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SERVICE MANUAL CV11-16, CV460-465, CV490-495

1. Cen IR Ge See l l f CAA E 321 Cylinder mi E 12 64 G ooo inl i di 137 5 rT Loe tA HH Eeo eee 5 41 aa iio im HIT o ili Exhaust Flange oe Engine Mounting Mounting Surface 2 46 Surface D l Starter Motor 25 4 74 1 00 6 34 250 Keyway Width Starter Side rsa 4 0 10 0 R Finnie ae Cylinder D i E dE e UU y Si THIR g 2 Studs Exhaust Flange Mounting Surface Engine Mounting Surface Figure 1 4 Typical Engine Dimensions 1 6 47 1 85 262 10 31 GC Cylinder E 25 4 Valve Cover End 1 00 JL 6 34 Keyway Width 250 Throttle Cable 207 80 16 176 6 IG 6 95 IN Cylinder N Oil Level Dipstick amp Fill 328 12 91 463 18 23 Flywheel End CV11 16 10 mm shorter Dimensions in are inch equivalents Section 1 Safety and General Information General Specifications Power 3600 RPM corrected to SAE J1995 CY E HE 8 2 kW 11 HP OMA EE 9 33 kW 12 5 HP Os KE 9 75 kW 13 HP Ee E eee eee eer E E ee E 10 5 kW 14 HP OVI asia orsces E E E 11 19 kW 15 HP CAE 11 9 kW 16 HP E EE 11 9 kW 16 HP 13 0 kW 16 5 HP CNAID E 12 7 kW 17 HP 13 4 kW 18 HP Max Torque RPM indicated OVT HE 27 4 N m 20 2 ft lb 2000 E EE aati A E E nents 27 8 N m 20 5 ft lb
2. 2500 GV 13 EEN 27 8 N m 20 5 ft lb 2500 OG E EE 28 9 N m 21 3 ft lb 2500 OF KEE 33 2 N m 24 5 ft Ib 2400 CWA E 35 3 N m 26 0 ft lb 2400 Eegeregie eege 36 3 N m 26 8 ft Ib 2400 EE EI EE 37 8 N m 27 9 ft Ilb 38 1 N m 28 1 ft lb 2400 Bore CV11 14 CV460 465 00 ec cccceeessseeeeeceeeseseeeeeeeeeeseeees 87 mm 3 43 in GV Ee Ee E E 90 mm 8 60 in Stroke TAG EE Sdn EET E E E teste eats 67 mm 2 64 in CV460 465 CV 490 495 E 77 mm 3 03 in Displacement KEN eebe ege 398 cc 24 3 cu in 3 GYI EE 426 cc 26 0 Cu in COV AGO E 460 cc 27 9 cu in DS EE 490 cc 29 9 cu in Compression aN EE 8 5 1 Weight approx TG E 39 54 kg 87 lb CV460 465 CV490 495 ccccssssssscsscsssersecsseusssersensuasseares 41 9 kg 90 lb HEEN 1 9 L 2 0 U S qt Air Cleaner Base Nut Ioroue E 9 9 N m 88 in Ib Wing NUU Le ie TE 1 5 N m 12 in Ib Angle of Operation Maximum at full oil level Intermittent All Drechons Jo Continuous All Directions ccccccceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeas 20 Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 1 7 Section 1 Safety and General Information Balance Shaft ERO E 0 0575 0 3625 mm 0 0027 0 0137 in TOLE ee 0 0250 0 1520 mm 0 0009 0 0059 in Bore I D VE 20 000 20 025 mm 0 7874 0 7884 in Max Wear Oger 20 038 mm 0 7889 in Balance Shaft
3. Relief Valve igure 9 40 Removing OIl Pressure Relief Valve Body Piston and Spring Early Style 9 11 Section 9 Disassembly Figure 9 41 Later Style Oil Pressure Relief Valve NOTE Later one piece relief valves Figure 9 41 are staked in place and do not require removal unless replacement is necessary 4 Remove the three hex flange screws oil pump cover O Ring and oil pump rotors See Figures 9 42 and 9 43 gt Ka Ze Be E Figure 9 43 New Style Removing Oil Pump Covers and Rotors Remove Hydraulic Lifters and Camshaft 1 From the cylinder head side pull lifters out of their bores with the lifters tool see Section 2 2 Mark or identify the hydraulic lifters as either intake or exhaust The exhaust lifter is nearest to the PTO side of the crankcase 3 Remove the camshaft and shim not on all models See Figure 9 44 Figure 9 42 Original Style Removing Oil Pump Covers and Rotors 9 12 Remove Balance Shaft 1 Remove the balance shaft from the crankcase See Figure 9 45 On CV460 495 engines rotate the crankshaft clockwise so the timing marks are one to two teeth past being aligned See Figure 9 46 This will permit the counterweights of the two shafts to clear Figure 9 46 Remove Connecting Rod and Piston 1 Remove the two hex flange screws and connecting rod cap See Figure 9 47 NOTE Ifa carbon ridge is present at the top of the bore use a rid
4. switch to the oil filter adapter of oil pan 1 Apply Loctite No 59241 pipe sealant with Teflon or equivalent to the threads of the switch 2 Install the switch into the tapped hole in oil filter adapter Torque the switch to 6 8 N m 60 in Ib Section 6 Lubrication System Testing the Oil Sentry Switch The Oil Sentry pressure monitor is a normally closed switch It is calibrated to open break contact with increasing pressure and close make contact with decreasing pressure within the range of 2 0 5 0 psi Compressed air a pressure regulator pressure gauge and a continuity tester are required to test the switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the switch The tester should indicate a change to no continuity switch open as the pressure increases through the range of 2 0 5 0 psi The switch should remain open as the pressure is increased to 90 psi maximum 3 Gradually decrease the pressure to the switch The tester should indicate a change to continuity switch closed as the pressure decreases through the range of 2 0 5 0 psi If the switch does not operate as specified replace the switch Testing Oil Pressure The engine oil pressure can be tested using the oil pressure tester described in
5. 27 1 33 9 20 25 ft Ib 27 1 33 9 20 25 ft Ib CV11 16 CV460 465 CV490 495 Section 2 Special Tools Kohler Special Service Tools Kohler Co has made an agreement with the Service Tools Div of SPX Corp a subsidiary of Owatonna Tool Corp to handle our special service tools The intent of this program is to provide you with a single source for all Kohler special tools and to make it easy and convenient to obtain those tools at reasonable cost Tool orders can be placed with SPX by any of three methods Mail orders should be sent to OTC SPX Corp 655 Eisenhower Dr Owatonna MN 55060 You can also fax the order to 800 578 7375 USA and Canada or 507 455 7063 International Finally you can order by phone at 800 533 0492 USA and Canada or 507 455 7223 International Repair Tools These quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using tools designed for the job you Can service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine down time Tool Kit No KO3211A This basic tool kit includes tools necessary to service Kohler K Series and Magnum engines COMMAND Tool Kit No KO3213 This kit is designed for the current Kohler Engine Service Dealer already having the KO3211A basic tool kit This kit includes all additional tools necessary to service c
6. Figure 9 6 Removing Air Cleaner Cover Section 9 Disassembly Breather Vt Hose Hose bk Air Cleaner amp Base Ch ages ECH D N Valve Cover Gasket Hex Flange Nuts Figure 9 7 Removing Air Cleaner Base Remove External Governor Components and Carburetor warnine Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 1 Remove the throttle linkage from the bushing in the governor lever See Figure 9 8 Reattach bushing to throttle linkage Remove the other end of the throttle linkage from the bushing in the carburetor throttle lever hrottle Linkage Figure 9 8 Removing Throttle Linkage 9 3 Section 9 Disassembly 2 Disconnect the governor spring from the governor lever and from the throttle control lever of the speed control bracket 3 Remove the two hex flange screws and speed control bracket See Figure 9 9 s Speed Control A Bracket inh Choke Linkage Choker D Control Lever D t H 3 he Hex fex Nut z SIE Pa A D H E Mounting Wi d Figure 9 9 Remo
7. Nippendenso Solenoid Shift Starter Some specifications call for the Nippendenso solenoid shift starter Operation of this starter is identical to that previously discussed There are however some differences in servicing the unit Refer to Figure 8 27 for exploded view of the starter Starter Disassembly 1 Disconnect the wire from the solenoid 2 Remove the hex nuts securing the solenoid and remove the solenoid from the starter assembly 3 Remove the two thru bolts 4 Remove the commutator end cap 5 Remove the insulator and brush springs from the brush spring holder 6 Remove the armature from the frame 7 Remove the drive lever and armature from the drive end cap NOTE When removing the lever and armature be careful not to lose the thrust washer 8 The stop collar consists of two similar pieces held in place by being snapped over a retainer The retainer is held in place by a groove in the armature shaft To remove the stop collar the two pieces must be pried off the retainer Section 8 Electrical System and Components Front Stop Collar 2 es Retainer Rear Stop eet Collar Assembly Armature Figure 8 27 Nippendenso Solenoid Shift Starter 9 When the stop collars are removed the retainer 4 The replacement brushes have a solid portion on can be removed from the armature shaft Electric them which should be crimped on the post starter service kit KO3226 see Section 2 includes a spec
8. Solenoid an ee fa Armature i U SH A GES F HAIG ata i a D 1 L sans VIE 1 1 L Frame amp Field Washer Brush Holder Nut CE Frame ASM Screw Bolt Figure 8 48 Delco Remy Solenoid Shift Starter Inspection Brushes and Springs Inspect both the springs and brushes for wear fatigue or damage Measure the length of each brush The minimum length for each brush is 7 6 mm 300 in See Figure 8 49 Replace the brushes if they are worn undersize or their condition is questionable Drive Pinion Check and inspect the following areas a The pinion teeth for abnormal wear or damage b The O D surface between the pinion and the clutch mechanism for nicks or burrs which could cause seal damage c Check the drive clutch by holding the clutch housing and rotating the pinion Pinion should rotate in one direction only Wear limit length 7 6 mm 300 in Figure 8 49 Checking Brushes 8 31 Section 8 Electrical System and Components Armature 1 Clean and inspect the commutator outer surface The mica insulation of the commutator must be lower than the O D surface undercut to ensure proper operation of the commutator See Figure 8 50 Commutator O D Mica Insulation Figure 8 50 Commutator Mica Inspection 2 Use an ohmmeter set to the Rx1 scale Touch the probes between two different segments of the commutator and check for continuity See Figure 8 5
9. center screw and other componenis for wear or damage 2 Replace all worn or damaged components Use only genuine Kohler replacement parts as specified in the Parts Manual All components shown in Figure 7 1 are available as service parts Do not use nonstandard parts 3 Do not attempt to rewind a spring that has come out of the keeper Order and install a new spring and keeper assembly 4 Clean all old grease and dirt from the starter components Generously lubricate the spring and center shaft with any commercially available bearing grease Reassembly 1 Make sure the spring is well lubricated with grease Place the spring and keeper assembly inside the pulley with spring toward pulley See Figure 7 8 Figure 7 8 Position of Spring and Keeper in Pulley 2 Install the pulley and spring into the starter housing See Figure 7 9 Make sure the pulley is fully seated against the starter housing Do not wind the pulley and recoil spring at this time ZA Housing Figure 7 9 Installing Pulley and Spring into Housing 3 Install the pawl springs and pawils into the starter pulley See Figure 7 10 N Ba Figure 7 10 Installing Pawls and Pawl Springs 4 Place the brake washer in the recess in starter pulley over the center shaft 5 Lubricate the brake spring sparingly with grease Place the spring on the plain washer Make sure the threads in center shaft remain clean dry and free of greas
10. Mass A t d ig in d 20 a E E E F e SR se ac E 8 EE d E S di j o j ea F 7 pal i A LA i a d e lt Cylinder Barrel Baffle Hex Flange Screw Starter Side Figure 11 50 Installing Starter Side Cylinder Baffle not on all models 3 Install gasket and heat deflector to the intake studs Place the carburetor side cylinder baffle in position and attach with the one hex flange screw Temporarily install the silver screw if the screw also attaches the fuel solenoid ground lead See Figure 11 51 Section 11 Reassembly a H e r A ofp lt Gasket Intake Studs y E Daa Heat Deflector E SC Bi dp Silver Screw for Ground Lead igure 11 51 Installing Heat Deflector ang Carburetor Side Baffle not on all models 4 Install the cylinder head baffle and secure with the two hex flange screws Later production models use one screw and one hex flange nut See Figure 11 52 Cylinder Head Figure 11 54 Installing Blower Housing E 6 Tighten all hardware securely when all sheet Hex Flange metal pieces are in position Screw or Nut Install Valve Cover and Muffler Bracket RTV silicone sealant is used between the valve cover and crankcase Refer to page 2 1 for the approved sealant Figure 11 52 Installing Cylinder Head Baffle 5 Install the grommet around the high tension lead metal blower housings only Insert the grommet into the
11. throttle shaft and choke shaft NOTE Do not submerge the carburetor in cleaner or solvent when fiber rubber or foam seals or gaskets are installed The cleaner may damage these componenis Inspection Carefully inspect all components and replace those that are worn or damaged e Inspect the carburetor body for cracks holes and other wear or damage e Inspect the float for cracks holes and missing or damaged float tabs Check the float hinge and pin for wear or damage e Inspect the fuel inlet needle and seat for wear or damage e Inspect the tip of the low idle fuel adjusting needle for wear or grooves e Inspect the throttle and choke shaft and plate assemblies for wear or excessive play Repair Always use new gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Always refer to the Parts Manual for the engine being serviced to ensure the correct repair kits are ordered Reassembly Choke Shaft Installation Non Self Relieving 1 Install the choke return spring to the choke shaft 2 Insert the choke shaft with return spring into the carburetor body 3 Rotate the choke lever approximately 1 2 turn counterclockwise Make sure the choke return spring hooks on the carburetor body 4 Position the choke plate as marked during disassembly Insert the choke plate into the slot in the choke shaft Make sure the choke shaft is locked betwe
12. voltage on voltmeter If voltage is 13 8 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter With engine stopped measure the resistance 3a across stator leads using an ohmmeter With the engine stopped measure the resistance from each stator lead to ground using an ohmmeter Perform same test as step 1 above Conclusion If voltage is 13 8 14 7 and charge rate increases when load is applied the charging system is OK and battery was fully charged If voltage is less than 13 8 or charge rate does not increase when load is applied test stator Tests 2 and 3 If voltage is 28 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 28 volts stator is probably faulty and should be replaced Test stator further using an ohmmeter Test 3 If resistance is 0 1 0 2 ohms the stator is OK If the resistance is infinity ohms stator is open Replace stator If the resistance is infinity ohms no continuity the stator is OK not shorted to ground If resistance or continuity is measured the stator leads are shorted to ground Replace stator If the voltage is
13. 0 0073 in Top Compression Ring End Gap New Bore CV11 14 e EE 0 250 0 500 mm 0 010 0 020 in CV15 GV 16 GV 490 49 in sisisinsinenaatannantenstiomnrencstivabintacatindlens 0 28 0 51 mm 0 011 0 020 in Used Bore MAY a ceacorvresaatcteetutants seme ynesssaruneonteciaracsasaumanenss 0 79 mm 0 031 in Section 1 Safety and General Information Piston Piston Rings and Piston Pin Cont d Center Compression Ring End Gap New Bore CV11 14 CNAGU AGb ek 0 250 0 510 mm 0 0010 0 020 in CV 15 CV16 CV 490249 5 ciccssavavncssvienstdesatandsaestiovsneatervees 0 22 0 48 mm 0 008 0 018 in Used Bore max 0 76 mm 0 030 in Oil Control Ring End Gap CV11 14 ET 0 250 1 020 mm 0 010 0 040 in CV15 CV16 CV 490 495 cciccsssaiccsnntnnnseseaeereeesnnnnstavansnssaenrs 0 250 0 760 mm 0 0098 0 0299 in Piston Thrust Face O D See Figure 10 4 New CV11 14 CNAGU AGb ek 86 941 86 959 mm 3 4229 3 4236 in CV15 CV16 CV 490 49 5 ee crassa cnenwinsncsesarnneversareaneoniesnenvs 89 951 89 969 mm 3 5413 3 5420 in Max Wear Limit OV 11914 CV E 86 814 mm 3 4179 in CV15 CV16 CV490 495 ae 89 824 mm 3 5363 in Piston Thrust Face See Figure 10 4 to Cylinder Bore Running Clearance New CV11 14 CV460 465 EE 0 041 0 044 mm 0 0016 0 0017 in CV15 CV16 CV490 495 00 cccececsessececsessereesesseeesseasanes 0 031 0 043 mm 0 0012 0 0016 in Retractable Starter Center Screw JOE geet 7 4 8 5 N m 65 75 in Ib Stator Stator
14. 025 mm 3 5433 3 5443 in Max Wear Limit CV11 14 CV RE 87 063 mm 3 4277 in CV15 CV16 CVAO0U A0D REENEN 90 063 mm 3 5458 in Max OUL OMAOUING WE 0 12 mm 0 0047 in NTs PANIC E 0 05 mm 0 0020 in 1 9 Section 1 Safety and General Information Cylinder Head Cylinder Head Fastener Torque torque in 2 increments 24 48 9 N m 18 36 ft Ib Max Out of FlatnessS ooannnnnannnnnannnnnennnnnennnnnennnennnnnenenereeenenne 0 076 mm 0 003 in Rocker Pedestal Fastener Torque 2 eeeeeeeceeeeeeeeeeees 11 3 N m 100 in Ib Electric Starter Starter Thru Bolt Torque UTE Johnson Electric Eaton Inertia Drive 00000 000005 4 5 5 7 N m 40 50 in Ib Nippendenso Solenoid ht 4 5 7 5 N m 40 84 in lb Delco Remy Solenoid Shift ccccccssssseceeeeeessseeeeeeeees 5 6 9 0 N m 49 79 in Ib Starter Mounting Screw Torque A 15 3 N m 135 in lb Solenoid Mounting Hardware Nut Screw Torque Nippendenso Starter ccccccsseesscceeeesseeceeeeeeeeseeeeeeeaeeees 6 0 9 0 N m 53 79 in Ib Bleu 4 0 6 0 N m 35 53 in Ib Brush Holder Mounting Screw Torque Delco Remy Ee 2 5 3 3 N m 22 29 in Ib Nut Positive Brush Lead Torque Nippendenso Starter lt cccc c 0 ccceescesseeecescsaseeeseesteesees 8 0 12 0 N m 71 106 in Ib Delco Remy Starter cccccccsccccccecsssseeeceeeseeseeeeeeeeeaas 6 0 9 0 N m 53 79 in Ib Fan Flywheel F n PaSl
15. 110 Volt AC Source Push Button Switch Push on Figure 8 25 110 Volt UL Approved Electric Starter 8 22 Section 8 Electrical System and Components Solenoid Shift Electric Starters The following subsection covers the solenoid shift electric starters Much of the information in the preceding subsection relates to these starters therefore it is not repeated here Refer to Figure 8 26 for disassembly and assembly procedure of the UTE solenoid shift starter The Nippendenso solenoid shift starter is covered starting on page 8 24 The Delco solenoid shift starter starts on page 8 28 Frame includes Hex Cap Screw 2 Permanent Magnets Drive End Plunger Hex Flange Screws 2 Spring ES ex Thrust Washer Brushes aoe gt Retainer and a Brush Seal fas oe Drive Pinion Oe Drive Lever LC OoOO Armature Starter Assembly Commutator End Cap Figure 8 26 UTE Solenoid Shift Electric Starter 8 23 Section 8 Electrical System and Components Operation Solenoid Shift Starters When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts and the start switch is released the starter solenoid is deactivated the drive lever moves back and the drive pinion moves out of mesh
16. 2 Insert the piston and spring into the body See Figure 11 15 Spring Piston Relief Valve Body S e r v Figure 11 15 Installing Oil Pressure Relief Valve Body Plunger and Spring Section 11 Reassembly 3 Push bracket down until it seats against top of relief valve body Secure with hex flange screw See Figure 11 16 Oil Pressure Hex Flange Relief Bracket Screw SE GE Relief Valve Body Figure 11 1 6 Installing Oil Pressure Relief Valve Bracket Later One Piece Style Oil Pressure Relief Valve 1 If this style relief valve is replacing an early five piece relief valve reinstall the original retaining screw to block the hole Tighten securely Figure 11 17 Later Style Oil Pressure Relief Valve 2 Use apiece of thin wall metal tubing or deep socket with a slightly smaller O D than base Press or tap new relief valve into the bore of the closure plate until it bottoms See Figure 11 18 11 6 Figure 11 18 Inserting New Relief Valve into Bore of Closure Plate 3 Stake the casting boss with a center punch in 3 or 4 locations near the inner edge to lock the relief valve into place See Figure 11 19 Do not use Loctite Center Punch Stake Marks 23 Figure 11 19 Center Punch Stake Marks Install Oil Pickup 1 Install the oil pickup screen screen cover and hex flange screw See Figure 11 20 Section 11 Reassembly 3 Install the oil pan to the crankc
17. 400 ohms NOTE This test cannot be performed Refer to the Disassembly and Reassembly unless module has been fired at Sections for complete ignition module least once removal and installation procedures If the resistance is within the specified range the module secondary is OK Figure 8 3 Ignition Tester Part No KO1047 Figure 8 4 Testing Module Secondary 8 4 Section 8 Electrical System and Components Electronic Ignition System with Spark Advance Smart Spark CV16 Engines 12 Volt Battery Kill Switch or Off z Position of Key Switch Spark Advance Module Spark Plug A F Air Gap 0 2 0 3 mm 0 008 0 012 in Ignition Module Magnet Flywheel Figure 8 5 Capacitive Discharge Ignition System with Spark Advance The CV16 engines are equipped with an electronic capacitive discharge ignition system with electronic spark advance A typical application Figures 8 5 and 8 6 consists of the following components e A magnet assembly which is permanently affixed to the flywheel e An electronic capacitive discharge ignition module which mounts on the engine crankcase e A spark advance module which mounts to the engine shrouding e A12 volt battery which supplies current to the Figure 8 6 Smart Spark Components spark advance module e Akill switch or key switch which grounds the spark advance module to stop the engine e A spark plug 8 5 Section 8 Electrical System and Co
18. 465 CV490 495 Electric Start Engines 15 amp Regulated Battery Charging System CV16 Electric Start Engines 15 amp Battery Charging System Ignition D Rectifier Regulator Engine Connector MA Optional Oh Sentry Optional Indicator Light Indicator Fuse e d starter Bendix 7 Solenoid Starter Figure 8 13 CV16 Electric Start Engines 15 amp Regulated Battery Charging System Optional Oil Sentry Switch Shutdown Section 8 Electrical System and Components Rectifier Regulator AC Leads 15 Amp Stator Figure 8 14 15 amp Stator and Rectifier Regulator DC Volt Meter Rectifier Regulator re Flywheel Stator Ammeter Battery Figure 8 15 Proper Connection to Test 15 amp Charging System 8 15 Section 8 Electrical System and Components Troubleshooting Guide 15 amp Regulated Battery Charging System NOTE Zero ohmmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load The battery must be fully charged No Charge to Battery Battery Continuously Charges at High Rate 8 16 Trace B lead from rectifier regulator to key switch or other accessible connection Disconnect it from switch or connection Connect an ammeter from loose end of B lead to positive terminal of battery Connect DC voltmeter from loose end of B lead to negative terminal of battery See Figure 8 9 With engine running at 3600 RPM read
19. 8 Install the O Ring in the groove in the oil pan Install the oil pump cover machined side towards O Ring Secure with three hex flange screws See Figure 11 24 Hex Flange Screws Oil Pump Cover 4 Torque the screws as follows Into new as cast hole 6 2 N m 55 in Ib Into used hole 4 0 N m 35 in Ib Install Oil Seals 1 Slide the seal protector sleeve Kit No KO1037 over the crankshaft Generously lubricate the lips of oil seal with light grease Slide the oil seal over the sleeve 2 Use handle Kit No KO1036 and seal driver Kit No KO1027 Install the seals until the driver bottoms against the crankcase or oil pan See Figure 11 25 Oil Seal KO1036 Handle and KO1027 Driver Figure 11 25 Installing Oil Seals Install Stator and Wiring Harness 1 Push the stator leads through the hole to the outside of the crankcase See Figure 11 26 _ Hex Head Socket Screws 4 Stator Figure 11 26 ineialling Stator 2 Install the stator using four hex socket head screws Torque the screws to 6 2 N m 55 in Ib 3 Secure the stator leads to the crankcase with the clip and hex flange screw 4 Be sure the locking tangs on the stator lead terminals are bent angled upward Insert and lock the terminals into the outer positions of the connector body 5 Install the kill lead through the same hole as the stator lead from the outside of the crankcase Secure the kill lead to the c
20. Bearing Surface O D VIE 19 962 19 975 mm 0 7859 0 7864 in Max Wear LIAN E 19 959 mm 0 7858 in Camshaft End Pilay E6 Se a i ae ee a ee 0 088 0 393 mm 0 003 0 015 in niet ST ie SNS EE 0 076 0 127 mm 0 003 0 005 in Kunn ele 0 025 0 105 mm 0 0010 0 0041 in Bore I D VIE 20 000 20 025 mm 0 7874 0 7884 in Xs WSR TEE 20 038 mm 0 7889 in Camshaft Bearing Surface O D KI 19 962 19 975 mm 0 7859 0 7864 in EK WV AE un EE 19 959 mm 0 7858 in Carburetor Preliminary Low Idle Fuel Needle Gettmg 1 Turn Fuel Bowl Retaining Screw Torque cccccccssssecceeeceeeseceeeeeseeeeeeeeeeeseeeeseeees 5 1 6 2 N m 45 55 in Ib Connecting Rod Cap Fastener Torque torque in increments 6 mm straight shank DOM EE 11 3 N m 100 in Ib o mM Ee Dee in ee EE 14 7 N m 130 in Ib 8 mm straight e E 22 7 N m 200 in Ib Connecting Rod to Crankpin Running Clearance at 21 C 70 F KSE 0 030 0 055 mm 0 0012 0 0022 in Max Wear LIMI E 0 07 mm 0 0025 in Connecting Rod to Crankpin Side Cearance 0 18 0 41 mm 0 007 0 016 in Connecting Rod to Piston Pin Running Clearance at 21 C 7099F 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D KS EN 19 015 19 023 mm 0 7486 0 7489 in Max Wear un erreien rsaacesutuateei ai i 19 036 mm 0 7495 in Crankcase Governor Cross Shaft Bore I D KS 6 025 6 050 mm 0 2372 0 2382 in EK E WS AE un EE 6 063 mm 0 2387 in 1 8 Section 1 Safety and General
21. Cl Ak Figure 9 35 Removing Stator Remove Oil Pan 1 Invert the engine so the PTO end of crankshaft is up 2 Remove the twelve hex flange screws securing the oil pan to the crankcase See Figure 9 36 L Ze E Hex Flange ae th Screws 12 Figure 9 36 Removing Oil Pan 3 Locate the splitting tabs on the oil pan and crankcase Insert the drive end of a 3 8 breaker bar between the splitting tabs and rotate the handle to break the RTV seal between the crankcases and oil pan See Figure 9 37 NOTE Pry only in the splitting tabs Do not pry on the gasket surfaces of the crankcase or oil pan as this can cause leaks Remove Oil Pickup Oil Pressure Relief Valve and Oil Pump 1 Remove the oil seal from the oil pan 2 Remove the hex flange screw oil pickup cover and oil pickup screen See Figure 9 38 Section 9 Disassembly Hex Flange Screw CA G Oil Pickup A J Screen Cover x Figure 9 38 Removing Oil Pickup 3 Identify the type of oil pressure relief valve used If the relief valve assembly is like that shown in Figures 9 39 and 9 40 remove the hex flange screw retaining bracket relief valve body piston and spring If the relief valve is like that shown in Figure 9 41 removal is not necessary Oil Pressure Relief Bracket Hex Flange Screw gt Relief Valve Body Figure 9 39 Removing Oil Pressure Relief Valve Bracket Early Style
22. If so equipped 16 Remove drive cup grass screen flywheel and fan 17 Remove stator and wiring harness 18 Remove oil pan 19 Remove oil pickup oil pressure relief valve and oil pump 20 Remove camshaft and hydraulic lifters 21 Remove balance shaft 22 Remove connecting rod and piston 23 Remove piston from connecting rod 24 Remove piston rings 25 Remove crankshaft 26 Remove flywheel end oil seal and bearing 2 7 Remove governor cross shaft and governor gear Disconnect Spark Plug Lead Drain Oil from Crankcase and Remove Oil Filter 1 Remove the oil drain plug and oil fill cap dipstick See Figure 9 1 2 Remove the oil filter drain plug located at the base of the oil filter adapter on some models 3 Allow ample time for the oil to drain from the crankcase and oil filter 4 Remove and discard the oil filter Remove Oil Sentry Pressure Switch on models so equipped 1 Disconnect the leads from the pressure switch 2 Unthread and remove the pressure switch from the oil filter adapter See Figure 9 1 9 1 Section 9 Disassembly Spark Plug Lead Oil Filter Oil Drain Optional Oil Sentry Switch or Oil Filter Drain Plug Figure 9 1 Removing Spark Plug Lead Oil Drains Oil Filter and Oil Sentry Switch oil filter drain plug not on all models Remove Muffler 1 Remove the hex flange nuts from exhaust studs and hex flange screws from muffler bracket See F
