Kohler EKT745 Generator Set

Tools: Feeler gauge, Hex wrench

1. Rotate crankshaft to TDC compression stroke for cylinder 1.
2. Insert 0.127 mm (0.005 in.) feeler gauge between valve and rocker arm.
3. Turn adjuster until slight drag is felt.
4. Hold position and tighten set screw; torque to 7.9 N·m (70 in. lb.).
5. Recheck adjustment.
6. Repeat for other valve on side 1.
7. Rotate crankshaft 270° counterclockwise to cylinder 2 TDC.
8. Repeat for side 2. Final valve clearance 0.101/0.152 mm (0.004/0.006 in.).

⚠ Do not tamper with governor setting. Overspeed is hazardous.

Tools: 7 mm hex socket, Torque wrench

1. Ensure throttle linkage is connected to governor arm and throttle lever.
2. Loosen nut holding governor lever to cross shaft.
3. Move governor lever toward throttle body as far as it will go.
4. Hold wide-open throttle.
5. Use 7 mm hex socket on cross shaft end.
6. Rotate shaft counterclockwise as far as it will turn.
7. Torque nut to 6.8 N·m (60 in. lb.).

1. Turn idle screw clockwise one full turn prior to key ON after ECU Reset.
2. Start engine; run at low idle until warm.
3. Idle speed must be above 1500 RPM.
4. If below, turn idle screw up to 1700 RPM; shut down; perform ECU Reset again.
5. Restart engine; adjust idle speed down to 1500 RPM.
6. Allow engine to dwell at 1500 RPM for about 3 seconds.
7. Adjust idle speed to final specified setting.
8. Turn key OFF and count to 10 seconds. Learn procedure complete.

Tools: Compression gauge

1. Warm engine; clean dirt from spark plug bases.
2. Remove spark plugs.
3. Ensure battery fully charged; unplug ECU.
4. Open throttle wide.
5. Install compression gauge.
6. Crank engine and record compression.
7. Compression should be at least 160 psi.
8. Variation between cylinders should not exceed 15%.

⚠ Carbon Monoxide can cause severe nausea, fainting or death. Never run engine indoors.

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

Tools: Water manometer, Rubber stopper, Pinch clamp

1. Insert rubber stopper into oil fill hole.
2. Connect hose between stopper and one manometer tube.
3. Leave other tube open to atmosphere.
4. Check water level at 0 line; close pinch clamp.
5. Start engine and run no-load high speed.
6. Open clamp and note water level.
7. Engine side level should be minimum 10.2 cm (4 in.) above open side.
8. Close pinch clamp before stopping engine.

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

Tools: Cylinder leakdown tester, Adapter hose, Holding tool, Air source

1. Run engine 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter.
3. Rotate crankshaft to TDC compression stroke of cylinder being tested.
4. Hold engine at TDC.
5. Install adapter into spark plug hole.
6. Connect air source of at least 50 psi to tester.
7. Adjust regulator until gauge needle is in yellow set area.
8. Connect tester to adapter; note gauge reading and listen for escaping air.

⚠ This system will NOT reset when battery is disconnected.

Tools: Kohler EFI service kit, Red wire jumper

1. Turn key/ignition OFF.
2. Install Red wire jumper from Kohler EFI service kit onto service port.
3. Turn key ON, then OFF; count 10 seconds.
4. Turn key ON, then OFF; count 10 seconds a second time.
5. Remove Red wire jumper.
6. Turn key ON, then OFF; count 10 seconds a third time.
7. ECU is reset.
8. A TPS Learn Procedure must be performed after ECU Reset.

⚠ Electrical Shock can cause injury. Do not touch wires while engine is running.

Tools: Ammeter, DC voltmeter, Carbon pile test tool

1. Insert ammeter in B+ wire at rectifier-regulator connector.
2. Run engine at 3600 RPM.
3. Measure B+ to ground with DC voltmeter.
4. If voltage is 13.8 volts or more, apply minimum 5 amp load.
5. Observe ammeter.
6. Or use carbon pile test tool at 3600 RPM.
7. Adjust carbon pile voltage to 12 volts.
8. Displayed amperage should be near or at maximum rated system output.

1. Rotate air cleaner cover levers outward to unlock cover; remove air cleaner cover. Or move bails on air cleaner cover up; remove latches from cover; remove cover.
2. Precleaner (if equipped): Remove precleaner from paper element. Replace or wash precleaner in warm water with detergent. Rinse and allow to air dry. Lightly oil precleaner with new engine oil; squeeze
3. Paper Element: Separate precleaner from element; service precleaner and replace paper element. Install precleaner over new paper element and install on base.
4. Position air cleaner cover with levers outward over air cleaner; turn levers inward to lock. Or reinstall cover; place latches onto cover; pull down bails to secure cover.

Tools: container

1. Change oil while engine is warm. Clean area around oil fill cap/dipstick. Remove drain plug and oil fill cap/dipstick. Allow oil to drain completely.
2. Clean area around oil filter. Place a container under filter to catch any oil and remove filter. Wipe off mounting surface. Reinstall drain plug. Torque to 10 ft. lb. (13.6 N·m).
3. Place new filter in shallow pan with open end up. Fill with new oil until oil reaches bottom of threads. Allow 2 minutes for oil to be absorbed by filter material.
4. Apply a thin film of clean oil to rubber gasket on new filter.
5. Refer to instructions on oil filter for proper installation.
6. Fill crankcase with new oil. Level should be at top of indicator on dipstick.
7. Reinstall oil fill cap/dipstick and tighten securely.
8. Start engine; check for oil leaks. Stop engine; correct leaks. Recheck oil level.
9. Dispose of used oil and filter in accordance with local ordinances.

⚠ To prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicator on dipstick.

1. Ensure engine is cool and level. Clean oil fill/dipstick areas of any debris.
2. Remove dipstick; wipe oil off.
3. Reinsert dipstick into tube; press completely down.
4. Remove dipstick; check oil level. Level should be at top of indicator on dipstick.
5. If oil is low on indicator, add oil up to top of indicator mark.
6. Reinstall and secure dipstick.

1. This engine has three (3) blade type automotive fuses. Replacement fuses must have same rating as blown fuse. Use fuse chart below to determine correct fuse.
2. 2 Solid Red Wires: 10-amp Fuse
3. 1 Red Wire with Black Stripe and 1 Red Wire with White Stripe: 10-amp Fuse
4. 2 Purple Wires: 30-amp Fuse