Kohler COMMAND CV11-16 Service Manual

Vertical crankshaft

Hide thumbs Also See for COMMAND CV11-16:

Service manual (149 pages)

Owner's manual (84 pages)

Table Of Contents

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

Need help?

Do you have a question about the COMMAND CV11-16 and is the answer not in the manual?

Questions and answers

Warren McGuire

March 17, 2025

What is the difference in a cv15 and a cv15s

Summary of Contents for Kohler COMMAND CV11-16

Page 1 ERVICE ANUAL CV11-16, CV460-465, CV490-495 ERTICAL RANKSHAFT...
Page 3: Table Of Contents
Contents Section 1. Safety and General Information ................Section 2. Special Tools ......................Section 3. Troubleshooting ...................... Section 4. Air Cleaner and Air Intake System ................. Section 5. Fuel System and Governor ..................Section 6. Lubrication System ....................Section 7. Retractable Starter ....................Section 8.
Page 5: Section 1. Safety And General Information
CV11-16 Section 1 CV460-465, CV490-495 Safety and General Information Section 1 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.
Page 6 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause ﬁ res and Explosive Fuel can cause ﬁ res and Carbon Monoxide can cause severe acid burns. severe burns. severe nausea, fainting or death. Charge battery only in a well Stop engine before ﬁ...
Page 7 SAFETY, MAINTENANCE SPECS CV13 AND ADJUSTMENTS. FOR SALES CV14 AND SERVICE IN US/CANADA CV15 CALL: 1-800-544-2444. CV16 www.kohlerengines.com CV460-465 CV490-495 KOHLER CO. KOHLER, WI USA C. Serial No. 2105810334 Year Manufactured Code Factory Code Code Model 1991 1992 1993 1994...
Page 8 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 Figure 1-3.
Page 9 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 and system are empty.
Page 10 Section 1 Safety and General Information Air Filter and Cover Cylinder Oil Filter Carburetor Fuel Shut-off Solenoid Carburetor (1.85) Fuel Inlet Engine Mounting Surface Oil Drain Plug 3/8 NPT Inch (.67) (10.31) Cylinder Oil Filter Side 24.0 (9.4) 25.4 Valve Cover End (1.00) (16.18) 6.34...
Page 11 Section 1 Safety and General Information General Speciﬁ cations¹ Power (@ 3600 RPM, corrected to SAE J1995) CV11 .................. 8.2 kW (11 HP) CV12.5 ................9.33 kW (12.5 HP) CV13 .................. 9.75 kW (13 HP) CV14 .................. 10.5 kW (14 HP) CV15 ..................
Page 12 Section 1 Safety and General Information Balance Shaft End Play ......................0.0575/0.3625 mm (0.0027/0.0137 in.) Running Clearance ..................0.0250/0.1520 mm (0.0009/0.0059 in.) Bore I.D. New ......................20.000/20.025 mm (0.7874/0.7884 in.) Max. Wear Limit ..................20.038 mm (0.7889 in.) Balance Shaft Bearing Surface O.D. New ......................19.962/19.975 mm (0.7859/0.7864 in.) Max.
Page 13 Section 1 Safety and General Information Crankshaft End Play (free)..................0.0575/0.4925 mm (0.0022/0.0193 in.) End Play (thrust bearing with shims) ............0.050/0.530 mm (0.0020/0.0209 in.) Crankshaft Bore in Crankcase I.D. New ....................44.965/44.990 mm (1.7702/1.7712 in.) Max. Wear Limit .................44.9758/45.0012 mm (1.7707/1.7717 in.) Crankshaft Bore in Crankcase Running Clearance New ....................0.0300/0.0770 mm (0.0011/0.0030 in.) Crankshaft Bore in Oil Pan I.D.
Page 14 Section 1 Safety and General Information Cylinder Head Cylinder Head Fastener Torque (torque in 2 increments) ..24, 48.9 N·m (18, 36 ft. lb.) Max. Out-of-Flatness ..............0.076 mm (0.003 in.) Rocker Pedestal Fastener Torque ..........11.3 N·m (100 in. lb.) Electric Starter Starter Thru Bolt Torque UTE/Johnson Electric, Eaton (Inertia Drive) ......
Page 15 Section 1 Safety and General Information Ignition (Cont'd) Spark Plug Torque ..............24.4-29.8 N·m (18-22 ft. lb.) Ignition Module Air Gap ............0.200/0.300 mm (0.0078/0.0118 in.) Ignition Module Fastener Torque ..........6.2 N·m (55 in. lb.) Into new as-cast hole 4.0 N·m (35 in.
Page 16 Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin (Cont'd.) Center Compression Ring End Gap New Bore CV11-14, CV460-465 ............0.250/0.510 mm (0.0010/0.020 in.) CV15, CV16, CV490-495 ..........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, CV460-465 ............
