TWO CYLINDER SERVICE MANUAL - Vintage Snow

1 ENS632 Class ITWOCYLINDERSERVICEMANUALMODELS:K295-2,K 295-2AX,K340-2,K340-2AX,SK340-2AS,K399-2 ,K399-2AX,K440-2,'.K440-2AS,K440-2AX, 73 Thisisacompleterevision .LITHO IN ..1:2 PrestartInstructions;; ce , ,Lines, gnitionCircui ts"""3."T"""Spark , (K6l8-2) (K6l8-2) ..SIXRopeReplacement-BlowerTypeStarters. . """"7":' .. ~ ..NINEToolRequirements'" ..10:2 SequenceofDisassembly ..~ .. ,Reboring& , .. , ~SequenceofReassembly .. ,ToolKits.. Makesureignitionswitchisin". :'positionandsparkplugdisconnectedbefore workingonengine. Makesureallsafetyguardsonengineanddriven equipmentareinproperpositionandsecure. Makesurehands,feetandclothingareatasafed istancefromanymovablepartspri?rtostartin g. Donotoperateengineinclosedbuildingunless exhaustispipedsafelyoutside. ,orfromexpansion, ! 1. PRE- (NEWENGINE):Duringthefirsthour,runforsho rtperiodsoftimeatvaryingspeedsupto3 ,operatenormallyuptofullthrottle--nofurt her"babying" :Ifbatteryhasbeenremovedordisconnectedfo ranyreason,makesurethatthenegative(-) :MixleadedRegularorPremiumgradeofgasolin e(92octaneminimum)withSAE30orSAE40two-cy cle,air-cooledtypeengineoilinagasolineto oilratioof20to1forthefirstfillon , <2 Gallonsc3<Ga110ns'}:4'Gallons 5 Gallons:; ~6 Ganonst'~OIL( ) (IMPERIALMEASURE) !

2 ;ine ha sbeenoutinsnow,rnakesureairintakeorbaffl eisc l e :'- , :Ifvehiclehasprimerbutton,pressbuttonsev eraltimesbeforeattemptingtostart(whencol d). :'JGINE:(.';)RETRACTABLESTARTMODELS:Turn ig nitio nswitchON,pullstartingropeInqUICK,steaay rnotron ,Donotallownandletosnapback.(B)ELECTRICS T.';RTMODELS:MoveswitchtoSTART position--releaseassoonasenginestarts( swrtc nwillremainin"ON"position). :' :Afteroperatingunderheavyloadinwarmerwea ther, , :Avoididlingorslowspeedoperationforprolo ngedperiodsasthiscanresultincrankcaseflo oding,carbonaccumulationinhead, ,determinewhatisactually ,orisitcausedbyaweakorimprop-erlytimedig nitionsparkorisitpoorcompression?Iftheco mplaintispoorperformance,don' , ,brokenwires, ,don' ,crackorbreaksimplybecausetheywerenottig htenedproperlyinthefirstplace,theroughte rrainsocommontovehiclespoweredbyZ-cyclee nginesisveryconducivetovibrationandthere sultinglooseningofnuts,bolts, ,aircoolingshrouds,intakemanifolds,start ermounts, :unevenlyworndrivebelts,missingcleats,mi saligneddrivecomponents, ,iftheenginedoesnotstart,itmayalsobeduet opoorcompressionwhichyou'llnoteisnotchec ked;however, , , ,",FUELPOSSIBLECAUSES(SEEDETAILSBELOWAND ONNEXTPAGE)x.

3 :.. ,.,----~----"I'I""----_IWILLNOTSTARTHARD STARTINGxxIIIIxXLACKSPOWERPOORACCELERATI ONxx:IIxxIIIIII:xxXxPINGSUNDERLOADxxBACK FIRES,RUNSUNEVENLYxIIIIxSTOPSORSTALLSSUD DENLYx,xxFUELRELATED CAUSES NOFUEL1. Tank empty2. Fuelvalveturnedoff3. Tankventclosedorplugged4. Linedisconnected5. Linekinked, , 'tvaporize2. Airleaks- loosecomponents3. Fuellinesrestricted6. Exhaustportblocked7. Vaporlock(TOOMUCHFUEL1. Overchoking, ,.~!FUELSYSTEMTESTS:FUELINCOMBUSTIONOlAM BER:Ifenginewon'tstart,removesparkplug, ,check out system fromcarburetorback :Iffuelflows outofcarburetorand frominletlinewhendisconnectedfromcarbure tor, wet2. Plug gapincorrect3. Plug Timingwrong8. CondenserweakIGNITIONTESTSSPARKPLUG:Remo veplug, ",placeplugwithsideelectrodeagainstcylin derheadthencrankengineatspeedsufficientt o produce a goodspark--ifa sharpsnappysparkisnotedbetween theelectrodes,thiseliminatestheignitionc omponents asthefault--wrongtimingcouldhowever :Unplug theswitch(disconnectallterminals)--ifthe engine can bestartedwithswitchdiscon-nected, :Use commercialcondensertesterpertestermanufa cturer'sinstructions--badcondenserwillca useprematurefailureofpoints.)

