SERVICE AND REPAIR MANUAL 4 STROKE ENGINE

Chapter 1 Introduction
Chapter 2 Body Cover and Exhaust System
Chapter 3 Schedule Maintenance
Chapter 4 Lubricating System
Chapter 5 Fuel System
Chapter 6 Engine Removal and Installation
Chapter 7 Cylinder Head Valve
Chapter 8 Cylinder and Piston
Chapter 9 Driving Belt Device & The Starting Lever
Chapter 10 The Final Transmission Assembly
Chapter 11 The Crankcase and the Crankshaft
Chapter 12 The Front Wheel, Front Brake, Front Buffer and The Front Fork
Chapter 13 The Rear Wheel, the Rear Brake & Rear Shock
Chapter 14 The Battery and the Charging System
Chapter 15 Ignition System
Chapter 16 Meters, Switches and Lighting System
INDEX
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Twin Cylinder Engine Sevice Manual

INTRODUCTION
Long-life strength an on-the-job durability are designed and built into these Kohler engines. Parts subject to most wear and tear-like cylinder, crankshafts and camshafts-are made from precision-formulated cast iron...and because the cast iron cylinder can be rebored, these engines can last oven longer.

These Kohler engines are easy to service. All routine service parts points, condenser, spark plugs, air cleaner, carburetor-areeasily and quickly accessible.
This manual provides the technician with information and instructions for servicing and repairing the KT17 & KT19 Series II, and KT17-KT19-KT21 engines. It is recommended the technician study the procedures and illustrations in this manual and use them as refrences when forming repairs.

Table of Contens
Section 1 GENERAL INFORMATION
Section 2 TROUBLESHOOTING
Section 3 AIR INTAKE SYSTEM
Section 4 FUEL SYSTEM AND GOVERNOR
Section 5 LUBRICATION SYSTEM
Section 6 ELECTRICAL SYSTEMS & COMPONENTS
Section 7 DISASSEMBLY
Section 8 ASSEMBLY
SUBJECT INDEX
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SERVICE MANUAL Model EH025/EH035 ENGINE

Table of Contents
1. SPECIFICATIONS
2. PERFORMANCE
2-1  MAXIMUM OUTPUT
2-2  CONTINUOUS RATED OUTPUT
2-3  MAXIMUM TORQUE AND FUEL CONSUMPTION WITH MAXIMUM OUTPUT       
2-4  PERFORMANCE CURVES
3. FEATURES
3-1  THE SMALLEST AND LIGHTEST 4-STROKE ENGINE IN THE MARKET
3-2  4-STROKE ENGINE ALLOWING OPERATION IN THE TILTED POSITION, REQUIRED IN BRUSH CUTTING WORK AND OTHER SIMILAR APPLICATIONS
4. GENERAL DESCRIPTION OF ENGINE COMPONENTS
4-1  CYLINDER BLOCK AND CRANKCASE
4-2  CRANKSHAFT AND CONNECTING ROD
4-3  PISTON
4-4  PISTON RINGS
4-5  CAM GEAR
4-6  COOLING SYSTEM
4-7  LUBRICATION SYSTEM
4-8  IGNITION SYSTEM
4-9  CARBURETOR
4-10  AIR CLEANER
4-11  DECOMPRESSION SYSTEM
4-12  SECTIONAL VIEW OF ENGINE
5. DISASSEMBLY AND REASSEMBLY
5-1  PREPARATIONS AND SUGGESTIONS
5-2  SPECIAL TOOLS
5-3  DISASSEMBLY PROCEDURES
5-4  REASSEMBLY PROCEDURES
6. MAGNETO
6-1  FLYWHEEL MAGNETO
6-2  IGNITION OF MAGNETO
7. AUTOMATIC DECOMPRESSION SYSTEM
7-1  FUNCTION AND MECHANISM
7-2  INSPECTION
8. CARBURETOR
8-1  OPERATION AND CONSTRUCTION
8-2  DISASSEMBLY AND REASSEMBLY
9. RECOIL STARTER
9-1    HOW TO DISASSEMBLE
9-2  HOW TO REASSEMBLE
9-3  CHECK AFTER REASSEMBLE
9-4    OTHER GUIDES
10. TROUBLESHOOTING
10-1  STARTING DIFFICULTIES
10-2  ENGINE MISFIRES
10-3  ENGINE STOPS
10-4  ENGINE OVERHEATS
10-5  ENGINE KNOCKS
10-6  ENGINE BACKFIRES THROUGH CARBURETOR
11.  INSTALLATION
11-1 INSTALLING
11-2  VENTILATION
11-3  EXHAUST GAS DISCHARGE
11-4 POWER TRANSMISSION TO DRIVEN MACHINES
12. SERVICE DATA
12-1  CLEARANCE DATA AND LIMITS
12-2  TORQUE SPECIFICATIONS
12-3  OIL GRADE CHART
13. MAINTENANCE AND STORAGE
13-1  DAILY MAINTENANCE
13-2  INITIAL 20 HRS. MAINTENANCE
13-3  EVERY 50 HRS. (10 DAYS) MAINTENANCE
13-4  EVERY 100-200 HRS. (MONTHLY) MAINTENANCE
13-5  ENGINE STORAGE
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