Kohler COMMAND CV490 Manuals

Manuals and User Guides for Kohler COMMAND CV490. We have 4 Kohler COMMAND CV490 manuals available for free PDF download: Service Manual, Owner's Manual

Kohler COMMAND CV490 Service Manual (149 pages)

VERTICAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 5.85 MB

Table of Contents
2
Section 1. Safety and General Information
3
- Engine Identification Numbers
  5
- Oil Recommendations
  6
- Fuel Recommendations
  6
- Periodic Maintenance
  7
- Maintenance Schedule
  7
- Storage
  7
- General Specifications
  9
- General Torque Values
  16
Section 2. Special Tools
17
- Section 2 Special Tools
  18
- Diagnostic and Repair Tools
  18
- Special Tools You Can Make
  19
- Flywheel Holding Tool
  19
- Rocker Arm/Crankshaft Tool
  19
Section 3. Troubleshooting
21
Section 4. Air Cleaner and Air Intake System
25
Section 5. Fuel System and Governor
29
- Fuel Pump
  30
- Fuel Filter
  30
- Fuel System Troubleshooting Guide (Gasoline)
  30
- Carburetor (Gasoline)
  31
- Troubleshooting - Gasoline Systems
  32
- Walbro Carburetor Adjustment
  33
- Fixed Main Jet Carburetor
  33
- Optimum Low Idle Fuel Setting
  33
- Carburetor Disassembly
  34
- Main Fuel Jet Removal
  35
- Fuel Inlet Seat Removal
  35
- Choke Shaft Removal (Self-Relieving)
  35
- Carburetor Inspection
  36
- Self-Relieving Choke Carburetor View
  36
- Carburetor Cleaning
  36
- Throttle Shaft Removal
  36
- Carburetor Repair
  37
- Carburetor Reassembly
  37
- Choke Shaft Installation (Self-Relieving)
  37
- Carburetor High Altitude Operation
  38
- Fuel Shut-Off Solenoid
  38
- Welch Plug Installation – Walbro Carburetors
  38
- LPG Systems
  39
- Fuel Recommendations (LPG)
  39
- Troubleshooting - LPG Systems
  40
- Adjust Carburetor
  40
- Main Components of Kohler Emission Sentry System
  40
- Kohler Emission Sentry System Operation
  41
- Operating with Emission Sentry
  41
- Troubleshooting the Emission Sentry System
  41
- Governor
  42
- Initial Adjustment
  43
- Unitized Throttle and Choke Control
  43
- Throttle Cable Adjustment
  43
- Speed Control Bracket Assembly View
  43
- High Idle Speed Adjustment
  44
- Aligning Holes in Speed Control Bracket and Throttle Lever
  44
- Adjusting High Idle Speed
  44
- Speed Control Bracket Service
  45
- Separate Throttle and Choke Control
  45
- Choke Adjustment
  45
- Governor Spring Location
  45
- Separate Choke and Throttle Cable Control View
  46
- Governed Idle Adjustment
  47
- Setting the Low Idle RPM
  47
- Starting an Engine Equipped with Separate Control Cable
  47
- Location of Governed Idle Adjusting Screw
  48
- Oil Type
  49
- Check Oil Level
  49
- Viscosity Grades Table
  49
Section 6. Lubrication System
49
- Change Oil and Oil Filter
  50
- Full-Pressure Lubrication System
  51
- Change Oil Filter
  51
- Oil Filter
  52
- Oil Sentry
  52
- Testing Oil Pressure
  53
- Testing the Oil Sentry Switch
  53
- Retractable Starter Removal and Installation
  55
Section 7. Retractable Starter
55
- Rope Replacement
  56
- Pawls (Dogs) Replacement
  56
- Retractable Starter Inspection and Service
  58
- Retractable Starter Reassembly
  58
- Spark Plug
  59
Section 8. Electrical System and Components
59
Section 9. Disassembly
95
- Remove Muffler
  96
- Remove Retractable Starter
  96
- Remove Electric Starter
  96
- Remove Air Cleaner
  97
- Remove External Governor Components and Carburetor
  97
- Removing Bendix Drive Starter
  97
- Removing Air Cleaner Base
  97
- Remove Fuel Pump
  98
- Remove Rectifier-Regulator
  99
- Remove Extended Oil Fill Tube
  99
