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ECH630-ECH749, CH735, CH26, CH745Service ManualIMPORTANT:Read all safety precautions and instructions carefully before operating equipment. Refer to operatinginstruction of equipment that this engine powers.Ensure engine is stopped and level before performing any maintenance or pecificationsTools and AidsTroubleshootingAir Cleaner/IntakeElectronic Fuel Injection (EFI) System-ECHElectronic Fuel Injection (EFI) System-BoschLubrication SystemElectrical SystemStarter SystemDisassembly/Inspection and ServiceReassembly24 690 01 Rev. DKohlerEngines.com1
SafetySAFETY PRECAUTIONSWARNING: 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 damage.NOTE: is used to notify people of important installation, operation, or maintenance information.WARNINGExplosive Fuel can causefires and severe burns.Do not fill fuel tank whileengine is hot or running.Gasoline is extremely flammableand its vapors can explode ifignited. Store gasoline only inapproved containers, in wellventilated, unoccupied buildings,away from sparks or flames.Spilled fuel could ignite if it comesin contact with hot parts or sparksfrom ignition. Never use gasolineas a cleaning agent.WARNINGRotating Parts can causesevere injury.Stay away while engineis in operation.Keep hands, feet, hair, andclothing away from all movingparts to prevent injury. Neveroperate engine with covers,shrouds, or guards removed.WARNINGCarbon Monoxide cancause severe nausea,fainting or death.Avoid inhaling exhaustfumes.Engine exhaust gases containpoisonous carbon monoxide.Carbon monoxide is odorless,colorless, and can cause death ifinhaled.WARNINGCAUTIONAccidental Starts cancause severe injury ordeath.Disconnect and groundspark plug lead(s) beforeservicing.Electrical Shock cancause injury.Do not touch wires whileengine is running.Before working on engine orequipment, disable engine asfollows: 1) Disconnect spark pluglead(s). 2) Disconnect negative (–)battery cable from battery.Damaging Crankshaftand Flywheel can causepersonal injury.WARNINGHot Parts can causesevere burns.Do not touch enginewhile operating or justafter stopping.Never operate engine with heatshields or guards removed.WARNINGCleaning Solvents cancause severe injury ordeath.Use only in wellventilated areas awayfrom ignition sources.Carburetor cleaners and solventsare extremely flammable. Followcleaner manufacturer’s warningsand instructions on its proper andsafe use. Never use gasoline as acleaning agent.CAUTIONUsing improper procedures canlead to broken fragments. Brokenfragments could be thrown fromengine. Always observe and useprecautions and procedures wheninstalling flywheel.WARNINGHigh Pressure Fluids canpuncture skin and causesevere injury or death.Do not work on fuelsystem without propertraining or safetyequipment.Fluid puncture injuries are highlytoxic and hazardous. If an injuryoccurs, seek immediate medicalattention.WARNINGExplosive Fuel cancause fires and severeburns.Fuel system ALWAYSremains under HIGHPRESSURE.Wrap a shop towel completelyaround fuel pump moduleconnector. Press release button(s)and slowly pull connector awayfrom fuel pump module allowingshop towel to absorb any residualfuel in high pressure fuel line. Anyspilled fuel must be completelywiped up immediately.2KohlerEngines.com24 690 01 Rev. D