Page 17 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.) 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.
Page 18 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 10% Property Class Noncritical 10.9 12.9 Fasteners Into Aluminum Size 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
Page 19: Section 2. Special Tools
Command series engines. source for all Kohler special tools, and to make it easy and convenient to obtain those tools, at reasonable COMMAND Tool Kit No. KO3214–This kit is for the cost.
Page 20: Section 2 Special Tools
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...
Page 21 I.D. to slip on the capscrew and an teeth on the ﬂ ywheel. The bosses will “lock” the tool O.D. of approximately 1". Kohler Part No. 12 468 05-S and ﬂ ywheel in position for loosening, tightening or can be used if you don’t have the right size on hand.
Page 22 Section 2 Special Tools...
Page 23: Section 3. Troubleshooting
CV11-16 Section 3 CV460-465, CV490-495 Troubleshooting Section 3 Troubleshooting Troubleshooting Guide Engine Will Not Crank 1. PTO drive is engaged. When troubles occur, be sure to check the simple 2. Battery (if equipped) is discharged. causes which, at ﬁ rst, may seem too obvious to be 3.
Page 24 Section 3 Troubleshooting • Check the carburetor throat for dirt. Dirt in the Engine Loses Power 1. Low crankcase oil level. throat is further indication that the air cleaner is 2. High crankcase oil level. not functioning properly. 3. Dirty air cleaner element. •...
Page 25 Section 3 Troubleshooting Basic Engine Tests 2. Start the engine and run at no-load, high idle speed (3200 to 3750 RPM). Crankcase Vacuum Test 3. Open the clamp and note the water level in the A partial vacuum should be present in the crankcase tube.
Page 26 Section 3 Troubleshooting Compression Test onto the crankshaft, align the slot/hole with one These engines are equipped with an automatic of mounting hold on the PTO face, and tighten compression release (ACR) mechanism. Because it onto the crankshaft. Install a 3/8" breaker bar of the ACR mechanism, it is difﬁ...
Page 27: Section 4. Air Cleaner And Air Intake System
CV11-16 Section 4 CV460-465, CV490-495 Air Cleaner and Air Intake System Section 4 Air Cleaner and Air Intake System Air Cleaner Air Duct These engines are equipped with a replaceable, high density paper air cleaner element and most also have Knob (Part the optional oiled, foam precleaner which surrounds of Cover)
Page 28: Section 4 Air Cleaner And Air Intake System
All types can element. Replace a dirty, bent, or damaged use either the standard size element or a higher, extra element with a genuine Kohler element. Handle capacity paper element. new elements carefully; do not use if the sealing surfaces are bent or damaged.
Page 29 If time will not permit air drying, keep 2. Install the gasket, air cleaner base, and base a spare ﬁ lter on hand (Kohler Part No. 12 050 02-S). mounting nuts. Torque the nuts to 9.9 N·m When reinstalling, make sure the foam ﬁ...
Page 30 Section 4 Air Cleaner and Air Intake System...
Page 31: Section 5. Fuel System And Governor
Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded WARNING: Explosive Fuel! gasoline by volume) is approved as a fuel for Kohler Gasoline is extremely ﬂ ammable and its vapors can engines. Other gasoline/alcohol blends are not explode if ignited. Store gasoline only in approved approved.
Page 32 Outlet Check Valve Some engines are equipped with an in-line fuel ﬁ lter. Camshaft Visually inspect the ﬁ lter periodically, and replace when dirty with a genuine Kohler ﬁ lter. Fuel Pump Some engines are equipped with an optional mechanical fuel pump.
Page 33 Section 5 Fuel System and Governor 3. Torque the hex. ﬂ ange screws as follows: Repair Nylon-bodied fuel pumps are not serviceable and must Into new as-cast hole–9.0 N·m (80 in. lb.). be replaced when faulty. Replacement pumps are available in kits that include the pump and mounting Into used hole–4.2-5.1 N·m (37-45 in.
Page 34 Section 5 Fuel System and Governor • Make sure the air cleaner base and carburetor Troubleshooting - Gasoline Systems are securely fastened to the engine using gaskets If engine troubles are experienced that appear to be in good condition. fuel system related, check the following areas before adjusting or disassembling the carburetor.
