SV710-SV740 SV810-SV840 Service Manual

1 Service ManualSV710-SV740SV810-SV8402 Safety3 Maintenance5 Specifications13 Tools and Aids16 Troubleshooting20 Air Cleaner/Intake21 Fuel System28 Governor System29 Lubrication System31 Electrical System43 Starter System49 Emission Compliant Systems52 Disassembly/Inspection and Service64 Reassembly132 690 01 Rev. : 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 PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property : is used to notify people of important installation, operation, or maintenance information. WARNINGE xplosive Fuel can cause fires and severe not fill fuel tank while engine is hot or is extremely flammable and its vapors can explode if ignited.

2 Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. WARNINGR otating Parts can cause severe away while engine is in hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed. WARNINGC arbon Monoxide can cause severe nausea, fainting or inhaling exhaust exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. WARNINGA ccidental Starts can cause severe injury or and ground spark plug lead(s) before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative ( ) battery cable from battery. WARNINGHot Parts can cause severe not touch engine while operating or just after operate engine with heat shields or guards removed.

3 WARNINGC leaning Solvents can cause severe injury or only in well ventilated areas away from ignition cleaners and solvents are extremely flammable. Follow cleaner manufacturer s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. CAUTIONE lectrical Shock can cause not touch wires while engine is running. CAUTIOND amaging Crankshaft and Flywheel can cause personal improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing 690 01 Rev. D3 Maintenance32 690 01 Rev. INSTRUCTIONS WARNINGB efore working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative ( ) battery cable from battery. Accidental Starts can cause severe injury or and ground spark plug lead(s) before maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized SCHEDULEE very 25 Hours Service /replace Cleaner/Intake Replace air cleaner element (if not equipped with precleaner).

4 Air Cleaner/IntakeEvery 100 Hours Replace air cleaner element (if equipped with precleaner).Air Cleaner/Intake Change oil and filter. Lubrication System Remove cooling shrouds and clean cooling Cleaner/IntakeEvery 100 Hours Check that all fasteners are in place and components are properly Replace fuel 200 Hours Have valve lash 500 Hours Replace spark plugs and set System Perform these procedures more frequently under severe, dusty, dirty conditions. Have a Kohler authorized dealer perform this PARTSK ohler genuine Service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit or call 1-800-544-2444 ( and Canada). 690 01 Rev. DOIL RECOMMENDATIONSWe recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) Service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below.

5 FUEL RECOMMENDATIONS WARNINGE xplosive Fuel can cause fires and severe not fill fuel tank while engine is hot or is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning : E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not must meet these requirements: Clean, fresh, unleaded gasoline. Octane rating of 87 (R+M)/2 or higher. Research Octane Number (RON) 90 octane minimum. Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable. Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved. Do not add oil to gasoline. Do not overfill fuel tank. Do not use gasoline older than 30 engine will be out of Service for 2 months or more follow procedure Add Kohler PRO Series fuel treatment or equivalent to fuel tank.

6 Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable).2. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute Disconnect negative (-) battery Store engine in a clean, dry 690 01 Rev. in equivalents shown in [ ].Engine 690 01 Rev. DDimensions in equivalents shown in [ ].Engine Dimensions7 Specifications32 690 01 Rev. mm ( in.)Stroke67 mm ( in.)Displacement725 cc (44 cu. in.)Oil Capacity (refill) L ( qt.)Maximum Angle of Operation (@ full oil level)425 TORQUE SPECIFICATIONS3,5SV710SV810SV715SV720SV8 20SV725SV730SV830SV735SV740SV840 Blower Housing and Sheet MetalM4 HI-LO N m (25 in. lb.)M5 N m (55 in. lb.) into new N m (35 in. lb.) into used holeM6 N m (95 in. lb.) into new N m (65 in. lb.)

