Table Of Contents - Kohler CV11-16 Service Manual

Table of Contents

Table Of Contents2
Section 1. Safety And General Information3
Engine Identification Numbers5
Oil Recommendations6
Fuel Recommendations6
Periodic Maintenance7
Maintenance Schedule7
Storage7
General Specifications9
General Torque Values16
Section 2. Special Tools17
Diagnostic And Repair Tools18
Section 2 Special Tools18
Special Tools You Can Make19
Flywheel Holding Tool19
Rocker Arm/Crankshaft Tool19
Section 3. Troubleshooting21
Section 4. Air Cleaner And Air Intake System25
Section 4 Air Cleaner And Air Intake System26
Air Intake/Cooling System27
Air Intake Filter (Optional)27
Fuel Type (Gasoline)29
Gasoline/Alcohol Blends29
Gasoline/Ether Blends29
Section 5. Fuel System And Governor29
Fuel System Troubleshooting Guide (Gasoline)30
Fuel Filter30
Fuel Pump30
Carburetor (Gasoline)31
Troubleshooting - Gasoline Systems32
Walbro Carburetor Adjustment33
Fixed Main Jet Carburetor33
Optimum Low Idle Fuel Setting33
Carburetor Disassembly34
Main Fuel Jet Removal35
Fuel Inlet Seat Removal35
Choke Shaft Removal (Self-Relieving)35
Throttle Shaft Removal36
Carburetor Cleaning36
Carburetor Inspection36
Self-Relieving Choke Carburetor View36
Carburetor Repair37
Carburetor Reassembly37
Choke Shaft Installation (Self-Relieving)37
Carburetor High Altitude Operation38
Fuel Shut-Off Solenoid38
Welch Plug Installation – Walbro Carburetors38
Lpg Systems39
Fuel Recommendations (Lpg)39
Troubleshooting - Lpg Systems40
Adjust Carburetor40
Main Components Of Kohler Emission Sentry System40
Kohler Emission Sentry System Operation41
Operating With Emission Sentry41
Troubleshooting The Emission Sentry System41
Governor42
Initial Adjustment43
Unitized Throttle And Choke Control43
Throttle Cable Adjustment43
Speed Control Bracket Assembly View43
High Idle Speed Adjustment44
Aligning Holes In Speed Control Bracket And Throttle Lever44
Adjusting High Idle Speed44
Speed Control Bracket Service45
Separate Throttle And Choke Control45
Choke Adjustment45
Governor Spring Location45
Separate Choke And Throttle Cable Control View46
Starting An Engine Equipped With Separate Control Cable47
Setting The Low Idle Rpm47
Governed Idle Adjustment47
Location Of Governed Idle Adjusting Screw48
Oil Type49
Check Oil Level49
Viscosity Grades Table49
Section 6. Lubrication System49
Change Oil And Oil Filter50
Full-Pressure Lubrication System51
Change Oil Filter51
Oil Filter52
Oil Sentry52
Testing Oil Pressure53
Testing The Oil Sentry Switch53
Retractable Starter Removal And Installation55
Section 7. Retractable Starter55
Rope Replacement56
Pawls (Dogs) Replacement56
Retractable Starter Inspection And Service58
Retractable Starter Reassembly58
Spark Plug59
Section 8. Electrical System And Components59
Spark Plug Inspection60
Electronic Magneto Ignition System61
Magneto Ignition System Troubleshooting Guide62
Electronic Ignition System With Spark Advance63
Troubleshooting Cd Ignition Systems65
Testing Of Smart Spark Ignition Systems On Cv16 Engines65
Battery Charging66
Battery Maintenance66
Battery Test67
Electrical Systems Wiring Diagrams And Battery Charging Systems67
Checking Battery Voltage67
3 Amp/70 Watt Stator67
3 Amp Unregulated Battery Charging System68
Troubleshooting 3 Amp Battery Charging System With 70 Watt Stator69
Troubleshooting Guide 3 Amp/70 Watt Braking Stator70
Electric Start Engines 15 Amp Battery Charging System72
15 Amp Stator And Rectifier-Regulator73
Proper Connection To Test 15 Amp Charging System73
Troubleshooting Guide 15 Amp Regulated Battery Charging System74
Electric Starters75
Starting Motor Precautions75
