Kohler Magnum M8

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Contents2
General Information3
Engine Identification Numbers3
Safety Information4
Oil/Fuel Recommendations7
Oil Type7
Check Oil Level7
Change Oil7
Fuel Type8
Overall Dimensions8
Gasoline/Alcohol Blends8
Standard Torque Values10
Specifications, Tolerances and Special Torque Values10
Special Tools15
Valve Service Tools16
Seal and Bearing Installers16
Tool Usage Chart18
Bearing and Seal Installers18
Miscellaneous Tools18
Engine Analysis Kit (no 25 800 01)19
Ignition System Tester20
Water Manometer20
Cylinder Leakdown Tester20
Inductance Tachometer20
Periodic Maintenance21
Required Maintenance21
Oil Sentry22
Service Air Cleaner22
Clean Air Intake/Cooling Areas23
Precleaner23
Paper Element23
Inspect Air Cleaner Components23
Check Spark Plug24
Service Optional Reduction Gear Unit24
Servicing Spark Plug24
Ignition System Service25
Check Fuel Filter25
Service Starter Motor Drive25
Clean Cylinder Head and Combustion Chamber25
Check Valve-To-Tappet Clearance26
Cylinder Head Fastener Tightening Sequence26
Measuring Valve-To-Tappet Clearance26
Storage27
Troubleshooting28
External Engine Inspection29
Cleaning the Engine29
Basic Engine Tests29
No Crankcase Vacuum/Pressure in Crankcase30
Air Cleaner Disassembly31
Air Cleaner Assembly - Exploded View31
Air Cleaner Reassembly/Service32
Fuel System and Governor33
Fuel System Operation33
Fuel System Troubleshooting33
Typical Fuel System33
Fuel Tank34
Fuel Filter35
Fuel Pump35
Fuel Shutoff Valve35
Isolation Mounts35
Carburetor36
Carburetor Adjustment37
Carburetor Disassembly38
Carburetor Cleaning38
Carburetor Inspection38
Carburetor Repair39
Throttle and Choke Shaft Replacement39
To Replace Throttle and Choke Shafts40
Disassemble Carburetor40
Remove Choke Plate and Choke Shaft; Transfer Choke Lever40
Remove Throttle Plate and Throttle Shaft; Transfer Throttle Lever40
Drill Choke Shaft Bores Using a Drill Press41
Installing Choke Shaft Bushings41
Install Throttle Shaft Bushing42
Installing Choke Shaft42
Install Throttle Shaft and Throttle Plate43
Setting Float Level43
Setting Float Drop43
Governor Operation44
Centrifugal Flyweight Mechanical Governor44
Checking Float Clearance44
Governor Adjustment45
Initial Governor Adjustment45
High Speed Adjusting Screw45
Engine Mounted Throttle and Choke Controls46
Sensitivity Adjustment46
Engine Mounted Throttle and Choke Controls - Exploded View47
Engine Mounted Throttle and Choke Controls - Disassembly/Reassembly48
Retractable Starters50
To Remove/To Install Starter50
Retractable Starter on Model M850
To Replace Starter Pawls (Dogs)50
Exploded View - Retractable Starter for Model M851
Starter Pawls51
To Replace Rope52
Removing Handle52
Installing Rope52
Releasing Spring Tension52
Starter Disassembly53
Position of Spring and Keeper on Pulley53
Removing Pulley from Housing53
Starter Inspection and Service54
Starter Reassembly54
Retractable Starter on Models M10, M12, M14, M16 Disassembly54
Installing Pulley and Spring into Housing54
Exploded View - Retractable Starter for Models M10, M12, M14, M1655
Removing Spring from Housing57
To Replace Recoil Spring57
Spring Reassembly58
Installing Spring Using Seal Installer and Handle58
Positioning New Spring/C-Ring58
Installing Pawls, Pawl Retainer and Related Components59
Tensioning Spring59
Winding Rope Onto Pulley60
Electrical Systems and Components61
Magnum Electronic Magneto Ignition System61
Ignition System Troubleshooting Guide62
Ignition Module Removal63
Ignition Module Installation63
Ignition Tester, Testing Module Secondary63
Setting Magnet-To-Module Air Gap63
Kill Lead with Optional Diode64
Spark Plug Service64
Kill Lead/Diode Replacement64
Diode Test64
Spark Plug Inspection65
Electrical System Wiring Diagram and Battery Charging Systems66
Manual Start Engines: Optional 70 Watt Lighting67