- Remove Blower Housing and Baffles
  99
- Remove Fuel Line
  100
- Remove Ignition Module
  100
- Remove Valve Cover and Cylinder Head
  101
- Disassemble Cylinder Head
  101
- Remove Drive Cup, Grass Screen, Flywheel and Fan
  103
- Remove the Stator and Wiring Harness
  104
- Remove Oil Pan
  104
- Remove Oil Pickup, Oil Pressure Relief Valve, and Oil Pump
  105
- Remove Hydraulic Lifters and Camshaft
  106
- Remove Balance Shaft
  107
- Remove Connecting Rod and Piston
  107
- Remove Piston from Connecting Rod
  107
- Remove Flywheel End Oil Seal
  108
- Remove Governor Cross Shaft and Governor Gear
  108
- Remove Crankshaft
  108
- Remove Piston Rings
  108
- Automatic Compression Release (ACR)
  111
Section 10. Inspection and Reconditioning
111
- Camshaft Inspection and Service
  112
- Crankshaft Inspection and Service
  112
- Crankcase Inspection and Service
  113
- Clean Cylinder Bore after Honing
  114
- Measuring Piston-To-Bore Clearance
  114
- Flywheel Inspection
  114
- Cylinder Head and Valves Inspection and Service
  115
- Pistons and Rings Inspection
  118
- Lapping Valves
  118
- Valve Seat Inserts Inspection and Service
  118
- Valve Guides Inspection and Service
  118
- Install Piston Rings
  120
- Connecting Rods Inspection and Service
  121
- Oil Pump Inspection and Service
  121
- Governor Gear and Shaft Inspection and Service
  121
- Stamped Steel Valve Cover
  122
- Install Governor Gear and Cross Shaft
  123
Section 11. Reassembly
123
- Install Crankshaft
  124
- Install Piston to Connecting Rod
  124
- Install Piston and Connecting Rod
  125
- Install Balance Shaft
  126
- Install Oil Pressure Relief Valve
  127
- Determine Camshaft End Play
  127
- Installing Camshaft
  127
- Install Oil Pickup
  128
- Install Oil Pan to Crankcase
  129
- Oil Pan Fastener Torque Sequence
  129
- Install Oil Pump
  130
- Install Oil Seals
  130
- Install Stator and Wiring Harness
  131
- Install Fuel Line
  131
- Install Fan and Flywheel
  131
- Install Hydraulic Lifters
  133
- Reassemble Cylinder Head
  134
- Cylinder Head Valve Train Differences
  134
- Install Cylinder Head
  136
- Install Ignition Module
  138
- Install Baffles and Blower Housing
  138
- Install Valve Cover and Muffler Bracket
  139
- Install Extended Oil Fill Tube
  140
- Install Rectifier-Regulator
  140
- Install Fuel Pump
  141
- Install Carburetor and External Governor Components
  141
- Install Air Cleaner and Make Initial Governor Adjustment
  142
- Installing Air Cleaner Base
  142
- Air Cleaner Details View
  143
- Install Electric Starter
  144
- Install Retractable Starter
  144
- Install Muffler
  144
- Prepare the Engine for Operation
  145
- Testing the Engine
  145

Kohler COMMAND CV490 Owner's Manual (17 pages)

COMMAND SERIES VERTICAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 2.04 MB

Safety Precautions
2
California Proposition 65 Warning
2
Oil Recommendations
4
Oil Type
4
Fuel Recommendations
5
Engine Identification Numbers
5
Specifications
6
Cold Weather Starting Hints
6
Maintenance Instructions
8
Maintenance Schedule
8
Clean Air Intake/Cooling Areas
11
Ignition System
11
Check Spark Plug
11
Battery Charging
12
Fuel Filter
12
Carburetor Troubleshooting and Adjustments
12
Troubleshooting
13
Parts Ordering
14
Major Repair
14
Model Designation
14

Kohler COMMAND CV490 Owner's Manual (16 pages)

Vertical Crankshaft

Brand: Kohler | Category: Engine | Size: 0.96 MB

Kohler COMMAND CV490 Owner's Manual (16 pages)

Vertical Crankshaft

Brand: Kohler | Category: Engine | Size: 0.96 MB

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