Kohler HD775 Generator Set

Tools: Pliers, Torque wrench

1. Move governor lever away from carburetor to limit of travel.
2. Hold at wide-open throttle; do not stress, flex, or distort linkage.
3. Grasp cross shaft with pliers; turn clockwise as far as it will go.
4. Hold and tighten nut; torque to 9.5 N·m (84 in. lb.).

Tools: Pliers, Torque wrench

1. Loosen nut holding governor lever to cross shaft.
2. Move governor lever away from carburetor (wide open throttle) and hold.
3. Do not apply excess force that may flex or distort throttle link.
4. Grasp cross shaft with pliers; turn clockwise as far as it will go.
5. Hold and tighten nut; torque to 9.5 N·m (84 in. lb.).

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

Tools: Water manometer or vacuum/pressure gauge (inches of water), Rubber stopper

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

Tools: Cylinder leakdown tester, 12 mm x 14 mm adapter, Holding tool

1. Run engine until oil temperature reaches and maintains 150°F (66°C) for 5 minutes.
2. Remove spark plug(s) and air filter.
3. Rotate crankshaft until piston is at top dead center (TDC).
4. Hold engine at TDC using holding tool.
5. Connect air source (at least 100 PSI) to tool.
6. Confirm both gauges read the same from 0 to 80 PSI.
7. Install adapter hose into spark plug hole of cylinder tested.
8. Slowly turn regulator until left gauge maintains selected test pressure.

Tools: Feeler gauge 0.254 mm (0.010 in.), Torque wrench

1. Rotate flywheel so ignition magnets are away from module legs.
2. Position ignition module on legs with kill tab down.
3. Loosely thread stud and screw into appropriate leg.
4. Pull module away from flywheel; tighten stud to hold it in place.
5. Rotate flywheel so ignition magnet aligns with module.
6. Set air gap using a 0.254 mm (0.010 in.) plastic feeler gauge.
7. Torque fasteners to 10 N·m (89 in. lb.).
8. Rotate flywheel to release feeler gauge; recheck air gap.

1. Change oil while engine is warm.
2. Clean area around oil fill cap/dipstick.
3. Remove oil fill cap/dipstick.
4. Tilt engine on its side with air cleaner facing up.
5. Drain oil into appropriate container.
6. Tilt engine upright after crankcase is drained completely.
7. Fill crankcase with new oil to top of dipstick indicator.
8. Reinstall oil fill cap/dipstick; tighten securely; dispose of used oil properly.

⚠ Never run engine with oil level below or above operating range indicator on dipstick.

1. Ensure engine is cool and level.
2. Clean oil fill cap/dipstick areas of any debris.
3. Remove dipstick; wipe oil off.
4. 1/4 turn cap: reinsert dipstick into tube, press down, turn 1/4 turn.
5. Threaded cap: reinsert dipstick, rest cap on tube, do not thread.
6. Remove dipstick and check oil level at top of indicator.
7. Add oil up to top of indicator mark if low.
8. Reinstall and secure dipstick.

1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank.
2. Run engine 2-3 minutes to get stabilized fuel into fuel system.
3. Change oil while engine is still warm from operation.
4. Remove spark plug(s); pour about 1 oz. engine oil into cylinder(s).
5. Replace spark plug(s); crank engine slowly to distribute oil.
6. Disconnect battery or negative (-) battery cable (if equipped).
7. Store engine in a clean, dry place.

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

Tools: Compressed air, Carburetor cleaner

1. Remove air cleaner and carburetor per Disassembly procedures.
2. Clean exterior surfaces of dirt before disassembling.
3. Remove bowl retaining screws; separate fuel bowl; do not damage O-rings.
4. Remove float pin and inlet needle; seat is not serviceable.
5. Clean carburetor bowl and inlet seat areas as required.
6. Remove main jet; remove main nozzles through bottom of main towers.
7. Clean slow jets using compressed air or carburetor cleaner; do not use wire.

Tools: Hose Removal Tool

1. Note orientation of pump before removing.
2. Disconnect fuel lines from inlet, outlet, and pulse fittings.
3. Inspect both in-nipple fuel filters; clean or replace as required.
4. Remove screws securing fuel pump to bracket; take off pump.
5. Connect pulse line to new pump; verify opposite end connected to valve cover fitting.
6. Secure new pump to bracket; torque screws to 2.3 N·m (20 in. lb.).
7. Connect fuel lines to inlet and outlet fittings; secure with clamps.

Tools: Clamp

1. Install a clamp to hold pulley in starter housing.
2. Unscrew center screw; lift off drive plate.
3. Note positions of pawls and pawl springs; remove parts.
4. Install pawl springs and pawls into pawl slots; all parts must be dry.
5. Position drive plate over pawls, aligning actuating slots.
6. Torque center screw to 5-6 N·m (44-54 in. lb.).
7. Remove clamp; pull starter rope out part way to check pawls.

⚠ Uncoiling spring can cause severe injury. Wear safety goggles when servicing retractable starter.

1. Remove starter assembly from engine.
2. Pull rope out approximately 12 in.; tie temporary slip knot.
3. Pull knot end out of handle, untie knot, slide handle off.
4. Hold pulley firmly; untie slipknot; allow pulley to rotate slowly.
5. Remove rope from pulley when spring tension is released.
6. Tie a double left-hand knot in one end of new rope.
7. Rotate pulley counterclockwise approximately 4 full turns to pre-tension spring.
8. Insert rope through pulley hole and guide bushing; tie slipknot.