MaintenanceMAINTENANCE INSTRUCTIONSWARNINGAccidental Starts can cause severe injury ordeath.Disconnect and ground spark plug lead(s)before servicing.Before working on engine or equipment, disable engine asfollows: 1) Disconnect spark plug lead(s). 2) Disconnectnegative (–) battery cable from battery.Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repairestablishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.MAINTENANCE SCHEDULEEvery 25 Hours or Annually¹ Service/replace low-profile precleaner (if equipped).Air Cleaner/IntakeEvery 100 Hours or Annually¹ Change oil. Replace low-profile air cleaner element. Remove and clean shrouds and cooling areas. Check oil cooler fins, clean as necessary (if equipped).Lubrication SystemAir Cleaner/IntakeAir Cleaner/IntakeLubrication SystemEvery 150 Hours Check heavy-duty filter minder. Inspect heavy-duty air filter paper element and inlet screen area.Air Cleaner/IntakeAir Cleaner/IntakeEvery 200 Hours¹ Replace unique Electronic Fuel Injection (EFI) fuel filter.Every 200 Hours Change oil filter. Replace spark plugs and set gap.Lubrication SystemElectrical SystemEvery 300 Hours¹ Replace heavy-duty air cleaner element and check inner element.Air Cleaner/IntakeEvery 600 Hours¹ Replace heavy-duty air cleaner inner element.Air Cleaner/Intake1Perform these procedures more frequently under severe, dusty, dirty conditions.REPAIRS/SERVICE PARTSKohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorizeddealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).24 690 01 Rev. DKohlerEngines.com3
MaintenanceOIL RECOMMENDATIONSWe recommend use of Kohler oils for best performance.Other high-quality detergent oils (including synthetic)of API (American Petroleum Institute) service class SJor higher are acceptable. Select viscosity based onair temperature at time of operation as shown in tablebelow.STORAGEIf engine will be out of service for 2 months or morefollow procedure below.1. Add Kohler PRO Series fuel treatment or equivalentto fuel tank. Run engine 2-3 minutes to get stabilizedfuel into fuel system (failures due to untreated fuelare not warrantable).2. Change oil while engine is still warm from operation.Remove spark plug(s) and pour about 1 oz. ofengine oil into cylinder(s). Replace spark plug(s) andcrank engine slowly to distribute oil.3. Disconnect negative (-) battery cable.4. Store engine in a clean, dry place.FUEL RECOMMENDATIONSWARNINGExplosive Fuel can cause fires and severeburns.Do not fill fuel tank while engine is hot orrunning.Gasoline is extremely flammable and its vapors canexplode if ignited. Store gasoline only in approvedcontainers, in well ventilated, unoccupied buildings,away from sparks or flames. Spilled fuel could igniteif it comes in contact with hot parts or sparks fromignition. Never use gasoline as a cleaning agent.NOTE: E15, E20 and E85 are NOT approved andshould NOT be used; effects of old, stale orcontaminated fuel are not warrantable.Fuel 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 isacceptable. Methyl Tertiary Butyl Ether (MTBE) and unleadedgasoline blend (max 15% MTBE by volume) areapproved. Do not add oil to gasoline. Do not overfill fuel tank. Do not use gasoline older than 30 days.4KohlerEngines.com24 690 01 Rev. D
SpecificationsEngine Dimensions with Heavy-Duty Air Cleaner424.29(16.704)130.00(5.118)Air Filter CoverAssembly Removal277.30(10.917)88.20(3.473)Dimensions in millimeters.Inch equivalents shown in [ ].135.00(5.315)Air Filter RainCap Removal304.72(11.997)230.20(9.063)Safety Air FilterElement Removal342.52(13.485)Primary Air FilterElement RemovalLIFT STRAP17.53(0.690)Spark Plug19.22(0.757)Spark .626)MountingHole 84)52.40(20.063)89.00(3.504)2X OIL DRAIN PLUG3/8 NPT (IN.)MOUNTINGHOLE “A”OIL FILL LOCATIONOIL DIPSTICK286.49(11.279)622.63(24.513)1/4 IN. TSTRAP7/16-20 UNF 2B (IN.)38.10 (1.500)155.58(6.125)152.08(5.987)OIL FILTEROIL FILL LOCATION97.38(3.834)30 52.75(2.077)OIL FILTER104.00(4.094)89.00(3.504)ENGINE MOUNTINGSURFACE30 30 30 301.59(11.874)SOLENOIDSHIFTSTARTER45 3/8-16 UNC 2B (IN.)17.0 (0.669)Ø142.88 (5.625) B.C.45 7/16-14 UNC 2B (IN.)21.0 (0.827)Ø196.85 (7.75) B.C.ENGINEMOUNTINGSURFACE24 690 01 Rev. DKohlerEngines.com5
