KT745

Questions and Answers

K
Keith WadeNov 21, 2025
How to fix Kohler Engine when it cranks but will not start?
- J
  Jamie MartinNov 21, 2025
  If your Kohler Engine cranks but doesn't start, several factors could be at play. First, check if the fuel tank is empty and refill it if needed. Ensure the fuel shut-off valve is open. Inspect the choke to make sure it is closing properly. Examine the battery connections and reconnect if connected backwards. Replace the fuse if it's blown. Also, verify that the key switch or kill switch is in the ON position. Low oil level can also prevent starting, so check and refill if necessary. Replace the fuel with fresh quality fuel to eliminate issues with fuel quality. If these steps don't resolve the issue, further inspection of components like the carburetor solenoid, fuel line or filter, diode in the wiring harness, DSAI or DSAM, electronic control unit, ignition coil(s), spark plug(s), fuel p...
H
Haley HarrisAug 25, 2025
Why Kohler KT735 Engine loses power?
- A
  Allen YoungAug 26, 2025
  If your Kohler Engine loses power, start by cleaning or replacing the air cleaner element. Ensure the engine isn't overheating by allowing it to cool down. Reduce the engine load if it's excessive. Inspect and clear any restrictions in the exhaust system. Check and replace the spark plug(s) if faulty. Verify and adjust the crankcase oil level if it's too high. Adjust the governor setting if it's incorrect. If the battery is low, charge or replace it. Inspect the engine for compression issues if compression is low. Check and refill the crankcase oil if the level is low. Finally, replace the fuel with fresh quality fuel to rule out fuel issues.
K
Kendra CollinsAug 27, 2025
What to do if Kohler KT735 starts but does not keep running?
- J
  Jessica BurnsAug 27, 2025
  If your Kohler Engine starts but doesn't keep running, there are several possible causes. A faulty carburetor could be the issue, so inspect and replace it if necessary. Also, a faulty cylinder head gasket can cause this problem, requiring replacement. Adjust the choke or throttle controls if they are faulty or misadjusted. Inspect the fuel pump and hoses for any malfunctions or clogs. Look for intake system leaks and repair them. Loose wires or connections that intermittently ground the ignition kill circuit can also be the cause, so tighten them. Replace the fuel with fresh quality fuel to ensure fuel quality isn't the problem. Lastly, clean or replace the fuel tank cap if the vent is restricted.
C
Christopher BurnettAug 27, 2025
What causes Kohler KT735 will not crank?
- A
  Andrea GalvanAug 28, 2025
  If your Kohler Engine will not crank, it could be due to several reasons. The battery might be discharged, so try charging or replacing it. Inspect and replace the electric starter or solenoid if they are faulty. Check and replace the key switch or ignition switch if they are faulty. Make sure the interlock switch is not engaged or faulty. Tighten any loose wires or connections that might be grounding the ignition kill circuit. Check the pawls engagement. Finally, inspect the engine for seized components.
J
Janice FosterAug 29, 2025
Why Kohler KT735 Engine starts hard?
- M
  Micheal SmithAug 29, 2025
  If your Kohler Engine starts hard, consider these potential causes: a clogged fuel line or fuel filter, which you should clean or replace. If the engine overheated, allow it to cool down. Inspect and replace the ACR mechanism if it's faulty. Adjust the choke or throttle controls if they are faulty or misadjusted. Inspect and replace the spark plug(s) if they are faulty. Replace the flywheel key if it's sheared. Inspect the fuel pump and hoses for any malfunctions. Check the interlock switch to ensure it is not engaged or faulty. Tighten any loose wires or connections that might be grounding the ignition kill circuit. Inspect the engine for compression issues if compression is low. Replace the fuel with fresh quality fuel. Finally, inspect the ignition system for a weak spark.
S
steven33Sep 18, 2025
What causes Kohler KT735 Engine Will Not Idle?
- D
  Debra HillSep 18, 2025
  If your Kohler engine will not idle, it could be due to the engine overheating, faulty spark plugs, improperly set idle fuel adjusting needles or idle speed adjusting screw, inadequate fuel supply, low compression, poor fuel quality (dirt, water, stale, or improper mixture), or a restricted fuel tank cap vent.
M
Marissa AustinSep 15, 2025
Why Kohler Engine Knocks?
- G
  Gary BarnesSep 16, 2025
  A knocking sound in your Kohler engine can be caused by excessive engine load, hydraulic lifter malfunction, incorrect oil viscosity/type, internal wear or damage, low crankcase oil level, or poor fuel quality (dirt, water, stale, or improper mixture).
O
ojacksonSep 17, 2025
What to do if Kohler KT735 Engine Will Not Crank?
- M
  Matthew ChavezSep 18, 2025
  If your Kohler engine won't crank, it could be due to a discharged battery, a faulty electric starter or solenoid, a faulty key or ignition switch, an engaged or faulty interlock switch, loose wires intermittently grounding the ignition kill circuit, pawls not engaging in the drive cup, or seized internal engine components.
A
Anthony BanksSep 7, 2025
What causes Kohler KT735 Engine Uses Excessive Amount of Oil?
- T
  Timothy BassSep 7, 2025
  Excessive oil consumption in your Kohler engine could be due to loose or improperly torqued fasteners, a blown head gasket or overheating, a broken breather reed, a clogged or inoperative crankcase breather, an overfilled crankcase, incorrect oil viscosity/type, a worn cylinder bore, worn or broken piston rings, or worn valve stems/valve guides.
B
Beverly MartinSep 4, 2025
How to troubleshoot Kohler Engine Starts Hard?
- R
  robertsstevenSep 5, 2025
  If your Kohler engine starts hard, the issue might stem from a clogged fuel line or fuel filter, the engine overheating, a faulty ACR mechanism, faulty or misadjusted choke or throttle controls, faulty spark plugs, a sheared flywheel key, a fuel pump malfunction (clogged or leaking vacuum hose), an engaged or faulty interlock switch, loose wires intermittently grounding the ignition kill circuit, low compression, poor fuel quality (dirt, water, stale, or improper mixture), or a weak spark.

Kohler KT735 Specifications

General

Compression Ratio	9.1:1
Fuel System	Carburetor
Cooling System	Air-cooled
Ignition System	Electronic
Starter	Electric
Displacement	725 cc
Power	24 hp
Lubrication	Full Pressure
Horsepower	24 hp
Oil Capacity	2 U.S. quarts
Dry Weight	85 lbs

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