Kohler KT740 Generator Set

Tools: Feeler gauge, Torque wrench

1. Rotate crankshaft to establish TDC on compression stroke for cylinder 1.
2. Insert a 0.127 mm (0.005 in.) feeler gauge between end of 1 valve and rocker arm. Turn adjuster until slight drag is felt.
3. Hold in this position and tighten setscrew securely. Torque setscrew to 7.9 N·m (70 in. lb.). Recheck adjustment.
4. Repeat procedure for other valve on side 1.
5. Viewed from PTO end, rotate crankshaft 270° (3/4 turn) counterclockwise and align crankshaft keyway with cylinder 2.
6. Repeat steps for setting valve clearance on side 2.
7. Rotate crankshaft to check for free operation of valve train.

Tools: Tachometer, Pliers

1. Hold governor lever away from carburetor so throttle lever is against idle speed (RPM) adjustment screw. Start engine and warm up.
2. Adjust screw to set approximately 1450 RPM. Turn adjustment screw (inner) clockwise (in) to increase or counterclockwise (out) to decrease speed.
3. Release governor lever and check that throttle lever is in idle position. Obtain equipment manufacturer's recommended idle speed (1750 RPM).
4. Use a pliers to bend tab to achieve recommended governed idle speed.
5. Move throttle lever to wide-open/full throttle position. Turn high speed screw to obtain intended high speed no-load RPM.

⚠ Inlet needle center pin is spring loaded. Make sure float assembly rests against fuel inlet needle without depressing center pin.

⚠ Walbro float is not adjustable.

1. Remove carburetor fuel bowl; do not damage fuel bowl O-rings.
2. Remove float pin and inlet needle.
3. Hold carburetor body so float assembly hangs vertically and rests lightly against fuel inlet needle without depressing center pin.
4. Correct float height is 12.0 mm (0.472 in.) measured from float bottom to body of carburetor. Adjust by carefully bending metal tang of float.

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

Tools: 7 mm hex socket, 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.
4. Round Cross Shaft End: Insert a long thin rod into hole on cross shaft and rotate counterclockwise as far as it will turn, then torque nut to 6.8 N·m (60 in. lb.).
5. 7 mm Hex Cross Shaft End: Use 7 mm hex socket on end of cross shaft and rotate counterclockwise as far as it will turn, then torque nut to 6.8 N·m (60 in. lb.).

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

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 clockwise (viewed from end) as far as it will turn, then torque nut to 6.8 N·m (60 in. lb.).

⚠ Carburetor adjustments should be made only after engine has warmed up.

Tools: Tachometer

1. Hold governor lever away from carburetor so throttle lever is against idle speed (RPM) adjustment screw. Start engine and warm up, then adjust screw to set approximately 1450 RPM. Turn adjustment scre
2. Release governor lever and check that throttle lever is in idle position. Obtain equipment manufacturer's recommended idle speed (1750 RPM) using the bendable tab.
3. Move throttle lever to wide-open/full throttle position and hold. Turn high speed screw to obtain intended high speed no-load RPM.

Tools: Ammeter, DC voltmeter, AC voltmeter, Ohmmeter

1. Insert an ammeter in B+ lead from rectifier-regulator. With engine running at 3600 RPM, measure B+ to ground using a DC voltmeter.
2. If voltage is 13.8 volts or more, place a minimum load of 5 amps on battery to reduce voltage. Observe ammeter.
3. If charge rate increases when load is applied, charging system is OK and battery was fully charged.
4. If charge rate does not increase, remove connector from rectifier-regulator. With engine running at 3600 RPM, measure AC voltage across stator leads using an AC voltmeter.
5. Voltage is 28 volts or more: stator is OK; rectifier-regulator is faulty; replace.
6. Voltage is less than 28 volts: stator is faulty; replace. Test stator further using an ohmmeter.
7. With engine stopped, measure resistance across stator leads. Resistance is 0.064/0.2 ohms: stator is OK.
8. Resistance is 0 ohms: stator is shorted; replace. Resistance is infinity ohms: stator is open; replace.
9. Measure resistance from each stator lead to ground. Resistance is infinity ohms (no continuity): stator is OK. Resistance measured: stator leads are shorted to ground; replace.

Tools: Compression tester

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

Tools: Water manometer, Rubber stopper, Pinch clamp, Tapered adapters

1. Insert rubber stopper into oil fill hole. Connect hose between stopper and one manometer tube. Leave other tube open. Check water level at 0 line.
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 level in open side.
4. If level is less than specified or pressure present, check for clogged or inoperative crankcase breather, leaking seals/gaskets, piston blow by, or restricted exhaust.
5. Close pinch clamp before stopping engine.

⚠ Carbon monoxide exhaust gases can cause severe nausea, fainting or death - never run engine indoors or enclosed

⚠ Rotating parts can cause severe injury - never operate with covers/shrouds/guards removed

Tools: Water manometer

1. Insert rubber stopper into oil fill hole; install pinch clamp on hose; use tapered adapters to connect hose between stopper and one manometer tube; leave other tube open to atmosphere; check water lev
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 level in open side
4. Close pinch clamp before stopping engine

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

⚠ Stay away while engine is in operation.

Tools: Water manometer, Rubber stopper

1. Insert rubber stopper into oil fill hole with pinch clamp installed; connect hose between stopper and one manometer tube, leaving other tube open. Check water level at 0 line; pinch clamp closed.
2. Start engine and run no-load high speed.
3. Open clamp and note water level. Level in engine side should be a minimum of 10.2 cm (4 in.) above level in open side.
4. Close pinch clamp before stopping engine.

Tools: Cylinder leakdown tester, Adapter, Holding tool

1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter from engine.
3. Rotate crankshaft until piston is at TDC of compression stroke. Hold engine in this position while testing.
4. Install adapter into spark plug hole but do not attach 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. Holding engine at TDC, gradually open tester valve. Note gauge reading and listen for escaping air.