SpecificationsEngine Dimensions with Low-Profile Air CleanerDimensions in millimeters.Inch equivalents shown in [ ].426.44(16.789)302.63(11.915)60.00(2.362)AIR CLEANERCOVER REMOVAL17.07(0.672)SPARK PLUG12.15(0.478)17.53(0.690)SPARK PLUG32.00 (1.260)EXHAUST PORT #250.00 (1.969)SPARK PLUG12.00 (0.472)EXHAUST PORT #1FUEL FILTER463.36(18.242)OIL DIPSTICKCRANKSHAFT15.70(0.618)OIL FILTERREMOVALMOUNTINGHOLES184.20(7.252)MOUNTING 5.626)370.05(14.569)3.05(0.120)OIL FILL30.00(1.181)SPARK PLUGFUEL PUMPOIL FILL12.19(0.480)OIL DRAIN PLUG3/8 IN. NPT51.00(2.008)67.50 (2.657)MUFFLER MOUNTINGBOSSES89.00(3.504)ENGINE MOUNTING SURFACE101.38(3.992)1/4 IN. SQ. KEYWAY8550(3.366)KEYWAY7/16-20 UNF 28 IN.38.10 .10(4.807)65.00(2.559)152.08(5.987)OIL FILTER4.00 (0.157)PILOT52.75(2.077)OIL FILTER51.00(2.008)ENGINE MOUNTING SURFACEMOUNTING 2.966)LIFT STRAPRECTIFIERREGULATOROIL DRAIN PLUG3/8 IN. NPTMOUNTINGHOLE “A”30 50.00(1.969)EXHAUST PORT #250.00(1.969)EXHAUSTPORT #1M8 X 1.254 STUDSM8 X 1.2520.5 DEEP2 HOLESMUFFLER MTGBOSSES283.58(11.164)SOLENOIDSHIFTSTARTERENGINE MTG SURFACE6PILOT 177.800(7.000)OPTIONAL PILOT ING HOLE “A”24 690 01 Rev. D
SpecificationsENGINE IDENTIFICATION NUMBERSKohler engine identification numbers (model, specification and serial) should be referenced for efficient repair,ordering correct parts, and engine replacement.Model. . . . . . . . . . . . . . . . . . . . . ECH630EFI Command EngineHorizontal ShaftNumerical DesignationSpecification . . . . . . . . . . . . . . . ECH630-3001Serial. . . . . . . . . . . . . . . . . . . . . 3923500328Year Manufactured CodeCodeYear392009402010412011GENERAL SPECIFICATIONS3,6BoreStrokeDisplacementOil Capacity (refill)Maximum Angle of Operation(@ full oil level)4ECH630-ECH680ECH730-ECH749CH26CH735CH74580 mm (3.15 in.)83 mm (3.27 in.)83 mm (3.27 in.)69 mm (2.72 in.)67 mm (2.64 in.)694 cc (42.4 cu. in.) 747 cc (45.6 cu. in.)725 cc (44 cu. in.)1.9 L (2.0 U.S. qt.)TORQUE SPECIFICATIONS3,5Blower HousingInto cored aluminum hole or weld nutM5M6Into extruded hole in sheet metalM5Factory CodeM6Closure PlateFastenerConnecting RodCap Fastener (torque in increments)8 mm straight shank8 mm step-down6 mm straight shank25 ECH630-ECH680 ECH730-ECH749CH26CH735CH7456.2 N·m (55 in. lb.) into new holes4.0 N·m (35 in. lb.) into used holes10.7 N·m (95 in. lb.) into new holes7.3 N·m (65 in. lb.) into used holes2.8 N·m (25 in. lb.) into new holes2.3 N·m (20 in. lb.) into used holes6.2 N·m (55 in. lb.) into new holes4.0 N·m (35 in. lb.) into used holes2.8 N·m (25 in. lb.) into new holes2.3 N·m (20 in. lb.) into used holes10.7 N·m (95 in. lb.) into new holes7.3 N·m (65 in. lb.) into used holes25.6 N·m (227 in. lb.)24.4 N·m (216 in. lb.)11.6 N·m (103 in. lb.)22.7 N·m (200 in. lb.)14.7 N·m (130 in. lb.)11.3 N·m (100 in. lb.)Values are in Metric units. Values in parentheses are English equivalents.Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.5Lubricate threads with engine oil prior to assembly.6Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hpstandards. Details on Certified Power Ratings can be found at KohlerEngines.com.3424 690 01 Rev. DKohlerEngines.com7
