Engine Removal (Fig. 9)
Park machine on a level surface, stop engine, en-
gage parking brake and remove key from the ignition
switch.
9. Remove cap screw (item 49) and flat washer (item
that secure r--clamp (item 51) and shift cables (item
to engine. Position shift cables away from engine.
50)
8)
1.
10.Disconnect engine electrical harness connector
from the main harness.
2.
Disconnect ground (black) cable from the battery.
Then, disconnect positive (red) cable from the battery.
11.Remove four (4) flange nuts and cap screws secur-
ing the engine to the engine tray.
3.
Remove cargo box to gain access to the engine (see
Cargo Box and Tailgate Removal in the Service and Re-
pairs section of Chapter 7 -- Chassis).
CAUTION
IMPORTANT: Make sure all hoses and engine open-
ings are plugged after disconnecting. This will pre-
vent contaminants from entering the engine and
fuel system.
One person should operate the hoist while a sec-
ond person guides the engine out of the frame.
12.Remove
engine from the engine tray.
4.
Disconnect the following components:
A. Attach a short section of chain between fuel
pump bracket lift hole and exhaust manifold (Fig.
10).
A. Choke and governor cables from the carburetor
and cable bracket.
B. Air intake hose (item 38) from the carburetor.
B. Connect hoist to center of chain.
C. Breather hose (item 42) from the engine valve
cover.
IMPORTANT: Make sure to not damage the en-
gine,fuelhoses,electricalharnessorotherparts
while removing the engine.
CAUTION
C. Slowly raise engine and attachments from the
machine.
Read safety precautions for handling gasoline
before working on the fuel system (see Safety In-
structions in Chapter 1 -- Safety).
13.Remove
sary to repair the engine.
engine parts and attachments as neces-
5.
Disconnect fuel hose from the fuel pump (Fig. 10).
Removecabletiesecuringthechokeandthrottlecables
to the fuel pump bracket.
2
3
6
6.
Remove muffler and exhaust coupler (see Muffler
4
Removal in this section).
5
7.
8.
Remove drive belt from drive clutch.
Loosen fasteners that secure starter/generator. Ro-
tate starter/generator toward engine to loosen tension
on starter belt. Remove beltfrom theengine and starter/
generator pulleys.
1
7
Figure 10
1.
2.
3.
4.
Fuel pump bracket
Exhaust manifold
Fuel line
5.
6.
7.
Starter/generator belt
Throttle cable
Governor cable
Drive belt
Workman MD
Page 4 -- 11
Kohler Gasoline Engine
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