Kohler XTX775 Generator Set

⚠ Do not apply excess force that may flex or distort throttle link

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 in this position. Do not apply excess force.
3. Grasp cross shaft with a pliers and turn clockwise as far as it will go, hold and tighten nut.
4. Torque nut to 9.5 N·m (84 in. lb.).

⚠ Installation and seating of push rods into tappet recesses is critical

Tools: Feeler gauge, Torque wrench, Grease

1. With tabs on guide plate facing down, install guide plate and secure with rocker studs.
2. Tighten rocker studs to 13.6 N·m (120 in. lb.).
3. Install push rods into intake and exhaust positions, as previously marked.
4. Apply grease to contact surfaces of rocker arms and pivots.
5. Install rocker arms onto rocker studs. Match rocker arm dimples with round push rod ends.
6. Loosely install pivots and jam nuts onto rocker studs.
7. Inspect push rod to guide plate clearance; push rods need to be centered in guide plate opening.
8. With piston at TDC of compression stroke, insert a 0.1 mm (0.004 in.) flat feeler gauge between one valve stem and rocker arm.
9. Tighten rocker pivot until a slight drag is felt on feeler gauge. Hold nut and tighten jam nut to 9.5 N·m (84 in. lb.). Recheck lash.
10. Perform same adjustment procedure on opposite valve.

⚠ Procedures are to be performed on a cold engine

Tools: Vacuum gauge or manometer, Vacuum pump

1. Remove air cleaner cover, air cleaner, and breather cover from air cleaner base.
2. Check choke linkage for binding or debris build up. Actuate linkage and observe choke plate has full range of movement.
3. Remove vacuum hose from carburetor vacuum fitting. Attach vacuum gauge/manometer to fitting. Run engine holding choke plate open; gauge should indicate minimum 15 in. of water.
4. If vacuum is less than 15 in. of water, problem is not an auto choke issue.
5. Attach a vacuum pump to vacuum hose. Choke plate should open 1/2 to 3/4 under vacuum with minimum 15 in. of water.
6. If diaphragm assembly cannot open choke plate, check hose for cracks, leaks, or restrictions; replace vacuum hose if necessary. If hose is good and plate fails to open, or diaphragm fails to hold plat
7. Attach vacuum hose to carburetor vacuum fitting and start engine. Choke plate should be 1/2 to 3/4 open, gradually changing to full open after 2 to 2-1/2 minutes of running.
8. If choke plate fails to open, recheck linkage for binding. If necessary replace bimetallic spring assembly.

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

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

Tools: Water manometer with rubber stopper and pinch clamp, Tapered adapters

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

⚠ To prevent damage to gauge assembly, always turn pressure regulator knob to zero after each test

Tools: Dual Gauge Cylinder Leakdown Tester, Adapter 12 mm x 14 mm, Holding tool, 3/8 in. breaker bar

1. Run engine until oil temperature reaches and maintains 150°F (66°C) or more for minimum 5 minutes under normal load.
2. Remove spark plug(s) and air filter from engine.
3. Rotate crankshaft until piston of cylinder being tested is at TDC of compression stroke and hold in position.
4. Connect an air source (at least 100 PSI) to tool.
5. Turn regulator knob clockwise; confirm both gauges read approximately the same air pressure from 0 to 80 PSI. Release pressure.
6. Install adapter hose into spark plug hole; use 12 mm x 14 mm adapter if required.
7. Hold engine at TDC, connect adapter hose to tool quick connect. Turn regulator until left gauge reads 20 PSI.
8. Slowly turn regulator clockwise until left hand gauge maintains selected test pressure (80 PSI over 200 cc; 35 PSI single cylinder walk-behind).
9. Compare right gauge reading to Test Pressure Chart to identify percentage of leakage.
10. For yellow or red zone leakage, repeat test after operating engine under normal load and confirming piston at TDC.

⚠ Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running.