SpecificationsTORQUE SPECIFICATIONS3,5CrankcaseBreather Cover FastenerOil Temperature Sensor (into breathercover)Oil SentryTM (into breather cover)Oil Drain PlugCylinder HeadHex Flange Nut (torque in 2increments)Head Bolt (torque in 2 increments)Rocker Arm ScrewFan/FlywheelFan FastenerFlywheel Retaining ScrewMetal Debris Screen Fastener (toflywheel)Plastic Debris Screen Fastener (to fan)Fuel PumpModule Baffle FastenerModule FastenerPulse Pump Bracket FastenerPulse Pump Fastener to BracketGovernorLever NutSpeed Control AssemblyAssembled to Cylinder HeadsAssembled to Blower HousingIgnitionSpark PlugCoil FastenerIgnition Module Fastener TorqueCrankshaft Position Sensor ScrewCrankshaft Position Sensor BracketScrewElectronic Control Unit ScrewBlower HousingRectifier-Regulator Ground StrapFastenerRectifier-Regulator Fastener35ECH630-ECH680 ECH730-ECH749CH2611.3 N·m (100 in. lb.) into new holes7.3 N·m (65 in. lb.) into used holes7.3 N·m (65 in. lb.)CH735CH7457.3 N·m (65 in. lb.)4.5 N·m (40 in. lb.)13.6 N·m (10 ft . lb.)first to 16.9 N·m (150 in. lb.)finally to 33.9 N·m (300 in. lb.)first to 22.6 N·m (200 in. lb.)finally to 41.8 N·m (370 in. lb.)11.9 N·m (105 in. lb.)11.3 N·m (100 in. lb.)9.9 N·m (88 in. lb.)71.6 N·m (52.8 ft . lb.)66.4 N·m (49 ft. lb.)9.9 N·m (88 in. lb.)4.0 N·m (35 in. lb.)11.9 N·m (105 in. lb.)9.2 N·m (81 in. lb.)2.1 N·m (25 in. lb.)7.3 N·m (68 in. lb.) into new holes6.2 N·m (55 in. lb.) into used holes7.1 N·m (63 in. lb.)6.8 N·m (60 in. lb.)10.7 N·m (95 in. lb.)2.8 N·m (25 in. lb.)10.2 N·m (90 in. lb.)27 N·m (20 ft. lb.)6.2 N·m (55 in. lb.)7.3 N·m (65 in. lb.)4.0-6.2 N·m (35-55 in. lb.)6.2 N·m (55 in. lb.)2.8 N·m (25 in. lb.) into new holes2.3 N·m (20 in. lb.) into used holes1.4 N·m (12.6 in. lb.)Values are in Metric units. Values in parentheses are English equivalents.Lubricate threads with engine oil prior to assembly.8KohlerEngines.com24 690 01 Rev. D
SpecificationsTORQUE SPECIFICATIONS3,5Intake ManifoldFastener (torque in 2 increments)Manifold Absolute Pressure (MAP)Sensor FastenerFuel Injector CapAir Cleaner to Throttle Body FastenerNutHeavy-Duty Air Cleaner MountingBracket FastenerFuel Injector Cap FastenerMufflerRetaining NutOxygen SensorOil CoolerOil Cooler/Adapter NippleFastenerInto Blower HousingBetween Oil Cooler HosesSpeed Control BracketFastener (assembled to cylinder heads)Fastener (assembled to blowerhousing)Fastener TorqueStarter AssemblyThru BoltNippondenso (Solenoid Shift)Delco-Remy (Solenoid Shift)ScrewBrush Holder Mounting ScrewDelco-Remy StarterStarter SolenoidMounting HardwareNippondenso StarterDelco-Remy StarterNut, Positive ( ) Brush LeadNippondenso StarterDelco-Remy StarterStatorScrew35ECH630-ECH680 ECH730-ECH749first to 7.8 N·m (69 in. lb.)finally to 10.5 N·m (93 in. lb.)7.3 N·m (65 in. lb.)CH26CH735CH745first to 7.4 N·m (66 in. lb.)finally to 9.9 N·m (88 in. lb.)7.3 N·m (65 in. lb.)8.2 N·m (73 in. lb.)5.8 N·m (51 in. lb.)7.3 N·m (65 in. lb.)27.8 N·m (246 in. lb.)50.1 N·m (37 ft . lb.)24.4 N·m (216 in. lb.)28.5 N·m (21 ft . lb.)27 N·m (20 ft. lb.)2.8 N·m (25 in. lb.)2.3 N·m (20 in. lb.)10.7 N·m (95 in. lb.) into new holes7.3 N·m (65 in. lb.) into used holes2.8 N·m (25 in. lb.) into new holes2.3 N·m (20 in. lb.) into used holes5.6-9.0 N·m (49-79 in. lb.)16.0 N·m (142 in. lb.)2.5-3.3 N·m (22-29 in. lb.)4.0-6.0 N·m (35-53 in. lb.)8.0-11.0 N·m (71-97 in. lb.)6.2 N·m (55 in. lb.) into new holes4.0 N·m (35 in. lb.) into used holes10.7 N·m (95 in. lb.) into new holes7.3 N·m (65 in. lb.) into used holes4.5-7.5 N·m (40-84 in. lb.)5.6-9.0 N·m (49-79 in. lb.)15.3 N·m (135 in. lb.)2.5-3.3 N·m (22-29 in. lb.)6.0-9.0 N·m (53-79 in. lb.)4.0-6.0 N·m (35-53 in. lb.)8.0-12.0 N·m (71-106 in. lb.)8.0-11.0 N·m (71-97 in. lb.)6.2 N·m (55 in. lb.)Values are in Metric units. Values in parentheses are English equivalents.Lubricate threads with engine oil prior to assembly.24 690 01 Rev. DKohlerEngines.com9
