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Kohler COMMAND CV17-745 Service Manual

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Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
S
M
ERVICE
ANUAL
COMMAND
CV17-745
V
C
ERTICAL
RANKSHAFT
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Summary of Contents for Kohler COMMAND CV17-745

  • Page 1 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 ERVICE ANUAL COMMAND CV17-745 ERTICAL RANKSHAFT www.mymowerparts.com...

  • Page 2: Table Of Contents

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Contents Section 1. Safety and General Information ................Section 2. Special Tools ......................Section 3. Troubleshooting ..................... Section 4. Air Cleaner and Air Intake System ................ Section 5. Fuel System and Governor ..................

  • Page 3: Section 1. Safety And General Information

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information CV17-745 Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below.
  • Page 4 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause fires and Explosive Fuel can cause fires and Carbon Monoxide can cause severe acid burns. severe burns. severe nausea, fainting or death.
  • Page 5 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification and Serial Numbers, including letter suffixes if there are any.
  • Page 6 SAE viscosity grade. See Figure 1-3. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines.
  • Page 7 ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service. ³Cleanout Kits 25 755 20-S (black) or 25 755 21-S (gold) allow cooling areas to be cleaned without removing shrouds.
  • Page 8 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information (Base engine illustrated) Figure 1-4. Typical Engine Dimensions CV Series with Standard Flat Air Cleaner. www.mymowerparts.com...
  • Page 9 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information (Base engine illustrated) Figure 1-5. Typical Engine Dimensions CV Series with Commercial Mower Air Cleaner. www.mymowerparts.com...
  • Page 10 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in (). Figure 1-6. Typical Engine Dimensions CV EFI Series with Heavy-Duty Air Cleaner. www.mymowerparts.com...
  • Page 11 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information General Specifications Power (@ 3600 RPM, corrected to SAE J1995) CV17 ..........................12.7 kW (17 HP) CV18 ..........................13.4 kW (18 HP) CV20 ..........................14.9 kW (20 HP) CV22/23 ........................
  • Page 12 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Blower Housing and Sheet Metal cont. M6 Fasteners Torque .................. 6.8 N·m (60 in. lb.) Rectifier-Regulator Fastener Torque ............4.0 N·m (35 in. lb.) Camshaft End Play (With Shim) ................. 0.076/0.127 mm (0.0030/0.0050 in.) Running Clearance ..................
  • Page 13 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Crankcase cont. Oil Drain Plug Torque .................. 13.6 N·m (10 ft. lb.) Oil Pan Oil Pan Fastener Torque ................24.4 N·m (216 in. lb.) Crankshaft End Play (Free) ..................0.070/0.590 mm (0.0028/0.0230 in.) Crankshaft Bore (In Crankcase) New ......................
  • Page 14 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Cylinder Bore cont. Max. Taper .................... 0.05 mm (0.0020 in.) Cylinder Head Cylinder Head Fastener Torque Hex. Flange Nut - Torque in Two Stages .......... initially to 16.9 N·m (150 in. lb.) finally to 33.9 N·m (300 in.
  • Page 15 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Muffler Muffler Retaining Nuts Torque ..............24.4 N·m (216 in. lb.) Oil Filter Oil Filter Torque ..................10.4-12.7 N·m (90-110 in. lb.) Oil Cooler Oil Cooler/Adapter Nipple Torque ............27 N·m (20 ft. lb.) Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance ..........
  • Page 16 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin cont. Piston Thrust Face O.D.² New - CV17 ..................72.966/72.984 mm (2.8727/2.8734 in.) New - CV18, CV20, CV22 (624 cc) ..........76.967/76.985 mm (3.0302/3.0309 in.) New - CV22/23 (674 cc) ..............
  • Page 17 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance ......0.0241/0.0501 mm (0.0009/0.0020 in.) Intake Valve Stem-to-Valve Guide Running Clearance ......0.038/0.076 mm (0.0015/0.0030 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance ......
  • Page 18 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Grade 2 or 5 Assembled Into Cast Iron or Steel...

