Kohler command cv17 Service Manual
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Kohler command cv17 Service Manual

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See also: Service Manual , Owner's Manual
CV17-CV25, CV620-CV730, CV740, CV750
Service Manual
IMPORTANT:
Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.
2
Safety
3
Maintenance
5
Specifications
16
Tools and Aids
19
Troubleshooting
23
Air Cleaner/Intake
24
Fuel System
30
Governor System
31
Lubrication System
33
Electrical System
49
Starter System
58
Disassembly/Inspection and Service
75
Reassembly
24 690 07 Rev. H
KohlerEngines.com
1

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  • Page 1 CV17-CV25, CV620-CV730, CV740, CV750 Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Safety Maintenance Specifications Tools and Aids...

  • Page 2: Safety Precautions

    Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING WARNING CAUTION...

  • Page 3: Maintenance Instructions

    Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 24 690 07 Rev. H...

  • Page 4: Oil Recommendations

    Maintenance OIL RECOMMENDATIONS STORAGE We recommend use of Kohler oils for best performance. If engine will be out of service for 2 months or more Other high-quality detergent oils (including synthetic) follow procedure below. of API (American Petroleum Institute) service class SJ 1.

  • Page 5: Specifications

    Specifications Engine Dimensions with Low-Profile Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. 24 690 07 Rev. H KohlerEngines.com...
  • Page 6 Specifications Engine Dimensions with Commercial Mower Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 24 690 07 Rev. H...
  • Page 7 Specifications Engine Dimensions with Heavy-Duty Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. 424.75 [16.722] 301.77 134.97 [11.881] [5.314] 130.03 AIR FILTER RAIN 89.94 275.56 [5.119] CAP REMOVAL [3.541] [10.849] AIR FILTER COVER ASSEMBLY REMOVAL 15.76 15.80 [.621] [.622] SPARK PLUG...

  • Page 8: Engine Identification Numbers

    Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.
  • Page 9 Specifications TORQUE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/ CV750 CV22/ CV620/ CV730/ CV620/CV621/ CV640/ CV740 CV640/CV641 CV670/CV680 Crankcase Breather Cover Fastener 7.3 N·m (65 in. lb.) Oil Drain Plug 13.6 N·m (10 ft. lb.) Cylinder Head Head Fastener Nut (torque in 2 increments) first to 16.9 N·m (150 in.

  • Page 10: Clearance Specifications

    Specifications TORQUE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/ CV750 CV22/ CV620/ CV730/ CV620/CV621/ CV640/ CV740 CV640/CV641 CV670/CV680 Starter Assembly Thru Bolt Inertia Drive 4.5-5.7 N·m (40-50 in. lb.) Nippondenso Solenoid Shift 4.5-7.5 N·m (40-84 in. lb.) Delco-Remy Solenoid Shift 5.6-9.0 N·m (49-79 in. lb.) Mounting Screw 15.3 N·m (135 in.
  • Page 11 Specifications CLEARANCE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/ CV750 CV22/ CV620/ CV730/ CV620/CV621/ CV640/ CV740 CV640/CV641 CV670/CV680 Crankcase Governor Cross Shaft Bore I.D. 6 mm Shaft 6.025/6.050 mm (0.2372/0.2382 in.) Max. Wear Limit 6.063 mm (0.2387 in.) 8 mm Shaft 8.025/8.075 mm (0.3159/0.3179 in.) Max.
  • Page 12 Specifications CLEARANCE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/ CV750 CV22/ CV620/ CV730/ CV620/CV621/ CV640/ CV740 CV640/CV641 CV670/CV680 Governor Governor Cross Shaft-to-Crankcase Running Clearance 6 mm Shaft 0.013/0.075 mm (0.0005/0.0030 in.) 8 mm Shaft 0.025/0.126 mm (0.0009/0.0049 in.) Cross Shaft O.D. 6 mm Shaft 5.975/6.012 mm (0.2352/0.2367 in.) Max.
  • Page 13 Specifications CLEARANCE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/ CV750 CV22/ CV620/ CV730/ CV620/CV621/ CV640/ CV740 CV640/CV641 CV670/CV680 Piston, Piston Rings, and Piston Pin (Style A continued) Top and Middle Compression Ring End Gap New Bore 0.25/ 0.18/ 0.25/0.56 mm 0.45 mm 0.46 mm (0.0100/0.0224 in.) (0.0098/...
  • Page 14 Specifications CLEARANCE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/ CV750 CV22/ CV620/ CV730/ CV620/CV621/ CV640/ CV740 CV640/CV641 CV670/CV680 Piston, Piston Rings, and Piston Pin (Style B continued) Top Compression Ring End Gap New Bore 0.100/ 0.189/0.277 mm 0.279 mm (0.0074/0.0109 in.) (0.0039/ 0.0110 in.) Used Bore (Max) 0.490 mm...