SpecificationsTORQUE SPECIFICATIONS3,5ECH630-ECH680 ECH730-ECH749Valve CoverFastenerGasket Style CoverBlack O-Ring Style Coverw/Shoulder Screwsw/Flange Screws and SpacersYellow or Brown O-Ring StyleCover w/Integral Metal SpacersCLEARANCESPECIFICATIONS3CamshaftEnd Play (with shim)Running ClearanceBore I.D.NewMax. Wear LimitBearing Surface O.D.NewMax. Wear LimitConnecting RodConnecting Rod-to-CrankpinRunning Clearance @ 21 C(70 F)NewMax. Wear LimitConnecting Rod-to-CrankpinSide ClearanceConnecting Rod-to-Piston PinRunning Clearance @ 21 C(70 F)Piston Pin End I.D. @ 21 C(70 F)NewMax. Wear LimitCrankcaseGovernor Cross Shaft Bore I.D.NewMax. Wear Limit6 mm ShaftNewMax. Wear Limit8 mm ShaftNewMax. Wear Limit35CH266.2 N·m (55 in. lb.)CH735CH7453.4 N·m (30 in. lb.)5.6 N·m (50 in. lb.)9.9 N·m (88 in. lb.)6.2 N·m (55 in. lb.)ECH630-ECH680ECH730-ECH7490.101/0.406 mm (0.0040/0.0160 in.)0.025/0.105 mm (0.001/0.004 in.)20.000/20.025 mm (0.7874/0.7884 in.)20.038 mm (0.7889 in.)19.920/19.975 mm (0.7843/0.7864 in.)19.914 mm (0.7840 in.)CH26CH735CH7450.076/0.127 mm (0.0030/0.0050 in.)0.025/0.063 mm (0.0010/0.0025 in.)20.000/20.025 mm (0.7874/0.7884 in.)20.038 mm (0.7889 in.)19.962/19.975 mm (0.7859/0.7864 in.)19.959 mm (0.7858 in.)0.043/0.073 mm (0.0017/0.0029 in.)0.030/0.055 mm (0.0012/0.0022 in.)0.088 mm (0.0035 in.)0.070 mm (0.0028 in.)0.26/0.63 mm (0.0102/0.0248 in.)0.26/0.63 mm (0.0102/0.0248 in.)0.015/0.028 mm (0.0006/0.0011 in.)0.015/0.028 mm (0.0006/0.0011 in.)17.015/17.023 mm (0.6699/0.6702 in.)17.036 mm (0.6707 in.)17.015/17.023 mm (0.6699/0.6702 in.)17.036 mm (0.6707 in.)8.025/8.075 mm (0.3159/0.3179 in.)8.088 mm (0.3184 in.)6.025/6.050 mm (0.2372/0.2382 in.)6.063 mm (0.2387 in.)8.025/8.075 mm (0.3159/0.3179 in.)8.088 mm (0.3184 in.)Values are in Metric units. Values in parentheses are English equivalents.Lubricate threads with engine oil prior to assembly. 5 Lubricate threads with engine oil prior to assembly.10KohlerEngines.com24 690 01 Rev. D
d Play (free)Bore (in crankcase)NewMax. Wear LimitBore (in closure plate)NewCrankshaft to Sleeve Bearing(closure plate) RunningClearanceNewCrankshaft Bore (In ClosurePlate)-to-Crankshaft RunningClearanceNewFlywheel End Main BearingJournalO.D. - NewO.D. - Max. Wear LimitMax. Taper LimitMax. Out-of-Round LimitClosure Plate End Main BearingJournalO.D. - NewO.D. - Max. Wear LimitMax. Taper LimitMax. Out-of-Round LimitConnecting Rod JournalO.D. - NewO.D. - Max. Wear LimitMax. Taper LimitMax. Out-of-Round LimitCrankshaft T.I.R.PTO End, Crank in EngineEntire Crank, in V-BlocksCylinder BoreBore I.D.NewO.D. - Max. Wear LimitMax. Out-of-Round LimitMax. TaperCylinder HeadMax. 5CH7450.070/0.590 mm (0.0028/0.0230 in.)0.070/0.590 mm (0.0028/0.0230 in.)40.972/40.997 mm (1.6131/1.6141 in.)41.011 mm (1.6146 in.)40.965/41.003 mm (1.6128/1.6143 in.)41.016 mm (1.6148 in.)40.974/41.000 mm (1.6131/1.6141 in.)40.987/40.974 mm (1.6136/1.6131 in.)0.03/0.12 mm (0.001/0.005 in.)0.03/0.09 mm (0.0012/0.0035 in.)0.039/0.087 mm (0.0015/0.0034 in.)0.039/0.074 mm (0.0015/0.0029 in.)40.913/40.935 mm (1.6107/1.6116 in.)40.843 mm (1.608 in.)0.022 mm (0.0009 in.)0.025 mm (0.0010 in.)40.913/40.935 mm (1.6107/1.6116 in.)40.84 mm (1.608 in.)0.022 mm (0.0009 in.)0.025 mm (0.0010 in.)40.913/40.935 mm (1.6107/1.6116 in.)40.843 mm (1.608 in.)0.022 mm (0.0009 in.)0.025 mm (0.0010 in.)40.913/40.935 mm (1.6107/1.6116 in.)40.84 mm (1.608 in.)0.022 mm (0.0009 in.)0.025 mm (0.0010 in.)35.950/35.973 mm (1.4153/1.4163 in.)35.941 mm (1.415 in.)0.018 mm (0.0007 in.)0.025 mm (0.0010 in.)35.955/35.973 mm (1.4156/1.4163 in.)35.94 mm (1.415 in.)0.018 mm (0.0007 in.)0.025 mm (0.0010 in.)0.279 mm (0.0110 in.)0.10 mm (0.0039 in.)0.279 mm (0.0110 in.)0.10 mm (0.0039 in.)80.000/80.025 mm 83.006/83.031 mm 82.988/83.013 mm (3.2672/3.2682 in.)