  • Page 19: Special Tools

    By using tools designed for the job, you can service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Kohler special tools are handled by SPX Corp., a division of Owatonna Tool Corp. (OTC). The tools are easy to purchase by contacting SPX/OTC by phone, fax, or mail.

  • Page 20: Section 2. Special Tools

    Obtain a flat washer with the correct I.D. to slip on the capscrew and an O.D. of approximately 1 in. or use Kohler Part No. 12 468 05. Assemble the capscrew and washer to the joint surface of the rod, as shown in Figure 2-3.
  • Page 21 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 2 Special Tools RTV Silicone Sealant RTV silicone sealant is used as a gasket between the crankcase and oil pan. Only oxime-based, oil resistant RTV sealants, such as those listed below, are approved for use. Loctite Nos.
  • Page 22 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 2 Special Tools www.mymowerparts.com...

  • Page 23: Section 3. Troubleshooting

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting CV17-745 Section 3 Troubleshooting Troubleshooting Guide Engine Starts Hard 1. PTO drive is engaged. When troubles occur, be sure to check the simple 2. Dirt or water in the fuel system.
  • Page 24 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting Engine Will Not Idle Engine Uses Excessive Amount of Oil 1. Dirt or water in the fuel system. 1. Incorrect oil viscosity/type. 2. Stale fuel and/or gum in carburetor.
  • Page 25 (SPX Part No. KO1048, formerly Crankcase vacuum should be 4-10 (inches of Kohler Part No. 25 761 02-S) or a vacuum gauge water) If the reading is below specification, or if (SPX Part No. KO3223, formerly Kohler Part No.
  • Page 26 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting No Crankcase Vacuum/Pressure in Crankcase Possible Cause Solution 1. Disassemble breather, clean parts thoroughly, 1. Crankcase breather clogged or inoperative. reassemble, and recheck pressure. 2. Replace all worn or damaged seals and 2.
  • Page 27 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting Leakdown Test Results Air escaping from crankcase breather ........... Rings or cylinder worn. Air escaping from exhaust system ............Defective exhaust valve. Air escaping from carburetor ..............Defective intake valve.
  • Page 28 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting www.mymowerparts.com...

  • Page 29: Section 4. Air Cleaner And Air Intake System

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System CV17-745 Section 4 Air Cleaner and Air Intake System Service Air Cleaners Check the air cleaner daily or before starting the engine. Check for and correct any buildup of dirt and General debris, along with loose or damaged components.
  • Page 30 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System Paper Element Service (Standard and Commercial Mower Types) Every 100 hours of operation (more often under Precleaner extremely dusty or dirty conditions), replace the paper element.
  • Page 31 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System Air Cleaner Base Spitback Cup Precleaner Spitback Cup Gasket Rubber Seal Air Cleaner Cover Element Knob Seal Element Element Cover Cover Nut Knob Figure 4-5. Air Cleaner System Components - Standard.
  • Page 32 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System Air Cleaner Components 4. Remove the base and gasket. Carefully feed the Whenever the air cleaner cover is removed, or the breather hose through the base.
  • Page 33 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System Heavy-Duty Air Cleaner Inner Element Element General The heavy-duty air cleaner consists of a cylindrical housing, typically mounted to a bracket, and connected with a formed rubber hose to an adapter on the carburetor or throttle body/intake manifold (EFI units).
  • Page 34 Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled. *Cleanout kits, Kohler Part No. 25 755 20-S (black) or 25 755 21-S (gold), are recommended to aid inspection and cleanout of the cooling fins. See Figure 4-11.