  • Page 15: General Torque Values

    Specifications GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
  • Page 16 Here is a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc. Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive supply. Lapeer, MI 48446 Westmont, IL 60559...
  • Page 17 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Reamer Handle Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 AIDS Description Source/Part No.
  • Page 18 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft flywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.

  • Page 19: Troubleshooting Guide

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check 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 general common causes of engine troubles are listed below and vary by engine specification. Use these to locate causing factors.
  • Page 20 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...

  • Page 21: Crankcase Vacuum Test

    Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.

  • Page 22: Compression Test

    Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.

  • Page 23: Air Cleaner

    Air Cleaner/Intake AIR CLEANER Low-Profile/Commercial Mower These systems are CARB/EPA certified and components Loosen knob and remove air cleaner cover. should not be altered or modified in any way. Precleaner Low-Profile and Commercial Mower Air Cleaner 1. Remove precleaner from paper element. Components 2.

  • Page 24: Fuel Pump

    3. Remove pulse line that connects pump to crankcase. Low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB 4. Install a new pump using screws. regulatory compliance. 5. Connect pulse line between pump and crankcase.
  • Page 25 Fuel System CARBURETORS Gasoline is extremely flammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fires and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 26 Fuel System Nikki One-Barrel Carburetor Components Keihin One-Barrel Carburetor Components Idle Fuel Idle Speed Screw Adjusting Screw Carburetor Body Idle Jet Plug Main Jet Idle Fuel Carburetor Body Adjusting Screw Shut-off Solenoid Float Assembly Idle Fuel Passage Cover Adjusting Spring Fuel Bowl Choke Lever Cover Retaining...
  • Page 27 Fuel System 5. Make sure air cleaner element (including precleaner if equipped) is clean and all air cleaner components are fastened securely. 6. Make sure ignition system, governor system, exhaust system, and throttle and choke controls are operating properly. Troubleshooting-Carburetor Related Causes Condition Possible Cause Conclusion...
  • Page 28 Fuel System 2. Release governor lever and check that throttle lever Carburetor Circuits is in idle position. Turn governed idle adjustment Float screw to obtain equipment manufacturer’s Fuel level in bowl is maintained by float and fuel inlet recommended idle speed (1500-1800 RPM). Some needle.
  • Page 29 Disconnect negative (–) battery cable from battery. 1219 meters (4000 ft.). To obtain high altitude kit information or to find a Kohler authorized dealer visit NOTE: Main and slow jets are fixed and size specific KohlerEngines.com or call1-800-544-2444 (U.S. and and can be removed if required.

  • Page 30: Governor System

    Governor System GOVERNOR ● When engine is at rest, and throttle is in FAST position, tension of governor spring holds throttle plate Engine is equipped with a centrifugal flyweight open. When engine is operating, governor gear mechanical governor. It is designed to hold engine assembly is rotating.

  • Page 31: Lubrication System

    Lubrication System This engine uses a full pressure lubrication system CHANGE OIL AND FILTER which delivers oil under pressure to crankshaft, Change oil while engine is warm. camshaft, connecting rod bearing surfaces, and 1. Clean area around oil fill cap/dipstick, drain plug/oil hydraulic valve lifters.

  • Page 32: Installation

    Lubrication System Installation 1. Apply pipe sealant with Teflon (Loctite 592™ ® ® ® Thread Sealant or equivalent) to threads of switch. 2. Install switch into tapped hole in breather cover. 3. Torque switch to 4.5 N·m (40 in. lb.). Testing Compressed air, a pressure regulator, pressure gauge, and a continuity tester are required to test switch.