(3.1496/3.2689 in.) (3.2680/3.2689 in.)80.075 mm83.081 mm (3.270983.051 mm (3.2697 in.)(3.1526 in.)in.)0.120 mm (0.0047 in.)0.12 mm (0.0047 in.)0.05 mm (0.0020 in.)0.05 mm (0.0020 in.)0.076 mm (0.003 in.)0.076 mm (0.003 in.)Values are in Metric units. Values in parentheses are English equivalents.24 690 01 Rev. DKohlerEngines.com11
rnor Cross Shaft -toCrankcase Running Clearance6 mm Shaft8 mm ShaftCross Shaft O.D.NewMax. Wear Limit6 mm ShaftNewMax. Wear Limit8 mm ShaftNewMax. Wear LimitGovernor Gear Shaft -toGovernor Gear RunningClearanceGear Shaft O.D.NewMax. Wear LimitIgnitionSpark Plug GapCrankshaft Position Sensor AirGapPiston, Piston Rings, and PistonPinPiston-to-Piston Pin RunningClearancePin Bore I.D.NewMax. Wear LimitPin O.D.NewMax. Wear LimitTop Compression Ring-toGroove Side ClearanceMiddle Compression Ring-toGroove Side ClearanceOil Control Ring-to-Groove SideClearanceTop and Center CompressionRing End GapNewMax. Wear LimitThrust Face O.D. 7Max. Wear Limit37ECH630-ECH680ECH730-ECH7490.025/0.126 mm (0.0009/0.0049 in.)CH26CH735CH7450.013/0.075 mm (0.0005/0.0030 in.)0.025/0.126 mm (0.0009/0.0049 in.)7.949/8.000 mm (0.3129/0.3149 in.)7.936 mm (0.3124 in.)5.975/6.012 mm (0.2352/0.2367 in.)5.962 mm (0.2347 in.)7.949/8.000 mm (0.3129/0.3149 in.)7.936 mm (0.3124 in.)0.090/0.160 mm (0.0035/0.0063 in.)0.015/0.140 mm (0.0006/0.0055 in.)5.990/6.000 mm (0.2358/0.2362 in.)5.977 mm (0.2353 in.)0.76 mm (0.030 in.)0.2-0.7 mm (0.008-0.027 in.)0.006/0.017 mm (0.0002/0.0007 in.)17.006/17.012 mm (0.6695/0.6698 in.)17.025 mm (0.6703 in.)16.995/17.000 mm (0.6691/0.6693 in.)16.994 mm (0.6691 in.)0.050/0.095 mm (0.0019/0.0037 in.)0.025/0.048 mm (0.0010/0.0019 in.)0.030/0.075 mm (0.0012/0.00307 in.)0.015/0.037 mm (0.0006/0.0015 in.)0.010/0.011 mm (0.0004/0.0043 in.)0.026/0.176 mm (0.0010/0.0070 in.)0.025/0.056 mm (0.0010/0.0022 in.)0.25/0.56 mm (0.0100/0.0224 in.)0.80 mm (0.0315 in.) 0.94 mm (0.037 in.)79.962/79.980 mm 82.949/82.967 mm(3.1481/3.1488 in.) (3.2657/3.2664 in.)79.831 mm82.818 mm(3.1430 in.)(3.2606 in.)0.94 mm (0.037 in.)82.986 mm (3.2671 in.)82.841 mm (3.2614 in.)Values are in Metric units. Values in parentheses are English equivalents.Measure 6 mm (0.236 in.) above bottom of piston skirt at right angles to piston pin.12KohlerEngines.com24 690 01 Rev. D
SpecificationsCLEARANCESPECIFICATIONS3Piston, Piston Rings, and PistonPin (continued)Piston Thrust Face-to CylinderBore7 Running ClearanceNewValves and Valve LiftersHydraulic Lifter to CrankcaseRunning ClearanceIntake Valve Stem-to-ValveGuide Running ClearanceExhaust Valve Stem-to-ValveGuide Running ClearanceIgnition Module Air GapSpeed Sensor Air GapIntake Valve Guide I.D.NewMax. Wear LimitExhaust Valve Guide I.D.NewMax. Wear LimitGuide Reamer SizeStandard0.25 mm O.S.Intake Valve Minimum LiftExhaust Valve Minimum LiftNominal Valve Seat Angle37ECH630-ECH680ECH730-ECH7490.020/0.063 mm(0.0008/0.0024 in.)0.0039/0.082 mm(0.0015/0.0032 in.)CH26CH735CH7450.001/0.045 mm (0.039/0.0018 in.)0.011/0.048 mm (0.0004/0.0019 in.)0.0241/0.0501 mm (0.0009/0.0020 in.)0.040/0.078 mm (0.0016/0.0031 in.)0.038/0.076 mm (0.0015/0.0030 in.)0.052/0.090 mm (0.0020/0.0035 in.)0.050/0.088 mm (0.0020/0.0035 in.)0.28/0.33 mm (0.011/0.013 in.)1.50 0.25 mm (0.059 0.010 in.)7.040/7.060 mm (0.2772/0.2780 in.)7.134 mm (0.2809 in.)7.038/7.058 mm (0.2771/0.2779 in.)7.134 mm (0.2809 in.)7.040/7.060 mm (0.2772/0.2780 in.)7.159 mm (0.2819 in.)7.038/7.058 mm (0.2771/0.2779 in.)7.159 mm (0.2819 in.)7.050 mm (0.2776 in.)7.048 mm (0.2775 in.)7.300 mm (0.2874 in.)7.298 mm (0.2873 in.)8.07 mm (0.3177 in.)8.07 mm (0.3177 in.)45 Values are in Metric units. Values in parentheses are English equivalents.Measure 6 mm (0.236 in.) above bottom of piston skirt at right angles to piston pin.24 690 01 Rev. DKohlerEngines.com13
