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
Specifi cations
15
Tools and Aids
18
Troubleshooting
22
Air Cleaner/Intake
23
Fuel System
29
Governor System
30
Lubrication System
32
Electrical System
48
Starter System
57
Disassembly/Inspection and Service
72
Reassembly
24 690 07 Rev. B
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Summary of Contents for Kohler Command CV17

  • 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 Specifi...

  • 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 fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 24 690 07 Rev. B...

  • 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 Specifi cations Engine Dimensions with Low-Profi le Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. 24 690 07 Rev. B KohlerEngines.com...
  • Page 6 Specifi cations Engine Dimensions with Commercial Mower Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 24 690 07 Rev. B...
  • Page 7 Specifi cations Engine Dimensions with Heavy-Duty Air Cleaner Dimensions in millimeters. 424.75 Inch equivalents shown in [ ]. [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]...

  • Page 8: Engine Identification Numbers

    Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
  • Page 9 Specifi cations TORQUE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/CV730/ CV750 CV22/ CV670-CV680 CV740 CV620-CV640 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 Hex Flange Nut (torque in 2 increments) fi...
  • Page 10 Specifi cations TORQUE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/CV730/ CV750 CV22/ CV670-CV680 CV740 CV620-CV640 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: Clearance Specifications

    Specifi cations CLEARANCE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/CV730/ CV750 CV22/ CV670-CV680 CV740 CV620-CV640 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 Specifi cations CLEARANCE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/CV730/ CV750 CV22/ CV670-CV680 CV740 CV620-CV640 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 Specifi cations CLEARANCE SPECIFICATIONS CV17 CV18/CV20/ CV22/CV23/ CV25/CV730/ CV750 CV22/ CV670-CV680 CV740 CV620-CV640 Piston, Piston Rings, and Piston Pin (continued) Used Bore (Max.) 0.77 mm 0.80 mm 0.94 mm (0.037 in.) (0.030 in.) (0.0315 in.) Top Ring 0.70 mm (0.028 in.) Middle Ring 0.90 mm (0.035 in.)

  • Page 14: General Torque Values

    Specifi cations 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 15 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 16 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. Design Technology Inc. Reamer Handle For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 SE Tools KLR-82415 Valve Guide Service Kit (Courage, Aegis, Command, OHC) For servicing worn valve guides.
  • Page 17 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A fl ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft fl ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.

  • Page 18: Troubleshooting Guide

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at fi rst, 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 specifi cation. Use these to locate causing factors.
  • Page 19 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 20: 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 21: 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 22: Breather Tube

    Air Cleaner/Intake AIR CLEANER Low-Profi le/Commercial Mower These systems are CARB/EPA certifi ed and components Loosen knob and remove air cleaner cover. should not be altered or modifi ed in any way. Precleaner Low-Profi le and Commercial Mower Air Cleaner 1.

  • Page 23: 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 24 Fuel System CARBURETORS Gasoline is extremely fl ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fi res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 25 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 Shut-off Solenoid Adjusting Screw Float Assembly Idle Fuel Passage Cover Fuel Bowl Choke Lever Adjusting Spring Cover Retaining...
  • Page 26 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 27 Fuel System 2. Release governor lever and check that throttle lever Carburetor Circuits is in idle position. Turn governed idle adjustment screw to obtain equipment manufacturer’s Float Fuel level in bowl is maintained by fl oat and fuel inlet recommended idle speed (1500-1800 RPM). Some needle.
  • Page 28 Disconnect negative (–) battery cable from battery. 1219 meters (4000 ft.). To obtain high altitude kit information or to fi nd a Kohler authorized dealer visit NOTE: Main and slow jets are fi xed and size specifi c KohlerEngines.com or call1-800-544-2444 (U.S. and and can be removed if required.