  • Page 35: Section 5. Fuel System And Governor

    Gasohol (up to 10% ethyl alcohol, 90% unleaded equipped with a fuel pump, the fuel tank outlet is gasoline by volume) is approved as a fuel for Kohler located above the carburetor inlet allowing gravity to engines. Other gasoline/alcohol blends are not feed fuel to the carburetor.
  • Page 36 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Fuel Filter Fuel System Tests Most engines are equipped with an in-line filter. When the engine starts hard, or turns over but will not Visually inspect the filter periodically and replace when start, it is possible that the problem is in the fuel dirty with a genuine Kohler filter.
  • Page 37 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor NOTE: Make sure the orientation of the new pump is consistent with the removed pump. Internal damage may occur if Inlet Line installed incorrectly. 5. Connect the pulse line between the pump and Outlet Line (to crankcase.
  • Page 38 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Slow Circuit: (See Figure 5-2) At low speeds the engine operates only on the slow circuit. As a metered amount of air is drawn through the slow air bleed jet, fuel is drawn through the main jet and further metered through the slow jet.
  • Page 39 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Main Circuit: (See Figure 5-3) At high speeds/loads the engine operates on the main circuit. As a metered amount of air is drawn through the main air bleed jet, fuel is drawn through the main jet. The air and fuel are mixed in the main nozzle and then enter the main body of airflow, where further mixing of the fuel and air takes place.
  • Page 40 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Troubleshooting Checklist Below is a simple test, made with the engine off, that When the engine starts hard, runs roughly or stalls at can determine if the solenoid is functioning properly: low idle speed, check the following areas before adjusting or disassembling the carburetor.
  • Page 41 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor NOTE: Carburetor adjustments should be made only 4. Low Idle Speed Setting: Place the throttle after the engine has warmed up. control into the “idle” or “slow” position. Set the low idle speed to 1200 RPM* (±...
  • Page 42 Use the carburetor repair kit (and the float repair kit if float components are to be replaced). Refer to Figure 5-7 for parts identification. The Kohler part number and 16.5 mm the Nikki lot number are stamped on the choke side (0.65 in.)
  • Page 43 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 1. Carburetor Body 2. Idle Fuel Adjusting Screw* 3. Idle Fuel Adjusting Spring* 4. Passage Cover 5. Cover Gasket* 6. Cover Retaining Screw 7. Main Jet 8.
  • Page 44 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Always use new gaskets when servicing or reinstalling carburetors. Repair kits are available which include new gaskets and other components. Service/repair kits available for Nikki carburetors and affiliated...
  • Page 45 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 8. When the proper float height is obtained, carefully reinstall the fuel bowl, with the O-Ring(s) in place, onto the carburetor. Secure with the four original screws.
  • Page 46 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 2. Remove the float pin screw and lift out the old NOTE: The carburetor is now disassembled for float, pin, and inlet needle. See Figure 5-15.
  • Page 47 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 11. Install the float and inlet needle down into the seat and carburetor body. Insert the new pivot pin through the float hinge and secure with the new retaining screw.
  • Page 48 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 14. When the proper float height is obtained, carefully install the new O-Rings for the fuel bowl and the accelerator pump transfer passage (if so equipped). See Figure 5-23.
  • Page 49 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 2. Remove the three screws securing the cover to the accelerator pump housing. Remove the cover, spring, and diaphragm. See Figure 5-27. Figure 5-29. Check Valve and Retaining Ring Installed.
  • Page 50 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 5. Use a screw extractor (easy out) and remove the original choke shaft bushing with the old choke lever from the carburetor housing. Save the bushing to use as a driver for installing the new bushing.
  • Page 51 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 9. Install the new return spring onto the new choke Governor shaft, so the upper leg of the spring is between the two formed “stops” on the end of the choke General shaft.
  • Page 52 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Adjustments Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes of the governor lever. If General speed surging occurs with a change in engine load, The governed speed setting is determined by the the governor is set too sensitive.
  • Page 53 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Throttle Control Left Side Pull Lever #2 Choke Control Choke Lever #1 Control Kill Switch Cable Choke Linkage Throttle Z Bend Control Cable Throttle Control Cable...
  • Page 54 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Choke Lever Detail Choke Lever Screw Washer Spring Washer Lock Spacer Fastener Choke Cable Choke Lever Bushing (See Detail at Left) Linkage Control Screw and Nut...
  • Page 55 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System CV26, CV745 Section 5B Electronic Fuel Injection (EFI) Fuel System Contents Page(s) Description Initial Starting/Priming Procedure ......................5B.2 Fuel Recommendations ........................5B.2-5B.3 EFI Fuel System Components ........................5B.3 Operation ..............................5B.3 Important Service Notes ..........................