SpecificationsGENERAL TORQUE VALUESEnglish Fastener Torque Recommendations for Standard ApplicationsBolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or SteelGrade 2 or 5 FastenersInto AluminumSizeGrade 2Tightening Torque: N·m (in. lb.) 20%8-322.3 (20)10-243.6 (32)10-323.6 (32)1/4-207.9 (70)1/4-289.6 (85)5/16-1817.0 (150)5/16-2418.7 (165)3/8-1629.4 (260)3/8-2433.9 (300)Grade 5Grade 82.8 (25)4.5 (40)4.5 (40)13.0 (115)15.8 (140)28.3 (250)30.5 (270)—————18.7 (165)22.6 (200)39.6 (350)———2.3 (20)3.6 (32)—7.9 (70)—17.0 (150)———Tightening Torque: N·m (ft. lb.) 20%5/16-24—3/8-16—3/8-24—7/16-1447.5 (35)7/16-2061.0 (45)1/2-1367.8 (50)1/2-2094.9 (70)9/16-12101.7 (75)9/16-18135.6 (100)5/8-11149.5 (110)5/8-18189.8 (140)3/4-10199.3 (147)3/4-16271.2 (200)—47.5 (35)54.2 (40)74.6 (55)101.7 (75)108.5 (80)142.4 (105)169.5 (125)223.7 (165)244.1 (180)311.9 (230)332.2 (245)440.7 (325)40.7 (30)67.8 (50)81.4 (60)108.5 (80)142.5 (105)155.9 (115)223.7 (165)237.3 (175)311.9 (230)352.6 (260)447.5 (330)474.6 (350)637.3 (470)—————————————Metric Fastener Torque Recommendations for Standard ApplicationsProperty ClassSize4.85.8NoncriticalFastenersInto Aluminum8.810.912.9Tightening Torque: N·m (in. lb.) 10%M41.2 (11)1.7 (15)M52.5 (22)3.2 (28)M64.3 (38)5.7 (50)M810.5 (93)13.6 (120)2.9 (26)5.8 (51)9.9 (88)24.4 (216)4.1 (36)8.1 (72)14.0 (124)33.9 (300)5.0 (44)9.7 (86)16.5 (146)40.7 (360)2.0 (18)4.0 (35)6.8 (60)17.0 (150)Tightening Torque: N·m (ft. lb.) 10%M1021.7 (16)27.1 (20)M1236.6 (27)47.5 (35)M1458.3 (43)76.4 (56)47.5 (35)82.7 (61)131.5 (97)66.4 (49)116.6 (86)184.4 (136)81.4 (60)139.7 (103)219.7 (162)33.9 (25)61.0 (45)94.9 (70)Torque ConversionsN·m in. lb. x 0.113in. lb. N·m x 8.85N·m ft. lb. x 1.356ft. lb. N·m x 0.73714KohlerEngines.com24 690 01 Rev. D
Tools and AidsCertain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. Byusing these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your servicecapabilities and customer satisfaction by decreasing engine downtime.Here is a list of tools and their source.SEPARATE TOOL SUPPLIERSKohler ToolsContact your local Kohler source ofsupply.SE Tools415 Howard St.Lapeer, MI 48446Phone 810-664-2981Toll Free 800-664-2981Fax 810-664-8181Design Technology Inc.768 Burr Oak DriveWestmont, IL 60559Phone 630-920-1300Fax 630-920-0011TOOLSDescriptionAlcohol Content TesterFor testing alcohol content (%) in reformulated/oxygenated fuels.Camshaft Endplay PlateFor checking camshaft endplay.Camshaft Seal Protector (Aegis)For protecting seal during camshaft installation.Cylinder Leakdown TesterFor checking combustion retention and if cylinder, piston, rings, or valves are worn.Individual component available:Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)Dealer Tool Kit (Domestic)Complete kit of Kohler required tools.Components of 25 761 39-SIgnition System TesterCylinder Leakdown TesterOil Pressure Test KitRectifier-Regulator Tester (120 V AC/60Hz)Dealer Tool Kit (International)Complete kit of Kohler required tools.Components of 25 761 42-SIgnition System TesterCylinder Leakdown TesterOil Pressure Test KitRectifier-Regulator Tester (240 V AC/50Hz)Digital Vacuum/Pressure TesterFor