  • Page 33: Spark Plugs

    Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
  • Page 34 Electrical System Carbon Fouled ELECTRONIC IGNITION SYSTEMS Ignition System Components Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich Kill Switch/Off carburetion, weak ignition, or poor compression. Position of Key Air Gap Switch Overheated Flywheel Magnet Spark Plug...
  • Page 35 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with Fixed Timing 24 690 07 Rev. H KohlerEngines.com...
  • Page 36 Electrical System Fixed Ignition System This system uses a capacitive discharge (CD) coil. Ignition timing and spark remains constant regardless of engine speed. Timing of spark is controlled by location of flywheel magnet group as referenced to engine TDC. A typical fixed ignition system consists of: ●...
  • Page 37 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with Smart-Spark 24 690 07 Rev. H KohlerEngines.com...
  • Page 38 Electrical System Smart-Spark Advance Ignition System ™ SMART-SPARK equipped engines utilize an electronic capacitive discharge ignition system with electronic spark ™ advance. A typical application consists of following components: ● 1 magnet assembly which is permanently affixed to flywheel. ● 2 electronic capacitive discharge ignition modules which mount on engine crankcase. ●...
  • Page 39 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Key Switch 24 690 07 Rev. H KohlerEngines.com...
  • Page 40 Electrical System DSAI Ignition System This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on engine RPM. A typical DSAI application consists of: ●...
  • Page 41 Electrical System Wiring Diagram-3 Amp Unregulated Battery Charging System/70 Watt Lighting Optional Oil Optional Oil Ground-To-Kill Sentry Switch 12 V. Battery Sentry Switch Light Lead (White) (Shutdown) (Indicator Light) Optional Ground Optional Fuse Key Switch Ammeter Blue Solenoid Lights Starter Yellow 3 Amp/70 Watt Diode...
  • Page 42 Electrical System Test for Spark NOTE: If 2 testers are available, testing can be performed simultaneously for both cylinders. However, if only 1 tester is available, 2 individual tests must be performed. Side not being tested must have spark plug lead connected or grounded.
  • Page 43 Electrical System Test Ignition Modules and Connections (Smart- Ignition Module Resistance Table Spark only) 24 584 03 24 584 15-S ™ NOTE: Resistance values apply only to modules that have been on a running engine. New service 24 584 11 24 584 36-S modules may have higher resistance until they (1 11/16 in.
  • Page 44 Electrical System Condition Possible Cause Conclusion Strong, steady spark is now present Problem should be corrected. Go to on both sides. Test SAM step 4. Still a spark problem. Test SAM. Test SAM 1. Trace red power source lead from SAM to harness connection. Separate connector and connect red lead of a DC voltmeter to harness terminal.

  • Page 45: Battery Charging System

    Electrical System To test ASAM only using 25 761 21-S tester: ● Yellow tester lead to long yellow module lead. ● Brown tester lead to long brown module lead. NOTE: SAM must be at room temperature when tested. ● Red tester lead to red module lead. Disconnect all SAM leads, isolating it from main ●...
  • Page 46 Electrical System 15/20/25 Amp Regulated Charging System Stator Stator is mounted on crankcase behind flywheel. Follow procedures in Disassembly and Reassembly if stator replacement is necessary. Rectifier-Regulator NOTE: When installing rectifier-regulator, take note of terminal markings and install plug(s) accordingly. NOTE: Disconnect all electrical connections attached to rectifier-regulator.
  • Page 47 Electrical System 15/20/25 Amp Battery Charging Systems NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be causing problems.
  • Page 48 Electrical System To test charging system for no lights: 3 Amp/70 Watt Lighting Stator 1. Make sure lights are not burned out. NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made Condition Conclusion with engine running at 3000 RPM with no load. Burned out lights.
  • Page 49 Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops sufficient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
  • Page 50 4. Clean splines on drive shaft thoroughly with solvent. Dry splines thoroughly. 5. Apply a small amount of Kohler electric starter drive lubricant, to splines. Use of other lubricants may cause drive pinion to stick or bind.
  • Page 51 A brush holder tool can easily be made 5. Install thru bolts and tighten securely. from thin sheet metal. 6. Lubricate drive shaft with Kohler starter drive 1. Remove brush springs from pockets in brush holder. lubricant. Install drive components following 2.
  • Page 52 Starter System SOLENOID SHIFT ELECTRIC STARTERS Nippondenso Starters Solenoid Shift Starter Components Starter Disassembly NOTE: When removing lever and armature be careful not to lose thrust washer. 1. Disconnect lead wire from solenoid. 2. Remove nuts securing solenoid, and remove solenoid from starter assembly.
  • Page 53 Brush Replacement 4 brushes and springs are serviced as a set. Use a new Kohler brush and spring kit if replacement is necessary. 1. Perform steps 1-5 in Starter Disassembly. 2. Remove screws securing brush holder assembly to end cap (plate).
  • Page 54 Starter System 10. Starter reassembly when replacing brushes/brush Starter Reassembly holder assembly: NOTE: Always use a new retainer. Do not reuse old a. Hold starter assembly vertically on end housing, retainers that have been removed. and carefully position assembled brush holder NOTE: Correctly installed, center pivot section of drive assembly, with supplied protective tube, against lever will be flush or below machined surface of...
  • Page 55 Starter System Solenoid Tests NOTE: DO NOT leave 12 volt test leads connected to solenoid for any time over what is necessary for performing each of individual tests. Internal damage to solenoid may occur. Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal. Remove mounting hardware and separate solenoid from starter for testing.