Page 35 Section 5 Fuel System and Governor Adjustment Now turn the adjusting needle in (clockwise). The NOTE: Carburetor adjustments should be made only engine speed may increase, then it will decrease as the needle is turned in (lean). Note the after the engine has warmed up. position of the needle.
Page 36 Section 5 Fuel System and Governor Disassembly Throttle Lever and Shaft Dust Seal Throttle Plate Screw(s) Choke Lever and Shaft Choke Return Spring Throttle Plate Low Idle Speed Adjusting Choke Plate Screw and Spring Fuel Inlet Seat Low Idle Fuel Adjusting Needle and Spring (may Float Fuel Inlet Needle...
Page 37 Section 5 Fuel System and Governor Choke Plate Tool No. KO1018 Pry Out Plug Do Not Allow Tip to Strike Carburetor Body Pierce Plug with Tip Carburetor Body Welch Plug Figure 5-7. Removing Welch Plug. Figure 5-8. Marking Choke Plate and Carburetor Body.
Page 38 Section 5 Fuel System and Governor Cleaning Dust Cap Choke Lever Spring WARNING: Flammable Solvents! Brass Carburetor cleaners and solvents are extremely Bushing ﬂ ammable. Keep sparks, ﬂ ames, and other sources of ignition away from the area. Follow the cleaner Stop Pin manufacturer’s warnings and instructions on its proper and safe use.
Page 39 Section 5 Fuel System and Governor Repair Top View Showing Always use new gaskets when servicing or reinstalling Spring Position Bottom of carburetors. Repair kits are available which include Spring in new gaskets and other components. Always refer to Position 2 the Parts Manual for the engine being serviced to ensure the correct repair kits are ordered.
Page 40 Section 5 Fuel System and Governor Welch Plug Installation–Walbro Carburetors 4. Insert the fuel inlet needle into the ﬂ oat. Lower Use Tool No. KO1017 and install new plugs as follows: the ﬂ oat/needle into the carburetor body. See Figure 5-14. 1.
Page 41 An air space must be present in the covers standard systems as shown in Figure 5-15 and tank to allow fuel to expand. ™ engines equipped with the Kohler Emission Sentry System. Tanks must be removed from equipment before ﬁ lling. Fuel Recommendations (LPG) WARNING: Pressurized LPG! Fuel tanks are ﬁ...
Page 42 Mufﬂ er (Not Shown) DC Stepper Motor Oxygen Sensor Coupling Adjustable Load Screw Electronic Control Unit LPG Carburetor Shown with To Unit Self-Relieving Wiring Harness Fuel Metering Choke (12 Volt Source) Valve Body Figure 5-17. Main Components of Kohler Emission Sentry™ System. 5.12...
Page 43 Kohler Emission Sentry System The oxygen sensor continually monitors the emission levels in the exhaust while the unit is running. If the Some Kohler Command engines are equipped with emission levels exceed a predetermined level, a fault ™ ™ the Emission Sentry System.
Page 44 2. The stepper motor, electronic control unit valve body, clean the threads with solvent, and (ECU) and oxygen sensor can all be checked reinstall. Check it again for binding. Do not use with the Kohler Emission Sentry ™ Tester (Kohler Part No. 12 761 07-S).
Page 45 Section 5 Fuel System and Governor When the engine is at rest, and the throttle is in the 1. With the governor lever loose on the cross shaft, ‘‘fast’’ position, the tension of the governor spring pull the lever towards the carburetor (wide open holds the throttle plate open.
Page 46 Section 5 Fuel System and Governor 1. Make sure the throttle cable is adjusted properly (see ‘‘Throttle Cable Adjustment"). 2. Start the engine and allow it to warm up. Place the throttle control lever into the ‘‘fast’’ or high idle position.
Page 47 Section 5 Fuel System and Governor Choke Adjustment This procedure must follow the "High Idle Speed Adjustment" just described. If not already completed, perform that operation ﬁ rst. 1. Turn the choke adjusting screw out (counterclockwise), until it no longer contacts the choke lever.
Page 48 Section 5 Fuel System and Governor 2. Position the application throttle control in the full 2. Position the choke cable under the cable clamp. (fast) throttle position. Then move the throttle lever back 3/16" or 4.75 mm. Insert the cable 3.
Page 49 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"...
Page 50 Section 5 Fuel System and Governor Governed Idle Adjusting Screw Figure 5-26. Location of Governed Idle Adjusting Screw. 5.20...
Page 51: Section 6. Lubrication System
CV11-16 Section 6 CV460-465, CV490-495 Lubrication System 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.
