Kohler ZT720 Generator Set

Tools: feeler gauge, torque wrench

1. Rotate crankshaft to establish TDC on compression stroke for cylinder 1. Check compression, keyway alignment, and rocker arm/push rod movement.
2. Insert 0.127 mm (0.005 in.) feeler gauge between end of 1 valve and rocker arm. Turn adjuster until slight drag is felt. Hold and tighten setscrew securely. Torque setscrew to 7.9 N·m (70 in. lb.).
3. Recheck adjustment. Proper valve clearance is 0.101/0.152 mm (0.004/0.006 in.).
4. Repeat procedure for other valve on side 1.
5. Viewed from PTO end, rotate crankshaft 270° counterclockwise and align crankshaft keyway with cylinder 2.
6. Repeat steps for setting valve clearance on side 2.
7. Rotate crankshaft to check free operation of valve train. Check clearance between valve spring coils at full lift.

1. Clean exterior surfaces. Remove bowl retaining screws or solenoid assembly and separate fuel bowl from carburetor. Do not damage fuel bowl O-rings.
2. Remove float pin (or screw) and inlet needle. Seat for inlet needle is not serviceable and should not be removed.
3. Attach inlet needle to metal tang of float with wire clip. Install new float and inlet needle down into seat and carburetor body.
4. Hold carburetor body so float assembly hangs vertically and rests lightly against fuel inlet needle; inlet needle fully seated without depressing center pin.
5. Correct float height is 12.0 mm (0.472 in.) from float bottom to body of carburetor. Adjust by carefully bending metal tang of float.

Tools: tachometer, pliers

1. Hold governor lever away from carburetor so throttle lever is against idle speed adjustment screw. Start engine and warm up.
2. Adjust screw to set approximately 1450 RPM. Check speed using tachometer. Turn adjustment screw clockwise to increase or counterclockwise 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 pliers to bend tab to achieve recommended speed.
5. Move throttle lever to wide-open position and hold. Turn high speed screw to obtain intended high speed no-load RPM.

⚠ 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.
4. Insert long thin rod or tool into hole on cross shaft and rotate shaft 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.

Tools: Long thin rod or tool

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. Insert a long thin rod or tool into hole on cross shaft and rotate shaft counterclockwise 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 screw. Start engine, warm up, adjust screw to approximately 1450 RPM.
2. Release governor lever and check that throttle lever is in idle position. Obtain equipment manufacturer's recommended idle speed (1750 RPM) by bending 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.

⚠ Choke is placed ON by moving throttle control slightly past fast position. Leave sufficient throttle control travel past fast position.

1. Loosen control cable clamp.
2. Place throttle control lever of equipment into fast or high speed position.
3. Pull on outer shield of throttle control cable until speed control lever rotates and makes contact with choke lever. Tighten cable clamp securely.

⚠ 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

1. Insert rubber stopper into oil fill hole. Connect manometer tube. Leave other tube open. Check water level at 0 line. Make sure pinch clamp is closed.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube. Level in engine side should be minimum 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.

Tools: Water manometer, Rubber stopper, Pinch clamp

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. Close pinch clamp.
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.

Tools: Cylinder leakdown tester, Breaker bar and socket

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 it to tester at this time.
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. Firmly hold engine at TDC, gradually open tester valve. Note gauge reading and listen for escaping air.

⚠ Gasoline is extremely flammable and its vapors can explode if ignited.

Tools: 12 volt power source, Shop towel

1. Shut off fuel and remove solenoid from carburetor. Have a container ready to catch fuel.
2. Wipe tip of solenoid with a shop towel or blow with compressed air. Take to a well ventilated location.
3. With power source OFF, connect positive lead to red lead of solenoid. Connect negative lead to solenoid body.
4. Turn power source ON and observe pin. Pin should retract with power ON and return with power OFF. Test several times.

1. Check for fuel in combustion chamber: disconnect and ground spark plug leads; close choke; crank engine several times; remove spark plug and check for fuel at tip.
2. Check fuel flow from tank to fuel pump: remove fuel line from inlet fitting of fuel pump; hold line below tank; open shut-off valve and observe flow.
3. Check operation of fuel pump: remove fuel line from inlet fitting of carburetor; crank engine several times and observe flow.