  • Page 56: Retractable Starters

    Starter System RETRACTABLE STARTERS Remove Starter 1. Remove screws securing starter to blower housing. WARNING 2. Remove starter assembly. Uncoiling Spring can cause severe injury. Wear safety goggles or face protection when Rope Replacement servicing retractable starter. NOTE: Do not allow pulley/spring to unwind. Enlist aid Retractable starters contain a powerful, recoil spring of a helper if necessary.
  • Page 57 Starter System Pawls (dogs) Replacement 1. Install a clamp to hold pulley in starter housing and prevent if from rotating. 2. Remove center screw, washer, and pawl retainer. 3. Note position of pawls and pawl springs before removing. Remove pawls, pawls springs, brake spring and brake washer from pulley.
  • Page 58 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 59 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Heavy-Duty Air Cleaner Only clean parts can be accurately inspected 1. Disconnect breather hose from fitting in adapter or and gauged for wear or damage. There are many elbow. Remove nuts securing adapter and any commercially available cleaners that will quickly remove attached clips to mounting studs.
  • Page 60 Disassembly/Inspection and Service Remove External Governor Controls Remove Throttle Controls Loosen nut and remove governor lever from cross shaft. Control Panel Components Leave lever attached to throttle linkage. Remove Carburetor WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running.
  • Page 61 Disassembly/Inspection and Service Remove Oil Sentry Remove Valve Covers ™ 1. Disconnect lead from Oil Sentry switch. Three valve cover designs have been used. First type ™ used a gasket and RTV sealant between cover and 2. Remove Oil Sentry switch from breather cover.
  • Page 62 Disassembly/Inspection and Service Cylinder Head Components Valves Cylinder Head Spark Plug Hydraulic Lifter Valve Stem Seal Valve Spring Keeper Valve Spring Valve Spring Rocker Arm Pivot Push Rod Retainer Rocker Arm Screw Valve Cover O-ring Grommet Valve Cover Gasket Remove Cylinder Heads and Hydraulic Lifters NOTE: Cylinder heads are retained using either screws or nuts and washers on studs.