4 ~Checkoncoiltester--continuitymust worn6. of ~ :Mostcausesof ,itwillbenecessarytodisassembleheads "i'J,t"SERVICEATINTERVALSINDICATED-!,",' I-EVERY50-HOURS::~J'710cr';150 HOURS:'":ii_l:';-'2no:?50'HOURS"~t~~SPAR KPLUG:Checkcondition,resetgap-------r--- ----XIISPARKPLUG:Replacewithnewplug----- -------r-----------------,---------XBREA KERPOINTS:Check,regap, retimeignitionr-----------------,------- --XICOMBUSTIONCHAMBER:Removecarbon------ ------r-----------------,---------XIEXHA USTPORT:Cleanout deposits-------------r-----------------, -----------------~---------XPISTONRINGS: Cleancarbon, free rings-------~-----------------~ )FUEL,FUELSYSTEMFUELREQUIREMENTSS incemost2-cycleengines,includingKohler,r eceivelubricationonlyfromtheoilwhichmust bemixedinwiththegasoline, ,overheating,scuffingandscoring, ,ontheotherhand, ,infact, ,however, "name"brandgasolinespurchasedfrompopular servicestationstoavoidstalegasolineorlef tovergasolinenotadjustedtoseasonalchange s.

5 ~---Ir.,---I'.1-:':1------==I~~-SILENCER ~FIl~::-"L~ORAIRVEHICLECLEANER::::..0 FUEL--=::::::::"P" ::FIGURE2-1 SCHEMATICOFATYPICAL2-CYCLEENGINEFUELSYST EMl~------CRANKCASEb:====~ ------IMPULSETUBEVAPORRETURNLINE~PRIMERF ITTING(ENGINESIDE~--OFTHROTTLE) , ,diluted, ;however, , , , . 'tdoitthisway!Agitatethoroughlyafterfina l-, , ,however,storingfuelforanylengthoftime, , ' (Special),PIPE~PLUGPRIMERFInINGFUEL'---- SUPPLyat::rrc=::::;;;;;;=:::::s:::n:::F- 'LIMPULSEFInINGoVAPORRETURNIFInING--=.:. .J/,FIGURE2-2--MODELWRCARBURETORFIGURE2- 3--MODELHRCARBURETORW iththepossibleexceptionofthecarburetor,f uelsystemcomponentsareusuallyfurnishedby thevehiclemanufacturerbutsincetheseparts canseriouslyaffectengineoperation, , ' ,butmoreimportant, , ". # # :Iftheareaaroundthecarburetororairintoth ecarburetorbecomeshotenoughtovapcrrzegas olineinsidethecarburetor,thepocketsofvap orsoformedwillstopallflowoffuel--wheneve rthisoccurs, , , CARBURETOR:Don' , , , "TOFANSIDESPARKPLUGHIGHTENSIONCABLE~---~ TOPTOSIDESPARKPLUGI,_____JP~V~C~--- :BLACKr--WHITE_:YELLOW,J;MOLDEO-INSULATO R-------CONNECTORSBLACK(Common)REDPTO)BL UE(Fan)WHITE(High)BLACK(Low).