Page 52 Section 6 Lubrication System Optional Oil Oil Fill Cap/Dipstick Filter Drain Plug Oil Filter Oil Fill Tube Oil Drain Plug (Carburetor Side) Optional Oil Sentry ™ Pressure Switch Figure 6-3. Checking Oil Level. 4. Remove the dipstick and check the oil level. Oil Filter The oil level should be up to, but not over the ‘‘F’’...
Page 53: Lubrication System
A pressure 200 hours of operation). Always use a genuine relief valve in the oil pan limits the maximum pressure Kohler oil ﬁ lter. of the system. Replace the oil ﬁ lter as follows:...
Page 54 Section 6 Lubrication System Figure 6-9. Engine Mounted Oil Filter. Figure 6-7. Oil Pickup. Oil Sentry ™ Some engines are equipped with an optional Oil Oil Pressure Sentry ™ oil pressure monitor. If the oil pressure Relief Valve ™ gets low, Oil Sentry will either shut off the engine or activate a warning signal, depending on the application.
Page 55 Section 6 Lubrication System Installation Testing the Oil Sentry ™ Switch ™ The pressure switch is installed in the oil ﬁ lter The Oil Sentry pressure monitor is a normally-closed adapter, in one of the main oil galleries of the oil pan. switch.
Page 56 Section 6 Lubrication System...
Page 57: Section 7. Retractable Starter
CV11-16 Section 7 CV460-465, CV490-495 Retractable Starter Section 7 Retractable Starter 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 Starter Housing 1.
Page 58 Section 7 Retractable Starter Rope Replacement 9. Insert the new rope through the rope hole in The rope can be replaced without complete starter starter pulley and rope guide bushing of housing. disassembly. See Figure 7-4. 1. Remove the starter from the engine blower Keep Pulley housing.
Page 59 Section 7 Retractable Starter Disassembly 4. Carefully note the positions of the pawls and pawl springs before removing them. CAUTION: Spring Under Tension! Remove the pawls and pawl springs from the Do not remove the center screw from the starter until starter pulley.
Page 60 Pulley & Spring 2. Replace all worn or damaged components. Use only genuine Kohler replacement parts as speciﬁ ed in the Parts Manual. All components shown in Figure 7-1 are available as service parts. Do not use nonstandard parts.
Page 61: Section 8. Electrical System And Components
Champion the gap by carefully bending the ground electrode. Premium Gold 2071 (used on Pro Series See Figure 8-1. engines, Kohler Part No. 12 132 06-S) is also available. Equivalent alternate brand plugs can also be used. Wire Gauge Gap: CV11-15,CV460-465,490-495 1.02 mm (0.040 in.)
Page 62 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. lb.). 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.
Page 63 Section 8 Electrical System and Components Electronic Magneto Ignition System, CV11-15, CV460-465, CV490-495 Engines Spark Plug Boot Spark Plug Terminal (C) Spark Plug Air Gap 0.2-0.3 mm (0.008-0.012 in.) Ignition Module Lamination (A) Kill Terminal (B) Magnet Flywheel Kill Switch or Off Position of Key Switch Figure 8-2.
Page 64 Section 8 Electrical System and Components Magneto Ignition System Troubleshooting Guide The following guide will help locate and correct ignition system problems. Conclusion Problem Test 1. Make sure the spark plug lead is connected to the spark plug. 2. Check the condition of spark plug. Make 2.
Page 65 Section 8 Electrical System and Components ™ Electronic Ignition System with Spark Advance (Smart Spark ), CV16 Engines 12 Volt Battery Kill Switch or Off Position of Key Switch Spark Advance Module Spark Plug Air Gap (0.2/0.3 mm) Ignition Module 0.008/0.012 in.
Page 66 Section 8 Electrical System and Components Operation capacitor exceeds the charge pump capacitor, the As the ﬂ ywheel rotates, the magnet grouping passes comparator changes state and activates the pulse the input coil (L1) of the ignition module, inducing generator, The ‘‘generated’’ pulse returns to the energy in the coil.
Page 67 Section 8 Electrical System and Components Troubleshooting CD Ignition Systems *NOTE: Ignition tester KO1046 must be used to test Smart Spark ™ ignition. Use of any other tester The CD ignition system is designed to be trouble- can result in inaccurate ﬁ ndings. Battery free for the life of the engine.
Page 68 Section 8 Electrical System and Components If the battery charge is not sufﬁ cient to crank the 4. Remove the blower housing from the engine. engine, recharge the battery. a. Trace the black ground lead from the SAM Battery Charging and check that the ground tab and terminal connections are all tight.