  • Page 63: Exhaust Valve

    Disassembly/Inspection and Service Disassemble Cylinder Heads NOTE: These engines use valve stem seals on intake valves. Use a new seal whenever valve is removed or if seal is deteriorated or damaged in any way. Never reuse an old seal. 1. Remove screws, rocker arm pivots and rocker arms from cylinder head. 2.
  • Page 64 If lifters need to be replaced, apply a liberal allowed on exhaust guide. Guides are not removable but coating of Kohler lubricant to base of each new lifter can be reamed 0.25 mm (0.010 in.) oversize. Valves with before it is installed.
  • Page 65 Replace flywheel if it is cracked. Replace flywheel, crankshaft, and key if flywheel key is sheared or keyway is damaged. Inspect ring gear for cracks or damage. Kohler does not provide ring gears as a serviceable part. Replace flywheel if ring gear is damaged.
  • Page 66 Disassembly/Inspection and Service Breather/Oil Pan/Oil Reservoir/Piston Components Oil Fill/Dipstick Dipstick Tube Oil Seal Breather Gasket Breather Cover Flat Washer Breather Reed Governor Cross Shaft Locking Tab Thrust Oil Pan Gasket Governor Gear Oil Screen (Style A) Washer Oil Pick-Up Tube Oil Pump Assembly Gerotor Gear (Style A) Piston Pin...
  • Page 67 Disassembly/Inspection and Service Governor gear assembly is located inside oil pan. If Remove Oil Pan Assembly service is required, refer to Inspection, Disassembly, and 1. Remove screws securing oil pan to crankcase. Reassembly procedures. 2. Locate splitting tabs cast into perimeter of oil pan. Inspection Insert drive end of a 1/2"...
  • Page 68 Disassembly/Inspection and Service Oil Pump Assembly (Style A) Oil Pump Oil Pump Oil Pickup Tube Roll Pin (Original Style A) (Later Style A) Piston Spring O-Ring Plastic Oil Pickup One-Piece Relief Torque Sequence Valve (Style A) Reassembly Oil Pump Assembly (Style A) 1.
  • Page 69 Disassembly/Inspection and Service Oil Pump Assembly (Style B) Remove Governor Cross Shaft Oil pump is mounted inside oil pan. If service is required, 1. Remove hitch pin and plain washer, or retainer and continue with Disassembly, Inspection, and Reassembly. nylon washer, from governor cross shaft. Disassembly 2.
  • Page 70 Disassembly/Inspection and Service Scratches on rings and pistons are caused by abrasive Piston and Rings material such as carbon, dirt, or pieces of hard metal. Inspection Detonation damage occurs when a portion of fuel charge Piston and Rings Components and Details ignites spontaneously from heat and pressure shortly after ignition.
  • Page 71 Disassembly/Inspection and Service Piston Style B Install New Piston Rings 1. Cylinder bore must be de-glazed before service ring Piston Ring Orientation sets are used. 2. If cylinder bore does not need re-boring and if old piston is within wear limits and free of score or scuff marks, old piston may be reused.
  • Page 72 Disassembly/Inspection and Service Inspect gear teeth of crankshaft. If teeth are badly worn, Connecting Rods chipped, or some are missing, replacement of crankshaft Offset, stepped-cap connecting rods are used in all will be necessary. these engines. Inspect crankshaft bearing surfaces for scoring, Inspection and Service grooving, etc.
  • Page 73 It washes necessary lubricating oils off piston and 23°-33° Crosshatch cylinder wall. As raw fuel seeps down cylinder wall, NOTE: Kohler pistons are custom-machined to exacting piston rings make metal to metal contact with wall. tolerances. When oversizing a cylinder, it should Scoring of cylinder wall can also be caused by localized be machined exactly 0.25 mm (0.010 in.) or...
  • Page 74 Disassembly/Inspection and Service Clean Cylinder Bore After Honing Measuring Piston-to-Bore Clearance Proper cleaning of cylinder walls following boring and/ Piston Detail or honing is very critical to a successful overhaul. Piston Detail Machining grit left in cylinder bore can destroy an engine in less than 1 hour of operation after a rebuild.
  • Page 75 Reassembly Breather/Oil Pan/Oil Reservoir/Piston Components Oil Fill/Dipstick Dipstick Tube Oil Seal Breather Gasket Breather Cover Flat Washer Breather Reed Governor Cross Shaft Locking Tab Thrust Oil Pan Gasket Governor Gear Oil Screen (Style A) Washer Oil Pick-Up Tube Oil Pump Assembly Gerotor Gear (Style A) Piston Pin (Style A)