23. Install the rubber fuel line and secure the rubber fuel line to the metal fuel line with a hose clamp 2 Install the bushing and attach the throttle linkage to the carburetor throttle lever See Figure 11 61 Throttle Linkage Bushing Figure 11 61 Installing Carburetor and External Governor Components 3 Install the gasket and carburetor onto the intake studs Install the free end of the rubber fuel line to the carburetor inlet fitting Secure the fuel line with the other hose clamp See Figure 11 62 Fuel Line Carburetor et a Figure 11 62 Installing Gasket Carburetor and Fuel Line 11 19 Section 11 Reassembly 4 S Attach the ground lead from carburetor fuel solenoid if applicable to the silver screw and lock washer on the cylinder baffle See Figure 11 63 Silver Screw Install the governor lever onto the cross shaft but DO NOT tighten at this time Adjustment and setting of the governor lever is performed after the air cleaner base is installed Install the throttle linkage and bushing to the governor lever Connect the long end of the choke linkage to the carburetor choke lever See Figure 11 64 Connect the other end of the choke linkage to the choke lever on speed control bracket Attach the speed control bracket assembly with the two mounting screws On some models the upper screw also secures a ground lead rectifier regulator and an attaching clip fuel line Insta
24. Mounting Screw TOrque cccccsecceeceesseceeeeeeeeeeeeeeeeeeas 6 2 N m 55 in Ib Throttle Choke Controls Governor Control Lever Fastener Toroue 9 9 N m 88 in Ib Speed Control Bracket Assembly Fastener Toroue 10 7 N m 95 in Ib Into new as cast hole 7 3 N m 65 in lb Into used hole Valve Cover Rocker Arms Valve Cover Fastener TOrque ccccssccecesececeeeceesaeeeeeeeeeeeaes 10 7 N m 95 in lb Into new as cast hole 7 3 N m 65 in lb Into used hole Rocker Arm I D VC 15 837 16 127 mm 0 63 0 64 in Max Wear Limit ceussneteeantscbosicns rosdni mere iunsasanbolaeacsannehapsnettn sans 16 13 mm 0 640 in Rocker Shaft O D VU 15 90 15 85 mm 0 63 in Max Wear Um 15 727 mm 0 619 in Non Adjustable Valve Lash Configuration Rocker Arm Screw TOrque n nnnoennnnnnnsnnnnnnnnnnnnnenssennennenne 11 3 N m 100 in Ib Adjustable Valve Lash Configuration Rocker Arm Pivot Stud Torque snseenennneenneennneeennerreenen 11 3 N m 100 in Ib Adjustment Set Screw Toroue RENE 7 3 N m 65 in Ib Section 1 Safety and General Information Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance 0 0124 0 0501 mm 0 0005 0 0020 in ER Intake Valve Stem to Valve Guide Running Clearance 0 038 0 076 mm 0 0015 0 0030 in Exhaust Valve Stem to Valve Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D KN 7 038 7 058
25. Oil Pressure Relief Valve Governor Gear and Shaft Inspection Inspect the governor gear teeth Look for any evidence of worn chipped or cracked teeth If one or more of these problems is noted replace the governor gear The gear is held on the governor shaft by molded tabs which are damaged when the gear is removed Never reuse the gear once it has been pulled from the shaft Replace the governor shaft only if it is damaged or worn Procedure to Remove Governor Shaft 1 Remove governor gear assembly and regulating pin 2 Locate governor pin from flywheel side of crankcase With a small punch drive the pin toward the inside of the crankcase This could also be done with a press DO NOT remove the governor pin with a vise grip or pliers you may damage the crankcase 10 11 Section 10 Inspection and Reconditioning Procedure to Install Governor Shaft 1 Install new pin by pressing or lightly tapping into crankcase It must be installed so that it protrudes 1 289 plus or minus 004 in above the crankcase boss See Figure 10 13 Figure 10 13 Governor Shaft 2 Install new governor regulating pin Part No 12 380 01 S and governor gear assembly Part No 12 043 05 S 3 Make sure governor gear assembly rotates freely 10 12 Stamped Steel Valve Cover If the engine has stamped steel valve cover the sealing surface must be checked for flatness prior to reinstallation Hold the valve cover down firmly aga
26. Positions 11 11 Section 11 Reassembly Reassemble Cylinder Head Refer to Figure 11 37 for cylinder head differences Assemble the components accordingly based on head configuration involved Rocker Bridge Rocker Shaft Rocker Bridge _ Stem Seal Spring Retainer Intake Spring __ Non Adjustable Valve Lash SS Keepers Round Pivot i Ki A Ch Retainer Kits Cylindrical Pivot Ki Not used on some models Figure 11 37 Cylinder Head Valve Train Differences 1 Rocker Bridge Heads Only Install the rocker bridge to the cylinder head See Figure 11 38 Make sure the small counterbored hole is towards the exhaust port side of the cylinder head Secure the rocker bridge with the two M6 hex cap screws Torque screws to 11 3 N m 100 in Ib 2 Install the intake valve stem seal intake valve spring retainer intake valve spring and valve spring cap Compress the valve spring using a valve spring compressor and install the keepers See Figure 11 39 11 12 ob Hydraulic ners Head Gasket ZA Rods Exhaust Port s SC Rotator Cylinder Head QO Spacer d 5 Position only Head Exhaust Bolts Spring Adjustable Valve Lash Pra Adjusting Nut 6 Pivot Stud Set Screw Install the exhaust valve stem seal if used exhaust valve spring retainer exhaust valve spring and valve spring cap Compress the valve spring using a valve spring compressor and
27. S When reinstalling make sure the foam filter seals against the blower housing around its base and is securely attached to the velstuds 4 3 Section 4 Air Cleaner and Air Intake System 4 4 CV11 16 CV460 465 CV490 495 Section 5 Fuel System and Governor Gasoline fuel systems are covered in the first part of this section LPG liquefied propane gas systems and the Kohler Emission Sentry LPG system are covered starting on page 5 11 The governor systems start on page 9 14 Fuel Recommendations Gasoline A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Gasoline Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to insure easy starting Do not add oil to the gasoline Do not overfill the
28. Section 2 Follow the instructions included with the tester The pressure can be tested by removing the oil filter and installing the tester adapter on the filter pad or by removing the Oil Sentry pressure switch or pipe plug and threading the tester hose directly into the hole See Figure 6 10 6 5 Section 6 Lubrication System 6 6 CV11 16 CV460 465 CV490 495 Section 7 Retractable Starter A WARNING Spring Under Tension Retractable starters contain a powerful recoil spring that is under tension Always wear safety goggles when servicing retractable starters and carefully follow instructions in this section for relieving spring tension To Remove Starter 1 Remove the five hex flange screws securing the Handle with starter to the blower housing Rope Retainer Starter Housing 2 Remove the starter To Install Starter 1 Install the retractable starter and five hex flange screws to blower housing Leave the screws slightly loose 2 Pull the starter handle out until the pawls engage the drive cup Hold the handle in this position and tighten the screws securely See Figure 7 2 Brake Spring Pawl Retainer e Plain Washer Center Screw f Drive Cup Figure 7 1 Retractable Starter Exploded View E Figure 7 2 Installing Retractable Starter 7 1 Section 7 Retractable Starter Rope Replacement 9 Insert the new rope through the rope hole in The rope can be replaced without co
29. Single Cylinder engines The purpose of the new system is to maintain a Changing the High Idle RPM on Engines with desired idle speed regardless of ambient conditions Separate Controls temperature parasitic load etc that often change Increase or Decrease RPM The new system requires an additional procedure See Figure 5 25 on page 5 18 for setting the idle speed If speed adjustments are required proceed as follows 1 Loosen the high idle stop screw retaining nut top side of control plate 1 Make any necessary speed or control adjustments following the appropriate instructions 2 Start the engine move the application throttle already covered in this section lever to full throttle fast loosen the throttle cable clamp screw on the engine control plate 2 Move the throttle control to the idle position Hold the governor lever away from the carburetor 3 To increase the RPM Turn high idle stop screw so the throttle lever is tight against the idle outward counterclockwise and pull on the speed adjusting screw Check the speed with a throttle control cable until the desired RPM is tachometer and adjust it to 900 1000 RPM Turn obtained the screw clockwise to increase the speed and counterclockwise to decrease the speed 4 Tighten the throttle cable clamp screw and the high idle stop screw retaining nut 3 Release the governor lever and allow the engine to return to the governed idle speed Check 5 To assure that the RPM
30. aligned with a premarked line on the starter frame The frame is not premarked on starters with Style B end caps Place a piece of masking tape on the frame and mark a line on the tape in line with the raised line on the end cap See Figure 8 23 Remove the thru bolts Remove the commutator end cap with brushes and brush springs Style A Style B end caps remove as a separate piece with the brushes and carrier remaining in the frame Remove the drive end cap Remove the armature and thrust washer if so equipped from inside the starter frame Remove the brush carrier assembly from the frame Style B end cap starters SE A End Cap Brush Replacement Remove the brush springs from the pockets in brush holder See Figure 8 21 Remove the self tapping screws negative brushes and plastic brush holder Remove the hex flange nut and fiber washer from the stud terminal Remove the stud terminal with positive brushes and plastic insulating bushing from the end cap Reinstall the insulating bushing to the new stud terminal with the positive brushes Install the stud terminal with bushing into the commutator end cap Secure the stud with the fiber washer and hex flange screw Install the brush holder new negative brushes and self tapping screws Install the brush springs and brushes into the pockets in brush holder Make sure the chamfered sides of brushes are away from the brush springs NOTE U
31. also when present Not used on some models NOTE Note the order of all parts removed Reassemble in the same order unless the head is being replaced and the instructions in the head kit specify otherwise 9 8 Figure 9 28 Removing Valves with Valve Spring Compressor A es Bridge Type Head Figure 9 29 Removing Valv Remove Drive Cup Grass Screen Flywheel and Fan NOTE Always use a flywheel strap wrench or flywheel holding tool see Section 2 to hold the flywheel when loosening or tightening the flywheel retaining screw Do not use any type of bar or wedge between the fins of the cooling fan as the fins could become cracked or damaged Recoil Start Models 1 Remove the hex flange screw plain washer and drive cup See Figures 9 30 and 9 31 Section 9 Disassembly ki 1 F O ES frain Washer HexgFlange 2 Figure 9 30 Removing Flywheel Retaining Screw and Drive Cup Recoil Start Models Figure 9 31 Loosening Flywheel Fastener 2 Remove the grass screen from fan See Figure 9 32 Electric Start Models 1 Engines without a retractable starter will not have a drive cup Remove the hex flange screw and washer NOTE Some engines have a domed cooling fan with a solid center hub covering the flywheel screw On those engines it will be necessary to remove the screen and fan first to access the screw and washer All Models The grass screen snaps onto six small knobs on
32. an ohmmeter If resistance is 0 ohms stator is shorted Replace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 8 12 Section 8 Electrical System and Components 1 Make sure lights are not burned out 1 Replace burned out lights 2 Disconnect the braking lead green from 2 If voltage is 35 volts or more stator the wiring harness is OK Circuitry on unit that grounds No braking lead is shorted Lights With engine running at 3400 RPM Or measure voltage from braking lead to If voltage is less than 35 volts test Battery ground using an AC voltmeter stator using an ohmmeter Test 3 Charging With the engine stopped measure the If resistance is approximately Braking resistance from braking lead to ground 0 2 0 4 ohms stator is OK System using an ohmmeter Test If resistance is 0 ohms stator is shorted Replace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 8 13 Section 8 Electrical System and Components CV11 15 CV460 465 CV490 495 Electric Start Engines 15 amp Battery Charging System Ground to Kill Lead White Violet Ignition Rectifier Module Regulator Key Switch Flywheel Optional Stator Fuse i Optional Oil Optional geld gn Choke Optional Oil Sentry Ammeter Ke ts Sentry Switch 1 Solenoid Switch Indicato Shutdown Light 8 n Battery Figure 8 12 CV11 15 CV460
33. arms or to turn the crankshaft you can make a tool for doing this out of an old junk connecting rod Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap If itis a Posi Lock rod you will also need to remove the studs If it is a Command rod you will need to grind off the aligning steps so the joint surface is flat Find a 1 long capscrew with the correct thread size to match the threads in the connecting rod Obtain a flat washer with the correct I D to slip on the capscrew and an O D of approximately 1 Kohler Part No 12 468 05 S can be used if you dont have the right size on hand Assemble the capscrew and washer to the joint surface of the rod as shown in Figure 2 2 Figure 2 2 Rocker Arm Crankshaft Tool 2 3 Section 2 Special Tools 2 4 CV11 16 CV460 465 CV490 495 Section 3 Troubleshooting Troubleshooting Guide When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common causes of engine troubles are listed below Use these to locate the causing factors Engine Cranks But Will Not Start Empty fuel tank Fuel shut off valve closed Dirt or water in the fuel system Clogged fuel line Spark plug lead disconnected Key switch or kill switch in off position Faulty spark plug Faulty ignition module eo Oe eS
34. base and valve cover NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components Disassembly The following procedure is for complete disassembly of all air cleaner components 1 Loosen the air cleaner cover retaining knob and remove the air cleaner cover 2 Remove the wing nut and air cleaner element 3 If so equipped remove the precleaner from the paper element 4 Disconnect the breather hose from the air cleaner base 5 Remove the air cleaner base mounting nuts air cleaner base and gasket 6 If necessary remove the self tapping screws and stud from the air cleaner base Reassembly The following procedure is for complete assembly of all air cleaner components 1 Install the stud and self tapping screws to the air cleaner base 2 Install the gasket air cleaner base and base mounting nuts Torque the nuts to 9 9 N m 88 in Ib 3 Connect the breather hose to the air cleaner base and valve cover Secure with hose clamps 4 If so equipped install the precleaner washed and oiled over the paper element 5 Install the air cleaner element and wing nut Thread the wing nut on the stud until it contacts the metal cap on the element then tighten an additional 1 2 1 turn 6 Install the air cleaner cover Tighten the knob securely Section 4 Air Cleaner and Air Intake Syst
35. control unit Once activated the fault detection circuit will continue to monitor the signal from the oxygen sensor for the next 45 60 seconds If the emission levels remain at an unsafe level the fault circuit will ground the ignition to kill the engine and illuminate a red LED lamp on the dash panel of the unit The fault circuit will reset itself automatically in about 2 3 minutes If the fault circuit is triggered repeatedly one of the components is malfunctioning or faulty and the unit should be serviced by an authorized dealer The fault circuit will not allow the engine to operate more than 45 60 seconds with emissions above the predetermined level Troubleshooting the Emission Sentry System lf the fault circuit is triggered repeatedly during operation a fault should be suspected in one of the following areas a Electrical wires for stepper motor oxygen sensor battery cable or ground cable have been disconnected b Stepper motor c Fuel adjusting screw in control valve is binding d Oxygen sensor e Electronic control unit If the fault circuit is triggered when the engine is idling a The idle mixture screw on the gas regulator may be improperly adjusted To determine where the fault lies proceed as follows 1 Check all electrical connections and leads from oxygen sensor stepper motor electronic control unit and battery cables It is best to disconnect wire connectors from oxygen sensor stepper
36. for damage or indications of improper fit and seal e Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate that the engine has been underserviced 3 2 e Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner is not functioning properly e Check the oil level Note if the oil level is within the operating range on the dipstick or if it is low or overfilled e Check the condition of the oil Drain the oil into a container the oil should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge deposits could indicate the oil has not been changed at the recommended intervals incorrect type or weight of oil was used overrich carburetion or weak ignition to name a few NOTE It is good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning the Engine After inspecting the external condition of the engine clean the engine thoroughly before disassembling it Also clean individual components as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will
37. fuel tank Leave room for the fuel to expand Fuel Type Gasoline For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however that the cylinder head will require more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel System Gasoline The typical fuel system includes the fuel tank in line fuel filter fuel pump carburetor and fuel lines Some applications use gravity feed without a fuel pump Operation The fuel from the tank is moved through the in line filter and fuel lines by the fuel pump On engines not equipped with a fuel pump the fuel tank outlet is located above the carburetor inlet and gravity moves the fuel Fuel then enters the carburetor float bowl and is moved into the carburetor body There the fuel is mixed with ai
38. leaks Remove fuel bowl and replace gasket Leaky cracked or damaged float Submerge float to check for leaks Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle Float level is set too low With fuel bowl removed and carburetor inverted the exposed surface of float must be parallel with the bowl gasket surface of the carburetor body Idle holes plugged dirt in fuel delivery channels Remove fuel bowl low idle fuel adjusting needle and welch plugs Clean main fuel jet and all passages blow out with compressed air Float level set too high See Remedy 2c Dirt under fuel inlet needle See Remedy 2d Bowl vent plugged Remove fuel bowl and clean bowl vent Blow out with compressed air Float is cracked or damaged Replace float Bowl retaining screw gasket damaged Replace gasket Bowl retaining screw loose Torque screw to specifications Adjustment NOTE Carburetor adjustments should be made only after the engine has warmed up The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The main fuel jet is calibrated at the factory and is not adjustable The idle fuel adjusting needle is also set at the factory and normally does not need adjustment NOTE Engines operating at altitudes above approximately 1830 m 6000 ft may require a special high altitude main jet Refer to High Altitude Operation later in this sec
39. may need an assistant to hold the breaker bar during testing If the engine is mounted in a piece of equipment you may be able to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction 4 Install the adapter into the spark plug hole but do not attach it to the tester at this time 5 Connect an adequate air source to the tester 6 Turn the regulator knob in the increase clockwise direction until the gauge needle is in the yellow set area at the low end of the scale 7 Connect tester quick disconnect to the adapter Note the gauge reading and listen for escaping air at the carburetor intake exhaust outlet and crankcase breather 8 Check your test results against the table below Leakdown Test Results Air escaping from crankcase breather Abee Air escaping from exhaust avstem Air escaping from carburetor ccceceeeeeceeseeeeeeeeeeeeeeseeees Gauge reading in low green zone Gauge reading in moderate yellow zone Gauge reading in high red zone 3 4 EEN Defective rings or worn cylinder walls SEENEN Defective exhaust valve Ee Defective intake valve SE Piston rings and cylinder in good condition re Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement eegen Rings and or cylinder have considerable wear Engine should be reconditioned or
40. mm 1 062 in long use a long 90 mm 3 5 in head bolt If the spacer used is 17 mm 669 in long use a shorter 81 mm 8 1 in head bolt Insert the appropriate head bolt through the spacer and washer and install it in position 5 See Figure 11 44 Install head bolts in the remaining positions Following the sequence in Figure 11 44 torque the bolts to 24 N m 18 ft Ib Then repeat the sequence to a final torque of 48 9 N m 36 ft Ib Figure 11 44 Cylinder Head Fastener Torque Sequence Install the push rods in their original position 4 Rocker Bridge Heads Figure 11 37 a Compress the valve spring and seat the push rods into the sockets under the end of the rocker arms Section 11 Reassembly Heads with Separate Pivots Rocker Arms Figure 11 37 e Non Adjustable Valve Lash Configuration a Seat the push rods into sockets under the end of the rocker arm and align the rocker arms over the valve stems Hold the rocker arm in the position and torque the screws to11 3 N m 100 in Ib See Figure 11 45 mg E 8 e EC D i Figure 11 46 Adjusting Valve Lash d Hold the adjustment nut from turning and tighten the set screw to lock it in position Torque the set screw to 7 3 N m 65 in Ib See Figure 11 47 After tightening verify lash is 07 12 mm 003 005 in readjust if necessary m Figure 11 45 Torquing Rocker Arm Mounting Screws e Adjustable Valve Lash Configurati
41. motor and engine functions and check for corrosion Reconnect and observe if fault occurs again 5 13 Section 5 Fuel System and Governor 2 The stepper motor electronic control unit ECU and oxygen sensor can all be checked with the Kohler Emission Sentry Tester Kohler Part No 12 761 07 S a Separate the plug connector between the electronic control unit ECU and the stepper motor Plug the separated connectors into the mating connectors on the Emission Sentry Tester Connect the single black lead to battery negative or a good ground on the engine unit Turn the key switch on the dash to the run position and push the small toggle switch on the tester to the open position Observe the red LED s for the ECU and the bicolor LED s for the stepper motor The red LED s should flash in sequence the bicolor LED s should alternate colors and you should hear the stepper motor turning Now push the toggle switch to the close position and repeat your observations The red LED s should flash in the reverse sequence the bicolor LED s should again alternate and you should again hear the stepper motor turning If any or all of the red LED s are not flashing the ECU is faulty If the bicolor LED s are not alternating and or the stepper motor is not running the stepper motor is faulty b Allow the toggle switch on the tester to return to the monitor position start the engine and place
42. must be allowed to come to a complete stop before attempting to restart the engine If the starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter Troubleshooting Guide Starting Difficulties 1 Check the specific gravity of battery If low recharge or replace Battery battery as necessary 1 Clean corroded connections and tighten loose connections Wiring 2 Replace wires in poor condition and with frayed or broken insulation Starter Does Not Energize l Starter Switch 1 Bypass the switch or solenoid with a jumper wire If starter cranks or Solenoid normally replace the faulty components Check the specific gravity of battery If low recharge or replace Battery battery as necessary Battery too small must be at least 250 cold cranking amps Check for excessively dirty or worn brushes and commutator Starter Clean using a coarse cloth not emery cloth Energizes Replace brushes if excessively or unevenly worn But Turns Slowly Make sure the clutch or transmission is disengaged or placed in neutral This is especially important on equipment with hydrostatic drive The transmission must be exactly in neutral to prevent resistance which could keep the engine from starting Check for seized engine components such as the bearings connecting rod and piston Transmission or Engine 8 17 Section 8 Electrical System and
43. of the crankshaft and crankcase with engine oil 2 Insert the crankshaft through the flywheel end bearing See Figure 11 4 Install Piston Rings NOTE For detailed piston inspection procedures and piston ring installation procedure refer to Section 10 Internal Components Install Piston to Connecting Rod 1 Assemble the piston to the connecting rod See Figure 11 5 J J ye i d E z Monte aches A Figure 11 5 Installing Piston to Connecting Rod Section 11 Reassembly On CV460 495 models the offset of the connecting rod and cap must be oriented to the left with the part number up The arrow on the piston must point away from the part number See Figure 11 6 and 11 7 Piston Ring Compressor Installed around Piston F Figure 11 6 Connecting Rod Configuration to Piston with the Part Number up 3 Place the ring compressor on the top surface of the crankcase and make certain it is seated down around the entire circumference The FLY arrow on the piston should point toward the flywheel side of the crankcase See Figure 11 9 Use a soft rubber grip hammer handle and tap the piston connecting rod into the bore The first tap should be rather firm so the oil ring moves from the compressor into the bore in one smooth quick motion Otherwise the oil ring rails may spring out and jam between the ring compressor and the top of the bore Figure 11 7 Arrow on Piston Arrow Mus
44. oil 4 Reinstall the oil fill cap dipstick and tighten securely NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Change Oil Filter Replace the oil filter every other oil change every 200 hours of operation A ways use a genuine Kohler oil filter Replace the oil filter as follows 1 Drain the oil from the engine crankcase 2 Remove the oil filter drain plug where applicable located at the base of the oil filter adapter Allow the oil filter to drain 3 Remove the old filter and wipe off the filter adapter Reinstall the oil filter drain plug Torque the drain plug to 7 3 9 0 N m 65 80 in Ib 4 Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material 5 Puta drop of oil on your fingertip and wipe it on the rubber gasket 6 Install the replacement oil filter to the filter adapter Turn the oil filter clockwise until the rubber gasket contacts the filter adapter then tighten the filter an additional 2 3 to 1 turn 7 Fill the crankcase with new oil of the proper type to the F mark on the dipstick 8 Test run the engine to ch
45. pinion 4 Clean the splines on drive shaft thoroughly with solvent Dry the splines thoroughly 5 Apply a small amount of Kohler electric starter drive lubricant Part No 52 357 01 S to the splines The use of other lubricants may cause the drive pinion to stick or bend 6 Apply a small amount of Loctite No 271 to the stop nut threads 8 18 7 Install the drive pinion dust cover spacer anti drift spring stop gear spacer and stop nut Torque the stop nut to 17 0 19 2 N m 150 170 in Ib Reinstall the dust cover Style A bb Dust Cover _ Stop Nut gt gt _7 Stop Gear Spacer Style B Dust De Retaining Ring Spring Retainer es Anti Drift Spring ez Bh Anti Drift Spring Dust Cover Spacer as Dust Cover Spacer Drive Pinion Drive Nut Collar amp Style A Style B Figure 8 16 Inertia Drive Electric Starter Style B Drive Service 1 The rubber dust cover has a molded lip on the inside that snaps into a groove in the dust cover spacer see Figure 8 17 Turn the drive pinion clockwise until it reaches the fully extended position While holding it in the extended position grasp the tip of the dust cover with a pliers or vise grip and pull it free from the spacer Dust Cover C Retainer __Retaining Ri Dust Cover Spacer Pinion Drive Nut Collar Figure 8 17 Drive Components Bonded Inertia Drive Starter 2 Disassemble removal tool 25 761
46. quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating at normal temperatures Pressure in the crankcase normally caused by a clogged or improperly assembled breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with a water manometer or vacuum pressure test gauge See Section 2 Complete instructions are provided with the testers Test the crankcase vacuum with the manometer as follows 1 Insert the rubber stopper into the oil fill hole Be sure the pinch clamp is installed on the hose and use the tapered adapters to connect the hose between the stopper and one of the manometer tubes Leave the other tube open to the atmosphere Check that the water level in the manometer is at the 0 line Make sure the pinch clamp is closed Section 3 Troubleshooting Start the engine and run at no load high idle speed 3200 to 3750 RPM Open the clamp and note the water level in the tube The level in the engine side should be a m
47. replaced CV11 16 CV460 465 CV490 495 Section 4 Air Cleaner and Air Intake System Air Cleaner These engines are equipped with a replaceable high density paper air cleaner element and most also have the optional oiled foam precleaner which surrounds the paper element Two basic types of air cleaners are used The original configuration is shown in Figure 4 1 and the later configuration in Figure 4 2 On the original style air is drawn through a duct from the blower housing and from the outside slot The later type uses a flat base plate with the enclosure provided by the cover Air Cleaner Cover Knob Air Cleaner Cover Optional Foam Precleaner Wing nut S Covered Air a Cleaner Element Bushing Base z Ca Figure 4 1 Original Air Cleaner Assembly Exploded View Air Duct Knob Part a of Cover S Air Cleaner Cover ee Optional Foam Precleaner Paper Element Extra Capacity Inner Air Cleaner Seal Air Cleaner Oo Base Seal Open Base Closed Base Figure 4 2 Later Style Air Cleaner Assemblies Exploded View 4 1 Section 4 Air Cleaner and Air Intake System On these air is drawn in around the bottom of the cover or from the blower housing rather than from slots The flat base allows debris to be brushed away before the paper element is removed All types can use either the standard size element or a hi
48. self discharge the battery Self discharging happens rapidly when moisture is present 3 Wash the cables terminals and external surfaces with a baking soda and water solution Rinse thoroughly with clear water NOTE Do not allow the baking soda solution to enter the cells as this will destroy the electrolyte Battery Test Test the battery voltage by connecting DC voltmeter across the battery terminals crank the engine If the battery drops below 9 volts while cranking the battery is discharged or faulty Refer to Figure 8 8 po Voltmeter Battery Figure 8 8 Checking Battery Voltage Electrical Systems Wiring Diagrams and Battery Charging Systems Most engines are equipped with 15 amp regulated battery charging systems Some have 3 amp unregulated systems with optional 70 watt lighting circuit Refer to the following wiring diagrams and troubleshooting guides to test and service system NOTE Observe the following guidelines to prevent damage to the electrical system and componenis Section 8 Electrical System and Components Lighting Lead Yellow Sas i ae Lighting Stator a Charging l Lead Black Figure 8 9 3 amp 70 Watt Stator 1 Diode Make sure the battery polarity is correct A negative ground system is used Disconnect the battery cables negative cable first before doing electric welding on the equipment powered by the engine Prevent the stator AC le
49. the cooling fan Some engines have additional push on retaining clips on three of the knobs to prevent the screen from working loose 9 9 Section 9 Disassembly 1 Check if the extra retaining clips are present If so cut the clips so they can be removed and discard Mark the tops of the knobs where they were located Order 3 new clips Part No 24 018 03 S for installation during reassembly 2 Remove the screen by unsnapping it from the fan See Figure 9 32 7v Unsnap Grass Screen from Fan a a a Figure 9 32 Removing Plastic Grass Screen 3 Remove the flywheel from the crankshaft using a puller See Figure 9 33 NOTE Always use a puller to remove the flywheel from the crankshaft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged Figure 9 33 Removing Flywheel with a Puller 4 Remove the four hex flange screws spacers and fan from flywheel See Figure 9 34 Later engines will have shoulder screws and no spacers 9 10 Hex Flange Screws 4 Spacers 4 A Flywheel Figure 9 34 Removing Fan from Flywheel Remove the Stator and Wiring Harness 1 Remove the stator leads from connector body 2 Remove the hex flange screw and clip securing the stator leads to the crankcase See Figure 9 35 3 Remove the hex flange screw and clip securing the kill lead to the crankcase Remove the four hex socket head screws and stator crew and
50. the throttle between midrange and fast Observe the LED s on the tester The red and bicolor LED s should flash as in the previous test The green LED oxygen sensor will be off initially unless the muffler is still hot from prior running As the oxygen sensor reaches operating temperature the green LED should begin to flash on and off If it stays on or off or the interval between flashes is more than 25 30 seconds the oxygen sensor could be faulty or the load adjusting screw in the fuel metering valve may be stuck or binding Proceed to step 3 3 Remove the stepper motor fuel metering valve assembly from the engine Remove the four small socket head screws and separate the fuel metering valve from the stepper motor Try to turn the load adjusting screw with the blade of a small screwdriver see inset in Figure 5 17 If the screw turns freely and easily the oxygen sensor was faulty step 2b 5 14 If the screw is stuck or binding remove it from the valve body clean the threads with solvent and reinstall Check it again for binding Do not use any type of lubricant on the threads of the load adjusting screw NOTE If the oxygen sensor is removed from the exhaust manifold for any reason a high temperature anti seize compound Loctite No 767 should be applied to the threads A new replacement sensor already has a dry anti seize compound on the threads additional compound is not required 4 If the fault circuit
51. while 7 159 mm 0 2819 in is the maximum allowed on the exhaust guide The guides are not removable but can be reamed 0 25 mm 0 010 in oversize with Tool No KO1026 Valves with 0 25 mm oversize stems must then be used If the guides are within limits but the valve stems are worn beyond limits replace with new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into the cylinder head The inserts are not replaceable on the engines but can be reconditioned if not too badly pitted or distorted If cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used A typical cutter is shown in Figure 10 6 The final cut should be made with an 89 cutter as specified for the valve seat angle in Figure 10 5 With the proper 45 valve face angle as specified in Figure 10 4 and the valve seat cut properly 44 5 as measured from centerline when cut 89 this would result in the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of valve face and seat 10 8 Figure 10 6 Typical Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provide fit Use a hand valve grinder with suction cup for final lapping Lightly coat valve face with fine grade of grinding compound then rotate valv
52. 030 in Thread Size 14 mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in Spark Plug Service Every 200 hours of operation remove the spark plug check its condition and reset the gap or replace with a new plug as necessary 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine Due to the deep recess around the spark plug blowing out the cavity with compressed air is usually the most effective method for cleaning 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable See figures on page 8 2 NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap using a wire feeler gauge Adjust the gap by carefully bending the ground electrode See Figure 8 1 Wire Gauge Ground Electrode Figure 8 1 Servicing Spark Plug 8 1 Section 8 Electrical System and Components 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 24 4 29 8 N m 18 22 ft Ib Inspection Inspect the spark plug as soon as it is removed from the cylinder head The deposits on the tip are an indication of the general condition of the piston rings valves and carburetor Normal and fouled plugs are shown in the following photos Normal A plug taken from an engine operatin
53. 1 Install the gasket muffler and hex flange nuts to the exhaust port studs Leave the nuts slightly loose See Figure 11 71 Start the two hex flange screws that fasten the muffler to the bracket See Figure 11 72 dex Flange Nuts Muffler 6S m Figure 11 71 Install Muffler 2 Torque the hex flange nuts to 24 4 N m 216 in Ib Tighten the hex flange screws securely Reassembly Figure 11 72 Installing Muffler Prepare the Engine for Operation The engine is now completely reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is tightened securely 2 Make sure the oil drain plugs Oil Sentry pressure switch if So equipped and a new oil filter are installed 3 Fill the crankcase with the correct amount weight and type of oil Refer to oil recommendations and procedures in the Safety and General Information and Lubrication System sections 4 Adjust the carburetor idle fuel needle or idle speed adjusting screw as necessary Refer to the Fuel System and Governor section Section 11 Before starting the engine turn the engine over slowly by hand If it can be turned over completely and compression is noted the engine can be test run If however it cannot be turned over completely locks up at some point return the piston to TDC between the intake and exhaust strokes and wait ten minutes to a
54. 1 Test all the segments Continuity must exist between all or the armature is bad Insulation Figure 8 51 Checking Armature 3 Check for continuity between the armature coil segments and the commutator segments See Figure 8 51 There should be no continuity If continuity exists between any two the armature is bad 4 Check the armature windings insulation for shorting Shift Fork Check that the shift fork is complete and the pivot and contact areas are not excessively worn cracked or broken 8 32 Brush Replacement The brushes and springs are serviced as a set 4 Use Brush and Spring Kit Kohler Part No 25 221 01 S if replacement is necessary 1 Perform steps 1 5 in Starter Disassembly 2 Remove the two screws securing the brush holder assembly to the end cap plate Note the orientation for reassembly later See Figure 8 52 Discard the old brush holder assembly P we Ps Figure 8 52 Removing Brush Holder 3 Clean the component parts as required 4 The new brushes and springs come preassembled in a brush holder with a protective sleeve that will also serve as an installation tool See Figure 8 53 Figure 8 53 Service Brush Kit 5 Perform Steps 10 13 in the Starter Reassembly sequence Installation must be done after the armature drive lever and frame are installed if the starter has been disassembled Section 8 Electrical System and Components Starter Servi
55. 14 7 volts or less the charging system is OK The battery is unable to hold a charge Service battery or replace as necessary If voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator Section 8 Electrical System and Components Electric Starters NOTE If the starter does not crank the engine shut Some engines in this series use inertia drive starting off the starter immediately Do not make motors while others use solenoid shift type The inertia further attempts to start the engine until the drive types are covered first and the solenoid shift condition is corrected type is covered starting on page 8 23 NOTE Do not drop the starter or strike the starter Starting Motor Precautions frame Doing so can damage the starter NOTE Do not crank the engine continuously for more than 10 seconds at atime Ifthe engine Starter Removal and Installation does not start allow a 60 second cool down Refer to the Disassembly and Reassembly period between starting attempts Failure Sections for starter removal and installation to follow these guidelines can burn out the procedures starter motor Inertia Drive Electric Starters NOTE If the engine develops sufficient speed to This subsection covers the operation troubleshooting disengage the inertia drive starter but does and repair of the inertia drive permanent magnet not keep running a false start the engine electric starters rotation
56. 18 S 3 Again referring to Figure 8 17 grasp the spring retainer and push it toward the starter compressing the anti drift soring and exposing the retaining ring 4 Holding the spring retainer in the retracted position assemble the inner halves of the removal tool around the armature shaft with the retaining ring in the inner groove see Figure 8 18 Slide the collar over the inner halves to hold them in position Section 8 Electrical System and Components Figure 8 18 Assembling Inner Half of Tool Around Armature Shaft and Retaining Ring 5 Thread the center screw into the removal tool until you feel resistance Use a wrench 1 1 8 or adjustable to hold the base of the removal tool Use another wrench or socket 1 2 or 13 mm to turn the center screw clockwise see Figure 8 19 The resistance against the center screw will tell you when the retaining ring has popped out of the groove in the armature shaft Figure 8 19 Holding Tool and Turning Center Screw Clockwise to Remove Retaining Ring 6 Remove the drive components from the armature shaft paying attention to the sequence If the splines are dirty clean them with solvent 7 The splines should have a light film of lubricant Relubricate as necessary with Kohler bendix starter lubricant Part No 52 357 01 S Reinstall or replace the drive components assembling them in the same sequence as they were removed 8 19 Section 8 Electrical
57. 4 Install the brush holder tool to keep the brushes in the pockets of the commutator end cap 5 Align the match marks on the commutator end cap and starter frame Hold the drive end and commutator end caps firmly to the starter frame Remove the brush holder tool For Style B Commutator End Caps 4a Ifthe brush assembly is not being replaced position the brushes in their pockets in the carrier move them to the retracted position and install carton staples to retain them See Figure 8 24 5a Align the terminal stud block with the notch in the starter frame and slide the brush carrier assembly into the frame The commutator will push the carton staples out as the brush assembly is inserted Position the end cap over the brush assembly so the holes for the thru bolts are aligned with those in the brush carrier 8 21 Section 8 Electrical System and Components 6 Install the thru bolts and tighten securely 7 Lubricate the drive shaft with Kohler bendix Starter drive lubricant Part No 52 357 01 S Install the drive components following the instructions for servicing the drive Figure 8 24 Style B Commutator End Cap with Brushes 110 Volt AC Starter Some engines on floor care equipment are equipped with 110 volt UL approved starters See Figure 8 25 These starters have no serviceable components If the starter is damaged worn or faulty the entire starter motor must be replaced To Pe a Do To
58. 7 35 63 mm 45 1 5 mm 6 982 7 000 mm 33 987 34 013 mm 6 5 mm 7 033 7 058 mm 31 37 31 63 mm 45 1 5 mm 6 970 6 988 mm Section 10 Inspection and Reconditioning Normal Even after long hours of operation a valve Leakage A poor grind on face or seat of valve will can be reconditioned and reused if the face and allow leakage resulting in a burned valve on one side margin are in good shape If a valve is worn to where only the margin is less than 1 32 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be Coking Coking is normal on intake valves and is not replaced Note the warped head margin damaged harmful If the seat is good the valve could be reused and too narrow These conditions could be attributed after cleaning to excessive hours or a combination of poor operating conditions 10 6 Excessive Combustion Temperatures The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture Gum Gum deposits usually result from using stale gasoline This condition is often noted in applications where fuel is not treated with stabilizer or drained out of tank during the off season Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition Section 10 Inspection and Recondit
59. Carburetor portions of the carburetor this section b Crank the engine several times and observe flow If fuel does not flow from the line check for clogged fuel line If the fuel line is unobstructed the fuel pump is faulty and must be replaced Fuel Filter Some engines are equipped with an in line fuel filter Outlet Check Valve Visually inspect the filter periodically and replace when dirty with a genuine Kohler filter Camshaft Fuel Pump Some engines are equipped with an optional mechanical fuel pump The fuel pump body is constructed of nylon The nylon body insulates the fuel from the engine crankcase This prevents the fuel from vaporizing inside the C2 Fuel Pump pump Lever Operation The mechanical pump is operated by a lever which Diaphragm rides on the engine camshaft The lever transmits a Inlet Check Valve pumping action to the diaphragm inside the pump body On the downward stroke of the diaphragm fuel is drawn in through the inlet check valve On the Figure 5 1 Cutaway Typical Fuel Pump upward stroke of the diaphragm fuel is forced out through the outlet check valve See Figure 5 1 5 2 Repair Nylon bodied fuel pumps are not serviceable and must be replaced when faulty Replacement pumps are available in kits that include the pump and mounting gasket Removal 1 Disconnect the fuel lines from the inlet and outlet fittings of the pump 2 Remove the hex flange screws fuel pump
60. Components Operation Inertia Drive Starters When power is applied to the starter the armature rotates As the armature rotates the drive pinion moves out on the splined drive shaft and into mesh with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts the flywheel rotates faster than the starter armature and drive pinion This moves the drive pinion out of mesh with the ring gear and into the retracted position When power is removed from the starter the armature stops rotating and the drive pinion is held in the retracted position by the anti drift spring Starter Drive Service Every 500 hours of operation or annually whichever occurs first clean and lubricate the splines on the starter drive shaft If the drive pinion is worn or has chipped or broken teeth it must be replaced See Figure 8 16 It is not necessary to completely disassemble the starter to service the drive components Style A Drive Service 1 Remove the starter from the engine and remove the dust cover 2 Hold the drive pinion in a vice with soft jaws when removing and installing the stop nut The armature will rotate with the nut until the drive pinion stops against internal spacers NOTE Do not overtighten the vise as this can distort the drive pinion 3 Remove the stop nut stop gear spacers anti drift spring dust cover spacer and drive
61. Engine Starts But Does Not Keep Running 1 Restricted fuel tank cap vent 2 Dirt or water in the fuel system 3 Faulty choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground 5 Faulty carburetor 6 Faulty cylinder head gasket Engine Starts Hard PTO drive is engaged Dirt or water in the fuel system Clogged fuel line Loose or faulty wires or connections Faulty choke or throttle controls Faulty spark plug Low compression Faulty ACR mechanism So ors Se NS Engine Will Not Crank Se ee En PTO drive is engaged Battery if equipped is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch or ignition switch Faulty electric starter if equipped Retractable starter not engaging in drive cup Seized internal engine components Engine Runs But Misses Dirt or water in the fuel system Spark plug lead disconnected Loose wires or connections that intermittently short the kill terminal of ignition module to ground Engine overheated Faulty ignition module Engine Will Not Idle e E en Se De Restricted fuel tank cap vent Dirt or water in the fuel system Faulty spark plug Idle fuel adjusting needle improperly set Idle speed adjusting screw improperly set Low compression Stale fuel and or gum in carburetor Engine Overheats 1 oe Air intake grass screen cooling fins
62. Information Crankshaft ENG SR 0 0575 0 4925 mm 0 0022 0 0193 in End Play thrust bearing With sbums 0 050 0 530 mm 0 0020 0 0209 in Crankshaft Bore in Crankcase I D KI 44 965 44 990 mm 1 7702 1 7712 in Max Wear Ela E 44 9758 45 0012 mm 1 7707 1 7717 in Crankshaft Bore in Crankcase Running Clearance Kl 0 0300 0 0770 mm 0 0011 0 0030 in Crankshaft Bore in Oil Pan I D KI 41 965 42 003 mm 1 6521 1 6536 in Max Wear EL DE 41 9760 42 0141 mm 1 6526 1 6541 in Crankshaft Bore in Oil Pan Running Clearance KI 0 0300 0 0880 mm 0 0011 0 0034 in Flywheel End Main Bearing Journal OD EE 44 913 44 935 mm 1 7682 1 7691 in OD y Max Wear IEMA E 44 84 mm 1 765 in Ke le 0 022 mm 0 0009 in Max AOU OF RO Die Le WE 0 025 mm 0 0010 in Oil Pan End Main Bearing Journal RE 41 915 41 935 mm 1 6502 1 6510 in O D Max Wear E EEN 41 86 mm 1 648 in Mac e 0 020 mm 0 0008 in Max AT sO FPO NG WEE 0 025 mm 0 0010 in Connecting Rod Journal OD NOW eer E E 38 958 30 970 mm 1 5338 1 5343 in O D Max Wear E nn E 38 94 mm 1 5328 in IEG TE e E E EE 0 012 mm 0 0005 in WAX COUT Ol PO in Le ME 0 025 mm 0 0010 in Crankshaft T I R PTO End Crank in ENGNG sczissccsdoucsuaceserecsesansceteemscdsdastivadesssiancessuaeands 0 30 mm 0 012 in Entire Crank in KE E el 0 10 mm 0 0039 in Cylinder Bore Cylinder Bore I D New CV11 14 CNAGO ADb EEN 87 000 87 025 mm 3 4252 3 4262 in CV15 EE Eege 90 000 90
63. It also extends the oil change interval and cools the oil 6 4 Oil Sentry Some engines are equipped with an optional Oil Sentry oil pressure monitor If the oil pressure gets low Oil Sentry will either shut off the engine or activate a warning signal depending on the application Operation The pressure switch is designed to break contact as the oil pressure increases and make contact as the oil pressure decreases At oil pressure above approximately 2 to 5 psi the switch contacts open At oil pressures below approximately 2 to 5 psi the switch contacts close On stationary or unattended applications pumps generators etc the pressure switch can be used to ground the ignition module to stop the engine On vehicular applications lawn tractors mowers etc the pressure switch can be used to activate a low oil warning light NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the F mark on the dipstick This includes engines equipped with Oil Sentry Installation The pressure switch is installed in the oil filter adapter in one of the main oil galleries of the oil pan See Figure 6 10 On engines not equipped with Oil Sentry the installation hole is sealed with a 1 8 27 N P T F pipe plug Figure 6 10 Oil Sentry Pressure Switch NOTE Some engines use adapter without oil drain plugs or provision for Oil Sentry To install the Oil Sentry
64. SERVICE MANUAL KOHLER Command CV11 16 CV460 465 CV490 495 VERTICAL CRANKSHAFT KOHLER ENGINES Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 Inspection and Reconditioning Contents Safety and General Information ccccccssseeeseseeeeeeneescenneeseenseeneenseesensseseonseesees Special COONS sgcecdacegstinvecaneasasansacanvessincetaatacceseudawnnsuvcaneadewsanneeysaeenacatecsaiwacesveunnavecasnants MPOUDICSMOOUNG H Air Cleaner and Air Intake System Fuel System and Governor Lubrication System Retractable Starter Electrical System and Components Disassembly SECHON Lis VC AS SO III EE Section 1 CV11 16 CV460 465 CV490 495 Safety and General Information Safety Precautions To insure safe operations please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning Is ignored A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note i
65. Section 1 Safety and General Information Periodic Maintenance A WARNING Accidental Starts ER Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up e Fill fuel tank Section 5 Daily or Before Check oil level Section 6 Starting Engine Check air cleaner for dirty loose or damaged parts Section 4 e Check air intake and cooling areas clean as necessary Section 4 Every 25 Hours Service precleaner element e j 1 Every Replace air cleaner element Section 4 100 Hours e Change oil Section 6 e Remove cooling shrouds and clean cooling areas Section 4 Every e Change oil filter Section 6 200 Hours e Check spark plug condition and gap Section 8 Annually or e Have bendix starter drive serviced Section 8 Every e Have solenoid shift starter disassembled and cleaned Section 8 500 Hours Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service Not necessary on Delco Starters Storage To empty the system run the engine until the tank If t
66. Starter Service Kit Used to service all electric starters including solenoid shift KO3226 Electric Starter Service Kit Used to remove and reinstall drive retainers on most inertia drive starters KO1049 Rectifier Regulator Tester Used for testing rectifier regulators KO3221 Spark Advance Module Tester Used to test the SAM on engines with Smart Spark KO3222 Vacuum Pressure Tester Used like the water manometer but easier to operate transport and maintain KO3223 Spanner Wrench Used for installing push rods or rotating crankshaft OEM6200 Engine Analysis Kit Used for testing running conditions of Kohler engines in applications KO1000A 2 2 Special Tools You Can Make Flywheel Holding Tool Flywheel removal and reinstallation becomes a snap using a handy holding tool you can make out of a piece of an old junk flywheel ring gear as shown in Figure 2 1 Using an abrasive cut off wheel cut out a six tooth segment of the ring gear as shown Grind off any burrs or sharp edges The segment can be used in place of a strap wrench Invert the segment and place it between the ignition module bosses on the crankcase so the tool teeth engage the ring gear teeth on the flywheel The bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 1 Flywheel Holding Tool Section 2 Special Tools Rocker Arm Crankshaft Tool If you don t have a spanner wrench to lift the rocker
67. System and Components Retaining Ring Installation 1 Position the retaining ring in the groove in one of the inner halves Assemble the other half over the top and slide on the outer collar 2 Be certain the drive components are installed in correct sequence onto the armature shaft 3 Slip the tool over the end of the armature shaft so the retaining ring inside is resting on the end of the shaft Hold the tool with one hand exerting slight pressure toward the starter Tap the top of the tool with a hammer until you feel the retaining ring snap into the groove Disassemble and remove the tool 4 Squeeze the retaining ring with a pliers to compress it into the groove 5 Assemble the inner halves with the larger cavity around the spring retainer see Figure 8 20 Slide the collar over them and thread the center screw in until resistance is felt Figure 8 20 Assembling Larger Inner Half Around Spring Retainer 6 Hold the base of the tool with a 1 1 8 wrench and turn the center screw clockwise with a 1 2 or 13 mm wrench to draw the spring retainer up around the retaining ring Stop turning when resistance increases Disassemble and remove the tool 7 Reinstall the dust cover Starter Disassembly 1 Remove the drive components following the instructions for servicing the drive 8 20 T Locate the small raised line on the edge of the drive end cap On starters with Style A commutator end caps it will be