Tools: Approved fuel container

1. Check for fuel in combustion chamber: disconnect and ground spark plug lead, close choke, crank engine several times, remove spark plug and check for fuel at tip.
2. Check for fuel flow from tank to carburetor: remove fuel line from carburetor inlet fitting; hold line below bottom of tank and observe flow.
3. Remove fuel line from fuel tank outlet fitting; check in-nipple fuel filter and clean or replace as required.
4. Check operation of fuel shut-off valve (if equipped) by turning ON and OFF and observing operation.

⚠ Do not reuse cylinder head gasket. Always replace with new gasket.

Tools: Torque wrench

1. Examine sealing surfaces of cylinder head and crankcase for nicks or burrs.
2. Using cylinder head dowels as a guide, install a new head gasket.
3. Match sides of head together and finger tighten screws.
4. Torque screws in two stages following sequence shown: first to 14 N·m (123 in. lb.), finally to 27.8 N·m (246 in. lb.).

⚠ Damaging Crankshaft and Flywheel can cause personal injury. Using improper procedures can lead to broken fragments.

⚠ Do not use any type of bar or wedge to prevent flywheel from rotating

Tools: Flywheel strap wrench, Torque wrench

1. Install key into crankshaft keyway. Make sure key is fully seated.
2. Install flywheel onto crankshaft aligning keyway with key.
3. Align teardrop slot on fan with raised teardrop on flywheel. Align drive cup on flywheel, install and hand tighten nut.
4. Using a flywheel strap wrench, hold flywheel still while tightening nut to 51.5 N·m (38 ft. lb.).

⚠ If stud was not kept segregated from the 2 fuel tank mounting studs, compare lengths and choose the short one

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

1. Rotate flywheel so ignition magnets are away from ignition module legs. Position module on legs with kill tab down.
2. Loosely thread stud and screw into appropriate leg. Pull module away from flywheel and tighten stud to hold it in place. Rotate flywheel so magnet aligns with module.
3. Set air gap with a 0.254 mm (0.010 in.) plastic feeler gauge between magnet and module. Loosen stud, let magnet draw module against feeler gauge.
4. Torque fasteners to 10 N·m (89 in. lb.).
5. Rotate flywheel to release feeler gauge; check module does not contact magnet. Recheck air gap.
6. Connect kill lead to ignition module kill tab.

⚠ Improper orientation of piston and connecting rod inside engine can cause extensive wear or damage

Tools: Piston ring compressor, Soft rubber-grip hammer, Torque wrench

1. Stagger piston rings in grooves until end gaps are 60° or more apart. Lubricate cylinder bore, crankshaft journal, connecting rod journal, piston, and rings with engine oil.
2. Compress piston rings using a piston ring compressor.
3. Position triangle on top of piston toward push rod chamber.
4. Carefully guide connecting rod, with piston attached, into bore.
5. Use handle of a soft, rubber-grip hammer to tap piston into bore.
6. Rotate crankshaft to mate with connecting rod. Align rod cap and connecting rod to match marks. Torque screws to 12.5 N·m (110 in. lb.).

⚠ Whenever possible, an impact wrench should be used to loosen nuts securing retractable starter

Tools: Torque wrench

1. Place starter onto studs protruding from blower housing. Start nuts onto studs, but do not tighten.
2. Pull starter handle out until pawls engage in drive cup. Hold handle in this position and torque nuts to 8 N·m (71 in. lb.).

⚠ Always use fresh sealant. Using outdated sealant can result in leakage.

Tools: Permatex Ultra Grey sealant, Torque wrench

1. Prepare sealing surfaces of cylinder head and valve cover; clean old RTV from surfaces.
2. Apply a 1.5 mm (1/16 in.) bead of Permatex Ultra Grey sealant to valve cover as shown. Valve cover must be installed within 10 minutes of RTV application.
3. Install valve cover and finger tighten screws.
4. Using sequence shown, tighten cover screws to 8 N·m (71 in. lb.).