6 >-r:-----------IVENTILATORHOUSING:STATOR ASSEMBLY!~1'-r------F===..;.;.'"""-'-"== ===:=..::.::.::==========,--I1V)V)Cl;1-- --1tx:o~Cl;za::LLJ~ ::ILLJ I<.!:I>-I<.! )Iex:V):I-Cl;L_j---i--:..:..:=-.,l.;..~ : :. , , (ALLPLUGS)..020"TIGHTENINGTORQUE. ;ne_.'."Plug,~, * *K295-2T14mm3813203W260T2W280T20SN2N57K2 95-2AX14mm3813203W260T2W280T20SN2N57K340 -2T14mm4013202W260 TlW280 MlL78L77JK340-2AX14mm3813203W260T2Vi280T 20SN2N57SK340-2 ASl4mm-----N19V**---K399-2T18mm3313202M2 40 TlM260 TlK8K7K399-2AX14mm3813203W260T2W280T20SN 2N57K440-2Tl8mm3313202M240 TlM260 TlK8K7K440-2 AXl4mm3813203W260T2Vi280T20SN2N57K440-2A S14mm-----N19V**-K618-218mm-M240 TlM260 TlK8K7*Beavydutyplugsforallterrainvehicl esandsummeruse.** <,FLYWHEEL-MAGNETOIGNITION! (lowtension) , , #1 HIGHTENSIONCOIL------1,~BLUE-WHITE,LEADB LUEJLEAD--(LOWTENSION( '' ~~CONDENSERIDOUBLELOWTENSIONCOILTYPEI #2 COIL#2 PLUGBLUE!ffilm;iffi:~-4~.~LEAD~I~~#2 POINTSPLUG~..--RED-BLUELEADLOWTENSION~~N ITIONCOIL/fCONDENSERS#1 POINTSfL,#1 COlL1------I1 IISINGLELOWTENSIONCOILTYPE~FIGURE3-1--SI NGLEANDDOUBLEPRIMARYCOILIGNITIONCIRCUITS T heignitionleadsarenotconnectedthesameont hetwosystems--afteridentifyingwhichsyste misinvolved, , (CDI) (ChampionN19 Vorequivalent) ,whichisshownschematicallyinFigure3-2, ' ,removetheretractablestarter, ,cleanthemoffwithasmallbrush--ifoily, , , ,removeterminalnutanddisconnectleadrunni ngtothecondenser, ' , , "(.

7 ").Ifadjustmentisneeded,loosenadjustings crew, , ,replacingorser,:icingpoints.~---------- --TOPBREAKERPOINTSFOR#2 CYLINDERBOTTOMBREAKERPOINTSFOR'--------- #1 CYLINDER c.",..',.-FIGURE3-3--BREAKERPOINTS,CONDE NSERCONDENSERLOCATEDUNDERFLYWHEELORHUBI fthecondensershortsout, , , , , , ,alowresistanceshouldbeindicated;however , , ,followinstructionsgivenbythetesterrnanu facturer ,Toreplacecondensers,itisnecessarytoremo vetheblowerhousing,flywheel, ~NITIONCOILS~_Ignitioncoils,internalorex ternal,donotrequireregularservice;howeve r, :'.,",'.VII,i IIIIIII1 LTIMINGPROCEDURE( ) (beforetopdeadcenter) , "isstatedtoaccountforthisvariation,howev er, ".Whenpointsarewideopenandadjustedproper ly, " # (for# 1first) " (dialwillsuddenlyreversedirection) ,repeatprocedureon# ,readjusttimingperthefollowinginstructor s.~..,..~'"\..';;,ooTURNFLYWHEELCOUNTERC LOCKWISEUNTILTIMINGLIGHTCHANGESINDICATIN GIGNITION--IFINDICATORISNOTINRANGESPECIF IED,RETIMEIGNITIONIGNITIONTIMINGPROCEDUR EWITHTIMINGGAUGE~ \ IoFIGURE3-5oTURNFLYWHEELCLOCKWISEUNTILPI STONISATTDCuSETDIALATZEROATTHISPOINTTIMI NGADJUSTMENT:Firsttrytocorrecttimingbyma kingslightchangestopointgapsetting--ifth etiminglightchangeoccurredbeforetheindic atorreachedthespecifiedtimingpoint, , , " #1,checktimingon#Z cylinderv-don'treadjust#Zbyshiftingthest atorplateasthiswouldthrowtimingofffor#l- -adjust# ;Ii1:1!