  • Page 56: Description

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Description 2. For plastic-cased ECU’s below 24 584 28, the system can be primed by manually cycling the fuel pump. WARNING a. Turn the key switch to the “on/run” position.

  • Page 57: Efi Fuel System Components

    Gasohol (up to 10% ethyl alcohol, 90% unleaded into the injectors, which inject it into the intake ports. gasoline by volume) is approved as a fuel for Kohler EFI The ECU controls the amount of fuel by varying the engines. Other gasoline/alcohol blends are not length of time that the injectors are “on.”...

  • Page 58: Important Service Notes

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System During certain operating periods such as cold starts, • Never start the engine when the cables are loose or poorly connected to the battery terminals. warm up, acceleration, etc., an air/fuel ratio richer than 14.7:1 is required and the system operates in an “open...

  • Page 59: Engine Speed Sensor

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Two different ECU styles have been used in CV EFI To prevent engine over-speed and possible failure, a production. Each has a plastic case, but they differ in “rev-limiting”...
  • Page 60 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System General The engine speed sensor is essential to engine Dual Aligning Rails operation; constantly monitoring the rotational speed (RPM) of the crankshaft. A ferromagnetic 60-tooth ring gear with two consecutive teeth missing is mounted on the flywheel.
  • Page 61 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System General 3. a. Use an ohmmeter and connect the ohmmeter The throttle position sensor (TPS) is used to indicate leads as follows to test: (See chart on throttle plate angle to the ECU.
  • Page 62 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System “24 Pin” (MSE 1.0) Plastic-Cased ECU: Pin 6. Shut off the engine. circuits #8 and #4. 7. Locate the service connector plug in the wiring “32 Pin” (MSE 1.1) Plastic-Cased ECU: Pin harness.

  • Page 63: Engine (Oil) Temperature Sensor

    The PC-based diagnostic KO3217-9). If using the PC-based diagnostic software may be used to read out the fault software (Kohler Part No. 25 761 23-S), go to code and assist with troubleshooting and “Special Tests” and follow the prompts to repair.

  • Page 64: Oxygen Sensor

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System General Oxygen Sensor The engine (oil) temperature sensor (Figure 5B-8) is used by the system to help determine fuel requirements for starting (a cold engine needs more fuel than one at or near operating temperature).
  • Page 65 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System The oxygen sensor can function only after being heated declines, without cycling, the engine may be by exhaust temperatures to a minimum of 375°C running lean due to incorrect TPS initialization.

  • Page 66: Electrical Relay

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System b. If the resistance is less than 1.0 MΩ Ω Ω Ω Ω , the 2. Loosen and remove the oxygen sensor from the sensor is bad, replace it.

  • Page 67: Fuel Injectors

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 2. Connect the black lead of VOA meter to a chassis Terminal #87 - Terminal #86 - Feed To ground location. Connect the red lead to the #86...
  • Page 68 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Figure 5B-15. Style 2 Fuel Injector. General The fuel injectors mount into the throttle body/intake Multi-Orifice manifold, and the fuel rail attaches to them at the top Director Plate With end.
  • Page 69 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System a. If flashing occurs, use an ohmmeter (Rx1 Listen Here scale) and check the resistance of each injector across the two terminals. Proper resistance is 12-20 Ω Ω Ω Ω Ω . If injector resistance is...
  • Page 70 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 10. Remove the manifold mounting bolts and separate the throttle body/manifold from the engine leaving the TPS, fuel rail, air baffle, injectors and line connections intact. Discard the old gaskets.

  • Page 71: Ignition System

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Ignition System 3. Using an ohmmeter set on the Rx1 scale, check the resistance in circuits as follows: General "24 Pin" (MSE 1.0) Plastic-Cased ECU: Check A high-voltage, solid-state, battery ignition system is between terminal #87 and pin #22 for coil #1.

  • Page 72: Spark Plugs

    EFI engines are equipped with Champion RC12YC performance. Corrosion, moisture, and poor (Kohler Part No. 12 132 02-S) resistor spark plugs. connections are more likely the cause of operating Equivalent alternate brand plugs can also be used, but problems and system errors than an actual must be resistor plugs or permanent damage to the component.