Page 69 Section 8 Electrical System and Components Battery Test 3 Amp Test the battery voltage by connecting DC voltmeter Charging across the battery terminals - crank the engine. If the Stator battery drops below 9 volts while cranking, the battery is discharged or faulty. Refer to Figure 8-8. Lighting Lead (Yellow) Diode...
Page 70 Section 8 Electrical System and Components Ground-To-Kill Lead (White) Ignition Light Diode (Blue) Module (Red) Spark Plug Key Switch (Black) Flywheel Optional Stator Fuse (Yellow) Optional Optional Oil Sentry Optional Ammeter Switch Stator Brake Optional 70 Watt (Indicator Optional Lighting Stator Light) Sentry Safety...
Page 71 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. Problem Test Conclusion...
Page 72 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. Problem Test Conclusion...
Page 73 Section 8 Electrical System and Components Conclusion Problem Test 1. Make sure lights are not burned out. 1. Replace burned out lights. 2. If voltage is 35 volts or more, stator 2. Disconnect the braking lead (green) from is OK. Circuitry on unit that grounds the wiring harness.
Page 74 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) (Blue) Spark Ignition Plug Module Rectiﬁ er (Red) Regulator Key Switch Flywheel Optional Stator Fuse Auto Diodes Optional Optional Oil Choke Ammeter Fuel...
Page 75 Section 8 Electrical System and Components Rectiﬁ er-Regulator AC Leads 15 Amp Stator Figure 8-14. 15 amp Stator and Rectiﬁ er-Regulator. DC Volt Meter Rectiﬁ er-Regulator Flywheel Stator Ammeter Battery Figure 8-15. Proper Connection to Test 15 amp Charging System. 8.15...
Page 76 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. Problem Test Conclusion...
Page 77 Section 8 Electrical System and Components Electric Starters NOTE: If the starter does not crank the engine, shut off the starter immediately. Do not make Some engines in this series use inertia drive starting further attempts to start the engine until the motors while others use solenoid shift type.
Page 78 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.
Page 79 (see Figure 7. The splines should have a light ﬁ lm of lubricant. 8-18). Slide the collar over the inner halves to Relubricate as necessary with Kohler bendix hold them in position. starter lubricant (Part No. 52 357 01-S). Reinstall...
Page 80 Section 8 Electrical System and Components Retaining Ring Installation 2. Locate the small raised line on the edge of 1. Position the retaining ring in the groove in one of the drive end cap. On starters with Style "A" the inner halves. Assemble the other half over the commutator end caps, it will be aligned with a top and slide on the outer collar.
Page 81 Section 8 Electrical System and Components NOTE: Use a brush holder tool to keep the Starter Reassembly brushes in the pockets. A brush holder 1. Place the thrust washer (if so equipped) over the tool can easily be made from thin sheet drive shaft of armature.
Page 82 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.
Page 83 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.
Page 84 UTE Starter Service NOTE: When removing the lever and armature Clean drive lever and armature shaft. Apply Kohler be careful not to lose the thrust washer. electric starter drive lubricant (52 357 02-S) to lever and shaft.
Page 85 If replacement is Starter Service necessary, all four brushes should be replaced. 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.
Page 86 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.
Page 87 Section 8 Electrical System and Components 8. Position the insulator over the brushes and springs. Hold it ﬁ rmly 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.
Page 88 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.
Page 89 Section 8 Electrical System and Components 3. Lift and unhook the plunger assembly from the drive lever. Remove the gasket from the recess in the housing. See Figure 8-40. Figure 8-42. Removing Commutator End Plate Assembly. 6. Remove the frame from the armature and drive Figure 8-40.
Page 90 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.
Page 91 Section 8 Electrical System and Components Screw Collar Ring Plunger Stop Spring Drive Lever Plate Plug Solenoid Armature Frame & Field Washer Brush Holder Tube CE Frame ASM Screw Bolt Figure 8-48. Delco-Remy Solenoid Shift Starter. Brushes and Springs Inspection Inspect both the springs and brushes for wear, fatigue, or damage.