68. ace 2 Install the oil fill tube into the hole in the crankcase See Figure 11 58 Figure 11 58 Installing Oil Fill Tube 3 Secure the oil fill tube to the crankcase with the hex flange screw Install Rectifier Regulator If So Equipped 1 Install the rectifier regulator including the ground lead if used and secure it with the two mounting screws See Figure 11 59 2 Be sure the B red lead is installed in the connector and plug the connector into the rectifier regulator Mounting Screws and Washers i we Regulator Connector 7 Ground L k i Figure 11 59 Installing Rectifier Regulator not on all models Install Fuel Pump If So Equipped 1 Install the rubber line and two hose clamps to the fuel pump end of the metal fuel line Secure the rubber fuel line to the steel fuel line with one of the clamps See Figure 11 60 V hb 1 Pump Outlet Fuel Line y Hex Flange Screws Gasket T Figure 11 60 Installing Fuel Pump 2 Install the gasket fuel pump and two hex flange screws Torque the screws as follows Into new as cast hole 9 0 N m 80 in Ib Into used hole 4 2 5 1 N m 37 45 in Ib 3 Install the opposite end of the rubber line to the outlet fitting of the fuel pump Secure the fuel line to the outlet fitting with the other hose clamp Section 11 Reassembly Install Carburetor and External Governor Components 1
69. ads from touching or shorting while the engine is running This could damage the stator 8 9 Section 8 Electrical System and Components Ground To Kill Lead White Ignition S Blue Diode Module B Red 3 7 i Key Switch Black EEN l l l L Flywheel Stator Optional Optional We nue Yellow Oil Sentry Optional m Switch princes gt Opti 170 Watt S ae sf Optional Indicator puona a d Oil Light SS Lighting Stator Lj S Senitry Le es z P Safety Switch Switch Solenoid Shutdown 12 V Battery Starter L L J Figure 8 10 CV11 15 CV460 465 CV490 495 3 amp Unregulated Battery Charging System Ignition Module Fuel Yellow Solenoid Black reen Optional Bendix EC Starter to ew ere were enna nn cose ern eernenwannnsecsccconenoene O O Figure 8 11 CV16 3 amp Unregulated Battery Charging System 8 10 Section 8 Electrical System and Components Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE Zero ohmmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3000 RPM no load Battery must be fully charged Conclusion 1 With engine running at 3000 RPM 1 If voltage is more than 12 5 volts measure voltage across battery terminals charging system is OK using a DC voltmeter If voltage is 12 5 volts or less the stator or diode are probably fa
70. all and tighten the two thru bolts 13 Make sure the dust cover is in place on the Figure 8 32 Tool on end of Armature solenoid Install solenoid engaging the plunger end with the yoke of the drive lever Check by 10 Carefully slide the frame with the brush plate pulling solenoid towards the rear Mount the assembly down over the tool and onto armature solenoid to the starter using the two hex flange and drive end cap aligning the cutout with lever nuts Tighten securely See Figure 8 35 section on top The rubber insulating grommet should also be up See Figure 8 33 NOTE Maintain pressure on the insulator while installing so the springs do not come out 8 27 Section 8 Electrical System and Components Starter Disassembly 1 Remove the hex nut and disconnect the positive brush lead bracket from the solenoid terminal 2 Remove the three screws securing the solenoid to the starter Remove the solenoid and plunger spring from the drive end cap See Figures 8 38 and 8 39 Some solenoids are fastened with external Torx head screws P Figure 8 35 Installing Thru Bolts 14 Connect the braided brush lead to lower main solenoid terminal and secure with the hex flange nut See Figure 8 36 Figure 8 39 Solenoid Removed From Starter Figure 8 37 8 28 Section 8 Electrical System and Components 3 Lift and unhook the plunger assembly from the drive lever Remove the gasket from
71. an to the flywheel using the spacers and hex flange screws or shoulder screws See Figure 11 28 Torque the hex flange screws to 9 9 N m 88 in Ib On electric start models with the domed fan proceed through step 4 before reattaching the fan Hex Flange Screws 4 Spacers 4 Figure 11 28 Installing Fan to Flywheel 3 Place the flywheel over the keyway crankshaift Retractable Starter Models Install grass screen drive cup plain washer flat side towards the drive cup and the hex flange screw See Figure 11 29 Lac Plain Washer y _ K Ss inl Flange 7 SCrew Ara Starter Models Electric Start Models Install the plain washer and the hex flange screw See Figure 11 30 11 10 j i j gl k 4 j L T G WH 284 Ei Ka Figure 11 30 Installing Flywheel Retaining Screw and Washer Electric Start Models 4 Hold the flywheel with a strap wrench or holding tool see Section 2 and torque the hex flange screw to 66 4 N m 49 ft Ib See Figures 11 31 and 11 32 NOTE Always use a flywheel strap wrench or flywheel holding tool to hold the flywheel when tightening the flywheel fastener Do not use any type of bar or wedge between the cooling fins or flywheel ring gear as these parts could become cracked or damaged Torque Wrench Retractable Starter Models Section 11 Reassembly Figure 11 34 Push Rod Tool NOTE Another tool for bleeding may
72. and gasket 3 If necessary remove the fittings from the pump body Installation 1 Fittings Apply a small amount of Permatex Aviation Perm A Gasket or equivalent gasoline resistant thread sealant to the threads of the fittings Turn the fittings into the pump 5 full turns continue turning the fittings in the same direction until the desired position is reached 2 Install new gasket fuel pump and hex flange screws NOTE Make sure the fuel pump lever is positioned to the right of the camshaft when looking at fuel pump mounting pad Damage to the fuel pump and severe engine damage could result if the lever is positioned to the left of the camshaft Co Hex Flange Screw 2 Gasket Fuel Fittings Figure 5 2 Installing Fuel Pump Section 5 Fuel System and Governor 3 Torque the hex flange screws as follows Into new as cast hole 9 0 N m 80 in Ib Into used hole 4 2 5 1 N m 37 45 in Ib 4 Connect the fuel lines to the inlet and outlet fittings Carburetor Gasoline These engines are equipped with one of two basic types of fixed main jet carburetors Walbro or Nikki See Figure 5 3 Walbro carburetors have a low idle speed screw and a low idle fuel adjusting needle Nikki carburetors only have a low idle speed screw Certified carburetors will have fixed idle fuel or a limiter cap on the idle fuel adjusting needle Low Idle Speed Adjustment Screw Low Idle Fuel Bas Adj
73. and precleaner Secure the element with 11 66 the wing nut See Figure 11 67 TF eee Governor Air Duct Lever Knob Part f Cover ae S OQ Air Cleaner S See a AS j l E C D i e F g i i ea V d A E gf Inner Air Cleaner Seal Air Cleaner a Base Seal ee ee ee Open Base Closed Base Original Design Later Design Figure 11 67 Air Cleaner Details 11 21 Section 11 Reassembly 6 Install the air cleaner cover and tighten the knob securely See Figure 11 68 Figure 11 68 Installing Air Cleaner Cover Install Electric Starter Electric Starter Bendix Drive or Solenoid Shift 1 Install the starter and secure with the two hex flange screws If there were spacers on the mounting screws be sure they are reinstalled Torque the screws to 15 3 N m 135 in Ib See Figure 11 69 Terminal i g Figure 11 69 Installing Bendix Drive Starter 2 Connect the starter leads to the terminals on the electric starter and or solenoid Install Retractable Starter 1 Install the retractable starter and five hex flange screws to blower housing Leave the screws slightly loose 11 22 2 Pull the starter handle out until the pawls engage in the drive cup Hold the handle in this position and tighten the screws securely See Figure 11 70 Figure 11 70 Installing Retractable Starter Install Muffler
74. ase and install the twelve hex flange screws Tighten the screws hand tight 4 Torque the fasteners in the sequence shown in Figure 11 22 to 24 4 N m 216 in Ib gt i i 4 H H he V q PZ Oil ickup b s CH _wocreen Figure 11 20 Installing Oil Pickup Components eat Install Oil Pan to Crankcase RTV silicone sealant is used as a gasket between the oil pan and crankcase Refer to page 2 1 for the approved sealant NOTE Always use fresh sealant Using outdated Figure 11 22 Oil Pan Fastener Torque Sequence sealant can result in leakage 1 Prepare the sealing surfaces of the crankcase and oil pan as directed in Service Bulletin 252 NOTE Do not scrape the surfaces when cleaning as this will damage the surfaces This could result in leaks The use of a gasket removing solvent is recommended 2 Apply a 1 16 bead of sealant to the oil pan as shown in Figure 11 21 Apply a second bead to the section between point A and point B Point B 7 Appearance and Width of Flange May Vary Between Points A amp B Apply Double Bead of RTV Sealant Between Points A amp Di B Point A Figure 11 21 Oil Pan Sealant Pattern Section 11 Reassembly Install Oil Pump 1 Lubricate the oil pump cavity and oil pump rotors with engine oil Install the outer and inner oil pump rotors See Figure 11 23 Figure 11 23 Installing Oil Pump Gears and O Ring 2 3 11
75. be made from an old tappet and ball bearing Start Models welded together See Figure 11 35 5 Install the grass screen onto the fan assembly electric start models See Figure 11 33 If the engine originally had extra retainers on three of the snap knobs you were instructed to mark those knobs during the disassembly procedure Install new retainers Part No 24 018 03 S on the opposite three knobs from where the original retainers were located Grass Screen Figure 11 35 Tappet and Ball Bearing Welded Together All Head Configurations 1 Lightly lubricate the bottoms of the lifters with oil and install into their respective bores See Figure 11 36 Do not prime the lifters NOTE Hydraulic lifters should always be installed in the same position as before disassembly Figure 11 33 Installing Grass Screen Electric Start Models Install Hydraulic Lifters Adjustable Valve Lash Configuration Only 1 Bleed the hydraulic lifters of internal oil so the plunger in the lifter can be depressed by hand Use an old cutoff push rod mounted in a drill press arbor press or vice and slowly apply Valve Lifter pressure two or three times to bleed the lifters See Figure 11 34 If a vice is used in bleeding Intake the lifters be sure to install protective coverings Valve Lifter over the jaws to avoid damage to the base of the Figure 11 36 Installing Hydraulic Lifters Camshaft lifter s Removed to Show Lifter
76. be used Refer to Figure 10 9 Top Compression Ring to Groove Side Clearance CV11 14 CV460 465 0 034 0 100 mm 0 0013 0 00339 in CV15 16 CV490 495 0 060 0 105 mm 0 0024 0 0041 in Middle Compression Ring to Groove Side Clearance CV11 14 CV460 465 0 040 0 080 mm 0 0016 0 0031 in CV15 16 CV490 495 0 040 0 085 mm 0 0016 0 0033 in 10 10 Figure 10 9 Measuring Piston Ring Side Clearance Install Piston Rings To install piston rings proceed as follows NOTE Rings must be installed correctly Ring installation instructions are usually included with new ring sets Follow instructions carefully Use a piston ring expander to install rings Install the bottom oil control ring first and the top compression ring last Refer to Figure 10 10 Piston Ring End Gap CH Pip Mark Piston Oil Control Ring Three Piece Figure 10 10 Piston Ring Installation Expander 1 Oil Control Ring Bottom Groove Install the expander and then the rails Make sure the ends of the expander are not overlapped 2 Compression Ring Center Groove Install the center ring using a piston ring installation tool Make sure the pip mark is up and the PINK dykem stripe if present is to the left of the end gap 3 Compression Ring Top Groove Install the top ring using a piston ring installation tool Make sure the pip mark is up and the BLUE dykem stripe if present is to the lef
77. cast hole 4 0 N m 35 in Ib Into used hole Muffler Muffler Retaining Nuts scccntcarssisnncwsvacieonometsirontcs nie teaaaatniesessavatt 24 4 N m 216 in Ib Oil Filter Oil Pan Oil Filt r Leide TEE 10 4 12 7 N m 90 110 in Ib Oil Filter Drain Plug 1 8 NPT Ioroue 7 3 9 0 N m 65 80 in Ib Oil Pan Fastener Toroue 24 4 N m 216 in Ib Oil Sentry Pressure Switch Ioroue 6 8 N m 60 in Ib Oil Pump Cover Fastener Toroue snonnnnnonnnnnnnnnnnnnnnnennnnnnnnne 6 2 N m 55 in lb Into new as cast hole 4 0 N m 35 in Ib Into used hole Piston Piston Rings and Piston Pin Piston to Piston Pin Selective mm 0 006 0 017 mm 0 0002 0 0007 in Piston Pin Bore I D KT 19 006 19 012 mm 0 7483 0 7485 in Max Wear Enn EE 19 025 mm 0 7490 in Piston Pin O D KEE 18 995 19 000 mm 0 7478 0 7480 in Max Wear E un E 18 994 mm 0 74779 in Top Compression Ring to Groove Side Clearance GV11 14 CV460 465 cc cssccsscsssssrsessssussssresnssouseerrensseeues 0 034 0 100 mm 0 0013 0 0039 in CV15 CV16 GV 490 45 NEE 0 060 0 105 mm 0 0023 0 0041 in Middle Compression Ring to Groove Side Clearance GV 11614 CV EEN 0 040 0 080 mm 0 0016 0 0032 in GV 15 GV 16 CV490 495 E 0 040 0 085 mm 0 0015 0 0033 in Oil Control Ring to Groove Side Clearance GV11 14 CV460 465 cc ccssccsscsssserscsssssssenresnsscuseerrensssenes 0 036 0 186 mm 0 0014 0 0073 in CV15 CV16 CV490 495 EE 0 036 0 186 mm 0 0014
78. ce Clean the drive lever and armature shaft Apply Kohler electric starter drive lubricant Part No 52 357 02 S Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the other starter parts for wear or damage as required Starter Reassembly 1 Apply new drive lubricant Kohler Part No 52 357 02 S to the armature shaft splines Install the drive pinion onto the armature shaft 2 Install and assemble the stop collar retainer assembly Figure 8 55 Installing Thrust Washer a Install the stop collar down onto the armature 4 Apply a small amount of oil to the bearing in the shaft with the counter bore recess up PPY g drive end cap and install the armature with the ae drive pinion b Install a new retainer in the larger rear p groove of the armature shaft Squeeze with a 5 SC Lubricate the fork end and center pivot of the pliers to compress it in the groove drive lever with drive lubricant Kohler Part No 52 357 02 S Position the fork end into the space between the captured washer and the rear of the pinion c Slide the stop collar up and lock it into place so the recess surrounds the retainer in the groove If necessary rotate the pinion outward a pions gas SE the retainer 6 Slide the armature into the drive end cap and to help seat the collar around the retainer at the same time seat the drive lever into the housing NOTE Correctly installed the center pivot se
79. ction of the drive lever will be flush or below the machined surface of the housing which receives the backup washer See Figure 8 56 NOTE Always use a new retainer Do not reuse old retainers 3 Install the offset thrust stop washer so the smaller offset of washer faces the retainer collar See Figure 8 55 Figure 8 56 Installing Armature and Pivot Lever 8 33 Section 8 Electrical System and Components 7 Install the backup washer followed by the rubber grommet into the matching recess of the drive end cap The molded recesses in the grommet should be out matching and aligned with those in the end cap See Figure 8 57 Figure 8 59 Installing Thrust Washer 10 Starter reassembly when replacing the Brushes Brush Holder Assembly h kl Figure 8 57 Installing Backup Washer and Grommet a Hold the starter assembly vertically on the end housing and carefully position the assembled brush holder assembly with the supplied protective tube against the end of the commutator armature The mounting screw holes in the metal clips must be up out Slide the brush holder assembly down into place around the commutator and install the positive brush lead grommet in the cutout of the frame See Figure 8 60 Save the protective tube it may be used for future Servicing 8 Install the frame with the small notch forward onto the armature and drive end cap Align the n
80. de screw between the intake and exhaust ports cylinder head push rods and cylinder head 1 Remove the spark plug See Figure 9 26 gasket 9 7 Section 9 Disassembly Exhaust Side Valve 8 SER ar Sprin Valve ee oF Cap i Rocker Arms Rocker Arm Pivot Ball ee Non Adjustable and Breather Reed Figure 9 26 Removing Spark Plug Breather and Rocker Arms Rocker Bridge Head 2 Remove the hex flange screw breather reed Rocker Arm retainer and breather reed 3 Rocker Bridge Heads Figure 9 26 a Remove the rocker shaft from the breather side of head and the rocker arms b Remove the two hex cap screws and the rocker bridge Heads with Separate Pivots Rocker Arms Figure 9 27 Adjustable e Non Adjustable Valve Lash Configurations Figure 9 27 Separate Rocker Arm Pivot Assembly Style Head a Remove the hex flange screws securing the rocker arm pivot assemblies and guide plate 4 Remove the valves if so equipped to the head a Compress the valve springs using a valve e Adjustable Valve Lash Configuration spring compressor See Figure 9 28 a Loosen the set screws and remove the b Remove the keepers valve spring caps valve adjustment nuts on the rocker arm pivot studs springs the retainers or exhaust valve rotator early models only and the intake valve stem b Remove the rocker arm pivot assemblies seal Some engines also have a stem seal on the exhaust valve Remove it
81. der Head 1 Remove the remaining hex flange mounting screws and any loose spacers stamped steel covers from the valve cover Note their placement orientation Remove the valve cover from the cylinder head assembly See Figure 9 23 and 9 24 NOTE The valve cover is sealed to the cylinder head using RTV silicone sealant When removing valve cover use care not to damage the gasket surfaces of cover and cylinder head To break the RTV seal hold a block of wood against one of the flat faces of the valve cover Strike the wood firmly with a mallet If the seal doesnt break loose after 1 or 2 attempts repeat procedure on other side Ka Figure 9 25 Removing Cylinder Head Gasket Disassemble Cylinder Head Valve Cover Two basic styles of heads are used The first style zl i utilizes a rocker bridge configuration as shown in Figure 9 26 The second style contains separate rocker arm assemblies with or without a guide plate and either a non adjustable or adjustable valve lash configuration Variations of this style are shown in Figure 9 27 Components are unique to each head configuration Follow the appropriate procedure based upon the configuration involved Hex Flange Screws NOTE Before disassembly determine the specific Figure 9 23 Removing Valve Cover head configuration involved and mark all valve train components to assure they are 2 Remove the hex flange screws spacer from the reassembled on same si
82. duced No KO1047 Disconnect spark plug the ignition module is OK lead and connect it to the post terminal If visible and audible sparks are not of the tester See Figure 8 3 Connect produced the clip to a good ground not the spark plug a Make sure the engine ignition switch l kill switch or key switch is in the run NOTE To maintain engine speeds position normally obtained during cranking do not remove the engine spark plug Check wires and terminals of ignition module and other components for Hia accidental grounding and damaged Make sure the engine ignition switch insulation Engine kill switch or key switch is in the run If wires and terminals are OK the ignition module is probably faulty Crank the engine and observe the and should be replaced Test module test plug Visible and audible sparks further using an ohmmeter Test 4 should be produced 4 Measure the resistance of module 4 Ifthe resistance is low or 0 ohms the secondary using an ohmmeter see module secondary is shorted Replace the Figures 8 2 and 8 4 module Will position Not Start Zero ohmmeter before testing Connect If the resistance is high or infinity ohms one ohmmeter lead to laminations A the module secondary is open Replace the Connect the other lead to the spark plug module terminal C of high terminal lead With the ohmmeter leads connected in this manner the resistance of secondary should be 7 900 to 18
83. e the plug below the surface of the cavity See Figure 5 13 Tool No KO1017 New Welch Plug Carburetor m l Figure 5 13 Installing Welch Plugs 4 After the plugs are installed seal them with Glyptal or an equivalent sealant Allow the sealant to dry NOTE Ifa commercial sealant is not available fingernail polish can be used Carburetor Reassembly 1 Install the low idle speed adjusting screw and spring 2 If removed during disassembly install the low idle fuel adjusting needle and spring Turn the adjusting needle in clockwise until it bottoms lightly NOTE The tip of the idle fuel adjusting needle is tapered to critical dimensions Damage to the needle and the seat will result if the needle is forced 3 Turn the low idle fuel adjusting needle out counterclockwise 1 turn 5 10 4 Insert the fuel inlet needle into the float Lower the float needle into the carburetor body See Figure 5 14 Install the float shaft A Ki b Figure 5 14 Installing Float and Fuel Inlet Needle 5 Install the bowl gasket fuel bowl bowl retaining screw gasket and bowl retaining screw or fuel solenoid Torque the bowl retaining screw to 5 1 6 2 N m 45 55 in Ib High Altitude Operation When operating the engine at altitudes of 1830 m 6000 ft and above the main fuel mixture tends to get overrich An overrich mixture can cause conditions such as black sooty exhaust smoke misfiring lo
84. e Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Check the cylinder bore wall for scoring In severe cases unburned fuel can cause scuffing and scoring of the cylinder wall It washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is scored worn tapered or out of round resizing is necessary Use an inside micrometer to determine amount of wear refer to the Specifications Tolerances and Special Torque Values in Section 1 then select the nearest suitable oversize of 0 08 mm 0 003 in 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies Replacement pistons are manufactured to precise tolerances It is not necessary to fit the piston to the cylinder Start with the new cylinder bore diameter from Section 1 add the desired oversize dimension and machine the cylinder to that exact size The corresponding oversize piston will then fit the cylinder with the correct running clearance Section 10 Inspection and Reconditioning Boring When ov
85. e and oil 6 Apply a small amount of Loctite No 271 to the threads of the center screw Install the center screw with washer and retainer to the center shaft Torque the screw to 7 4 8 5 N m 65 75 in Ib 7 Tension the spring and install the rope and handle as instructed in steps 6 through 12 under Rope Replacement on page 7 2 8 Install the starter to the engine blower housing CV11 16 CV460 465 CV490 495 Section 8 Electrical System and Components This section covers the operation service and repair of the electrical system and electrical system components Major electrical systems and components covered in this section include the ignition system battery battery charging systems and electric starters A WARNING Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Spark Plug Engine misfire or starting problems are often caused by a spark plug that is in poor condition or has an improper gap setting These engines are equipped with one of the following Spark plugs Type The standard spark plug is a Champion RC12YC Kohler Part No 12 132 02 S A high performance spark plug Champion Premium Gold 2071 used on Pro Series engines Kohler Part No 12 132 06 S is also available Equivalent alternate brand plugs can also be used Gap CV11 15 CV460 465 490 495 1 02 mm 0 040 in CV11 14 LP CV16 0 76 mm 0
86. e of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES ly II mmm 0 20 80 100 a F 20 32 40 60 rr wa 20 10 0 10 20 30 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 40 F Synthetic oils will provide better starting in extreme cold below 10 F Figure 6 1 Viscosity Grades Table NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 2 Sn Figure 6 2 Oil Container Logo Check Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it 3 Unthread and remove the oil fill cap dipstick wipe oil off Reinsert the dipstick into the tube and rest the oil fill cap on the tube Do not thread the cap onto the tube See Figure 6 3 6 1 Section 6 Lubrication System Oil Fill Cap Dipstick ne ch gtt Figure 6 3 Checking Oil Level 4 Remove the dipstick and c
87. e on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Thoroughly clean cylinder head in soap and hot water to remove all traces of grinding compound After drying cylinder head apply a light coating of SAE 10 oil to prevent rusting Valve Stem Seals These engines use valve stem seals on the intake valves and sometimes on the exhaust Always use a new Seal when valves are removed from cylinder head The seals should also be replaced if deteriorated or damaged in any way Never reuse an old seal Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the welding point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is part of the piston assembly if the pin boss or the pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter the combustion chamber where it is burned along with the fuel High oil consumption can also occur wh
88. eat during the first part of the compression stroke The reduced 2 Electric start models can use a starter and battery compression results in an effective compression ratio size that are practical for the applications in which of about 2 1 during cranking these engines are used After starting engine speed increases to over 700 3 ACR eliminates the need for a spark retard RPM and centrifugal force overcomes the force of advance mechanism A spark retard advance the flyweight spring The flyweight moves outward mechanism would be required on engines without pulling the arm of the control pin so it pivots into the ACR to prevent the kickback that would occur run position The control pin no longer has any effect during starting ACR eliminates this kickback on the exhaust valve and the engine operates at full making manual starting safer power 10 1 Section 10 Inspection and Reconditioning 4 The choke control setting is less critical with ACR In the event of flooding excess fuel is blown out the opened exhaust valve and does not hamper starting 5 Engines with ACR start much faster in cold weather than engines without ACR 6 Engines with ACR can be started with spark plugs that are worn or fouled Engines without ACR probably could not be started with those same spark plugs Camshaft Inspection and Service Inspect the gear teeth of the camshaft If the teeth are badly worn chipped or some are
89. eck for leaks Stop the engine allow a minute for the oil to drain down and recheck the level on the dipstick Add more oil as necessary so the oil level is up to but not over the F mark on the dipstick Section 6 Lubrication System Full Pressure Lubrication System Operation This engine uses a full pressure lubrication system This system delivers oil under pressure to the crankshaft camshaft balance shaft and connecting rod bearing surfaces In addition to lubricating the bearing surfaces the lubrication system feeds oil to the hydraulic valve lifters A high efficiency Gerotor oil pump is located in the oil pan and is driven by the balance shaft A pressure relief valve in the oil pan limits the maximum pressure of the system Service The oil pump rotors can be serviced without removing the oil pan Remove the oil pump cover on the PTO side of oil pan to service the rotors The oil pan must be removed to service the oil pickup and oil pressure relief valve See Figures 6 6 through 6 8 Also refer to the Disassembly and Reassembly sections for lubrication system components removal and installation procedures 6 3 Section 6 Lubrication System Oil Pressure Relief Valve Figure 6 8 Oil Pressure Relief Valve Styles Oil Filter These engines are equipped with a full flow oil filter See Figure 6 9 The oil filter helps remove sludge and other combustion by products from the oil