checking crankcase vacuum.Individual component available:Rubber Adapter PlugElectronic Fuel Injection (EFI) Diagnostic SoftwareFor Laptop or Desktop PC.EFI Service KitFor troubleshooting and setting up an EFI engine.Components of 24 761 01-SFuel Pressure TesterNoid Light90 AdapterIn-line "T" FittingCode Plug, Red WireCode Plug, Blue WireShrader Valve Adapter HoseFlywheel Holding Tool (CS)For holding flywheel of CS series engines.Flywheel PullerFor properly removing flywheel from engine.Flywheel Strap WrenchFor holding flywheel during removal.24 690 01 Rev. DKohlerEngines.comSource/Part No.Kohler 25 455 11-SSE Tools KLR-82405SE Tools KLR-82417Kohler 25 761 05-SDesign Technology Inc.DTI-731-03Kohler 25 761 39-SKohler 25 455 01-SKohler 25 761 05-SKohler 25 761 06-SKohler 25 761 20-SKohler 25 761 42-SKohler 25 455 01-SKohler 25 761 05-SKohler 25 761 06-SKohler 25 761 41-SDesign Technology Inc.DTI-721-01Design Technology Inc.DTI-721-10Kohler 25 761 23-SKohler 24 761 01-SDesign Technology 037SE Tools KLR-82407SE Tools KLR-82408SE Tools KLR-8240915
Tools and AidsTOOLSDescriptionHydraulic Valve Lifter ToolFor removing and installing hydraulic lifters.Ignition System TesterFor testing output on all systems, including CD.Inductive Tachometer (Digital)For checking operating speed (RPM) of an engine.Offset Wrench (K and M Series)For removing and reinstalling cylinder barrel retaining nuts.Oil Pressure Test KitFor testing/verifying oil pressure on pressure lubricated engines.Radiator TesterFor pressure testing radiator and cap on Aegis liquid-cooled engines.Rectifier-Regulator Tester (120 volt current)Rectifier-Regulator Tester (240 volt current)For testing rectifier-regulators.Components of 25 761 20-S and 25 761 41-SCS-PRO Regulator Test HarnessSpecial Regulator Test Harness with DiodeSpark Advance Module (SAM) TesterFor testing SAM (ASAM and DSAM) on engines with SMART-SPARK .Starter Servicing Kit (All Starters)For removing and reinstalling drive retaining rings and brushes.Individual component available:Starter Brush Holding Tool (Solenoid Shift)Triad/OHC Timing Tool SetFor holding cam gears and crankshaft in timed position while installing timing belt.Valve Guide Reamer (K and M Series)For properly sizing valve guides after installation.Valve Guide Reamer O.S. (Command Series)For reaming worn valve guides to accept replacement oversize valves. Can be usedin low-speed drill press or with handle below for hand reaming.Reamer HandleFor hand reaming using Kohler 25 455 12-S reamer.Valve Guide Service Kit (Courage, Aegis, Command, OHC)For servicing worn valve guides.AIDSDescriptionCamshaft Lubricant (Valspar ZZ613)Dielectric Grease (GE/Novaguard G661)Dielectric GreaseKohler Electric Starter Drive Lubricant (Inertia Drive)Kohler Electric Starter Drive Lubricant (Solenoid Shift)RTV Silicone SealantLoctite 5900 Heavy Body in 4 oz. aerosol dispenser.Only oxime-based, oil resistant RTV sealants, such as those listed, are approvedfor use. Loctite Nos. 5900 or 5910 are recommended for best sealingcharacteristics.Spline Drive Lubricant16KohlerEngines.comSource/Part No.Kohler 25 761 38-SKohler 25 455 01-SDesign Technology Inc.DTI-110Kohler 52 455 04-SKohler 25 761 06-SKohler 25 455 10-SKohler 25 761 20-SKohler 25 761 41-SDesign Technology Inc.DTI-031DTI-033Kohler 25 761 40-SSE Tools KLR-82411SE Tools KLR-82416Kohler 28 761 01-SDesign Technology Inc.DTI-K828Kohler 25 455 12-SDesign Technology Inc.DTI-K830SE Tools KLR-82415Source/Part No.Kohler 25 357 14-S
1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. 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.