  • Page 73: Fuel Pressure Regulator

    If the pump still does not operate, replace it. relay may be conducted. Fuel Pressure Regulator 1. Connect the black hose of Kohler pressure tester (SPX Part No. KO3217-4) to the test valve in the fuel rail. Route the clear hose into a portable gasoline container or the equipment fuel tank.
  • Page 74 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System a. Remove the two screws securing the General mounting bracket to the regulator housing. The fuel pressure regulator assembly maintains the Remove the O-Ring and pull the regulator out required operating system pressure of 39 psi ±...

  • Page 75: Fuel Filter

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 6. Install the new regulator by carefully pushing and Fuel Rail rotating it slightly into the base or housing. a. External Regulators with Square Base Housing Only; Install a new O-Ring between the Fuel Rail regulator and the mounting bracket.

  • Page 76: Throttle Body/Intake Manifold Assembly

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System General Service High-pressure fuel line with an SAE 30 R9 rating is The throttle body/intake manifold is serviced as an required for safe and reliable operation, due to the assembly, with the throttle shaft, TPS, throttle plates, higher operating pressure of the EFI system.

  • Page 77: Initial Governor Adjustment

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Idle Speed Screw Linkage Throttle Bushing Linkage Damper Spring Figure 5B-34. Throttle Linkage/Governor Lever Connection. 2. Check if the engine has a high-speed throttle stop Figure 5B-33. Idle Speed Screw Details.
  • Page 78 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System B. Setting the Initial Adjustment 1. Check the split where the clamping screw goes through the governor lever. See Figure 5B-38. There should be a gap of at least 1/32". If the tips are touching and there is no gap present, the lever should be replaced.

  • Page 79: Troubleshooting

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Engine starts hard or fails to start when hot 4. Verify that the governor has been set correctly. With the linkage still retained in the “Full Throttle”...
  • Page 80 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Keep in mind that EFI-related problems are more often If a fault code indicates a problem with an electrical caused by the wiring harness or connections than by component, disconnect the ECU connector and test for the EFI components.
  • Page 81 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 82 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 83 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System “32 Pin” (MSE 1.1) Plastic-Cased ECU Systems Pin # Function Permanent Battery Voltage Switched Battery Voltage TPS Set; “Auto-Learn” Initialization Terminal Throttle Position Sensor (TPS) and Temperature Sensor Ground...

  • Page 84: Fuel System

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Fuel System Fault Codes The ECU continuously monitors engine operation WARNING: Fuel System Under Pressure! against preset performance limits. If the operation is The fuel system operates under high pressure. System...
  • Page 85 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Example of Diagnostic Display 1. Diagnostic display initiated through ignition key sequencing. Long Pause Short Pause Code 32 Long Pause Code 61 Long Pause Light remains on at end of transmission Figure 5B-40.
  • Page 86 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Diagnostic Code Summary cont. 2 " " n 3 " " n c i l 3 " " n u l i i r c c i t...
  • Page 87 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: Code: Source: Engine Speed Sensor Source: Throttle Position Sensor (TPS) Explanation: ECU receiving inconsistent tooth Explanation: Unrecognizable signal is being sent count signals from speed sensor.
  • Page 88 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: Expected Engine Source: Response: System operates under “open loop” Explanation: ECU is unable to recognize or process control only. Until fault is detected and signals from its memory.
  • Page 89 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 2. Oxygen Sensor Related f. Fuel in the crankcase oil. a. Sensor connector or wiring problem. g. Blocked or restricted fuel return circuit to tank. b. Sensor contaminated or damaged.
  • Page 90 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: a. Broken or shorted wire in harness. Source: Engine (Oil) Temperature Sensor ECU pin 18 to TPS pin 1. Explanation: Not sending proper signal to ECU.
  • Page 91 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 3. Fuel Pump Relay Related Code: “32 Pin” (MSE 1.1) Plastic- a. Bad fuel pump relay. Cased ECU only. Primary side functional but pin 30 to pin 87...