Troubleshooting Guide: 70 Watt Lighting Stator67
Electric Start Engine: 1.25 Amp or 3 Amp Unregulated Charging System, Optional 70 Watt Lighting68
Wiring Diagram - Electric Start Engine/1,25 Amp or 3 Amp Unregulated Battery Charging System/70 Watt Lighting68
1.25 Amp or 3 Amp Stator /70 Watt Lighting Stator68
Troubleshooting Guide: 1,25 Amp Battery Charging System69
Troubleshooting Guide: 3 Amp Battery Charging System with 70 Watt Lighting Stator70
Electric Start Engines: 15 Amp Regulated Charging System71
Amp Stator and Rectifier Regulator71
Troubleshooting Guide: 15 Amp Battery Charging System72
Electric Start Engines: 25 Amp Regulated Charging System73
25 Amp Stator and Rectifier Regulator73
Troubleshooting Guide: 25 Amp Battery Charging System74
Keyswitch75
Battery Test75
Battery Charging, Maintenance75
Checking Battery Voltage75
Battery Testing76
Solenoid Testing76
Electric Starter76
Electric Starter Operation77
Bendix Drive Electric Starter77
Electric Starter Troubleshooting Guide78
Starter Removal and Installation78
Starter Drive Service78
Commutator End Cap with Brushes79
Commutator Service Reassembly79
Starter Assembly Match Marks79
Oil Sentry , Oil Level Monitor Operation80
Float Switch Removal80
Float Switch Installation/Removal81
Float Switch Test83
Automatic Compression Release - Operation85
Automatic Compression Release - Starting Position85
Automatic Compression Release - Running Position85
Benefits86
Compression Testing86
Inspection and Service86
Disassembly Procedure87
Disconnect Spark Plug Lead Drain Oil from Crankcase87
Remove Air Cleaner87
Removing Spark Plug Lead, Oil Drain Plug and Air Cleaner Cover87
Remove Muffler88
Removing Choke Linkage, Throttle Linkage and Carburetor88
Removing Air Cleaner Element88
Removing Air Cleaner Base88
Remove Fuel Pump89
Removing Fuel Pump, External Governor Components, and Throttle and Choke Controls89
Remove External Governor Components, and Throttle and Choke Controls89
Remove Retractable Starter90
Remove Electric Starter and Solenoid90
Remove Fuel Tank90
Removing Starter from Bearing Plate90
Remove Cylinder Head Baffle, Blower Housing and Side Air Baffles91
Remove Breather Assembly91
Removing Cylinder Head Baffle, Blower Housing and Breather Cover91
Removing Fuel Tank Bracket from Crankcase91
Remove Spark Plug and Cylinder Head92
Remove Ignition Module and Air Baffle92
Remove Drive Cup or Rope Start, Pulley, Grass Screen, Flywheel and Fan92
Rope Start Models93
Electric Start Models93
Retractable Start Models93
Remove Valves94
Remove Stator94
Remove Oil Pan94
Remove Connecting Rod and Piston95
Remove Piston Rings95
Remove Piston from Connecting Rod95
Remove Crankshaft and Bearing Plate95
Remove Camshaft and Tappets96
Remove Governor Gear and Cross Shaft96
Remove Oil Seals97
Remove Bearings97
Model M10, M12, M14, M16 Disassembly98
Disconnect Spark Plug Lead98
Drain Oil from Crankcase98
Remove Rectifier-Regulator99
Remove Choke Linkage, Throttle Linkage and Carburetor99
Remove External Governor Components and Throttle and Choke Controls100
Remove Breather100
Remove Fuel Pump, Remove Retractable Starter100
Remove Fuel Tank and Solenoid101
Remove Oil Fill/Dipstick Tube101
Remove Electric Starter101
Removing Starter Tail Brace and Starter102
Removing Carburetor Side Air Baffle102
Remove Drive Cup or Rope Start Pulley, Grass Screen, Flywheel and Fan103
Removing Flywheel Fastener103
Removing Fan from Flywheel104
Remove Stator, Valves, Oil Pan105
Remove Balance Gears107
Removing Bearing Plate Using a Puller107
Removing Tappets107
Remove Governor Gear, Cross Shaft108
Remove Oil Seals, Bearings108
Removing Balance Gears, Governor Gear and Cross Shaft108
Inspection and Repair/Reconditioning109
Flywheel Inspection109
Cylinder Head Inspection109
Checking Cylinder Head Flatness109
