Does anyone have a current repair manual link for the KT735 series engines?

A

Auto Doc's

Lawn Addict
Community Leader
I have a Kohler PT-KT735-3077 engine that I am getting ready to put a set of new factory heads on and would like the most current engine repair information if anyone has it in the library or links available. I've check mine and do not have it. The heads will not likely be here until next week.

Any help is appreciated.
 
Auto Doc's said:
I have a Kohler PT-KT735-3077 engine that I am getting ready to put a set of new factory heads on and would like the most current engine repair information if anyone has it in the library or links available. I've check mine and do not have it. The heads will not likely be here until next week.

Any help is appreciated.
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Why are you replacing the heads?
 
Hello H.,

Valve springs collapsed, rocker studs backing out and both intake valves very badly stuck in guides due to suspected bad/contaminated fuel being used.

The part numbers for the heads have had 3 different revisions. I figured that I am better off going with the Rehlko/Kohler head kits that have the heads with valves installed already along with gaskets pushrods, rockers and hardware.

The instruction paper in the kit only has the head bolt torque and sequence.
 
I also have a fairly good library though being authorized to access Kolher dealer site I update to the '26 from the '22 version.

I also been pulling all my manuals off Goggle drive since I was getting requests for edit access. Not suppose to have any access other the share directory. Now I got a 2TB external drive that I can put in my shirt pocket but I still keep a copy all SM files on the local HD too.

Just remember to do a 3 step torquing.
 
Auto Doc's said:
Hello H.,

Valve springs collapsed, rocker studs backing out and both intake valves very badly stuck in guides due to suspected bad/contaminated fuel being used.

The part numbers for the heads have had 3 different revisions. I figured that I am better off going with the Rehlko/Kohler head kits that have the heads with valves installed already along with gaskets pushrods, rockers and hardware.

The instruction paper in the kit only has the head bolt torque and sequence.
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Ok Don't blame you for that.
 
Hello H.,

Yep, once I added up all the separate parts prices (and shipping), it made more sense to go with the head kits

Everyone seems to think every little part is gold these days. Of course, a complete replacement engine is not cheap either.
 
It does reduces overall labor time. Reduces repair warranty issues. Also reduces overall parts cost when you need everything. Yes they not cheap but every little helps.

One note AutoDoc per a service bulletin they did change the exhaust screws from metric to SAE. New screws comes in the kit.
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Hi Star Tech,

We had a "Blue Northern" 20-degree temperature drop in the past 24 hours. We went from the mid 90's to the 70's in the daytime and upper 40's at night. We don't get many slow seasonal weather transitions here in South Texas.

Thanks for the bulletin.

The #2 head kit came in late yesterday evening and I noticed the exhaust port studs were already installed, and the two nuts were in a small package. Yes, they are SAE 5/16-18 studs & nuts.

I guess the #1 head kit will be in next week some time.

I'm prepping for the installation and getting everything laid out so the assembly should go pretty smooth.

While I am at it, I'm also going to remove the fuel tank and clean it out good along with the lines to make sure whatever caused the original heads to seize the intake valves in the guides is gone. This is a Craftsman zero turn and the under-seat fuel tank is pretty simple to remove from what I can tell.

Everything about this situation points towards contaminated fuel. What little fuel that is left in the tank does not smell old and rancid, but I think the owner said he put in some canned Tru-fuel while he was trying to figure the problem out himself.
 
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