  • Page 92: Troubleshooting Flow Chart

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: “32 Pin” (MSE 1.1) Plastic- Code: Cased ECU only. Source: Source: Fuel pump relay circuit open, shorted Explanation: Denotes the end of fault codes. If to ground, or shorted to battery...
  • Page 93 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System *Operate for an appropriate period of time based upon original fault codes. Figure 5B-41. 5B.39 www.mymowerparts.com...

  • Page 94: Flow Chart Diagnostic Aids

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 15. Code 61 - End of Fault/Blink Code Transmission Flow Chart Diagnostic Aids Diagnostic Aid #1 “SYSTEM POWER” (MIL does not Diagnostic Aid #3 “RUN/ON” (MIL remains “on” while illuminate when key is turned “on”)
  • Page 95 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Diagnostic Aid #5 “FUEL PUMP” (fuel pump not Diagnostic Aid #8 “FUEL SYSTEM-ELECTRICAL” turning on) (no fuel delivery) Possible causes: Possible causes: 1. Fuel pump fuse 1. No fuel 2.
  • Page 96 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 5B.42 www.mymowerparts.com...

  • Page 97: Lubrication System

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System CV17-745 Section 6 Lubrication System General NOTE: Using other than service class SG, SH, SJ or higher oil, or extending oil change intervals This engine uses a full pressure lubrication system,...

  • Page 98: Section 6 Lubrication System

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System NOTE: To prevent extensive engine wear or damage, Checking Oil Level always maintain the proper oil level in the The importance of checking and maintaining the crankcase. Never operate the engine with the...
  • Page 99 In order to be effective, the oil cooler must be kept free (every 200 hours of operation). Always use a of debris. genuine Kohler oil filter. Change the filter as follows. See Figure 6-5 or 6-6. 1. An oil drain plug is located on either side of the oil sump;...
  • Page 100 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System To service the blower housing mounted oil cooler, clean the outside of the fins with a brush. (See Figure 6-7.) Remove the two screws holding the cooler unit to the blower housing.
  • Page 101 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter CV17-745 Section 7 Retractable Starter WARNING: Spring Under Tension! Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in this section for relieving spring tension.

  • Page 102: Section 7 Retractable Starter

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter 6. Tie a single knot in one end of the new rope. Pawls (Dogs) Replacement To replace the pawls, follow disassembly steps 1-4 and 7. Rotate the pulley counterclockwise (when viewed reassembly steps 3-8 on the following pages.
  • Page 103 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter Center Screw Pawl Retainer and Washer Housing Pulley Figure 7-4. Center Screw, Washer and Pawl Figure 7-6. Removing Pulley from Housing. Retainer. 8. Note the position of the spring and keeper assembly in the pulley.
  • Page 104 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter 3. Do not attempt to rewind a spring that has come out of the keeper. Order and install a new spring Pawl and keeper assembly. 4. Clean all old grease and dirt from the starter components.