Cylinder Block Inspection and Reconditioning110
Honing110
Cylinder Bore Crosshatch after Honing110
Measuring Cylinder Bore110
Valves Inspection and Service111
Measuring Piston-To-Bore Clearance111
Measuring Piston Diameter111
Valve Spring Free Height111
Valve Details112
Valve Guides114
Install Valve Guide114
Valve Seat Inserts114
Reaming Valve Guide114
Remove Valve Seat Insert115
Install Valve Seat Insert115
Pulling Valve Seat Insert115
Piston and Rings Identification116
Piston and Rings Inspection116
Piston and Rings Service117
Common Types of Piston and Ring Damage117
Intall Piston Rings118
Measuring Piston Ring Side Clearance/End Gap118
Posi-Lock Connecting Rods119
Piston Ring Installation119
Magnum M8 Posi-Lock Connecting Rods119
Piston Ring Inspection and Service120
Balance Gears and Stub Shafts120
Governor Gear120
Camshaft and Crankshaft Inspection and Service120
Crankpin Fillets121
Model M8 Reassembly122
Install Rear Bearing122
Install Governor Gear and Cross Shaft122
Install Tappets and Camshaft123
Installing Governor Gear123
Measuring Camshaft End Play123
Install Crankshaft124
Install Bearing Plate124
Install Fuel Line and Wiring Harness124
Install Front Bearing124
Install Oil Seals125
Install Piston to Connecting Rod125
Install Piston Rings125
Install Piston/Connecting Rod126
Install Oil Pan126
Installing Pistons126
Install Valves127
Install Stator128
Install Fan, Flywheel, Grass Screen and Drive Cup or Rope Start Pulley128
Install Fan to Flywheel128
Install Ignition Module and Air Baffle129
Installing Ignition Module129
Install Cylinder Head and Spark Plug130
Install Side Air Baffles, Blower Housing and Cylinder Head Baffle130
Installing Breather Components130
Cylinder Head Fastener Torque Sequence130
Install Fuel Tank and Brackets131
Installing Blower Housing, Keyswitch Panel and Side Air Baffle131
Installing Fuel Tank Bracket to Crankcase131
Install Solenoid and Electric Starter132
Install Retractable Starter132
Installing Starter and Starter Tail Brace132
Installing Fuel Tank132
Install External Governor Components, and Throttle and Choke Controls133
Install Fuel Pump133
Install Carburetor, Throttle Linkage and Choke Linkage133
Install Rectifier-Regulator134
Installing Carburetor, Throttle Linkage and Choke Linkage134
Adjusting Governor Arm/Cross Shaft134
Install Muffler135
Install Air Cleaner135
Prepare the Engine for Operation136
Install Air Cleaner Cover, Oil Drain and Spark Plug136
Models M10, M12, M14, M16 Reassembly137
Installing Tappets, Governor Gear and Cross Shaft138
Install Balance Gears (on Engines so Equipped)139
Install Crankshaft (on Engines Without Balance Gears)139
Installing Balance Gears, Camshaft Pin and Cup Plug139
Install Crankshaft (on Engines with Balance Gears)140
Aligning Crankshaft and Camshaft Timing Marks, Balance Gears140
Installing Balance Gear Timing Tool, Aligning Crankshaft and Camshaft Timing Marks140
Install Front Bearing, Fuel Line and Wiring Harness141
Timing Marks on Balance Gear and Crankshaft141
Checking Crankshaft and Balance Gear Alignment141
Install Bearing Plate, Oil Seals142
Installing Wiring Harness and Bearing Plate142
Measuring Crankshaft End Play142
Installing Oil Seals Using Sleeve142
Install Piston Rings, Install Piston to Connecting Rod143
Install Oil Pans, Valves144
Install Stator, Fan, Flywheel, Grass Screen and Drive Cup or Rope Start Pulley145
Retractable Start, Electric Start, Rope Start146
Install Cylinder Head and Spark Plug, Side Air Baffles, Blower Housing and Cylinder Head Baffle147
Install Electric Starter, Fuel Tank148
Install Retractable Starter, Fuel Pump149
Install Breather Assembly, External Governor Components and Throttle and Choke Controls150
Install Rectifier-Regulator, Muffler151
Install Air Cleaner, Prepare the Engine for Operation152

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