Page 92 The brushes and springs are serviced as a set surface). The mica insulation of the commutator (4). Use Brush and Spring Kit, Kohler Part No. must be lower than the O.D surface (undercut) to 25 221 01-S, if replacement is necessary.
Page 93 Section 8 Electrical System and Components Starter Service 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.
Page 94 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.
Page 95 Section 8 Electrical System and Components Figure 8-61. Removing Retaining Caps. Figure 8-63. Installing Brush Holder Assembly Using Tool with Extension. b. Position each of the brushes back in their slots so they are ﬂ ush with the I.D. of 11.
Page 96 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.
Page 97: Section 9. Disassembly
CV11-16 Section 9 CV460-465, CV490-495 Disassembly Section 9 Disassembly WARNING: 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.
Page 98 Section 9 Disassembly Mufﬂ er Hex. Flange Nuts Spark Plug Lead Oil Filter Gasket Oil Drain Optional Oil Sentry ™ Switch or Oil Filter Drain Plug Figure 9-3. Removing Mufﬂ er. Figure 9-1. Removing Spark Plug Lead, Oil Drains, ™ Oil Filter, and Oil Sentry Switch (oil ﬁ...
Page 99 Section 9 Disassembly Breather Air Cleaner Hose Hex. Flange Base Hose Screws Clamps Electric Starter Valve Cover Stud Terminal Hex. Flange Nuts Gasket Figure 9-5. Removing Bendix Drive Starter. Figure 9-7. Removing Air Cleaner Base. Remove External Governor Components Remove Air Cleaner 1.
Page 100 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. ﬂ ange screws and speed control bracket. See Figure 9-9. Speed Control Choke Linkage Bracket Choke...
Page 101 Section 9 Disassembly Remove Rectiﬁ er-Regulator (If Required) Blower 1. Remove the connector from the rectiﬁ er-regulator. Housing See Figure 9-13. Mounting Screws 2. Remove the two screws securing the rectiﬁ er- regulator and individual ground lead (if used). Hex. Flange Screws Rectiﬁ...
Page 102 Section 9 Disassembly 3. Remove the hex. ﬂ ange nut on stud securing the carburetor side bafﬂ e,* if not removed Hex. Flange previously during carburetor removal. Remove Screws the screws attaching the cylinder head bafﬂ e. See Figure 9-18. * If so equipped.
Page 103 Section 9 Disassembly If the push rods will be reused, they should be Rubber marked with a piece of tape ("I" or "E" at the time Grommet of removal, so they are reinstalled in the same location. See Figures 9-24 and 9-25. Fuel Line Hex.
Page 104 Section 9 Disassembly Exhaust Side Valve Rocker Shaft Rocker Arms Spring Valve Keepers Rocker Hex. Rocker Pivot Ball Flange Screw Breather Reed Parts Breather Reed Retainer Breather Reed Retainer Spark Plug Guide Plate and Breather Reed and Breather Reed Non-Adjustable Figure 9-26.
Page 105 Section 9 Disassembly Hex. Flange Plain Washer Screw Drive Figure 9-30. Removing Flywheel Retaining Screw Figure 9-28. Removing Valves with Valve Spring and Drive Cup. (Recoil Start Models.) Compressor. Strap Wrench Figure 9-31. Loosening Flywheel Fastener. Figure 9-29. Removing Valves. (Bridge Type Head.) 2.
Page 106 Section 9 Disassembly 1. Check if the extra retaining clips are present. Hex. Flange Screws (4) If so, cut the clips, so they can be removed Spacers (4) and discard. Mark the tops of the knobs where they were located. Order 3 new clips, Part No. Flywheel 24 018 03-S, for installation during reassembly.
Page 107 Section 9 Disassembly Hex. Flange Screws (12) Hex. Flange Screw Oil Pickup Screen Cover Oil Pan Oil Pickup Screen Figure 9-38. Removing Oil Pickup. Figure 9-36. Removing Oil Pan. 3. Identify the type of oil pressure relief valve used. 3. Locate the splitting tabs on the oil pan and If the relief valve assembly is like that shown in crankcase.
Page 108 Section 9 Disassembly Hex. Flange Screws Oil Pump Cover O-Ring Figure 9-41. Later Style - Oil Pressure Relief Valve. Pump NOTE: Later one-piece relief valves (Figure 9-41) Rotors are staked in place and do not require removal, unless replacement is necessary. 4.
Page 109 Section 9 Disassembly 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 Connecting Connecting one to two teeth past being aligned. See Figure Rod Cap Rod Cap 9-46.