90. ectronic control unit then sends a signal to the stepper motor which adjusts the fuel metering valve thus controlling the amount of fuel entering the engine The air fuel ratio is maintained within a set band under all operating conditions By maintaining the air fuel ratio at peak performance levels maximum efficiency is also realized from the 3 way catalytic converter to further reduce emissions Operating with Emission Sentry The equipment has a 12 volt battery and the engine has an integral electric starter and charging system Starting is accomplished by simply setting the throttle choke control and activating the key switch on the dash panel of the unit When the engine starts a green light emitting diode LED will illuminate to indicate that the Emission Sentry is on It will require a warm up period of about sixty seconds to allow the oxygen sensor to heat up and the fuel metering valve to stabilize When first started the engine will be running rich and may sound rough As the oxygen sensor heats up and the system stabilizes however operation should become progressively smoother After the system has stabilized about 1 minute operation of the equipment can begin Section 5 Fuel System and Governor The oxygen sensor continually monitors the emission levels in the exhaust while the unit is running If the emission levels exceed a predetermined level a fault detection circuit will be activated in the electronic
91. ed during disassembly to the camshaft 2 Install the camshaft end play checking Tool No KO1031 to the crankcase and camshaft Secure the tool to the crankcase with the hex flange screws provided See Figure 11 14 Camshaft End Play Checking Shim S acer Tool 3 y Hex Flange ia Es i Gauge Screws oo a Figure 11 14 Checking Camshaft End Play Section 11 Reassembly 3 Using a flat feeler gauge measure the camshaft end play between the shim spacer and the end play checking tool Camshaft end play should be 0 076 0 127 mm 0 003 0 005 in Not on all models 4 Ifthe camshaft end play is not within the specified range remove the end play checking tool and add remove or replace shims as necessary Several color coded shims are available White 0 69215 0 73025 mm 0 02725 0 02875 in Blue 0 74295 0 78105 mm 0 02925 0 03075 in Red 0 79375 0 83185 mm 0 03125 0 03275 in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gray 0 94615 0 98425 mm 0 03725 0 03875 in Black 0 99695 1 03505 mm 0 03925 0 04075 in 5 Reinstall the end play checking tool and recheck end play 6 Repeat steps 4 and 5 until the end play is within the specified range Install Oil Pressure Relief Valve Early Five Piece Style Oil Pressure Relief Valve 1 Place the relief valve body in the cavity of the oil pan so the relief hole is just above the boss
92. ed or replaced Throttle Lever and Shaft Choke Plate Float Ns Float Shaft C Bowl Gasket Fuel Bowl Bowl Retaining Screw Gasket or cy _ Bowl Retaining Screw Welch Plug Removal Walbro Carburetors In order to clean the idle ports and bowl vent thoroughly remove the welch plugs covering these areas Use Tool No KO1018 and the following procedure to remove the welch plugs See Figure 5 7 1 Pierce the welch plug with the tip of the tool NOTE To prevent damage to the carburetor do not allow the tool to strike the carburetor body 2 Pry out the welch plug with the tip of the tool Do Not Allow Tip to Strike Carburetor Body Pierce Plug with Tip Welch Plug Figure 5 7 Removing Welch Plug Main Fuel Jet Removal The main jet on Walbro carburetors is pressed into the side of the tower portion of the body Removal is not recommended unless a high altitude kit is being installed in which case the removal instructions will be included in the kit The main jet on Nikki carburetors is threaded into the tip of the fuel shut off solenoid It can be removed for inspection or cleaning Fuel Inlet Seat Removal The fuel inlet seat is pressed into the carburetor body do not attempt to remove it If necessary clean it in place with aerosol carburetor cleaner Choke Shaft Removal Non Self Relieving 1 Because the edges of the choke plate are beveled mark the choke plate and carburetor bod
93. efied propane gas system are shown in Figure 5 15 This subsection covers standard systems as shown in Figure 5 15 and engines equipped with the Kohler Emission Sentry System Fuel Recommendations LPG A WARNING Pressurized LPG Fuel tanks are filled under pressure and should be handled with care To prevent tank damage which could endanger the safety of the operator or persons in the area do not drop or drag tanks on any surface Use a hand truck when moving or tilt the tank on its footring in a position slightly off vertical and roll it Avoid personal contact with LPG fuel to prevent frostbite See a physician if frostbite occurs LP Carburetor WF Vacuum Lines XX OLL Ai et Delivery Line i ot Wei Dry Gas Regulator N a Section 5 Fuel System and Governor A WARNING Explosive Fuel LPG is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area LPG fuel consists primarily of propane although the fuel supplier may sometimes mix other gases with propane Fuel tanks must be filled only by persons qualified in the handling of LPG Tanks are filled by weight and should not be overfilled never to more than 80 of total capacity An air soace must be present in the tank to allow fuel
94. efully Use gasket remover or paint remover to remove the old RTV from valve cover cylinder head crankcase and oil pan Do not scrape the surfaces when cleaning as this will damage the surfaces This could result in leaks Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Refer to A Guide to Engine Rebuilding TP 2150 for additional information Measurement Guide TP 2159 A and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR When the engine is stopped the spring returns This engine is equipped with an Automatic the flyweight lever and control pin assembly to the Compression Release ACR mechanism The ACR compression release position ready for the next start lowers compression at cranking speeds to make starting easier Benefits 10 Because of the reduced compression at cranking Operation speeds several important benefits are obtained The ACR mechanism consist of a flyweight spring and pivoting control pin assembly attached to the gear on 1 Manual retractable starting is much easier the camshaft At cranking speeds 700 RPM or lower Without ACR manual starting would be virtually the control pin protrudes above the exhaust cam lobe impossible This pushes the exhaust valve off its s
95. em Air Intake Cooling System Clean Air Intake Cooling Areas To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times Every 100 hours of operation more often under extremely dusty dirty conditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating Air Intake Filter Optional Some engines used under extremely dusty conditions such as floor buffer applications are equipped with a foam air filter which fits over the retractable starter The filter is held in place by velcro studs affixed to the starter cover This filter must be checked daily before each start and frequently during operation It should be serviced whenever wax dust or dirt builds up on its surface If it becomes clogged the engine can not receive sufficient cooling air and will overheat To service peel the filter loose from the velstuds lift the filter and carefully work the recoil starter handle through the hole in filter Clean the filter in soap and warm water rinse squeeze out excess water and allow it to air dry If time will not permit air drying keep a spare filter on hand Kohler Part No 12 050 02
96. emer LO QUC essea a aa r Ni 9 9 N m 88 in Ib Flywheel Retaining Screw Torque sssssssnsreresernrrrenserrrrree n 66 4 N m 49 ft Ib Fuel Pump Fuel Pump Fastener TOrque nnnannnnnannnnnennnnnennnnnnnnnnnnnnenennne 9 0 N m 80 in Ib Into new as cast hole 4 2 5 1 N m 37 45 in lb Into used hole Fuel Pump Pad Cover Fastener Torque ssseseenneenseereeeee 10 7 N m 95 in lb Into new as cast hole 7 3 N m 65 in lb Into used hole Governor Governor Cross Shaft to Crankcase Running Clearance 0 025 0 075 mm 0 0010 0 0030 in Governor Cross Shaft O D VIC 5 975 6 000 mm 0 2352 0 2362 in Max Wear MINA sirra ERE 5 962 mm 0 2347 in Governor Gear Shaft to Governor Gear Running Clearance 0 050 0 160 mm 0 0019 0 0063 in Governor Gear Shaft O D RER 5 990 6 000 mm 0 2358 0 2362 in Max Wear LIMA E 5 977 mm 0 2353 in Ignition Spark Plug Type Champion or eouivalent RC12YC Standard or Premium Gold 2071 Pro Series Spark Plug Gap CV11 15 CV460 465 CNAO0 A0 1 02 mm 0 040 in CV11 14 LE 0 76 mm 0 030 in 1 10 Section 1 Safety and General Information Ignition Cont d Spark Plug Torque cc ccscecsscesccescesseceeeceseceeseesesesseesereseeeeeanees 24 4 29 8 N m 18 22 ft Ib ER Ignition Module Air Gap 0 200 0 300 mm 0 0078 0 0118 in Ignition Module Fastener Torque snsnnnsennnennnnnnnnsennesnnnnnnnnne 6 2 N m 55 in lb Into new as
97. en the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fuels 4 d Overheated or Deteriorated Oil Section 10 Inspection and Reconditioning Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits blocked fins improperly seated valve or wrong spark plug See Figure 10 7 for some common types of piston and ring damage Replacement pistons are available in STD bore size and in 0 08 mm 0 003 in 0 25 mm 0 010 in and 0 50 mm 0 020 in oversizes Replacement pistons include new piston rin
98. en the tabs on the choke plate If the choke plate was attached with screws loosely attach the plate to the shaft Close the choke and center the choke plate in the bore Tighten but do not over tighten the screws Check that the choke moves freely and that the plate does not bind in the bore Choke Shaft Installation Self Relieving Ad warnine Prevent Eye Injury Suitable eye protection safety glasses goggles or face shield should be worn for any procedure involving the use of compressed air punches hammers chisels drills or grinding tools 1 Before installing kit parts thoroughly clean the carburetor body with compressed air 2 Install the new bushing through the new lever and align the slot in the bottom of the lever over the lever stop pin To ensure the proper alignment of the upper bushing and the lower shaft hole use a 3 16 diameter drill blank to align the bushing as it is pressed into the casting 3 Install choke shaft and spring assembly with the lower spring tang installed in the second notch from the right See Figure 5 11 Section 5 Fuel System and Governor Top View Showing Spring Position Bottom of Spring in Position 2 Figure 5 11 Choke Lever with Cap Removed 4 Loosely attach the choke plate to the choke shaft using the two screws provided in the choke repair kit Apply Loctite No 609 to the threads of the choke plate retaining screws Secure these screws ONLY after the choke pla
99. end of the new rope The starter must be disassembled to replace the starter pawls A pawl repair kit is available which 7 Rotate the pulley counterclockwise when viewed includes the following components from pawl side of pulley until the spring is tight Approximately 6 full turns of pulley Pawl Repair Kit Wi Qy 8 Rotate the pulley clockwise until the rope hole Pawl Retainer Center Screw Pawl Dog Spring in pulley is aligned with rope guide bushing of starter housing Brake Spring Starter Pawl Dog Brake Washer Washer NOTE Do not allow the pulley spring to unwind Enlist the aid of a helper if necessary or use a C clamp to hold the pulley in position 7 2 Section 7 Retractable Starter Disassembly 4 Carefully note the positions of the pawls and pawl springs before removing them A CAUTION Spring Under Tension Do not remove the center screw from the starter until Remove the pawls and pawl springs from the the spring tension is released Removing the center starter pulley screw before releasing spring tension or improper starter disassembly can cause the sudden and 5 Rotate the pulley clockwise 2 full turns This will potentially dangerous release of the spring Follow ensure the spring is disengaged from the starter these instructions carefully to ensure personal safety housing and proper starter disassembly Make sure adequate eye and face protection is worn by all persons in the 6 Hold the pul
100. ent 2 Remove the precleaner if so equipped from the paper element 4 2 3 Gently tap the flat side of the paper element to dislodge dirt Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing Surfaces are bent or damaged 4 Inspect the rubber seal sleeve on the stud If it is worn damaged or questionable replace it A new seal comes packed with each replacement element 5 Reinstall the precleaner paper element wing nut and air cleaner cover Make sure the knob is tightened securely Inspect Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or precleaner are serviced check the following areas components Air Cleaner Base Make sure the base is secured and not cracked or damaged Since the air cleaner base and carburetor are secured to the intake port with common hardware it is extremely important that the nuts securing these components are tight at all times Before reinstalling an air cleaner base that has been removed make sure the metal bushings in the base mounting holes are present See Figure 4 3 The bushings prevent damage to the base and maintain the proper mounting torque Bushings Figure 4 3 Bushings in Air Cleaner Base Breather Tube Make sure the tube is attached to both the air cleaner
101. ependable electronic magneto ignition system The system consists of the following components e A magnet assembly which is permanently affixed to the flywheel e An electronic magneto ignition module which mounts on the engine crankcase e Akill switch or key switch which grounds the module to stop the engine e A spark plug Operation As the flywheel rotates and the magnet assembly moves past the ignition module a low voltage is induced in the primary windings of the module When the primary voltage is precisely at its peak the primary circuit is interrupted inducing a high voltage in the secondary windings This high voltage creates a spark at the tip of the spark plug which ignites the fuel air mixture in the combustion chamber The timing of the spark is automatically controlled by the module Therefore other than periodically checking replacing the spark plug no maintenance timing or adjustments are necessary or possible with this system 8 3 Section 8 Electrical System and Components Magneto Ignition System Troubleshooting Guide The following guide will help locate and correct ignition system problems 1 Make sure the spark plug lead is connected to the spark plug 2 Check the condition of spark plug Make 2 If plug is in good condition check adjust sure gap Is set correctly See page 8 1 gap and reinstall a Test for spark with ignition tester Part 3 If visible and audible sparks are pro
102. er sizing to 0 25 mm 0 010 in or 0 50 mm 0 020 in the initial resizing should be done with a boring bar until the cylinder is within 0 08 0 12 mm 0 003 0 005 in of the desired size Then use the following procedures for honing to the final dimension For 0 08 mm 0 003 in oversize skip the boring bar and go right to honing Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill soeed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so that the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move the hone up and down while resizing to prevent the formation of cutting ridges Check the size frequently Make sure the bore is cool when measuring 3 When the bore is within 0 064 mm 0 0025 in of desired size remove the coarse stones and replace with burnishing stones Continue with the burnishing stones until within 0 013 mm 0 0005 in of desired size and then use finish stones 220 280 grit and polish to f
103. ffle Nut or Screw Figure 9 18 Removing Blower Housing and Baffles Cylinder Baffle 4 Carefully loosen and remove the heat deflector and gasket from intake studs The heat deflector is made from a plastic that is quite brittle Do not pry on the corners or you risk cracking breaking the deflector If prying is necessary to loosen the deflector pry near the intake studs See Figure 9 19 Intake Stud Deflector Figure 9 19 Removing Heat Deflector 5 Remove the two hex flange screws and starter side cylinder barrel baffle 6 Remove the two hex flange screws and blower housing back plate See Figure 9 20 9 6 Hex Flange Screws 3 Du ver Housing E Sach Plate q Figure 9 20 Removing Back Plate Remove Ignition Module 1 Disconnect the kill lead from the ignition module See Figure 9 21 Figure 9 21 Removing Ignition Module 2 Rotate flywheel magnet away from ignition module 3 Remove the two hex flange screws and ignition module Remove Fuel Line 1 Remove the hex flange screw clip fuel line and rubber grommet See Figure 9 22 Section 9 Disassembly If the push rods will be reused they should be marked with a piece of tape I or E at the time all y of removal so they are reinstalled in the same Fuel aan EN WS Y location See Figures 9 24 and 9 25 Line gt e eh Figure 9 22 Removing Fuel Line not on all models Remove Valve Cover and Cylin
104. fore doing step 2 2 Low Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed to 1200 RPM 75 RPM by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application refer to equipment manufacturer s recommendations The recommended low idle speed for basic engines is 1200 RPM To ensure best results when setting the low idle fuel needle the low idle soeed must not exceed 1200 RPM 75 RPM 5 5 Section 5 Fuel System and Governor Disassembly Dust Seal Throttle Plate Screw s Throttle Plate Low Idle Speed Adjusting Screw and Spring Low Idle Fuel Adjusting ___ Needle and Spring may Fuel Inlet Needle not be present or may have limiter cap on certified engines Fuel Shut off Solenoid a Figure 5 6 Carburetor Exploded View 1 5 6 Remove the bowl retaining screw retaining screw gasket and fuel bowl Remove the bowl gasket float shaft float and fuel inlet needle Remove the low idle speed screw and spring If there is a low fuel adjusting needle without a limiter cap remove the needle and spring Do not attempt to remove the needle if it has a limiter cap Further disassembly to remove the welch plugs main fuel jet fuel inlet seat throttle plate and shaft and choke plate and shaft is recommended only if these parts are to be clean
105. g sets and new piston pins Service replacement piston ring sets are also available separately for STD 0 25 mm 0 010 in and 0 50 mm 0 020 in oversized pistons The 0 08 mm 0 003 in oversize piston uses a STD ring set Always use new piston rings when installing pistons Never reuse old rings The cylinder bore must be deglazed before service ring sets are used OK Look A H 4 j e Hit IK ki ki TI ab laos d H I Scored Piston and Rings Figure 10 7 Common Types of Piston and Ring Damage 10 9 Section 10 Inspection and Reconditioning Some important points to remember when servicing piston rings 1 If the cylinder bore does not need reboring and if the old piston is within wear limits and free of score or scuff marks the old piston may be reused 2 Remove old rings and clean up grooves Never reuse old rings 3 Before installing the rings on the piston place each of the top two rings in its running area in the cylinder bore and check the end gap see Figure 10 8 This gap should be 0 77 mm 0 030 in max in a used cylinder bore and 0 3 0 5 mm 0 012 0 020 in in a new cylinder bore Figure 10 8 Measuring Piston Ring End Gap 4 After installing the new compression top and middle rings on the piston check piston to ring side clearance using a feeler gauge Compare readings against the indicated specifications If the side clearance is greater than the maximum specified a new piston must
106. g under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be regapped and reused zF Worn On a worn plug the center electrode will be rounded and the gap will be eroded 010 or more beyond the correct gap Replace a worn spark plug immediately 8 2 Chalky White Deposits Chalky white colored deposits indicate overheating This condition is usually accompanied by excessive gap erosion A clogged grass screen clogged cooling fins and lean carburetion are some causes of overheating Carbon Fouled Soft sooty black deposits indicate incomplete combustion Incomplete combustion is usually caused by overrich carburetion weak ignition or poor compression Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by operating the engine with too much choke or a dirty air filter Oil in the combustion chamber is usually caused by worn piston rings or valve guides Section 8 Electrical System and Components Electronic Magneto Ignition System CV11 15 CV460 465 CV490 495 Engines Air Gap 0 2 0 3 mm 0 008 0 012 in Spark Plug Boot _ Spark Plug Ignition Module ne k Kill Switch or Off Position of Key Switch Figure 8 2 Electronic Magneto Ignition System CV11 15 CV460 465 CV490 495 Engines CV11 15 CV460 465 CV490 495 engines are equipped with a d
107. ge reamer tool to remove it before attempting to remove the piston Section 9 Disassembly Figure 9 47 2 Carefully push the connecting rod and the piston away from the crankshaft and out of the cylinder bore Remove Piston from Connecting Rod 1 Remove the wrist pin retainer and wrist pin Separate the piston from the connecting rod See Figure 9 48 Wrist Pi Retainer Connecti Rod AS a f v MI Ae ae at Figure 9 48 Separating Piston from Connecting Rod 9 13 Section 9 Disassembly Remove Piston Rings 1 Remove the top and center compression rings using a ring expander tool See Figure 9 49 Piston Ring Piston Ring Expander Figure 9 49 Removing Piston Rings 2 Remove the oil control ring rails then remove the spacer Remove Crankshaft 1 Remove the woodruff key from the flywheel taper end of crankshaft 2 Remove the crankshaft from the crankcase See Figure 9 50 Ce St i M Figure 9 50 Removing Crankshaft Remove Flywheel End Oil Seal 1 Remove the oil seal from the crankcase Remove Governor Cross Shaft and Governor Gear 1 Remove the hitch pin and plain washer from the governor cross shaft See Figure 9 51 9 14 Plain Washer Hitch Pin Governor Cross Shaft Plain Washer Figure 9 51 Removing Governor Cross Shaft 2 Remove the cross shaft and plain washer from the crankcase 3 Remove the governor shaft oil seal from the cran
108. gher extra Capacity paper element The original type uses a separate cover retaining knob which has to be turned completely off to remove the cover With the later style the knob snaps into the cover and is turned counterclockwise until it disengages the stud Other differences are pointed out in the exploded views Service Check the air cleaner daily or before starting the engine Check for and correct any buildup of dirt and debris and loose or damaged components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Precleaner Service If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions 1 Remove the precleaner from the paper element 2 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 3 Saturate the precleaner with new engine oil Squeeze out all excess oil 4 Reinstall the precleaner over the paper element 5 Reinstall air cleaner cover and tighten the retaining knob Paper Element Service Every 100 hours of operation more often under extremely dusty or dirty conditions check the paper element Clean or replace the element as necessary 1 Remove the wing nut and air cleaner elem
109. gine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Figure 1 1 Engine Identification Decal Location A Model No CV 12 5 ST Command Engine ee a TL Version Code Vertical Crankshaft S Electric Start T Retractable Start Ge eni co a SE ST Electric Retractable Start 490 490 cc 12 5 12 5 HP 13 13 HP 14 14 HP 15 15 HP 16 16 HP B Spec No 1203 Engine Model Code TT Variation of MODEL NO CV12 55 A Code Model Basic Engine SPEC NO 1203 B 71 CVIT SERIAL NO 2105810334 C 12 CV12 5 REFER TO OWNER S MANUAL FOR ER CV13 SAFETY MAINTENANCE SPECS AND ADJUSTMENTS FOR SALES 14 CV14 AND SERVICE IN US CANADA 41 CV15 CALL 1 800 544 2444 43 CV16 www kohlerengines com 265 CV460 465 275 CV490 495 KOHLER ENGINES C Serial No 2105810334 ec Year Manufactured Code IL Factory Code Code Model 21 1991 22 1992 23 1993 24 1994 25 1995 26 1996 21 1997 28 1998 29 1999 30 2000 31 2001 32 2002 Figure 1 2 Explanation of Engine Identification Numbers 1 3 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase Is extremely important as is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Synthetic oil is recommended for use in LPG fueled engines because there is less oxidation or thickening and deposit accumulation on
110. has been obtained it with a tachometer against the equipment move the throttle lever to low idle slow then back manufacturers recommended idle speed If to full throttle fast and check the RPM with a adjustment is necessary use the governed idle tachometer adjusting screw on the speed control assembly see Figure 5 26 Turn the screw clockwise 6 To decrease the RPM Follow steps 1 and 2 to increase the governed idle speed and Then push the throttle cable in toward the control counterclockwise to decrease it bracket assembly to decrease the RPM check with a tachometer until the desired RPM is obtained Tighten the cable clamp screw 5 19 Section 5 Fuel System and Governor Governed Idle Adjusting Screw Figure 5 26 Location of Governed Idle Adjusting Screw 5 20 CV11 16 CV460 465 CV490 495 Section 6 Lubrication System Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Synthetic oil is recommended for use in LPG fueled engines because there is less oxidation or thickening and deposit accumulation on intake valves is substantially reduced Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the tim
111. he engine will be out of service for two months or and system are empty more use the following storage procedure 4 Remove the spark plug Add one tablespoon of 1 Clean the exterior surfaces of the engine engine oil into the spark plug hole Install the plug but do not connect the plug lead Crank the 2 Change the oil and oil filter while the engine is engine two or three revolutions still warm from operation See Change Oil and Oil Filter in Section 6 5 Remove the spark plug Cover the spark plug hole with your thumb and turn the engine 3 The fuel system must be completely emptied over until the piston is at the top of its stroke or the gasoline must be treated with a stabilizer Pressure against thumb is greatest Reinstall to prevent deterioration If you choose to the plug but do not connect the plug lead use a Stabilizer follow the manufacturers recommendations and add the correct amount 6 Store the engine in a clean dry place for the capacity of the fuel system Fill the fuel tank with clean fresh gasoline Run the engine for 2 3 minutes to get stabilized fuel into the carburetor 1 5 Section 1 Safety and General Information Air Filter and Cover G Cylinder Oil Filter Carburetor Fuel Shut off Sol id Cee Carburetor Fuel Inlet Surface Oil Drain Plug 3 8 NPT Inch 17 67 Oil Filter Side 3 T chet 411 a 16 18 ales e Air Cleaner ae Cover Removal 296 11 65 a
112. he rectifier regulator See Figure 9 13 2 Remove the two screws securing the rectifier regulator and individual ground lead if used og AP EM Figure 9 13 Removing Rectifier Regulator not on all models Remove Extended Oil Fill Tube 1 Remove the hex flange screw securing the oil fill tube to the blower housing crankcase See Figure 9 14 2 Pull the oil fill tube out of the crankcase flange Figure 9 14 Removing Oil Fill Tube Remove Blower Housing and Baffles 1 See Figure 9 15 9 16 and 9 17 Remove the Six screws securing the blower housing and any commonly mounted clamps brackets Remove the blower housing Section 9 Disassembly Blower Housing Mounting Screws ylinder Baffle Figure 9 15 Removing Blower Housing and Baffles a a E Figure 9 16 Removing Blower Housing and Baffles Hex Flange Screws Figure 9 17 Removing Blower Housing and Baffles 2 Remove the hex flange valve cover screws and any loose spacers stamped steel valve covers which also attach the muffler and or lift bracket Note the assembly orientation for proper reassembly later 9 5 Section 9 Disassembly 3 Remove the hex flange nut on stud securing the carburetor side baffle if not removed previously during carburetor removal Remove the screws attaching the cylinder head baffle See Figure 9 18 If so equipped d i d amp T ylinder H He ge Carburetor Side ead Ba