  • Page 105: Section 8. Electrical System And Components

    RC12YC (Kohler Part No. 12 132 02-S). A ® high-performance spark plug, Champion Platinum 3071 (used on Pro Series engines, Kohler Part No. 25 132 12-S) is also available. Equivalent alternate brand plugs can also be used. Gap: 0.76 mm (0.030 in.)
  • Page 106 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Normal: A plug taken from an engine operating under Wet Fouled: A wet plug is caused by excess fuel or oil normal conditions will have light tan or gray colored in the combustion chamber.
  • Page 107 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Battery 2. Keep the cables, terminals, and external surfaces of the battery clean. A build-up of corrosive acid or grime on the external surfaces can cause the General battery to self-discharge.
  • Page 108 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Electronic CD Ignition Systems Carburetor Solenoid Starter and Ignition Spark Pressure Carburetor Module Advance Safety Green Solenoid Input Module Input (Optional) White Oil Pressure B+ and...
  • Page 109 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Kill Switch or Ignition ‘‘Off’’ Position of Modules Key Switch Spark Plug Magnet 0.28/0.33 mm (0.011/0.013 in.) Flywheel Air Gap Figure 8-4. Capacitive Discharge (Fixed Timing) Ignition System.
  • Page 110 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components B. Capacitive Discharge with Electronic Spark Advance (SMART-SPARK ™ SMART-SPARK equipped engines utilize an ™ electronic capacitive discharge ignition system with electronic spark advance. A typical application (Figure 8-6) consists of the following components: •...
  • Page 111 CAUTION: High-Energy Electric Spark! 2. Test for spark on both cylinders with Kohler The CD ignition systems produce a high-energy ignition tester, SPX Part No. KO1046 (formerly electric spark, but the spark must be discharged, or Kohler Part No.
  • Page 112 *NOTE: Ignition tester (SPX Part No. KO1046 formerly Kohler Part No. 24 455 02-S) must be used 2. Crank the engine over, establishing a minimum of to test ignition on these engines. Use of any 550-600 RPM, and observe tester(s) for spark.
  • Page 113 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components b. If you were able to check timing on both Test 3 – Check for timing advance cylinders, the lines you made on the blower housing should be 90° apart. If they’re not, go to Test 4.
  • Page 114 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Ignition Module Resistance Table 4) Position a 0.33 mm (0.013 in.) feeler gauge between the magnet and all three 24 584 03 or legs of the module. The ignition module...
  • Page 115 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components † The 24 584 15-S ignition modules have a Test 5 – Test the SAM Trace the red power source lead from the separator/barrier between the terminals. On these modules, seal the base of the terminal SAM to the harness connection.
  • Page 116 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components *IMPORTANT! Allow 15-20 seconds for the tester to clear and reset itself between tests or if the test is interrupted before completion of the test cycle. Otherwise, a false reading may be displayed in the form of a “-”...
  • Page 117 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components To replace the battery, remove the outer set of screws NOTE: Observe the following guidelines to avoid on the faceplate and carefully lift the panel from the damage to the electrical system and body.
  • Page 118 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Figure 8-15. 15 amp Stator and Rectifier-Regulator. Figure 8-16. 20 amp Stator and Rectifier-Regulator. 8.14 www.mymowerparts.com...
  • Page 119 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 1st Style 25 Amp Stator 2nd Style Figure 8-17. 25 Amp Stator and Rectifier-Regulators. 3 amp Unregulated Charging System Ground-To-Kill Lead (White) Light Ignition (Blue) Modules...

  • Page 120: Section 9. Disassembly

    AC terminals. See Figure 8-21. Rectifier- Regulator Ground Strap (or lead) Figure 8-20. Rectifier-Regulator. Testing of the rectifier-regulator may be performed as Figure 8-21. follows, using the Rectifier-Regulator Tester (SPX Part No. KO3221, formerly Kohler Part No. 25 761 20-S). 8.16 www.mymowerparts.com...
  • Page 121 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 20/25 Amp Rectifier-Regulators 3. Plug the tester into a 110 volt AC outlet and turn on the power switch. See Figure 8-22. The 1. Connect the single lead adapter in between the ‘‘POWER’’...
  • Page 122 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 6. Press the ‘‘TEST’’ button until a ‘‘click’’ is heard and then release. See Figure 8-23. Momentarily one of the four status lights will illuminate indicating the partial condition of the part.
  • Page 123 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 4. Press the ‘‘TEST’’ button until a “click” is heard and then release. See Figure 8-23. Momentarily either the ‘‘HIGH’’, ‘‘LOW’’, or ‘‘SHORT’’ light will flash.
  • Page 124 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Troubleshooting Guide 15/20/25 amp Battery Charging Systems When problems occur in keeping the battery charged or the battery charges at too high a rate, the problem can usually be found somewhere in the charging system or with the battery.
  • Page 125 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3000 RPM - no load.

