Kohler CV732 Generator Set

1. To increase sensitivity, move spring closer to governor lever pivot point.
2. To decrease sensitivity, move spring away from governor lever pivot point.

⚠ Do not tamper with governor setting. Overspeed is hazardous and could cause personal injury.

Tools: long thin rod or tool, torque wrench

1. Make sure throttle linkage is connected to governor arm and throttle lever on carburetor.
2. Loosen nut holding governor lever to cross shaft.
3. Move governor lever toward carburetor as far as it will go (wide open throttle) and hold in this position.
4. Insert a long thin rod or tool into hole on cross shaft and rotate shaft counterclockwise (viewed from end) as far as it will turn, then torque nut to 6.8 N·m (60 in. lb.).

Tools: compression gauge

1. Perform test on a warm engine. Clean dirt from base of spark plug(s) before removing.
2. Be sure choke is off and throttle is wide open during test.
3. Compression should be at least 160 psi and should not vary more than 15% between cylinders.

⚠ Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes.

⚠ Rotating Parts can cause severe injury. Stay away while engine is in operation.

Tools: water manometer, rubber stopper, pinch clamp, tapered adapters

1. Insert rubber stopper into oil fill hole, install pinch clamp on hose and connect hose between stopper and one manometer tube; leave other tube open.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube; level in engine side should be a minimum of 10.2 cm (4 in.) above open side.
4. Close pinch clamp before stopping engine.

⚠ Rotating Parts can cause severe injury. Stay away while engine is in operation.

Tools: vacuum/pressure gauge, adapter, stopper

1. Remove dipstick or oil fill plug/cap.
2. Install adapter into oil fill/dipstick tube opening or directly into engine if a tube is not used. Insert barbed gauge fitting into hole in stopper.
3. Run engine and observe gauge reading; crankcase vacuum should be a minimum of 10.2 cm (4 in.) of water.

Tools: cylinder leakdown tester, holding tool, breaker bar, adapter hose

1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter.
3. Rotate crankshaft until piston being tested is at top dead center of compression stroke; hold engine in this position.
4. Install adapter into spark plug hole, but do not attach it to tester yet.
5. Turn regulator knob completely counterclockwise.
6. Connect an air source of at least 50 psi to tester.
7. Turn regulator knob clockwise until gauge needle is in yellow set area at low end of scale.
8. Connect tester quick-connect to adapter hose; while holding engine at TDC, gradually open tester valve. Note gauge reading and listen for escaping air at intake, exhaust outlet, and crankcase breather

⚠ Disconnect and ground spark plug lead(s) before servicing.

1. Disconnect and ground spark plug leads, close choke, crank engine several times, remove spark plug and check for fuel at tip.
2. Remove fuel line from inlet fitting of fuel pump, hold below bottom of tank, open shut-off valve and observe flow.
3. Remove fuel line from inlet fitting of carburetor, crank engine several times and observe flow.

⚠ Do not use a feeler gauge to measure piston-to-bore clearance.

Tools: micrometer, inside micrometer, telescoping gauge, bore gauge

1. Use a micrometer and measure diameter of piston above bottom of piston skirt at dimension A and perpendicular to piston pin.
2. Use an inside micrometer, telescoping gauge, or bore gauge and measure cylinder bore approximately 63.5 mm (2.5 in.) below top of bore.
3. Piston-to-bore clearance is the difference between bore diameter and piston diameter.

Tools: continuity tester, compressed air, pressure regulator, pressure gauge

1. Connect continuity tester across blade terminal and metal case of switch.
2. With 0 psi applied, note continuity/non-continuity per switch type.
3. Gradually increase pressure through range of 2-5 psi; tester should indicate a change of state.
4. Switch should remain in state as pressure is increased to 90 psi maximum.
5. Gradually decrease pressure through range of 2-5 psi; tester should indicate a change back down to 0 psi.
6. Replace switch if it does not operate as specified.

⚠ DO NOT leave 12 volt test leads connected to solenoid longer than necessary. Internal damage to solenoid may occur.

Tools: 12 volt power supply, test leads, ohmmeter

1. Use a 12 volt power supply and 2 test leads.
2. Connect 1 lead to flat spade S/start terminal on solenoid; momentarily connect other lead to lower large post terminal.
3. Solenoid should energize (audible click) and plunger retract; repeat test several times.
4. Use an ohmmeter set to audible or Rx2K scale, connect leads to 2 large post terminals and check for continuity.
5. Replace solenoid if it fails to activate or no continuity is indicated.

Tools: torque wrench

1. Check for nicks or burrs on sealing surfaces.
2. If studs were disturbed or removed, install new mounting studs into crankcase using locked nuts and steady tightening motion.
3. Studs closest to lifters must have exposed height of 75 mm (2 15/16 in.); studs furthest from lifters 68 mm (2 3/4 in.).
4. Check dowel pins and install a new cylinder head gasket (printing up).
5. Install cylinder head matching numbers on head and crankcase.
6. Lightly lubricate exposed threads of studs with engine oil; install new flat washer and nut on each stud.
7. Torque nuts in two stages; first to 16.9 N·m (150 in. lb.), then finally to 35.5 N·m (315 in. lb.), following sequence shown.

Tools: torque wrench

1. Check for nicks or burrs on sealing surfaces of cylinder head or crankcase.
2. Install a new cylinder head gasket (with printing up).
3. Install cylinder head and start four screws.
4. Torque screws in two stages; first to 22.6 N·m (200 in. lb.), then finally to 41.8 N·m (370 in. lb.), following sequence shown.