113. heck the oil level The oil level should be up to but not over the F mark on the dipstick See Figure 6 4 Operating Figure 6 4 Oil Level Dipstick 5 If the level is low add oil of the proper type up to the F mark on the dipstick Always check the level with the dipstick before adding more oil NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Change Oil and Oil Filter Change Oil Change oil after every 100 hours of operation Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling or checking oil Change the oil as follows see Figure 6 5 6 2 Optional Oil axe Filter Draih Plug i Oil Filter Jl KE Oil Drain Plug Carburetor Side Optional Oil Sentry Oil Drain Plug Starter Side Figure 6 5 Oil Drain Plugs Oil Filter Oil Filter Drain Plug and Optional Oil Sentry Switch 1 Remove the oil drain plug and oil fill cap dipstick Be sure to allow ample time for complete drainage 2 Reinstall the drain plug Make sure it is tightened to 13 6 N m 10 ft Ib torque 3 Fill the crankcase with new oil of the proper type to the F mark on the dipstick Always check the level with the dipstick before adding more
114. ial pliers for removing the retainer 5 Solder the crimped portion to the post Do not reuse the retainer 6 Replace the brush holder in the frame and place Brush Replacement the brushes in the brush holder Reinstall the The brushes in the starter are part of the starter springs Snap the insulator into the brush holder frame Brush kit Part No 52 221 01 S contains four to keep the springs from popping out replacement brushes and springs If replacement is necessary all four brushes should be replaced Starter Service Clean drive lever and armature shaft Apply Kohler 1 Remove brushes from brush holder and remove electric starter drive lubricant 52 357 02 S to lever brush holder from frame and shaft 2 Cut the brush lead wire at the edge of the post with a pair of nippers 3 File off burrs on the post 8 25 Section 8 Electrical System and Components Starter Reassembly 1 Install the drive pinion onto the armature shaft 2 Slide the stop collar onto the armature shaft below the retaining ring groove Make sure the recessed side of the stop collar is up 3 Position a new retainer in the groove of the armature shaft and carefully tighten with a pliers to secure NOTE Always use a new retainer Do not nick or damage armature shaft Figure 8 29 Installing Armature 4 Use an open end wrench and slide the stop collar up until the recessed section encases the retaining ring and locks the collar into po
115. igures 9 2 and 9 3 2 Remove the muffler and gasket from exhaust outlet flange Some engines may have an additional heat deflector insert tube in the exhaust port behind the muffler flange If present remove it also Figure 9 2 Removing Muffler 9 2 Figure 9 3 Removing Muffler Remove Retractable Starter 1 Remove the five hex flange screws and retractable starter See Figure 9 4 Hex Flange Screws 5 Figure 9 4 Removing Retractable Starter Remove Electric Starter Electric Starter Bendix Drive or Solenoid Shift 1 Disconnect the lead from the stud terminal on the electric starter See Figure 9 5 Disconnect both leads on Solenoid Shift Starter 2 Remove the two hex flange screws and starter assembly Some bendix drive starters have additional spacers between the mounting flange and crankcase or under the head of the mounting bolt After noting their placement remove and retain the spacers Hex Flange Screws Electric _ Starter gi Figure 9 5 Removing Bendix Drive Starter Remove Air Cleaner 1 Loosen the knob and remove the air cleaner cover See Figure 9 6 2 Remove the wing nut air cleaner element and precleaner if So equipped 3 Loosen the hose clamps and disconnect the breather hose from the air cleaner base and valve cover See Figure 9 7 4 Remove the hex flange nuts from the intake studs Remove air cleaner base and gasket from studs Air Cleaner Cover
116. inal size A crosshatch should be observed if honing is done correctly The crosshatch should intersect at approximately 23 33 off the horizontal Too flat an angle could cause the rings to skip and wear excessively too steep an angle will result in high oil consumption refer to Figure 10 3 10 3 Section 10 Inspection and Reconditioning Figure 10 3 Cylinder Bore Crosshatch after Honing 4 After resizing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements The measurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder Bore after Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild The final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent that is capable of breaking down the machining oil while maintaining a good level of suds If the suds break down during cleaning discard the dirty water and start again with more hot water and detergent Following the scrubbing rinse the cylinder with very hot clear water dry it completely and apply a light coa
117. ing fuel tank Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent AA WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent 1 2 AA WARNING Carbon Monoxide can cause severe nausea fainting or death Do not operate engine in closed or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area AA WARNING Uncoiling Spring can cause severe injury Wear safety goggles or face protection when servicing retractable starter Spring Under Tension Retractable starters contain a powe
118. inimum of 10 2 cm 4 in above the level in the open side If the level in the engine side is the same as the open side no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table below Close the shut off clamp before stopping the engine To perform the test with the vacuum pressure gauge insert the stopper as in step 1 Insert the barbed gauge fitting into the hole in the stopper Be sure the gauge needle is at 0 Run the engine as in step 2 and observe the gauge reading Needle movement to the left of O is a vacuum and movement to the right indicates a pressure Incorrect Vacuum in Crankcase Possible Cause po Solution S 1 Crankcase breather clogged or inoperative Seals and or gaskets leaking Loose or improperly torqued fasteners Piston blowby or leaky valves Confirm with cylinder leakdown test Restricted exhaust 1 Disassemble breather clean parts thoroughly reassemble and recheck pressure Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Recondition piston rings cylinder bore valves and valve guides Repair replace restricted muffler exhaust system 3 3 Section 3 Troubleshooting Compression Test These engines are equipped with an automatic compression release ACR mechanism Because of
119. injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery The following sequence is suggested for complete engine disassembly This procedure can be varied to accommodate options or special equipment Clean all parts thoroughly as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oll Typical Disassembly Sequence Disconnect spark plug lead Drain oil from crankcase and remove oil filter Remove Oil Sentry pressure switch Remove muffler Remove retractable starter Remove electric starter Remove air cleaner Remove external governor components and carburetor Remove fuel pump Remove rectifier regulator Remove extended oil fill tube Remove blower housing and baffles Remove ignition module Remove fuel line Remove valve cover and cylinder head oe eae W DT h sesch wesch zech sesch dE
120. inst a flat level surface or piece of glass and check around the entire perimeter that a 012 in 30 mm feeler gauge cannot be inserted anywhere See Figures 10 14 If the gauge goes in anywhere the cover needs to be replaced Figure 10 14 Checking with Feeler Gauge CV11 16 CV460 465 CV490 495 Section 11 Reassembly The following sequence is suggested for complete 23 Install carburetor and external governor engine reassembly This procedure assumes that all components components are new or have been reconditioned 24 Install air cleaner and adjust governor and all component subassembly work has been 25 Install electric starter completed This procedure may be varied to 26 Install retractable starter accommodate options or special equipment 2 7 Install muffler 28 Install oil filter and oil drain plugs NOTE Make sure the engine is assembled using 29 Prepare the engine for operation all specified torque values tightening sequences and clearances Failure to Install Governor Gear and Cross Shaft observe specifications could cause severe NOTE Do not reuse an old removed governor engine wear damage or failure gear NOTE Always use new gaskets 1 Install the thrust washer to governor gear shaft NOTE Make sure all components have been 2 Position the regulating pin to governor gear cleaned BEFORE reassembly flyweights as shown in Figure 11 1 Slide the governor gear regulating pin over the governor Typica
121. install the keepers See following NOTE regarding exhaust valve rotator use NOTE Exhaust valve rotators are no longer used Do not attempt to install rotators if a new head is being installed or head did not use one originally Not used on some models agi E z w Valve Spring Figure 11 39 Installing Valve Keepers 4 Rocker Bridge Heads Figure 11 40 a Position the rocker arms over the valve stems and rocker arm bridge Insert the pin through the rocker bridge and rocker arms from the breather reed side Rocker Shaft gel ee LU EN i ZS Breather Reed Retainer and Breather Reed Figure 11 40 Installing Rocker Arms Rocker Bridge Type LU D St X amp Section 11 Reassembly Heads with Separate Pivots Rocker Arms Figure 11 37 e Non Adjustable Valve Lash Configuration a Position the pivots in the sockets of the rocker arms Insert the screws through the pivots rocker arms and guide plate some models Start the screws into the cylinder head and finger tighten only at this time e Adjustable Valve Lash Configuration a Position the guide plate on the head with the formed lips down and install the two pivot studs Torque the pivot studs to 11 3 N m 100 in Ib Lubricate the bottoms of the rocker arm pivots with oil and position within rocker arms Install the rocker arm pivot assemblies on the studs Figure 11 41 Torquing Pivot Studs Adjustable Va
122. intake valves is substantially reduced Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown below RECOMMENDED SAE VISCOSITY GRADES WR ee ee ee eee 10W 30 a a 5W 20 5W 30 SS Kohler Command F 20 0 20 32 40 60 80 l DH i clo 20 40 0 10 20 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 3 Figure 1 3 Oil Container Logo Refer to Section 6 Lubrication System for detailed oil check oil change and oil filter change procedures 1 4 Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from igniti
123. ioning Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Overheating An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake and blocked fins when this condition is noted 10 7 Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter Then using an outside micrometer measure the diameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance If the intake clearance exceeds 0 038 0 076 mm 0 0015 0 003 in or the exhaust clearance exceeds 0 050 0 088 mm 0 0020 0 0035 in determine whether the valve stem or guide is responsible for the excessive clearance Maximum I D wear on the intake valve guide is 7 134 mm 0 2809 in
124. kcase See Figure 9 52 Cross Shaft Oil Seal Figure 9 52 Removing Cross Shaft Oil Seal 4 If necessary remove the governor gear and regulating pin See Figure 9 53 NOTE The governor gear is held onto the governor gear shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary such as when reboring doing major engine rebuilding etc Section 9 Disassembly S A da Bn ee Rea ulating Pin oe N len Te q g i m i af w SeaGovernor Gear t Figure 9 53 Removing Governor Gear 9 15 Section 9 Disassembly 9 16 CV11 16 CV460 465 CV490 495 Section 10 Inspection and Reconditioning This section covers the operation inspection and repair reconditioning of major internal engine components The following components are not covered in this section They are covered in sections of their own Air Cleaner Section 4 Carburetor amp External Governor Section 5 Retractable Starter Section 7 Ignition Charging amp Electric Starter Section 8 Clean all parts thoroughly Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions car
125. kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present a lf the problem is gone the electrical system on the unit is suspect Check the key switch wires connections safety interlocks etc b If the problem persists continue with the following troubleshooting procedure Leave the kill lead isolated until all testing is completed Troubleshooting Procedure kb Disconnect spark plug lead and attach it to tester KO1046 Attach tester clip to a good ground not to the spark plug Crank the engine and observe tester for spark Do not touch tester while cranking If no spark is observed verify that spark advance module SAM is getting proper voltage a Return to the connector where the engine and unit wiring harnesses are joined and find the double red lead in the back of the engine connector Using a DC voltmeter with a probe lead test the voltage at the terminal on the double red lead with the key switch in both the start and run positions At least 7 2 volts must be present If voltage is low proceed to step 4 If voltage is above 7 2 proceed to step 5 8 7 Section 8 Electrical System and Components 4 Remove the blower housing from the engine a Trace the black ground lead from the SAM and check that the ground tab and terminal co
126. kshaft and the key if flywheel key is sheared or the keyway is damaged Inspect the ring gear for cracks or damage Kohler does not offer replacement ring gears Replace the flywheel if the ring gear is damaged Section 10 Inspection and Reconditioning Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Inspection and Service Although these symptoms could also be attributed to Carefully inspect the valve mechanism parts Inspect worn rings remove and check the valves first After the valve springs and related hardware for excessive removal clean the valve heads faces and stems with wear or distortion Check the valves and valve seat a power wire brush Then carefully inspect each valve area or inserts for evidence of deep pitting cracks for defects such as warped head excessive corrosion or distortion Check clearance of the valve stems burned face or worn stem end Replace valves found in guides See Figure 10 5 for valve details and to be in bad condition A normal valve and valves specifications in bad condition are shown in the accompanying illustrations Cylinder Head and Valves Exhaust Valve Intake Valve Exhaust Insert Intake Insert Seat Angle Insert O D Guide Depth Guide D Valve Head Diameter Valve Face Angle Valve Margin Mm Valve Stem Diameter Figure 10 5 Valve Details A B C D F G H 37 987 38 013 mm 6 5 mm 7 033 7 058 mm 35 3
127. l Reassembly Sequence gear shaft 1 Install governor gear and cross shaft 2 Install crankshaft V Regulating 3 Install piston rings a Pin 4 Install piston to connecting rod Zeg Governor 5 Install piston and connecting rod Gear 6 Install balance shaft 7 Install hydraulic lifters and camshaft 8 Install oil pressure relief valve and oil pickup 9 Install oil pan to crankcase 10 Install oil pump 11 Install oil seals 12 Install stator and wiring harness 13 Install fuel line 14 Install fan flywheel grass screen and drive cup 15 Reassemble cylinder head components Figure 11 1 Installing Governor Gear 16 Install cylinder head 17 Install ignition module 18 Install baffles and blower housing 19 Install valve cover and muffler bracket 20 Install extended oil fill tube 21 Install rectifier regulator 22 Install fuel pump If so equipped Section 11 Reassembly 3 Using the KO1030 oil seal installer install a new governor cross shaft oil seal into the crankcase See Figure 11 2 Cross Shaft Oil Seal Figure 11 2 Cross Shaft Oil Seal 4 Install smaller plain washer to the cross shaft and insert the cross shaft from inside through the crankcase and oil seal See Figure 11 3 5 Install larger plain washer and hitch pin Plain Washer Hitch Pin Figure 11 3 Installing Cross Shaft Install Crankshaft 1 Lubricate the flywheel end bearing surfaces
128. l circuit Disconnect any auxiliary kill wires or safety switches connected to the kill circuit and operate the engine to determine if the reported problem is gone NOTE The spark advance module SAM used with Smart Spark requires an external power source of at least 7 2 volts DC If you are installing a replacement battery on a unit that has an engine with Smart Spark be certain the battery is fully charged prior to installation Testing of Smart Spark Ignition Systems on CV16 Engines The following procedure is provided for troubleshooting ignition problems on CV16 engines It will allow you to pinpoint the failed components Special Tools Required e Tester KO1046 e Multi meter digital Specifications Required e Spark plug gap 0 030 e Ignition module air gap 0 008 0 012 0 010 Section 8 Electrical System and Components NOTE Ignition tester KO1046 must be used to test Smart Spark ignition Use of any other tester can result in inaccurate findings Battery on unit must be fully charged and properly connected before making any of these tests Be sure drive is in neutral and all external loads are disconnected Preliminary Test To be certain the reported problem is in the engine ignition system it should be isolated from the unit as follows ls Locate the plug connectors where the wiring harnesses from the engine and unit are joined Separate the connectors and remove the white
129. ley into the starter housing Invert the area pulley housing so the pulley is away from your face and away from others in the area 1 Release spring tension and remove the handle and starter rope Refer to Rope Replacement 7 Rotate the pulley slightly from side to side and steps 2 through 5 on page 7 2 carefully separate the pulley from the housing See Figure 7 7 2 Remove the center screw washer and pawl retainer See Figure 7 5 If the pulley and the housing do not separate easily the spring could be engaged in the starter housing or there is still tension on the spring Return the pulley to the housing and repeat step 5 before separating the pulley and housing enter Screwand ff Pawl Rob e Figure 7 5 Center Screw Washer and Pawl Retainer 3 Remove the brake spring and brake washer See Figure 7 6 Figure 7 7 Removing Pulley from Housing 8 Note the position of the spring and keeper assembly in the pulley See Figure 7 8 Remove the spring and keeper assembly from the pulley as a package A CAUTION Spring Under Tension Do not remove the spring from the keeper Severe personal injury could result from the sudden uncoiling of the spring AA g i P 7 i f ring Se es i V fs EW CG N R g e Figure 7 6 Brake Spring and Was Pawl Springs her Pawls and 7 3 Section 7 Retractable Starter Inspection and Service 1 Carefully inspect the rope pawls housing
130. lign the hole in the throttle lever with the hole in the speed control bracket by inserting a pencil or 6 35 mm 1 4 in drill bit See Figure 5 21 Choke Adjusting Is E ever Speed Control van i Bracket a gt ji e A Thre ttle Lever AA we E Figure 5 21 Aligning Holes in Speed Control Bracket and Throttle Lever 4 Pull up on the outer shield of the throttle control cable to remove any slack Tighten the cable clamp securely High Idle Speed Adjustment The recommended maximum no load high idle speed for most of these engines is 3750 RPM The actual high idle soeed depends on the application Refer to the equipment manufacturer s instructions for specific information A WARNING Overspeed is Hazardous Do not tamper with the governor setting Overspeed is hazardous and could cause personal injury 5 16 Make sure the throttle cable is adjusted properly see Throttle Cable Adjustment Start the engine and allow it to warm up Place the throttle control lever into the fast or high idle position Align the hole in the throttle lever with the hole in the speed control bracket by inserting a pencil or 6 35 mm 1 4 in drill bit See Figure 5 21 Loosen the speed control bracket mounting screws Move the bracket up or down until the desired high idle speed is reached See Figure 5 22 Check the speed with a tachometer Pay sf N Screw To increase the high idle speed
131. ll the governor spring in the appropriate hole in the governor arm and through the hole slot in the throttle lever on the governor bracket assembly See Figure 11 64 Refer to Section 5 for correct hole use spring installation 11 20 Carburetor Choke Linkage Choke Lever Choke Lever IA l Speed Control Bracket Governor Lever S S Governor Spring Figure 11 64 Installing Choke Linkage and Speed Control Bracket Install Air Cleaner and Make Initial Governor Adjustment 1 Make sure the metal bushings in the air cleaner base mounting flange are in place and in good condition 2 Install the gasket air cleaner base and hex flange nuts Torque the nuts to 9 9 N m 88 in Ib See Figure 11 65 Gasket Air Cleaner Base Figure 11 65 Installing Air Cleaner Base 3 Make sure that the hose clamps are installed on the breather hose at least 1 in from the ends Attach the end with the larger I D to the air cleaner base and the other end to the valve cover nipple Secure with the hose clamps 4 Make the initial governor adjustment a Push the governor lever and throitle linkage towards the carburetor wide open throttle and hold Section 11 Reassembly b Grasp the cross shaft with a pliers and turn 5 Be sure the rubber sleeve seal is installed on the shaft couterclockwise as far as it will go the air cleaner base stud Install the air cleaner then tighten the hex nut securely See Figure element
132. llow the lifters time to bleed down then check for compression again If still improper repeat the hydraulic valve lifter and rocker arm pivot assembly installation for the head configuration used Testing the Engine lt is recommended that the engine be operated on a test stand or bench prior to installation in the piece of equipment 1 Set the engine up on a test stand Install an oil pressure gauge Refer to Lubrication System section Figure 6 9 Start the engine and allow it to idle for 90 seconds Check to be certain that oil pressure 40 psi or more is present Run the engine for 5 10 minutes between idle and mid range Adjust the carburetor settings as necessary Make sure the maximum engine speed does not exceed 3750 RPM Adjust the throttle and choke controls and the high speed stop as necessary Refer to the Fuel System and Governor section 11 23 Section 11 Reassembly 11 24 KOHLER ENGINES FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2011 by Kohler Co All rights reserved FORM NO 1269001 Rev ISSUED 4 11 REVISED LIPIA 090 U1 g 896012 098157
133. longer it takes the delay circuit to surpass the reference voltage in the charge pump capacitor the later the trigger pulse will occur retarding the timing accordingly The trigger pulse exiting the SAM activates the reset circuit discharging the capacitor and resetting the circuits for the next cycle Green or V 7 2 V B 12 VDC Red Conditioning Delay Circuit Circuit Yellow To Semi Comparator b Generator Conductor Switch Circuit Advance Module SAM Yellow Figure 8 7 8 6 Troubleshooting CD Ignition Systems The CD ignition system is designed to be trouble free for the life of the engine Other than periodically checking replacing the spark plug no maintenance or timing adjustment is necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a reported problem Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain all ignition related wires are connected including the spark plug lead Be certain all terminal connections fit snugly Make sure the ignition switch is in the run position NOTE The CD ignition systems are sensitive to excessive load on the kill lead If a customer complains of hard starting low power or misfire under load it may be due to excessive draw on the kil
134. loose connections or shorts in wiring harness With engine running at 3000 RPM measure voltage from lighting lead to If voltage is less than 13 volts test stator ground using an AC voltmeter using an ohmmeter Test 3 3 With engine stopped measure the 3 If resistance is approximately 0 2 ohms No Lights resistance of stator from lighting lead to stator is OK ground using an ohmmeter If resistance is 0 ohms stator is shorted Replace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 8 11 Section 8 Electrical System and Components Troubleshooting Guide 3 amp 70 Watt Braking Stator NOTE Zero ohmmeteres on each scale to ensure accurate readings Voltage tests should be made with engine running at 3400 RPM no load Battery must be fully charged 1 With engine running at 3400 RPM 1 If voltage is more than 12 5 volts charging measure voltage across battery terminals system is OK using a DC voltmeter If voltage is 12 5 volts or less the stator or diode are probably faulty Test the stator and diode Test 2 3 and 4 2 Disconnect the charging lead black from 2 If voltage is 5 volts or more stator winding the wiring harness is OK With engine running at 3400 RPM If voltage is less than 5 volts test stator measure voltage from charging lead to using an ohmmeter Tests 3 and 4 ground using a DC voltmeter 3 With charging lead disconnected from 3 If re
135. lve Lash 11 13 Section 11 Reassembly b Start the set screw into the nut but only a few turns or it may hamper lash adjustment Start the adjustment nut with the set screw on the end of each stud Figure 11 42 Installing Adjustment Nut 5 Install breather reed and reed retainer secure with the M5 hex flange screw Torque the screw to 6 2 N m 55 in Ib in a new hole or 3 9 N m 35 in Ib in a used hole Install the exhaust studs if removed previously or a new head is being installed The threaded end with the oval point or identification symbol must be out Install Cylinder Head 1 2 Rotate the crankshaft to TDC of the compression stroke and make sure the lifters are installed in the lifter bores with the socket end up a Install a new cylinder head gasket and the cylinder head assembly on the crankcase Hex Flange Screws AN K Figure 11 43 Installing Cylinder Head Rocker Bridge Type Shown 11 14 Apply Loctite No 59241 thread sealant to the threads of two of the shorter 81 mm 3 1 in head bolts and install them into location 3 and 4 See Figure 11 44 If the engine has a high temperature cutout switch insert a long 90 mm 3 5 in head bolt through the special washer flat on one edge and the cutout switch Install it in position 1 Determine the correct length head bolt for position 5 based upon the length of spacer used If the spacer used is 27
136. missing replacement of the camshaft will be necessary Crankshaft Inspection and Service Inspect the gear teeth of the crankshaft If the teeth are badly worn chipped or some are missing replacement of the crankshaft will be necessary Some engines have replaceable crankshaft bearings most do not Inspect the crankshaft bearing and or journal surface for scoring grooving etc Do not replace bearings unless they show signs of damage or are out of running clearance specifications If the crankshaft turns easily and noiselessly and there is no evidence of scoring grooving etc on the races or bearing surfaces the bearings can be reused Inspect the crankshaft keyways If worn or chipped replacement of the crankshaft will be necessary Inspect the crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits as stated in Specifications and Tolerances are exceeded it will be necessary to either replace the crankshaft or regrind the crankpin to 0 25 mm 0 010 in undersize If reground a 0 25 mm 0 010 in undersize connecting rod big end must then be used to achieve proper running clearance Measure the crankpin for size taper and out of round NOTE Ifthe crankpin is reground visually check to insure that the fillet blends smoothly with the crankpin surface See Figure 10 1 10 2 High Point From Fillet Intersections The Fillet Mu