Page 110 Section 9 Disassembly Remove Piston Rings Plain Washer 1. Remove the top and center compression rings using a ring expander tool. See Figure 9-49. Hitch Pin Governor Piston Ring Cross Shaft Plain Washer Piston Ring Expander Figure 9-51. Removing Governor Cross Shaft. 2.
Page 111 Section 9 Disassembly Regulating Pin Regulating Pin Governor Gear Governor Gear Figure 9-53. Removing Governor Gear. 9.15...
Page 112 Section 9 Disassembly 9.16...
Page 113: Section 10. Inspection And Reconditioning
CV11-16 Section 10 CV460-465, CV490-495 Inspection and Reconditioning 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 &...
Page 114 Section 10 Inspection and Reconditioning 4. The choke control setting is less critical with ACR. High Point From In the event of ﬂ ooding, excess fuel is blown out Fillet Intersections the opened exhaust valve and does not hamper starting. The Fillet Must Blend Smoothly 5.
Page 115 Section 10 Inspection and Reconditioning Boring When over-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 Self-Tapping Screw following procedures for honing to the ﬁ...
Page 116 ﬂ ywheel key is sheared or the keyway is damaged. rinse the cylinder with very hot, clear water, dry it completely, and apply a light coating of engine oil to Inspect the ring gear for cracks or damage. Kohler prevent rusting. does not offer replacement ring gears. Replace the ﬂ...
Page 117 Section 10 Inspection and Reconditioning Cylinder Head and Valves Hard starting or loss of power, accompanied by high fuel consumption, may be symptoms of faulty valves. Although these symptoms could also be attributed to Inspection and Service worn rings, remove and check the valves ﬁ rst. After Carefully inspect the valve mechanism parts.
Page 118 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.
Page 119 Section 10 Inspection and Reconditioning Excessive Combustion Temperatures: The white Stem Corrosion: Moisture in fuel or from deposits seen here indicate very high combustion condensation are the most common causes of valve temperatures, usually due to a lean fuel mixture. stem corrosion.
Page 120 Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond speciﬁ cations, it will not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and Valve Seat Cutter excessive oil consumption.
Page 121 Section 10 Inspection and Reconditioning Ring failure is usually indicated by excessive oil Preignition or ignition of the fuel charge before the consumption and blue exhaust smoke. When rings timed spark can cause damage similar to detonation. fail, oil is allowed to enter the combustion chamber Preignition damage is often more severe than where it is burned along with the fuel.
Page 122 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.
Page 123 Section 10 Inspection and Reconditioning 1. Oil Control Ring (Bottom Groove): Install the Oil Pressure expander and then the rails. Make sure the ends Relief Bracket of the expander are not overlapped. Relief Valve Hex. Flange Body Screw 2. Compression Ring (Center Groove): Install the center ring using a piston ring installation tool.
Page 124 Section 10 Inspection and Reconditioning Procedure to Install Governor Shaft: Stamped Steel Valve Cover 1. Install new pin by pressing or lightly tapping into If the engine has stamped steel valve cover, the crankcase. It must be installed so that it protrudes sealing surface must be checked for ﬂ...
Page 125: Section 11. Reassembly
CV11-16 Section 11 CV460-465, CV490-495 Reassembly 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.
Page 126 Section 11 Reassembly 3. Using the KO1030 oil seal installer, install a new governor cross shaft oil seal into the crankcase. Crankshaft See Figure 11-2. Cross Shaft Oil Seal Figure 11-4. Installing Crankshaft. Install Piston Rings NOTE: For detailed piston inspection procedures Figure 11-2.
Page 127 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...
Page 128 Section 11 Reassembly 4. Lubricate the crankshaft journal and connecting rod bearing surfaces with engine oil. Install the Connecting Rod Cap 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.
Page 129 Section 11 Reassembly Installing Camshaft 3. Using a ﬂ at feeler gauge, measure the camshaft end play between the shim* spacer and the end 1. Lubricate the camshaft lobes and bearing play checking tool. surfaces with engine oil. Camshaft end play should be 0.076/0.127 mm 2.