8 ,IGNITIONTIMINGSTATOR, :Theflywheelrotor,whichincorporatesaspec ialflexiblemagnetandismountedontheengine crankshaft, ,nineofwhichsupplypowerforthevehicle's-l ightsand/orforchargingthebattery, ,revolvingwithinthetimingring,triggersth edis-chargeofthesecondensersthroughtheel ectronicboxtotheignitiontransformers,whi ch"stepup"thevoltagetoalevelnecessarytoi nsuresuccessfulfiringofthes u r fa c , (Wico#14281).Turntheswitchtotheonpositio n, ,forbothcylinders,theproblemlieselsewher eintheengine(carburetion,timing,ormechan icalfailure), ,theproblemliesinthecoilorhightensionlea d;thetimingring, ._,.~.. rn?''P'ELECTRONICS~::.-----MODULEV_----- -JUMPERLEADSELECTRONICSMODULE100 toOHMS100TO300~OHMS ;however, (redorwhitelead). , ,thecoilisdefectiveandmustbereplaced.(Ch eckhighfensionleadbeforereplacingcoil) (Couldusejumperleadswithsmallalligatorcl lps ; ) (Makesureofgoodelectricalconnections.) , ,theproblemliesintheelectronicsmoduleand itmustbereplaced.~ , ,beforetestingthesystem, ,positiontheleadsotheterminalcannotconta ctground, ,thefollowingsequenceisrecommended.

9 ~.. (infinity)atallthreeterminals.( )Ifthesereadingsarenotobtained, '~ :::iL FIGURE3-12--ALTERNATQRSTATORACOUTPUTTEST STEP2:Unplugthetwo-leadconnectorfromthee lectronicsmoduleandmakethefollowingcheck sattheconnectoronthewiringharness.( ) (Changescalesandresetohmmetertozeroifnec essary.)Ifthesereadingsarenotobtained,th estatorassemblyisdefectiveandmustberepla ced .STEP3 (redorwhitelead). ( ) , , (Checkhightensionleadbeforereplacingcoil .)STEP4:Ifallteststothispointhavebeenwit hinthelistedspecifications, , ALTERNATOR , :ConnecttheACvoltmetertothegreen/yellowl eadandwhitelead.( ) :Connectthetestbulbtothegreen/yellowlead andwhitelead.( ) , ,thebulbshouldbeaboutnormalbrightness .6--------------------DIALINDICATOR__~~- -------TIMINGTOOL'..ol(3845503)FIGURE3-1 3--TIMINGKOHLER-TRONSYSTEMWITHTIMINGTOOL ."TIMINGENGINESWITHKOHLER- :Removerecoil,startercap,sheaves,flywhee lassembly, :Installdialindicatorin#Icylindersparkpl ughole,setdialat"0"withpistonatTDC,insta llKohlertimingtoolpart#3845503oncranksha ftasillustratedmakingsurethetoolisallthe wayonthecrankshaftkeyandtaper,loosenthet wotriggerringscrews STEP3 ,rotatetriggerringuntilpointerontoolisma tchedwithtimingmark(timingmarkisthelongm arkinthemiddle)onthetriggerring, ,withtheexceptionoftheSK340-2 ASandK440-2AS,use40,75, ,aheavygaugegroundwire(#4or6) # , ,', '" , :RESISTORI~*NOTE:OnK295-2 AXand KJ40-2AX Modelswithyellow-gpeenleads, (YELLOW-GREENONK295-2AX&K340-2 AXMODELS)31 SPARKPLUG31b.

10 -__--.;:----<:>ONEALTERNATORLEADISOLATED*EXTERNALIGNITI ONCOILFIGURE4-1~-75 WATT,MANUALSTARTSYSTEMWITHKOHLERSWITCHFL YWHEEL-ALTERNATORSYSTEMST heelectricalsystemfunctionstoprovideener gyforlightingandlorcharginga , , ,rectificationisnotrequired;there-fore,o neleadisisolatedandtheotherisbroughtoutt othelightswitch. Someapplicationsuseseparatevoltageregula torswhichcontrolvoltageregardlessofload- -most,however,haveunregulatedsystemswhic harecontrolledonlybyamount{) , ,thisusuallyindicatesanovervoltagecondit ion--ontheotherhand, ,ifyouhaveamanualstartenginewitha40watts ystem,usea 5watttaillightanda ' , ~ '.. (32amphrmin)+ ~3c50,,--.;;..-_.,-RECTIFIER51r---.,53,. -(>---------------------5153~>---------' "' , , , , k{'\'\'f!I)/+ ,..-''f'-.,OFFONSTART75 WATT, ,53~..-----'"' ,batteryWithvoltageregulatorandbrakeligh tr-yeliow/grCen_Gouge12.,Switchpositions :oIgnitionoffIlightsonIIlightsof!BRAKEII IS tartingBRAKElIGHTLIGHTSWITP~I':In/53c'.. __050:ITI7 IgnitioncoilsSparkplug~ \\~.}}