  • Page 76 Reassembly NOTE: Make sure engine is assembled using all Install Connecting Rods with Pistons and Rings specified torque values, tightening sequences, Piston and Connecting Rod Details and clearances. Failure to observe specifications could cause severe engine wear or damage. Always use new gaskets. Apply a small amount of oil to threads of critical fasteners before assembly, unless a sealant or Loctite ®...
  • Page 77 Reassembly 4. Make sure Fly stamping on piston is facing towards Oil Pump Assembly flywheel side of engine. Use a hammer with a rubber Oil pump is mounted inside oil pan. If service was grip and gently tap piston into cylinder. Be careful required, and oil pump was removed, refer to that oil ring rails do not spring free between bottom Disassembly/Inspection and Service.
  • Page 78 Reassembly RTV sealant is used as a gasket between oil pan and Install Oil Pan Assembly crankcase on CV17-23 engines. CV25-750 engines use Sealant Pattern an oil pan gasket. Refer to Tools and Aids for a listing of approved sealants. Always use fresh sealant. Using outdated sealant can result in leakage.
  • Page 79 Reassembly Flywheel/Ignition Components Install Stator and Backing Plates 1. Apply pipe sealant with Teflon (Loctite 592™ ® ® ® Thread Sealant or equivalent) to stator mounting holes. 2. Position stator aligning mounting holes so that leads are at bottom, towards crankcase. 3.
  • Page 80 Reassembly Install Supports for Metal Debris Screen 1. If a metal debris screen is used, with threaded individual supports, install a spacer washer on external threads. Apply blue Loctite (removable) to threads. Install supports as shown. ® ® 2. Tighten supports with a torque wrench to 9.9 N·m (88 in. lb.). Debris screen will be installed to supports after blower housing is in place.
  • Page 81 Reassembly b. Thread opposite end of stud, with preapplied Assemble Cylinder Heads locking compound, into crankcase, until specified Prior to installation, lubricate all components with engine height from crankcase surface is achieved. When oil, paying particular attention to lip of valve stem seal, threading in studs, use a steady tightening motion valve stems, and valve guides.
  • Page 82 Reassembly Install Ignition Modules Install Breather Cover and Inner Baffles 1. Rotate flywheel to position magnet away from Breather Cover Torque Sequence ignition module bosses. 2. On engines equipped with SMART-SPARK both ™, modules are installed similarly with tabs out. On engines not equipped with SMART-SPARK ™...
  • Page 83 Reassembly 5. If engine had a plastic debris screen that overlaps Install Blower Housing and Outer Baffles blower housing, reinstall it now. Torque mounting Wires on Starter Side of Engine screws to 4.0 N·m (36 in. lb.). For a metal screen, apply Loctite to screw threads and torque ®...
  • Page 84 Reassembly Torque Specifications-Covers Install Valve Covers Gasket/RTV 3.4 N·m (30 in. lb.) Torque Sequence Black O-ring w/shoulder screws 5.6 N·m (50 in. lb.) w/screws and spacers 9.9 N·m (88 in. lb.) Yellow or Brown O-ring w/integral spacers 6.2 N·m (55 in. lb.) Install Carburetor WARNING Explosive Fuel can cause fires and severe...
  • Page 85 Reassembly Two-barrel carburetor models: Move control panel Control Panel Components into position on blower housing and connect choke linkage into bushing/lever from backside. Make certain that control shaft offset is back and towards cylinder side 2. Connect throttle linkage and spring to governor lever.
  • Page 86 Reassembly Governor Lever Hole Position (6 mm) CV18 Engines Engine Mounted Intended Standard Throttle Control Maximum RPM Throttle Control Pivot Shaft High Spring Hole Spring Hole Idle Color Color 3888 3600 Green Orange 3780 3500 Blue Green 3672 3400 Orange Blue 3564 3300...
  • Page 87 Reassembly CV750 Engines Intended Maximum RPM With Governed Idle Systems Governor Shaft Configuration High Idle Spring Color Hole No. 3888 3600 Clear 3780 3500 Orange 3672 3400 Blue Standard (Parent Material) 3564 3300 3456 3200 Clear 3348 3100 Clear NOTE: Fuel pumps may be made of metal or plastic. If Install Electric Starter Motor a new fuel pump is being installed, make sure 1.
  • Page 88 Reassembly Install Muffler Prepare Engine for Operation 1. Install port liners (if equipped). Install muffler and Engine is now completely reassembled. Before starting attaching hardware to muffler bracket. Torque or operating engine, be sure to do following. screws to 9.9 N·m (88 in. lb.). 1.
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