137. mm 0 2771 0 2779 in Max Wear Limit E 7 134 mm 0 2809 in Exhaust Valve Guide I D KEN 7 038 7 058 mm 0 2771 0 2779 in Max Wear LINN case anes eavamseenaetieantacotanentexacaunnanesn a 7 159 mm 0 2819 in Valve Guide Reamer Size SE eee eee ee ree ee eee 7 048 mm 0 2775 in BE lune EE 7 298 mm 0 2873 in Intake Valve Minimum LM sancsucicrvecseoteetiniennnsaseiacoreiareeeseiwanenans 8 96 mm 0 353 in Exhaust Valve Minimum BE 9 14 mm 0 360 in Nominal Valve Seat Ange 45 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 10 Property Class Noncritical Fasteners Into Aluminum Se 2 9 26 1 36 M5 g a E Zei 5 8 gt 1 7 M6 4 3 38 5 7 50 9 9 88 bk O 124 300 M8 10 5 93 13 6 120 24 4 216 33 9 Tightening Torque N m ft Ib or 10 O Class o Noncritical Fasteners Into Aluminum M10 7 We K Vi 5 35 66 4 Ki 33 9 25 M12 36 6 ai 47 5 82 7 61 116 6 86 61 0 45 M14 583 A 76 4 131 5 ES 184 4 1 a 94 9 70 Oil Drain Plugs Tightening Torque Nem English Equiv Torque Into Cast Iron Into Aluminum Conversions i N m in Ib x 0 113 17 0 150 in Ib 11 3 100 in Ib 20 3 180 in Ib 13 6 120 in Ib Wm ft Ib x 1 356 in lb N m x 8 85 27 1 20 ft Ib 17 6 13 ft Ib ft Ib N m x 0 737 33 9 25 ft Ib 21 7 16 ft Ib
138. move the bracket up towards flywheel To decrease the high idle speed move the bracket down towards PTO Tighten the speed control bracket mounting screws Recheck the speed with a tachometer and readjust if necessary Torque the mounting screws as follows Into new as cast hole 10 7 N m 95 in Ib Into used hole 7 3 N m 65 in Ib Adjust the choke see Choke Adjustment which follows Choke Adjustment This procedure must follow the High Idle Speed Adjustment just described If not already completed perform that operation first 1 Turn the choke adjusting screw out counterclockwise until it no longer contacts the choke lever Then turn it back in clockwise until it just makes contact 2 While observing the choke link move the throttle control lever to the low idle slow position then back to full throttle fast The choke link should not move as the throttle moves through the normal range If it does back the adjusting screw out until it no longer moves 3 Move the throttle control lever to the choke position Check if the choke has fully closed by placing your finger behind right side the link loop and applying pressure toward the carburetor If the controls have been properly set the link should not move Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes in the governor arm If soeed surging occurs with a cha
139. mplete starter starter pulley and rope guide bushing of housing disassembly See Figure 7 4 1 Remove the starter from the engine blower housing e Rope Guide l l _ SCO Bu shin 2 Pull the rope out approximately 12 and tie a gt gt usning temporary slip knot in it to keep it from retracting into the starter See Figure 7 3 1 j t j 1 j f Fj d d Rope Hole ce in Pulley Slip Knot Figure 7 4 Installing Rope 10 Tie a slip knot approximately 12 from the free end of rope Hold the pulley firmly and allow it to rotate slowly until the slip knot reaches the guide bushing of housing Figure 7 3 Removing Starter Handle 11 Slip the handle and rope retainer onto the rope Tie a single knot at the end of the rope Install the 3 Remove the rope retainer from inside the starter rope retainer into the starter handle handle Untie the single knot and remove the rope retainer and handle 12 Untie the slip knot and pull on the handle until the rope is fully extended Slowly retract the rope into 4 Hold the pulley firmly and untie the slip knot the starter Allow the pulley to rotate slowly as the spring tension is released When the spring is properly tensioned the rope will retract fully and the handle will stop against 5 When all spring tension on the starter pulley is the starter housing released remove the rope from the pulley Pawls Dogs Replacement 6 Tie a single knot in one
140. mponents Operation As the flywheel rotates the magnet grouping passes the input coil L1 of the ignition module inducing energy in the coil The resultant pulse is rectified by diode D1 and charges capacitor C1 Current from the same pulse also travels through the brown lead to the spark advance module SAM and enters the input of the conditioning circuit The conditioning circuit shapes this pulse putting it in a useable form for the other circuits The conditioned pulse starts the charge pump which charges a capacitor in linear fashion directly related to engine speed The pulse also resets the delay circuit The comparator is off during this period When the flywheel magnet group has passed the input coil and the original pulse drops back to zero the capacitor in the delay circuit begins to charge off of the power source When the charge on the delay capacitor exceeds the charge pump capacitor the comparator changes state and activates the pulse generator The generated pulse returns to the ignition module through the yellow lead and turns on the semiconductor switch SCS completing the circuits between the charging capacitor C1 and the transformer T1 The charging capacitor discharges into the transformer primary P inducing a high voltage pulse in the transformer secondary S The high voltage pulse arcs across the spark plug gap igniting the fuel air mixture in the combustion chamber The
141. nge in load the governor is set too sensitive If a big drop in speed occurs when normal load is applied the governor should be set for greater sensitivity The position of the governor spring in the governor arm depends on the high idle no load speed setting see Figure 5 23 If the high idle no load speed is 3600 RPM or less use the 2 hole count outward from cross shaft If the high idle speed is greater than 3600 RPM use the 3 hole count outward from cross shaft Section 5 Fuel System and Governor Figure 5 23 Governor Spring Location Speed Control Bracket Service The only serviceable components of the speed control bracket assembly are the choke adjusting screw and spring choke return spring and throttle cable clamp and screw Install the choke return spring as shown See Figure 5 24 Replace the assembly if other parts are worn or damaged Throttle Cable Clamp and J A Bracket Assembly Choke Adjusting Screw and Spring Figure 5 24 Speed Control Bracket Assembly Separate Throttle and Choke Control Some engines are equipped with separate throttle and choke controls This allows you to adjust the choke and throttle controls individually Install Separate Control Cables See Figure 5 25 Throttle Control 1 Loosen the 2 cable clamp screws on the engine control plate 5 17 Section 5 Fuel System and Governor 2 Position the application throttle control in the full fas
142. nnections are all tight Recheck voltage at engine connector If voltage is still low check battery key switch and wiring on unit b When you are certain there is proper voltage at the connector retest for spark If there is still no spark proceed to step 5 5 If you skipped step 4 remove the blower housing at this time Check all leads and connections from the SAM to the wiring harness and from the SAM to the ignition module Pay special attention to the connection in the red lead as the connectors can be misaligned in a way that the terminals don t make contact Correct any problems found with the wiring or connections and retest for spark If no wiring problems were found or there is still no spark proceed to step 6 6 Zero ohmmeter and perform the following resistance checks on the ignition module Module should be at room temperature 70 F a Remove the brown lead and test resistance from the wide tab to the laminations Resistance should be 145 160 ohms b Remove the yellow lead and test resistance from the narrow tab to the laminations Resistance should be 900 1000 ohms c Test resistance from the spark plug lead terminal to the laminations Resistance should be 3800 4400 ohms If any of the resistance readings are outside of the specified ranges replace the ignition module If the resistance readings are all good replace the SAM Battery A 12 volt battery with a minimum current rating of 250 cold c
143. on a Position the push rods within slots in guide plate and seat the push rods into sockets under the end of the rocker arms Align the rocker arms over the valve stems b Apply downward pressure to the push rod side of rocker arm to compress the lifter and e bottom the plunger in the lifter bore Hold in Figure 11 47 Torquing Set Screw Adjusting Valve this position for Steps c Lash NOTE It takes two hands to make the lash e Repeat steps b c and d on the other adjustment You will probably need a rocker arm clamping device or an assistant to hold the lifter compressed while you make the 5 Ifthe head has a threaded hole in the intake port adjustment install the pipe plug or vacuum line The pipe plug should be installed for all applications which do c Insert a 07 12 mm 003 005 in feeler not have a metal vacuum line at this location Use gauge between the rocker arm and end of pipe sealant with Teflon on the threads valve and turn the adjustment nut clockwise down until a slight drag is felt on the feeler 6 Install the spark plug into the cylinder head gauge See Figure 11 46 Torque the spark plug to 24 4 29 8 N m 18 22 ft Ib 11 15 Section 11 Reassembly Install Ignition Module 1 Rotate the flywheel so the magnet is away from the ignition module bosses Install the ignition module to the bosses on crankcase using the hex flange screws The directional arrow on some module
144. on Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to insure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however that the cylinder head will require more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved
145. or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oil level Faulty carburetor Engine Knocks de 2 3 4 Excessive engine load Low crankcase oil level Old improper fuel Internal wear or damage 3 1 Section 3 Troubleshooting Engine Loses Power Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheated Faulty spark plug Low compression Exhaust restriction EE EE Engine Uses Excessive Amount Of Oil Incorrect oil viscosity type Clogged or improperly assembled breather Crankcase being overfilled Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides E GE Der External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled e Check for buildup of dirt and debris on the crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas are causes of overheating e Check for obvious oil leaks and damaged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn or damaged seals and gaskets or loose or improperly torqued fasteners e Check the air cleaner cover and base
146. otch with the corresponding section in the rubber grommet Install the drain tube in rear cutout if it was removed previously See Figure 8 58 Figure 8 58 Installing Frame and Drain Tube 9 Install the flat thrust washer onto the commutator k end of the armature shaft See Figure 8 59 Figure 8 60 Installing Brush Holder Assembly With Supplied Tube Starter reassembly when not replacing the Brushes Brush Holder Assembly a Carefully unhook the retaining caps from over each of the brush assemblies Do not lose the springs 8 34 Section 8 Electrical System and Components Dy bg Figure 8 61 Removing Retaining Caps Figure 8 63 Installing Brus Using Tool with Extension h Holder Assembly b Position each of the brushes back in their slots so they are flush with the I D of 11 Install the end cap onto armature and frame the brush holder assembly Insert Brush aligning the thin raised rib in the end cap with the Installation Tool No KO3226 1 w extension corresponding slot in the grommet of the positive or use the tube described above from a prior brush lead brush installation through the brush holder assembly so the holes in the metal mounting 12 Install the two thru bolts and the two brush clips are up out holder mounting screws Torque the thru bolts to 5 6 9 0 N m 49 79 in Ib Torque the c Install the brush springs and snap on the four brush holder mounting screws to 2 5 3 3 N m re
147. r This fuel air mixture is then burned in the engine combustion chamber Troubleshooting Use the following procedure to check for a suspected fuel delivery problem 5 1 Section 5 Fuel System and Governor Fuel System Troubleshooting Guide Gasoline Test Conclusion 1 Check for the following a Make sure the fuel tank contains clean fresh proper fuel b Make sure the vent in fuel cap is open c Make sure the fuel valve is open 2 Check for fuel in the combustion chamber lf there is fuel at the tip of the spark plug fuel is a Disconnect and ground spark plug lead reaching the combustion chamber b Close the choke on the carburetor c Crank the engine several times If there is no fuel at the tip of the spark plug check d Remove the spark plug and check for fuel at for fuel flow from the fuel tank Test 3 the tip 3 Check for fuel flow from the tank to the fuel pump If fuel does flow from the line reconnect line and a Remove the fuel line from the inlet fitting of check for faulty fuel pump Test 4 the fuel pump b Hold the line below the bottom of the tank If fuel does not flow from the line check for Open the shutoff valve if so equipped and clogged fuel tank vent fuel pickup screen shutoff observe flow valve and fuel lines 4 Check the operation of fuel pump lf fuel does flow from the line check for faulty a Remove the fuel line from the inlet fitting of carburetor Refer to the
148. r in the cylinder bore Figure 11 11 Installing Connecting Rod Fasteners Install Balance Shaft 1 Lubricate the balance shaft bearing surfaces of crankcase and balance shaft with engine oil 2 Align the timing marks on the balance shaft gear and the larger gear on the crankshaft Lower the balance shaft into the bearing surface in the crankcase On CV460 495 models the crankshaft and the balance shaft must be rotated down three teeth past the timing marks for the counterweights of both shafts to clear when installing After sliding the balance shaft into place rotate the shaft upward and check to make sure the two timing marks are aligned See Figure 11 12 On all other models make sure the balance shaft gear large crankshaft gear and the governor gear teeth mesh and the timing marks are aligned See Figure 11 12 e gt i r h i Le P SA Figure 11 12 Aligning to Check Installed Position Installing Camshaft 1 Lubricate the camshaft lobes and bearing surfaces with engine oil 2 Align the timing marks on the camshaft gear and the smaller crankshaft gear Lower the camshaft into the bearing surface in crankcase Make sure the camshaft gear and smaller gear on crankshaft mesh and the timing marks are aligned See Figure 11 13 rankshaft Timing Mark Small Crankgea Figure 11 13 Aligning Timing Marks on Crank Gear and Cam Gear Determine Camshaft End Play 1 Install the shim spacer remov
149. r to those listed in the filter screen in line fuel filter fuel lines and fuel following table exist it may be necessary to adjust or pump for restrictions or faulty components as service the carburetor necessary Troubleshooting Gasoline Fuel Systems Carburetor Possible Cause Probable Remedy 1 Engine starts hard runs roughly or stalls at idle speed 2 Engine runs rich Indicated by black sooty exhaust smoke misfiring loss of speed and power governor hunting or excessive throttle opening 3 Engine runs lean Indicated by misfiring loss of speed and power governor hunting or excessive throttle opening 4 Fuel leaks from carburetor 5 4 Low idle fuel mixture speed improperly adjusted Adjust the low idle speed screw then adjust the low idle fuel needle Choke partially closed during operation Check the choke lever linkage to ensure choke is operating properly Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle Float level is set too high With fuel bowl removed and carburetor inverted the exposed surface of float must be parallel with the bowl gasket surface of the carburetor body Dirt under fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Remove fuel bowl low idle fuel adjusting needle and welch plugs Clean vent ports and air bleeds Blow out all passages with compressed air Fuel bowl gasket
150. rankcase with the clip and hex flange screw See Figure 11 26 Section 11 Reassembly Install Fuel Line 1 Install the grommet to the carburetor side of fuel line 2 Install the fuel line clamp and hex flange screw Make sure the grommet is inserted in the notch in the crankcase See Figure 11 27 Not on all models Rubber Grommet d Se ss GEES Serew and Clip Figure 11 27 Installing Fuel Line Install Fan and Flywheel A WARNING Damaging Crankshaft and Flywheel can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel NOTE Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean dry and completely free of lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the flange screw is torqued to specification 1 Install the woodruff key into the keyway in the crankshaft Lubricate threads of flywheel retaining Screw NOTE Make sure the flywheel key is installed properly in the keyway The flywheel can become cracked or damaged if the key is not installed properly in the keyway Section 11 Reassembly 2 Reattach the f
151. ranking amps is recommended The requirement depends on engine size applications and starting temperatures Cranking requirements increase as temperatures decrease and at the same time battery capacity shrinks Refer to the operating instructions of the equipment this engine powers for specific battery requirements 8 8 If the battery charge is not sufficient to crank the engine recharge the battery Battery Charging A WARNING Explosive Gases Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present Battery Maintenance Regular maintenance will ensure the battery will accept and hold a charge 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not overfill the battery Poor performance or early failure due to loss of electrolyte will result 2 Keep the cables terminals and external surfaces of battery clean A build up of corrosive acid or grime on the external surfaces can
152. rful recoil spring that is under tension Always wear safety goggles when servicing retractable starters and carefully follow instructions in Retractable Starter Section 7 for relieving spring tension AA WARNING Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present AA CAUTION K Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Section 1 Safety and General Information Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers of the engine The engine identification numbers appear a on decal or decals affixed to the en
153. s denoting proper flywheel rotation must be up Move the module as far from the flywheel magnet as possible Tighten the hex flange screws Slightly 2 Insert a 0 25 mm 0 010 in flat feeler gauge or shim stock between the magnet and ignition module See Figure 11 48 Loosen the screws so the magnet pulls the module against the feeler gauge s o mg en E F Flat Feeler a D SIE Se e Ze F e T Ss Figure 11 48 Installing Ignition Module 3 Tighten the hex flange screws as follows Into new as cast hole 6 2 N m 55 in Ib Into used hole 4 0 N m 35 in Ib 4 Rotate the flywheel back and forth check to make sure the magnet does not strike the module Check the gap with feeler gauge and readjust if necessary Final Air Gap 0 203 0 305 mm 0 008 0 012 in 5 Connect the kill lead to the tab terminal on the ignition module Install Baffles and Blower Housing NOTE Leave all hardware slightly loose until all sheet metal pieces are in position 1 Install the blower housing back plate and two hex flange screws See Figure 11 49 11 16 Blower Housing Back Plate g o S Figure 11 49 installing Blower Housing Back Plate 2 Install the starter side cylinder barrel baffle and one hex flange screw See Figure 11 50 i w ef TT 4 J i l e E E Fest t a Tgr ja ae 4h Ed Se r TET EN tb d mn Gas oF z 4 j 3 f LI 1 a d Sji S
154. s used to notify people of installation operation or maintenance information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery WARNING K Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information AA WARNING Explosive Fuel can cause fires and severe burns Stop engine before fill
155. se a brush holder tool to keep the brushes in the pockets A brush holder tool can easily be made from thin sheet metal See Figure 8 22 Stud Terminal with Positive Brushes Self Tapping 44 if Screw A Negative Sa Brush Springs Under Brushes Figure 8 21 Style A Commutator End Cap with Brushes Brush Holder Tool Installed p Over Brushes and End Cap Sheet Metal Brush Holder Tool Figure 8 22 Brush Holder Tool Style A End Cap Style B End Cap Brush Replacement Starters with Style B end caps have the brushes in a plastic carrier housing separate from the end cap Replacement brushes come preassembled in the carrier housing retained with two carton staples Commutator Service Clean the commutator with a coarse lint free cloth Do not use emery cloth If the commutator is badly worn or grooved turn it down on a lathe or replace the armature Section 8 Electrical System and Components Starter Reassembly 1 Place the thrust washer if so equipped over the drive shaft of armature 2 Insert the armature into the starter frame Make sure the magnets are closer to the drive shaft end of armature The magnets will hold the armature inside the frame 3 Install the drive end cap over the drive shaft Make sure the match marks on the end cap and starter frame are aligned See Figure 8 23 Match Marks Figure 8 23 Starter Assembly Match Marks For Style A Commutator End Caps
156. sion Sentry controls have a fixed main jet carburetor Adjustable Coupling L D Load Screw LPG Carburetor Shown with Self Relieving Choke Ay Valve Body Fuel Metering Electronic Control Unit i To Unit L H Wiring Harness 12 Volt Source Figure 5 17 Main Components of Kohler Emission Sentry System 5 12 Kohler Emission Sentry System Some Kohler Command engines are equipped with the Emission Sentry System Emission Sentry is a feature which assures the operator that the exhaust emission levels of the engine are well within safe exposure limits The system does not require any additional daily maintenance beyond the schedule normally specified for Command engines Principle of Operation The Emission Sentry System can be broken down into two functions One function is to control the ratio of air and fuel entering the engine The second function is treating the exhaust gas utilizing a 3 way catalytic converter The function of air fuel ratio control is carried out by an oxygen sensor placed in the exhaust stream an electronic control unit a stepper motor anda fuel metering valve The oxygen sensor indirectly measures the oxygen level in the exhaust stream An abundance of oxygen indicates a lean condition and a lack of oxygen indicates a rich condition The sensor sends an electrical signal to the electronic control unit where the signal is analyzed The el
157. sistance is low in both directions the No battery and engine stopped measure diode is shorted Replace the diode resistance from charging lead to ground To using an ohmmeter Note reading If resistance is high in both directions the diode or stator winding is open Reverse the leads and measure Use Test 4 resistance again Charge Battery In one direction the resistance should be infinity ohms open circuit With the leads reversed some resistance should be measured about midscale on Rx1 range 4 Disconnect the lighting lead yellow from 4 If resistance is approximately 0 15 ohms the wiring harness stator winding is OK Measure the resistance from the lighting If resistance is 0 ohms stator winding is lead to ground using an ohmmeter shorted Replace stator If resistance is infinity ohms stator winding or lead is open Replace stator 1 Make sure lights are not burned out 1 Replace burned out lights 2 Disconnect the lighting lead yellow from 2 If voltage is 13 volts or more stator is OK the wiring harness Check for loose connections or shorts in wiring harness With engine running at 3400 RPM No measure voltage from lighting lead to If voltage is less than 13 volts test stator Lights ground using an AC voltmeter using an ohmmeter Test 3 3 With engine stopped measure the 3 If resistance is approximately 0 15 ohms resistance of stator from lighting lead to stator is OK ground using
158. sition See Figure 8 28 7 Mount the brush holder to rear of starter frame Install the four brushes into the corresponding slots Then carefully work set each of the four brush springs into position behind the brushes Slide the rubber insulating grommet onto the small corresponding plastic tab on frame See Figure 8 30 Figure 8 28 Lock Collar around Retaining Ring 5 Install the thrust washer onto the armature shaft and lightly lubricate the end of the shaft with drive lubricant Figure 8 30 Mounting Brush Holder to Frame 6 Position the lubricated drive lever around the drive pinion assembly and insert the assembly into the drive end cap Seat the pivot section of drive lever into the corresponding section within the housing See Figure 8 29 8 26 Section 8 Electrical System and Components 8 Position the insulator over the brushes and springs Hold it firmly in place so the springs do not come out See Figure 8 31 Figure 8 33 Installing Frame with Brush Plate Assembly 11 Remove the tool and install the commutator Figure 8 31 Holding Insulator in Place end cap aligning the cutout with the insulating grommet See Figure 8 34 9 Stand the armature drive end cap assembly on end so the commutator end is up Place brush armature installation tool over the end of the armature shaft until it rests against the commutator See Figure 8 32 Figure 8 34 Installing End Cap 12 Inst
159. slot in the end of the blower housing NOTE Always use fresh sealant Using outdated Plastic blower housings have a formed slot to sealant can result in leakage contain the lead Install the blower housing and secure with the mounting screws See Figures 1 Prepare the sealing surfaces of the cylinder head 11 53 and 11 54 and valve cover following Service Bulletin 252 If it is a stamped steel valve cover the flatness of the sealing surface must be checked prior to reinstallation See Section 10 11 17 Section 11 Reassembly 2 Apply a 1 16 bead of RTV sealant to the cylinder head as shown in Figure 11 55 NOTE To ensure proper adhesion of the sealant to both sealing surfaces perform Step 3 immediately 5 minutes maximum after application of RTV sealant Figure 11 55 Valve Cover Sealant Pattern 3 Install the valve cover any attached mounting brackets muffler fuel tank lifting along with any spacers Stamped steel cover originally used Secure with the five hex flange screws Cover Screws Figure 11 56 Installing Valve Cover Cast Aluminum Cover Shown 4 Torque the screws in the sequence shown in Figure 11 57 as follows Into new as cast hole 10 7 N m 95 in Ib Into used hole 7 3 N m 65 in Ib 11 18 Figure 11 57 Valve Cover Torque Sequence Install Extended Oil Fill Tube 1 Make sure the two O Rings on the oil fill tube and the O Ring in the oil fill cap are in pl
160. ss of speed and power poor fuel economy and poor or slow governor response To compensate for the effects of high altitude a special high altitude main fuel jet can be installed High altitude jets are sold in kits which include the jet and necessary gaskets Refer to the Parts Manual for the engine being serviced for the correct kit number Fuel Shut off Solenoid Optional Some gasoline fueled engines are equipped with the optional fuel shut off solenoid which is installed in place of the bowl retaining screw to eliminate backfiring when the engine is shut down If a solenoid equipped engine will not start check whether sufficient voltage is reaching the solenoid A minimum of 7 3 volts DC is required to activate the solenoid Also check to see that the ground lead from the carburetor body to the air cleaner base mounting stud is properly connected If these check out the solenoid should be removed for bench testing Remember to shut off fuel supply and catch any fuel spilling from the carburetor as the solenoid is removed Bench test the solenoid by grounding the solenoid case and applying 12 volt DC to the spade terminal If the plunger does not retract in this test the solenoid is faulty and must be replaced Always use a new fuel bowl gasket whenever the solenoid is installed Refer to the appropriate wiring diagram in Section 8 for connecting the fuel shut off solenoid LPG Systems Components of a typical LPG liqu