Troubleshooting Guide - Starting Difficulties75
Operation - Inertia Drive Starters76
Starter Drive Service76
Style "A" Drive Service76
Style "B" Drive Service77
Retaining Ring Installation78
Starter Disassembly78
Remove The Thru Bolts78
Style "A" End Cap Brush Replacement78
Style "B" End Cap Brush Replacement79
Commutator Service79
Starter Reassembly79
110 Volt Ac Starter80
Solenoid Shift Electric Starters81
Ute Starter Disassembly82
Ute Starter Reassembly82
Nippendenso Solenoid Shift Starter Disassembly82
Brush Replacement (Nippendenso Solenoid Shift Starter)83
Nippendenso Solenoid Shift Starter Service83
Nippendenso Solenoid Shift Starter Reassembly84
Delco-Remy Starters Disassembly86
Delco-Remy Starter Inspection89
Delco-Remy Starter Armature90
Delco-Remy Starter Brush Replacement90
Delco-Remy Starter Service91
Delco-Remy Starter Reassembly91
Drain Oil From Crankcase And Remove Oil Filter95
Remove Oil Sentry Pressure Switch95
Section 9. Disassembly95
Remove Muffler96
Remove Retractable Starter96
Remove Electric Starter96
Remove Air Cleaner97
Remove External Governor Components And Carburetor97
Removing Bendix Drive Starter97
Removing Air Cleaner Base97
Remove Fuel Pump98
Remove Rectifier-Regulator99
Remove Extended Oil Fill Tube99
Remove Blower Housing And Baffles99
Remove Ignition Module100
Remove Fuel Line100
Remove Valve Cover And Cylinder Head101
Disassemble Cylinder Head101
Remove Drive Cup, Grass Screen, Flywheel And Fan103
Remove The Stator And Wiring Harness104
Remove Oil Pan104
Remove Oil Pickup, Oil Pressure Relief Valve, And Oil Pump105
Remove Hydraulic Lifters And Camshaft106
Remove Balance Shaft107
Remove Connecting Rod And Piston107
Remove Piston From Connecting Rod107
Remove Piston Rings108
Remove Crankshaft108
Remove Flywheel End Oil Seal108
Remove Governor Cross Shaft And Governor Gear108
Automatic Compression Release (Acr)111
Section 10. Inspection And Reconditioning111
Camshaft Inspection And Service112
Crankshaft Inspection And Service112
Crankcase Inspection And Service113
Clean Cylinder Bore After Honing114
Measuring Piston-To-Bore Clearance114
Flywheel Inspection114
Cylinder Head And Valves Inspection And Service115
Valve Guides Inspection And Service118
Valve Seat Inserts Inspection And Service118
Lapping Valves118
Pistons And Rings Inspection118
Install Piston Rings120
Connecting Rods Inspection And Service121
Oil Pump Inspection And Service121
Governor Gear And Shaft Inspection And Service121
Stamped Steel Valve Cover122
Install Governor Gear And Cross Shaft123
Section 11. Reassembly123
Install Crankshaft124
Install Piston To Connecting Rod124
Install Piston And Connecting Rod125
Install Balance Shaft126
Installing Camshaft127
Determine Camshaft End Play127
Install Oil Pressure Relief Valve127
Install Oil Pickup128
Install Oil Pan To Crankcase129
Oil Pan Fastener Torque Sequence129
Install Oil Pump130
Install Oil Seals130
Install Stator And Wiring Harness131
Install Fuel Line131
Install Fan And Flywheel131
Install Hydraulic Lifters133
Reassemble Cylinder Head134
Cylinder Head Valve Train Differences134
Install Cylinder Head136
Install Ignition Module138
Install Baffles And Blower Housing138
Install Valve Cover And Muffler Bracket139
Install Extended Oil Fill Tube140
Install Rectifier-Regulator140
Install Fuel Pump141
Install Carburetor And External Governor Components141
Install Air Cleaner And Make Initial Governor Adjustment142
Installing Air Cleaner Base142
Air Cleaner Details View143
Install Electric Starter144
Install Retractable Starter144
Install Muffler144
Prepare The Engine For Operation145
Testing The Engine145