Kohler Command 5 HP Manuals

Manuals and User Guides for Kohler Command 5 HP. We have 1 Kohler Command 5 HP manual available for free PDF download: Service Manual

Kohler Command 5 HP Service Manual (110 pages)

Kohler Automobile Parts Service Manual

Brand: Kohler | Category: Engine | Size: 5.01 MB

Content
2
Safety and General Information
3
Safety Information
3
Engine Identification Numbers
5
Oil Recommendations
6
Oil Type
6
Fuel Recommendations
6
General Recommendations
6
Periodic Maintenance
7
Maintenance Schedule
7
Storage
7
Typical CH5 Engine Dimensions
8
Typical CH6 Engine Dimensions
9
Specifications
12
Torque Information
17
Oil Drain Plugs Tightening Torque
17
Special Tools
19
Special Service Tool Kits
19
Tester Construction
26
Using the Tester
26
Water Nanometer
26
Cylinder Tester
26
Troubleshooting
27
External Engine Inspection
28
Cleaning the Engine
28
Engine Loses Power
28
Engine Uses Excessive Amount of Oil
28
Basic Engine Tests
29
Crankcase Vacuum Test
29
Compression Test
29
Cylinder Leak down Test
30
Leakdown Test Instructions
30
Leakdown Test Results
30
Air Cleaner
31
Air Intake System
31
Service Precleaner
32
Service Paper Element
32
Inspect CH5 Air Cleaner Components
33
CH5 Air Cleaner
33
Clean Air Intake/Cooling Areas
33
Air Cleaner Service
34
Fuel System and Governor
37
Fuel Type
37
Fuel System
37
Troubleshooting Fuel System
38
Carburetor
38
Fuel Inlet Seat Removal
44
Choke Shaft Removal
44
Throttle Shaft Removal
44
Throttle Shaft Installation
45
Fuel Inlet Seat Installation
46
Welch Plug Installation
46
Choke Shaft Installation
46
Carburetor Reassermbly
46
Governor
47
Initial Adjustment
48
High Idle Speed Adjustment
48
Constant Speed Variation
49
Low Idle Speed Adjustment
49
Sensitivity Adjustment
49
Lubrication System
50
Check Oil Level
50
Oil Sentry
51
Change Oil
52
Retractable Starter
53
To Remove Starter
54
To Install Starter
54
Rope Replacement
54
Pawls Replacement
55
Electrical System and Components
58
Spark Plug
58
Spark Plug Service
58
Electronic Magneto Ignition System
60
Ignition System
62
Ignition Module Removal and Installation
63
Battery Charging
63
Battery Maintenance
63
Battery Test
63
Electric Starter
65
Bendix Drive Electric Starter
66
Starter Removal and Installation
67
Starter Drive Service
67
Starter Disassembly
68
Brush Replacement
68
Commutator Service
69
Starter Reassembly
69
Float Switch Removal
70
Float Switch Installation
71
Float Switch Test
73
Operational Test
74
Disassembly
75
Disconnect Spark Plug Lead
75
Typical Disassembly Sequence
75
Remove Air Cleaner Components
75
Remove Retractable Starter
76
Remove Dipstick and Fill Tube
76
Remove Fuel Tank and Line
76
Control Panel Removal
77
Remove Carburetor and Linkage
77
Remove Muffler
77
Remove Blower Housing and Baffles
78
Remove Governor, Throttle and Kill Switch Linkage
78
Remove Valve Cover and Cylinder Head
79
Remove Ignition Module
80
Disassemble Cylinder Head
80
Remove Flywheel
81
Remove Camshaft and Tappets
82
Remove Governor Gear and Cross Shaft
83
Remove Oil Sentry
83
Remove Connecting Rod and the Piston
83
Remove Piston from Connecting Rod
84
Remove Crankshaft
84
Remove Piston Rings
84
Remove Crankshaft Oil Seals and Bearings
84
Internal Components
85
Automatic Compression Release
85
Benefits
86
Camshaft
86
Crankshaft
86
Crankcase
86
Honing
87
Clean Cylinder Bore after Honing
87
Flywheel
88
Measuring Piston-To-Bore Clearance
88
Cylinder Head and Valves
88
Measuring Piston Diameter
88
Valve Details
89
Normal
90
Leakage
90
Bad Condition
90
Coking
90
Carbon Cut
91
Stem Corrosion
91
Gum
91
Overheating
91
Valve Guides
92
Reconditioning Valve Guide
92
Valve Seat Inserts
92
Lapping Valves
92
Pistons and Rings
93
Closure Plate and Crankcase
93
Common Types of Piston and Ring Damage
94
Install Piston Rings
95
Connecting Rods
96
Governor Gear
96
Piston Ring Installation
96
Reassembly
97
Install Crankshaft Bearings
97
Typical Reassembly Sequence
97
Install Crankshaft
97
Install Piston and Connecting Rod
98
Assemble Piston to Connecting Rod
98
Installing Piston to Connecting Rod
98
Install Oil Sentry
99
Install Governor Gear and Cross Shaft
99
Install Tappets and Camshaft
100
Install Closure Plate
100
Install Oil Seals
101
Install Flywheel
101
Install Ignition Module
102
Installing the Flywheel
102
Tightening Flywheel Fastener
102
Reassemble Cylinder Head Components
103
Install Cylinder Head
103
Install Kill Switch, Throttle and Governor Linkage
104
Adjusting Rocker Arm/Valve Clearance
104
Installing Breather Assembly
104
Install Baffles and Blower Housing
105
Install Muffler
105
Install Carburetor and Linkage
106
Install Fuel Tank and Line
106
Install Control Panel
106
Install Fill Tube and Dipstick
107
Install the Attachable Starter
107
Install Air Cleaner
107
Prepare the Engine for Operation
108
Tighten Wing Nut
108
Installing Air Cleaner Base
108

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