161. st Blend Smoothly With The Bearing 456 Journal Surface Minimum This Fillet Area Must Be Completely Smooth Figure 10 1 Crankpin Fillets On engines with a replaceable bearing insert on the flywheel end the crankshaft flywheel end main bearing journal can be ground two sizes under The connecting rod journal can be ground one size under When grinding a crankshaft on a CV11 16 CV460 465 CV490 495 engine grinding stone deposits can get caught in the oil passages which could cause severe engine damage Removing the plug each time the crankshaft is ground provides easy access for cleaning any grinding deposits that may collect in the oil passages Use the following procedure to remove and replace the plug Procedures to Remove Plug 1 Drill a 3 16 hole through the plug in the crankshaft 2 Thread a 3 4 or 1 long self tapping screw with a flat washer into the drilled hole The flat washer must be large enough to seat against the shoulder of the plug bore See Figure 10 2 3 Tighten the self tapping screw until it draws the plug out of the crankshaft Procedure to Install New Plug 1 Use a single cylinder camshaft pin Part No 47 380 09 S as a driver and tap the plug into the plug bore until it seats at the bottom of the bore Make sure the plug Is tapped in evenly to prevent leakage Self Tapping Screw Flat Washer Plug Crankshaft Figure 10 2 Removing Plug Crankcase Inspection and Servic
162. t throttle position Then move the throttle lever back 3 16 or 4 75 mm Insert the cable boden wire into the throttle control lever on the control plate 3 Position the throttle cable under the cable clamp 4 Pull on the throttle cable until it stops hold it and tighten the cable clamp screw 5 Move application throttle lever to the slow position then to full throttle Check the engine control to assure it stops against the stop screw which means it is properly set Choke Control 1 Insert the choke cable boden wire into the engine choke control lever on the control plate HIGH IDLE Turn Screw Inward to decrease RPM Turn Screw Outward to Lock Nut Increase RPM Tighten Lock Nut When Desired RPM Is Obtained Position 4 Choke Throttle aam Ten Choke Position 3 Throttle Position the choke cable under the cable clamp Push the choke knob handle in the application panel until it bottoms then pull it back approximately 1 16 Push on the choke cable above the clamp on the engine control plate until the choke lever stops Then tighten the cable clamp screw Pull the choke knob handle until it stops check to assure the choke link cannot be moved towards the carburetor by applying finger pressure on the link loop behind the engine control plate If the choke link moves adjust by following steps 3 and 4 Push the choke knob handle in until it bottoms The choke control link should be free so
163. t Point Install Piston and Connecting Rod Towards Flywheel NOTE Proper orientation of the piston connecting l a i rod inside the engine is extremely important e ge e Improper orientation can cause extensive d wear or damage 1 Stagger the piston rings in the grooves until the end gaps are 120 apart 2 Lubricate the cylinder bore piston and rings with engine oil Compress the piston rings using a piston ring compressor See Figure 11 8 Push the piston through the compressor so the oil control bottom ring is just above the lower edge of the compressor 11 3 Section 11 Reassembly 4 Lubricate the crankshaft journal and connecting rod bearing surfaces with engine oil Install the rod cap to connecting rod 5 Three different types of connecting rod bolts have been used in production and each has a different torque value See Figures 11 10 and 11 11 The 8 mm straight shank style rod bolts must be torqued in increments to 22 7 N m 200 in Ib The 8 mm step down shank style rod bolts must be torqued in increments to 14 7 N m 130 in Ib The 6 mm straight shank style rod bolts must be torque in increments to 11 3 N m 100 in Ib Illustrated instructions are also provided in the service rod package Torque these to 22 7 N m 200 in Ib 8 mm Straight Shank orque these to 11 6 mm Straight Shank hmmm Figure 11 10 Connecting Rod Bolts 6 Rotate the crankshaft until the piston is at top dead cente
164. t from the carburetor 4 Remove the upper brass bushing using one of the following procedures a Use a slide hammer type bearing puller b Use a 3 for 5 32 dia hole screw extractor Secure extractor in a vise Turn carburetor on to the extractor While pulling on the carburetor lightly tap the carburetor casting with a hammer or use a size 12 28 tap if a 3 screw extractor is not available Throttle Shaft Removal Do not attempt to remove the throttle shaft as repair kits are not available Throttle shaft wear is normally accompanied by corresponding wear to the carburetor body making it impractical to attempt a cost effective repair Replace the entire carburetor if the throttle shaft is worn 5 8 Cleaning A WARNING Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent All parts should be cleaned thoroughly using a commercial carburetor cleaner Make sure all gum deposits are removed from the following areas e Carburetor body and bore especially the areas where the throttle plate choke plate and shafts are seated e Idle fuel and idle ports in carburetor bore main jet bowl vent and fuel inlet needle and seat e Float and float hinge e Fuel bowl e Throttle plate choke plate
165. t of the end gap Connecting Rods Offset stepped cap connecting rods are used in all these engines Inspection and Service Check bearing area big end for excessive wear score marks running and side clearances refer to Section 1 Specifications Tolerances and Special Torque Values Replace rod if scored or excessively worn Service replacement connecting rods are available in STD crankpin size and 0 25 mm 0 010 in undersize Always refer to the appropriate parts information to ensure that correct replacements are used Oil Pump Inspection and Service Pump can be checked replaced without removing oil pan Oil Pressure Relief Valve If an early style five piece oil pressure relief valve body piston and spring is used see Figure 10 11 Check that piston and body are free of nicks or burrs Check the spring for any wear or distortion The free length of the spring should be approximately 0 992 in Replace the spring if worn out of specification or damaged distorted lf the later style one piece oil pressure relief valve see Figure 10 12 is used staked to the closure plate it should only be removed if it is going to be replaced Check to see that internal spring loaded piston is free Section 10 Inspection and Reconditioning Oil Pressure Relief Bracket Relief Valve Body Pra a Hex Flange Screw Figure 10 11 Five Piece Oil Pressure Relief Valve Figure 10 12 One Piece
166. t should be made with air cleaner base installed Sectio n5 Fuel System and Governor 1 With the governor lever loose on the cross shaft pull the lever towards the carburetor wide open throttle 2 Grasp the cross shaft with a pliers or insert a nail into the hole in the end of the cross shaft Rotate the shaft counterclockwise as far as it will turn then tighten hex nut securely 3 Torque the hex nut to 9 9 N m 88 in Ib Unitized Throttle and Choke Control Some engines are equipped with a unitized throttle and choke control bracket assembly This assembly controls the choke and engine speed with a single lever Throttle Cable Adjustment 1 Loosen the throttle control cable clamp See Figure 5 19 Throttle Control Cable SE 78 a Sg 8 Speed a Sc Control a L Brack Throttle DM w AD Figure 5 19 Speed Control Bracket Assembly 2 Place the throttle control lever of the equipment into the fast or high idle position NOTE The choke is placed on by moving the throttle control slightly past the fast position If the throttle control does not have a designated choke on position be sure to leave sufficient throttle control travel past the fast position This will enable the choke to be placed on See Figure 5 20 5 15 Section 5 Fuel System and Governor Figure 5 20 Typical Throttle Choke Controls 3 A
167. tainer caps See Figure 8 62 22 29 in Ib See Figures 8 64 and 8 65 Figure 8 62 Brush Installation Tool with Extension Figure 8 64 Torquing Thru Bolts d Hold the starter assembly vertically on the end housing and carefully place the tool w extension and assembled original brush holder assembly onto the end of the armature shaft Slide the brush holder assembly down into place around the commutator install the positive brush lead grommet in the cutout of the frame See Figure 8 63 8 35 Section 8 Electrical System and Components Figure 8 65 Torquing Brush Holder Screws Figure 8 67 Positive Brush Lead Connection 13 Hook the plunger behind the upper end of Completed Starter Photo the drive lever and install the spring into the solenoid Insert the three mounting screws through the holes in the drive end cap Use these to hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in Ib See Figure 8 66 as d SC meg nn a L Figure 8 68 Delco Remy Solenoid Shift Starter Figure 8 66 Installing Solenoid Screws 14 Connect the positive brush lead bracket to the solenoid and secure with the hex nut Torque the nut to 6 9 N m 53 79 in Ib do not overtighten See Figure 8 67 8 36 CV11 16 CV460 465 CV490 495 Section 9 Disassembly A WARNING Accidental Starts Disabling engine Accidental starting can cause severe
168. te is properly aligned in the choke bore To align choke plate insert a 010 in shim between the top right edge of the choke plate and bore See Figure 5 12 Then while pushing down on the top of the choke shaft tighten screws securely Figure 5 12 Measuring Clearance 5 Check choke shaft and choke plate for freedom of movement by performing the following a Using the choke lever close the choke plate The choke lever and choke plate should move in unison b While holding the choke lever in the closed position push on the long side of the choke plate The choke plate should open and spring closed freely c While holding the choke lever in the wide open position the choke plate should be against the wide open choke plate stop pin Install new dust cover by pushing it down until it Snaps into place After the carburetor is reinstalled on the engine recheck choke system for freedom of movement by moving the wire link in the direction to close the choke and releasing it The link should move freely in both directions 5 9 Section 5 Fuel System and Governor Welch Plug Installation Walbro Carburetors Use Tool No KO1017 and install new plugs as follows 1 Position the carburetor body with the welch plug cavities to the top 2 Place a new welch plug into the cavity with the raised surface up 3 Use the end of the tool that is about the same size as the plug and flatten the plug Do not forc
169. the engine does not run on partial choke High Idle Speed Screw Throttle Choke Position 1 High Idle RPM Control Stop Pad ene zf Throttle Choke Position 2 Figure 5 25 Separate Choke and Throttle Cable Control 4 Positions Shown 5 18 Section 5 Fuel System and Governor Starting an Engine Equipped with Separate 7 Turn the high idle stop screw inward clockwise Control Cables until it stops against the throttle control lever 1 Place the throttle control midway between the Then tighten the stop screw retaining nut slow and fast positions Place the choke control into the on position 8 Recheck high idle RPM to assure the required RPM has been obtained 2 Start the engine Setting the Low Idle RPM 3 For a Cold Engine Gradually return the choke 1 Move the application control to slow position control to the off position after the engine starts and warms up 2 Using a tachometer check the RPM Then using a screwdriver turn the low idle stop screw The engine equipment may be operated during located at the top of the carburetor inward the warm up period but it may be necessary clockwise to increase the RPM and outward to leave the choke partially on until the engine counterclockwise to lower the RPM warms up Governed Idle Adjustment 4 For a Warm Engine Return choke to off A new governed idle control system is now being D position as soon as engine starts supplied on some CV
170. the ACR mechanism it is difficult to obtain an accurate compression reading As an alternate use the leakdown test described below Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly The tester listed on page 2 2 is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run engine for 3 5 minutes to warm it up 2 Remove spark plug s and air filter from the engine 3 Rotate the crankshaft until the piston is at top dead center TDC of the compression stroke You will need to hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible Slide the holding tool onto the crankshaft align the slot hole with one of mounting hold on the PTO face and tighten it onto the crankshaft Install a 3 8 breaker bar into the slot or square hole of the holding tool so It is perpendicular to both the holding tool and crankshaft PTO or insert a shoulder bolt through the slot and thread it into the mounting hole If the flywheel end is more accessible you can use a breaker bar and socket on the flywheel nut screw to hold it in position You
171. the recess in the housing See Figure 8 40 Figure 8 42 Removing Commutator End Plate Assembly S Se A Pi 6 Remove the frame from the armature and drive ged ege e end cap See Figure 8 43 4 Remove the two thru larger bolts See Figure 8 41 Figure 8 43 Starter Frame Removed 7 Remove the drive lever pivot bushing and backing plate from the end cap See Figure 8 44 5 Remove the commutator end plate assembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 8 42 Figure 8 44 8 29 Section 8 Electrical System and Components 8 Take out the drive lever and pull the armature out from the drive end cap See Figure 8 45 9 Remove the thrust washer from the armature shaft See Figure 8 45 Figure 8 47 Removing Retaining Ring 12 Remove the drive pinion assembly from the armature 13 Clean the parts as required Figure 8 45 Armature and Lever Removed NOTE Do not soak the armature or use solvent when cleaning Wash and dry clean using a soft cloth or compressed air 10 Push the stop collar down to expose the retaining ring See Figure 8 46 Figure 8 46 Retaining Ring Detail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer 8 30 Section 8 Electrical System and Components Plunger Spring Lever e Eis i
172. ting of engine oil to prevent rusting Measuring Piston to Bore Clearance Before installing the piston into the cylinder bore it is necessary that the clearance be accurately checked This step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer 10 4 Use the following procedure to accurately measure the piston to bore clearance 1 Use a micrometer and measure the diameter of the piston perpendicular to the piston pin and up from the bottom of the piston skirt as indicated in Figure 10 4 based on the model involved Measure 6 mm 0 24 in on CV11 14 CV460 465 Engines 8 5 mm 0 33 in on CV15 16 CV490 495 Engines Above the Bottom of Piston Skirt at Right Angles to Piston Pin Egger Measure Here Toy T Figure 10 4 Measuring Piston Diameter 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 63 5 mm 2 5 in below the top of the bore and perpendicular to the piston pin 3 Piston to bore clearance is the difference between the bore diameter and the piston diameter step 2 minus step 1 Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace flywheel if cracked Replace the flywheel the cran
173. tion If however the engine is hard starting or does not operate properly it may be necessary to adjust or service the carburetor Low idle Speed Screw H ke SL BE E Low Idle Fuel Needle w Figure 5 4 Fixed Main Jet Carburetor Walbro Carburetor Adjustment NOTE Certified engines may have a fixed idle or limiter cap on the idle fuel adjusting needle Step 2 can only be performed within the limits allowed by the cap 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before doing step 2 2 Low idle Fuel Needle Setting Place the throttle into the idle or slow position Turn the low idle fuel adjusting needle out counterclockwise from the preliminary setting until engine speed decreases rich Note the position of the needle Section 5 Fuel System and Governor Now turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle Set the adjusting needle midway between the rich and lean settings See Figure 5 5 Adjust to Midpoint Bee Figure 5 5 Optimum Low Idle Fuel Setting Nikki Carburetor Adjustment NOTE Certified engines have the idle mixture preset and sealed at the factory No adjustment is possible Low Idle Speed Setting 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm be
174. to expand Tanks must be removed from equipment before filling High Pressure Lines Automatic Shut off Valve Vacuum Lockoff On some applications the vacuum line goes directly into the intake side of the cylinder head maybe part of regulator Propane Supply Tank Vapor Withdrawal Figure 5 15 Schematic Showing Components of Typical LPG System 5 11 Section 5 Fuel System and Governor Troubleshooting LPG Systems If engine troubles are experienced that appear to be caused by the carburetor check the following areas before adjusting the carburetor e Make sure the air cleaner element is clean and all air cleaner components are fastened securely This is especially critical on propane fueled engines e Check for a loose or kinked vacuum line causing regulator not to open e Check to make sure the fuel valve on the LPG tank is fully opened e Check gauge on LPG tank to make sure there is sufficient fuel present If after checking the items listed above adjust or service the carburetor as follows 3 Way Catalytic Muffler Not Shown Adjust Carburetor 1 With the engine stopped reset the main fuel setting by closing the adjusting screw until it bottoms then turn it 2 1 4 to 2 1 2 turns open see Figure 5 16 Fuel Inlet from Regulators Main Fuel Set g 2 1 4 to 2 1 2 Turns Open Adjustable Type Only Figure 5 16 LPG Main Fuel Setting NOTE Engines equipped with Kohler Emis
175. triggers while the engine is idling but not during normal operation the idle mixture screw on the regulator is probably out of adjustment Turn the screw 1 2 turn clockwise start the engine and run it at idle for approximately two minutes If the fault circuit does not trigger the problem has been corrected If the fault circuit is triggered and the engine shuts off before two minutes turn the screw an additional 1 4 turn clockwise and test again for two minutes Governor These engines are equipped with a centrifugal flyweight mechanical governor It is designed to hold the engine speed nearly constant under changing load conditions The governor gear flyweight mechanism is mounted inside the crankcase and is driven off the gear on the balance shaft Operation As the governor gear rotates centrifugal force causes the flyweights to move outward as speed increases As the flyweights move outward they cause the regulating pin to move outward The regulating pin contacts the tab on the cross shaft causing the shaft to rotate when the engine speed changes One end of the cross shaft protrudes through the side of the crankcase Through external linkage attached to the cross shaft the rotating action is transmitted to the throttle lever of the carburetor When the engine is at rest and the throttle is in the fast position the tension of the governor spring holds the throttle plate open When the engine is operating the go
176. ulty Test the stator and diode Test 2 3 and 4 2 Disconnect the charging lead from battery 2 If voltage is 20 volts or more stator winding is OK With engine running at 3000 RPM measure voltage from charging lead to If voltage is less than 20 volts test stator ground using a DC voltmeter using an ohmmeter Tests 3 and 4 3 With charging lead disconnected from 3 If resistance is low in both directions the battery and engine stopped measure diode is shorted Replace the diode resistance from charging lead to ground No using an ohmmeter Note reading If resistance is high in both directions Charge the diode or stator winding is open Use To Reverse the leads and measure resistance Test 4 Battery again In one direction the resistance should be infinity ohms open circuit With the leads reversed some resistance should be measured about midscale on Rx1 range 4 Cut the sleeving on the charging lead to 4 lf resistance is approximately 0 5 ohms expose the diode connections stator winding is OK Measure the resistance from the stator side If resistance is 0 ohms stator winding is of diode to ground using an ohmmeter shorted Replace stator If resistance is infinity ohms stator winding or lead is open Replace stator 1 Make sure lights are not burned out 1 Replace burned out lights 2 Disconnect the lighting lead from the wiring 2 If voltage is 13 volts or more stator is OK harness Check for
177. urrent Command series engines COMMAND Tool Kit No KO3214 This kit is for the new Kohler Dealer servicing the Command series engines only RTV Silicone Sealant RTV silicone sealant is used as a gasket between the crankcase and closure plate and between the valve cover and head The recommended sealant is Loctite 5900 available under Kohler Part No 25 597 07 S Prepare the sealing surfaces of the crankcase and closure plate as directed by the sealant manufacturer or refer to Service Bulletin 252 2 1 Section 2 Special Tools Diagnostic and Repair Tools The tools listed in the following table are used for specific diagnosis or repair procedures as described Order from SPX Corp Description SPX Part No Hydraulic Lifter Tool Designed to remove and install hydraulic lifters KO1044 Ignition Tester Used for testing output on capacitive discharge CD ignition systems KO1046 Ignition Tester Used for testing ouput on all other systems except CD KO1047 Water Manometer Used for testing crankcase vacuum and exhaust back pressure KO1048 Inductive Tachometer Used for checking the operating speed RPM of an engine KO3216 Ammeter Set Used for checking current flow in charging and cranking circuits KO3218 Cylinder Leakdown Tester Used for checking combustion retention and if cylinder piston rings or valves are worn KO3219 Oil Pressure Test Kit Used to test verify oil pressure on pressure lubricated engines KO3220 Electric
178. ustment Needle Nikki Low Idle Speed Adjustment Screw gr Figure 5 3 Carburetor Adjustment A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 5 3 Section 5 Fuel System and Governor Troubleshooting Gasoline Systems e Make sure the air cleaner base and carburetor If engine troubles are experienced that appear to be are securely fastened to the engine using gaskets fuel system related check the following areas before in good condition adjusting or disassembling the carburetor e Make sure the air cleaner element is clean and all e Make sure the fuel tank is filled with clean fresh air cleaner components are fastened securely gasoline e Make sure the ignition system governor system e Make sure the fuel tank cap vent is not blocked exhaust system and throttle and choke controls and that it is operating properly are operating properly e Make sure fuel is reaching the carburetor This If after checking the items listed above starting includes checking the fuel shut off valve fuel tank problems or conditions simila
179. vernor gear assembly is rotating the force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin are in equilibrium during operation holding the engine speed nearly constant When load is applied and the engine speed and governor gear speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This allows more fuel into the engine increasing engine speed This action takes place very rapidly so a reduction in speed is hardly noticed As the speed reaches the governed seiting the governor spring tension and the force applied by the regulating pin will again be in equilibrium This maintains the engine speed at a relatively constant level The governed speed seiting is determined by the position of the throttle control It can be variable or constant depending on the application Initial Adjustment Make this initial adjustment whenever the governor arm is loosened or removed from the cross shaft To ensure proper setting make sure the throttle linkage is connected to the governor arm and the throttle lever on the carburetor See Figure 5 18 Governor Lever y KN bei j i E A e e RS e 5 ES e d i A K J ft ER IS Ka Zs e Ed ross Shaft Hex Nut Figure 5 18 Initial Governor Adjustment NOTE Air cleaner removed to show linkage Adjustmen
180. ving Speed Control Bracket 4 Disconnect the choke linkage from the choke control lever of speed control bracket 5 Loosen the hex flange nut and remove the governor arm from the cross shaft 6 Disconnect the fuel line from the inlet fitting of the carburetor See Figure 9 10 Gasket Carburetor Figure 9 10 Sa Fuel Line and Carburetor 7 Remove the baffle screw and internal tooth washer securing the ground lead for the fuel solenoid if So equipped See Figure 9 11 9 4 Saffle Screw Bn and Washer Figure 9 11 SSES Baffle Screw and Washer 8 Remove the carburetor and gasket from the intake studs Remove Fuel Pump If So Equipped WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings from sparks or flames Do not fill the fuel tank w e engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 1 Disconnect the fuel lines from the outlet and inlet fittings of the fuel pump See Figure 9 12 2 Remove the two hex flange screws fuel pump and gasket Pump Outlet as Line Ea lt Flange t _ A f e Figure 9 12 Removing Fuel Pump Remove Rectifier Regulator If Required 1 Remove the connector from t
181. with the ring gear into the retracted position Starter Removal and Installation Refer to the Disassembly and Reassembly sections for starter removal and installation procedures UTE Starter Disassembly 1 Remove clip 2 Remove cap screws and solenoid Scribe alignment marks on caps and frame to aid assembly 3 Remove the thru bolts drive end cap commutator end cap and frame 4 Remove drive lever 5 Remove thrust washer and retainer to remove drive pinion from shaft UTE Brush Replacement Replacing brushes in the solenoid shift starters is exactly the same procedure as explained for the UTE starter in the previous subsection UTE Starter Service Clean drive lever and armature shaft Apply Kohler electric starter drive lubricant 52 357 02 S to lever and shaft UTE Starter Reassembly 1 Slide frame over armature and place commutator end cap in position Hold in position temporarily with tape NOTE Be sure alignment marks on caps and frame are in proper position 2 Place drive pinion with seal thrust washer and retainer on drive shaft 8 24 3 Place lever in position on drive shaft 4 Place solenoid plunger on drive lever and position drive end cap over drive shaft be sure the rubber dust cover is in place at the drive lever 5 Fasten the end caps with the thru bolts 6 Place the spring in the solenoid and fasten solenoid to drive end cap using hex cap screws 7 Replace the clip
182. y to ensure correct reassembly See Figure 5 8 Also take note of the choke plate position in bore and the position of the choke lever and choke return spring Section 5 Fuel System and Governor Choke Plate Figure 5 8 Marking Choke Plate and Carburetor Body 2 Some carburetors have the choke plate inserted into a slot in the choke shaft Grasp the choke plate with a pliers and pull it out of the slot See Figure 5 9 Other carburetors will have the choke plate fastened to the shaft with screws Carefully remove the screws and separate the plate from the shaft Use a fine toothed file to remove any burrs from the shaft Choke Plate Figure 5 9 Removing Choke Plate 3 Remove the choke shaft and choke return spring Choke Shaft Removal Self Relieving The self relieving choke used on some carburetors is shown in cutaway Figure 5 10 Use the following procedure to replace the self relieving choke components using Choke Repair Kit No 12 757 11 S 5 7 Section 5 Fuel System and Governor Ipi X A Y if lt Choke Lever ly ll RZ SH y X LMA YA Screws S SY N BSNS Figure 5 10 Cutaway View Showing Self Relieving Choke Carburetor Removing Old Parts 1 Remove the black dust cover This cover snaps on and off 2 Remove and discard the two screws fastening the choke plate to the choke shaft 3 Remove and discard the choke plate and choke shaf

SERVICE MANUAL CV11-16, CV460-465, CV490-495

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