  • Page 29: Governor System

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

  • Page 30: Check Oil Level

    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 fi ll cap/dipstick, drain plug/oil hydraulic valve lifters.
  • Page 31 Lubrication System Installation 1. Apply pipe sealant with Tefl on (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 32: 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 33 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 34 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with Fixed Timing KohlerEngines.com 24 690 07 Rev. B...
  • Page 35 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 fl ywheel magnet group as referenced to engine TDC. A typical fi xed ignition system consists of: ●...
  • Page 36 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with Smart-Spark KohlerEngines.com 24 690 07 Rev. B...
  • Page 37 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 affi xed to fl ywheel. ●...
  • Page 38 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Key Switch KohlerEngines.com 24 690 07 Rev. B...
  • Page 39 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 40 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 41 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 42 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 43 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 44: 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 45 Electrical System 15/20/25 Amp Regulated Charging System Stator Stator is mounted on crankcase behind fl ywheel. Follow procedures in Disassembly and Reassembly if stator replacement is necessary. Rectifi er-Regulator NOTE: When installing rectifi er-regulator, take note of terminal markings and install plug(s) accordingly. NOTE: Disconnect all electrical connections attached to rectifi...
  • Page 46 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 47 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 48 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 suffi cient 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 49 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 50 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 51 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 52 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 53 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 fl...
  • Page 54 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 55: 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 56 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 57 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 58 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 fi tting in adapter or and gauged for wear or damage. There are many elbow.
  • Page 59 Disassembly/Inspection and Service Remove External Governor Controls Remove Throttle Controls Loosen nut and remove governor lever from cross shaft. Leave lever attached to throttle linkage. Control Panel Components Remove Carburetor WARNING Explosive Fuel can cause fi res and severe burns. Do not fi...
  • Page 60 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 61 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 62: 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 63 If lifters need to be replaced, apply a liberal (0.2809 in.) while 7.159 mm (0.2819 in.) is maximum coating of Kohler lubricant to base of each new lifter allowed on exhaust guide. Guides are not removable but before it is installed.
  • Page 64 fl ywheel, crankshaft, and key if fl ywheel 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 fl ywheel if ring gear is damaged.
  • Page 65 Disassembly/Inspection and Service Breather/Oil Pan/Oil Reservoir/Piston Components Remove Oil Pan Assembly 1. Remove screws securing oil pan to crankcase. 2. Locate splitting tabs cast into perimeter of oil pan. Insert drive end of a 1/2" breaker bar between splitting tab and crankcase and turn it to break RTV seal.
  • Page 66 Disassembly/Inspection and Service Oil Pump Assembly Oil Pump Oil Pump Oil Pickup Tube Roll Pin (Original Style) (Later Style) Piston Spring O-Ring Plastic Oil Pickup One-Piece Relief Torque Sequence Valve Governor Gear Assembly Governor gear assembly is located inside oil pan. If service is required, refer to Inspection, Disassembly, and Governor Shaft Component and Details Reassembly procedures.
  • Page 67 Disassembly/Inspection and Service Oil Pump Assembly 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 refer to Disassembly, Inspection, and Reassembly nylon washer, from governor cross shaft. procedures below.
  • Page 68 Disassembly/Inspection and Service Ring failure is usually indicated by excessive oil Piston and Rings consumption and blue exhaust smoke. When rings fail, Inspection oil is allowed to enter combustion chamber where it is burned along with fuel. High oil consumption can also Piston and Rings Components and Details occur when piston ring end gap is incorrect because ring cannot properly conform to cylinder wall under this...
  • Page 69 Disassembly/Inspection and Service 3. Top compression ring (top groove): Install top ring NOTE: If crankpin is reground, visually check to insure using a piston ring expander. Make sure fi llet blends smoothly with crankpin surface. identifi cation mark is up or dye colored stripe (if Carefully pull crankshaft from crankcase.
