Kohler COMMAND CV495 Manuals

Manuals and User Guides for Kohler COMMAND CV495. We have 1 Kohler COMMAND CV495 manual available for free PDF download: Service Manual

Kohler COMMAND CV495 Service Manual

Kohler COMMAND CV495 Service Manual (149 pages)

VERTICAL CRANKSHAFT

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

Table of Contents

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

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