Page 130 Section 11 Reassembly 3. Push bracket down until it seats against top of relief valve body. Secure with hex. ﬂ ange screw. See Figure 11-16. Oil Pressure Relief Bracket Hex. Flange Screw Relief Valve Body Figure 11-18. Inserting New Relief Valve into Bore of Closure Plate.
Page 131 Section 11 Reassembly 3. Install the oil pan to the crankcase and install the twelve hex. ﬂ ange screws. Tighten the screws hand tight. Hex. Flange 4. Torque the fasteners, in the sequence shown in Screw Figure 11-22 to 24.4 N·m (216 in. lb.). Pickup Screen Cover...
Page 132 Section 11 Reassembly Install Oil Pump Hex. Flange Screws 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. Outer Rotor Oil Pump Cover Inner Rotor Hex.
Page 133 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. ﬂ ange screw. Make sure the grommet is inserted in the notch in the crankcase. See Figure 11-27.* Oil Seal *Not on all models.
Page 134 Section 11 Reassembly 2. Reattach the fan to the ﬂ ywheel, using the Hex. Flange Screw spacers and hex. ﬂ ange screws, or shoulder Washer screws. See Figure 11-28. Torque the hex. ﬂ ange screws to 9.9 N·m (88 in. lb.). On electric start models, with the domed fan, proceed through step 4 before reattaching the fan.
Page 135 Section 11 Reassembly Figure 11-34. Push Rod Tool. NOTE: Another tool for bleeding may be made from an old tappet and ball bearing Figure 11-32. Torquing Flywheel Fastener (Electric welded together. See Figure 11-35. Start Models). 5. Install the grass screen onto the fan assembly (electric start models).
Page 136 Section 11 Reassembly Reassemble Cylinder Head Refer to Figure 11-37 for cylinder head differences. Assemble the components accordingly, based on head conﬁ guration involved. Rocker Bridge Hydraulic Lifters Rocker Shaft Head Gasket Push Rods Rocker Bridge Intake Valve Bridge Screw Rocker Exhaust Valve Stem Seal*...
Page 137 Section 11 Reassembly Heads with Separate Pivots/Rocker Arms–Figure Rocker Hex. Cap 11-37 Bridge Screws • Non-Adjustable Valve Lash Conﬁ guration 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 ﬁ...
Page 138 Section 11 Reassembly b. Apply Loctite ® No. 59241 thread sealant to b. Start the set screw into the nut, but only a few the threads of two of the shorter (81 mm/3.1 turns or it may hamper lash adjustment. Start in.) head bolts, and install them into location 3 the adjustment nut with the set screw on the and 4.
Page 139 Section 11 Reassembly Heads with Separate Pivots/Rocker Arms–Figure 11-37 • Non-Adjustable Valve Lash Conﬁ guration 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.
Page 140 Section 11 Reassembly Install Ignition Module 1. Rotate the ﬂ ywheel so the magnet is away from the ignition module bosses. Install the ignition Blower Housing Back Plate module to the bosses on crankcase, using the hex. ﬂ ange screws. The directional arrow (on some modules) denoting proper ﬂ...
Page 141 Section 11 Reassembly Mounting Screws Intake Studs Gasket Heat Deﬂ ector Silver Screw for Ground Lead Figure 11-51. Installing Heat Deﬂ ector and Figure 11-53. Installing Blower Housing. Carburetor Side Bafﬂ e (not on all models). 4. Install the cylinder head bafﬂ e and secure with the two hex.
Page 142 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.
Page 143 Section 11 Reassembly Install Carburetor and External Mounting Screws Governor Components and Washers 1. 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.
Page 144 Section 11 Reassembly 4. Attach the ground lead from carburetor fuel Choke Linkage Carburetor solenoid (if applicable) to the silver screw and Choke Lever lock washer on the cylinder bafﬂ e. See Figure Choke Lever 11-63. Silver Screw Speed Control Bracket Governor Lever Governor Spring Figure 11-64.
Page 145 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.
Page 146 Section 11 Reassembly 2. Pull the starter handle out until the pawls 6. Install the air cleaner cover and tighten the knob engage in the drive cup. Hold the handle in this securely. See Figure 11-68. position and tighten the screws securely. See Figure 11-70.
Page 147 Section 11 Reassembly 5. Before starting the engine, turn the engine Hex. Flange Screws over slowly by hand. If it can be turned over Mufﬂ er 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...
Page 148 Section 11 Reassembly 11.24...
Page 150 FORM NO.: 12 690 01 Rev. -- ISSUED: 4/11 REVISED: 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.

This manual is also suitable for:

Command cv460-465 Command cv490-495