7 Into used holeCarburetorMounting N m (55-65 in. lb.)Connecting RodCap Fastener (torque in increments) N m (100 in. lb.)CrankcaseBreather Assembly Inner Cover Fastener Outer Cover Stud Outer Cover Hex N m (95 in. lb.) into new N m (65 in. lb.) into used N m (55 in. lb.) into new N m (35 in. lb.) into used N m ( in. lb.)Oil Drain N m (10 ft. lb.)ENGINE IDENTIFICATION NUMBERSK ohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine .. sv710 Courage EngineVertical ShaftNumerical DesignationSpecification .. sv710 -0001 Serial ..3923500328 Year Manufactured Code Factory Code Code Year 39 2009 40 2010 41 20113 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient Lubricate threads with engine oil prior to Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards.

8 Details on Certified Power Ratings can be found at 690 01 Rev. DTORQUE SPECIFICATIONS3,5SV710SV810SV715SV720SV8 20SV725SV730SV830SV735SV740SV840 Cylinder HeadHead Bolt Fastener (torque in 2 increments)first to N m (200 in. lb.)finally to N m (370 in. lb.)Rocker Arm N m (100 in. lb.)Rocker Arm Stud (AVT) N m (100 in. lb.)Rocker Arm/Valve Adjustment Jam N m (65 in. lb.)Rocker Arm/Valve Adjustment Setscrew (AVT) N m (70 in. lb.)FlywheelRetaining N m (55 ft. lb.)Fuel N m (20 in. lb.)GovernorLever N m (60 in. lb.)IgnitionSpark Plug27 N m (20 ft. lb.)Module N m (35-55 in. lb.)Rectifier-Regulator N m (35 in. lb.)Intake ManifoldMounting Fastener (torque in 2 increments)first to N m (66 in. lb.)finally to N m (88 in. lb.)MufflerM8 Hex N m (216 in. lb.)5/16-18 N m (150 in. lb.)Bracket N m (88 in. lb.)Oil N m (300 in. lb.)Oil N m (216 in. lb.)Oil Sentry Pressure N m (40 in. lb.)Solenoid (Starter)Mounting N m (35-53 in.)

9 Lb.)Nut, Positive (+) Brush N m (71-97 in. lb.)Speed Control N m (95 in. lb.) into new N m (65 in. lb.) into used holes3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to 690 01 Rev. SPECIFICATIONS3,5SV710SV810SV715SV720SV8 20SV725SV730SV830SV735SV740SV840 Starter AssemblyThru Bolt Inertia Drive Solenoid N m (40-50 in. lb.) N m (49-79 in. lb.)Mounting N m (135 in. lb.)Brush Holder Mounting N m (22-29 in. lb.)StatorMounting N m (55 in. lb.)Valve N m (55 in. lb.)CLEARANCE SPECIFICATIONS3SV710SV810SV715SV720SV820 SV725SV730SV830SV735SV740SV840 CamshaftEnd Play (with shim) mm ( in.)Running mm ( in.)Bore New Max. Wear mm ( in.) mm ( in.)Bearing Surface New Max. Wear mm ( in.) mm ( in.)Connecting RodConnecting Rod-to-Crankpin Running Clearance New Max. Wear mm ( in.) mm ( in.)Connecting Rod-to-Crankpin Side mm ( in.

10 Connecting Rod-to-Piston Pin Running mm ( in.)Piston Pin End New Max. Wear mm ( in.) mm ( in.)CrankcaseGovernor Cross Shaft Bore New Max. Wear mm ( in.) mm ( in.)3 Values are in Metric units. Values in parentheses are English 690 01 Rev. DCLEARANCE SPECIFICATIONS3SV710SV810SV715SV720SV820 SV725SV730SV830SV735SV740SV840 CrankshaftEnd Play (free) mm ( in.)Bore (in crankcase) New Max. Wear mm ( in.) mm ( in.)Bore (in oil pan) mm ( in.)Crankshaft Bore (in oil pan)-to-Crankshaft Running Clearance mm ( in.)Flywheel End Main Bearing Journal - New - Max. Wear Limit Max. Taper Max. mm ( in.) mm ( in.) mm ( in.) mm ( in.)Oil Pan End Main Bearing Journal - New - Max. Wear Limit Max. Taper Max. mm ( in.) mm ( in.) mm ( in.) mm ( in.)Connecting Rod Journal - New - Max. Wear Limit Max. Taper Max. mm ( in.) mm ( in.)