  • Page 70 Measuring Piston-to-Bore Clearance Piston Detail 23°-33° Crosshatch NOTE: Kohler pistons are custom-machined to exacting tolerances. When oversizing a cylinder, it should be machined exactly 0.25 mm (0.010 in.) or 0.50 mm (0.020 in.) over new diameter (refer to 6 mm (0.24 in.)
  • Page 71 Disassembly/Inspection and Service Before installing piston into cylinder bore, it is necessary clearance be accurately checked. This step is often overlooked, and if clearances are not within specifi cations, engine failure will usually result. Use following procedure to accurately measure piston- to-bore clearance: 1.
  • Page 72 Reassembly NOTE: Make sure engine is assembled using all Breather/Oil Pan/Oil Reservoir/Piston Components specifi ed torque values, tightening sequences, and clearances. Failure to observe specifi cations 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 73 Reassembly 4. Make sure Fly stamping on piston is facing towards Install Connecting Rods with Pistons and Rings fl ywheel side of engine. Use a hammer with a rubber grip and gently tap piston into cylinder. Be careful Piston and Connecting Rod Details that oil ring rails do not spring free between bottom of ring compressor and top of cylinder.
  • Page 74 Reassembly Oil Pump Assembly Install Oil Pan Assembly Oil pump is mounted inside oil pan. If service was Sealant Pattern required, and oil pump was removed, refer to Disassembly/Inspection and Service. Governor Gear Assembly Governor gear assembly is located inside oil pan. If service was required, and governor was removed, refer to Disassembly/Inspection and Service.
  • Page 75 Reassembly 5. Install oil pan to crankcase. Carefully seat camshaft Flywheel/Ignition Components and crankshaft into their mating bearings. Rotate crankshaft slightly to help engage oil pump and governor gear meshes. 6. Install screws securing oil pan to crankcase. Torque fasteners to 24.4 N·m (216 in. lb) following sequence.
  • Page 76 Reassembly Install Stator and Backing Plates Install Fan and Debris Screen 1. Apply pipe sealant with Tefl on (Loctite 592™ NOTE: Position locating tabs on back of fan in recesses ® ® ® Thread Sealant or equivalent) to stator mounting of fl...
  • Page 77 Reassembly 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 Install Hydraulic Lifters Valve Stem Seals NOTE: Hydraulic lifters should always be installed in These engines use valve stem seals on intake valves...
  • Page 78 Reassembly obtained. Otherwise frictional heat from engaging Install Cylinder Heads threads may cause locking compound to set up prematurely. Torque Sequence Studs closest to lifters must have an exposed height of 75 mm (2 15/16 in.). Studs furthest from lifters must have an exposed height of 68 mm (2 3/4 in.).
  • Page 79 Reassembly 3. Install each ignition module to crankcase bosses Install Breather Cover and Inner Baffl es with screws (hex fl ange or allen head, based on model). Slide modules up as far away from fl ywheel Breather Cover Torque Sequence as possible and snug screws to hold them in that position.
  • Page 80 Reassembly 3. Connect choke control cable to throttle control Wires on Oil Filter Side of Engine bracket. 4. Connect Oil Sentry indicator light wires. ™ Reconnect Rectifi er-Regulator 1. Install rectifi er-regulator in blower housing if removed previously, then connect rectifi er-regulator ground lead with washer and silver screw through eyelet.
  • Page 81 Reassembly 3. For covers requiring RTV sealant, apply a 1.5 mm Control Panel Components (1/16 in.) bead to sealing surface of both cylinder heads, install a new cover gasket on each, then apply a second bead of sealant on top surface of gaskets.
  • Page 82 Reassembly 3. Connect governor spring from throttle control bracket Install External Governor Controls to appropriate hole in governor lever, as indicated in 1. Install governor lever onto governor cross shaft. applicable chart. Note that hole positions are counted from pivot point of governor lever. 2.
  • Page 83 Reassembly CV18 Engines CV17, CV20-740 Engines Without Throttle Limiter Engine Mounted Engine Mounted Intended Standard Intended Standard Throttle Control Throttle Control Maximum RPM Throttle Control Maximum RPM Throttle Control Pivot Shaft Pivot Shaft High Spring Hole Spring Hole High Spring Hole Spring Hole No.
  • Page 84 Reassembly Install Electric Starter Motor Install Air Cleaner Assembly 1. Install starter motor using screws. Position lift Low-Profi le and Commercial Mower Air Cleaners bracket to also secure dipstick tube. Some inertia- 1. Connect breather hose and attach breather drive starters have a pinion cover and spacers on separator to valve cover.
  • Page 85 Reassembly Install Oil Filter and Fill Crankcase with Oil NOTE: Make sure that both oil drain plugs are installed and torqued to above specifi cations to prevent oil leakage. 1. Install oil drain plug(s). Torque plug(s) to 13.6 N·m (10 ft. lb.). If oil drain valve is used, make sure valve body is closed and cap is on.
  • Page 86 KohlerEngines.com 24 690 07 Rev. B...
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  • Page 88 © 2011 by Kohler Co. All rights reserved. KohlerEngines.com 24 690 07 Rev. B...

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