  • Page 126: Section 11. Reassembly

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components NOTE: If the starter does not crank the engine, shut Electric Starting Motors off the starter immediately. Do not make Some engines in this series use inertia drive starting further attempts to start the engine until the motors while most use solenoid shift starters.
  • Page 127 4. Clean the splines on the drive shaft thoroughly with solvent. Dry the splines thoroughly. 5. Apply a small amount of Kohler electric starter drive lubricant, Part No. 52 357 01-S, to the splines. The use of other lubricants may cause the drive pinion to stick or bind.
  • Page 128 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Style ‘‘B’’ Drive Service 1. The rubber dust cover has a molded lip on the inside that snaps into a groove in the dust cover spacer (see Figure 8-31). Turn the drive pinion clockwise until it reaches the fully extended position.
  • Page 129 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Retaining Ring Installation Starter Disassembly 1. Position the retaining ring in the groove in one of 1. Remove the drive components following the the inner halves. Assemble the other half over the instructions for servicing the drive.
  • Page 130 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components NOTE: Use a brush holder tool to keep the 2. Insert the armature into the starter frame. Make brushes in the pockets. A brush holder sure the magnets are closer to the drive shaft end tool can easily be made from thin sheet of the armature.
  • Page 131 7. Lubricate the drive shaft with Kohler starter drive with the ring gear into the retracted position. lubricant (Part No. 52 357 01-S). Install the drive components following the instructions for servicing the starter drive.
  • Page 132 2. Remove the hex. nuts securing the solenoid, and disassembled, cleaned and relubricated. Apply starter remove the solenoid from the starter assembly. lubricant (Kohler Part No. 52 357 02-S) to the lever and shaft. Failure to do so could result in an 3. Remove the two thru bolts.
  • Page 133 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Phillips Head Screws Torx Head Screws Figure 8-41. Removing Solenoid Screws. Figure 8-42. Solenoid Removed from Starter. 3. If the solenoid was mounted with Phillips head screws, separate the solenoid and plunger spring from the drive end cap.
  • Page 134 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 7. Remove the drive lever pivot bushing and backing plate from the end cap. See Figure 8-47. Figure 8-44. Removing Thru Bolts. 5. Remove the commutator end plate assembly, Figure 8-47.
  • Page 135 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Figure 8-49. Retaining Ring Detail. Figure 8-50. Removing Retaining Ring. 11. Remove the retainer from the armature shaft. 12. Remove the drive pinion assembly from the Save the stop collar.
  • Page 136 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Inspection Commutator O.D. Drive Pinion Check and inspect the following areas: a. The pinion teeth for abnormal wear or damage. b. The surface between the pinion and the clutch mechanism for nicks, or irregularities which could cause seal damage.
  • Page 137 Brush Replacement Starter Service The brushes and springs are serviced as a set (4). Clean the drive lever and armature shaft. Apply Kohler Use Brush and Spring Kit, Kohler Part No. electric starter drive lubricant Part No. 52 357 02-S 25 221 01-S, if replacement is necessary.
  • Page 138 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 7. Install the backup washer, followed by the rubber grommet, into the matching recess of the drive end cap. The molded recesses in the grommet should be “out”, matching and aligned with those in the end cap.
  • Page 139 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Figure 8-62. Installing Thrust Washer. Figure 8-64. Removing Retaining Clips. 10. Starter reassembly when replacing the Brushes/ b. Position each of the brushes back in their slots Brush Holder Assembly: so they are flush with the I.D.
  • Page 140 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Figure 8-66. Installing Brush Holder Assembly Figure 8-68. Torquing Brush Holder Screws. using Tool with Extension. 13. Hook the plunger behind the upper end of the 11.
  • Page 141 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 CV17-745 Disassembly Section 9 Disassembly 16. Remove valve covers. WARNING: Accidental Starts! 17. Remove ignition modules. Disabling engine. Accidental starting can cause 18. Remove intake manifold. severe injury or death. Before working on the engine 19.
  • Page 142 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 3. Remove the mounting screw and detach the oil fill tube. See Figure 9-3. 4. Remove and discard the oil filter. See Figure 9-4. Remove Oil Cooler If equipped, the oil cooler can now be removed from the engine.
  • Page 143 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-8. Removing Commercial Mower Element Figure 9-6. Removing Standard Element and Precleaner. and Precleaner. 3. Remove the element cover, element and precleaner. See Figure 9-6. Hex. Flange Nuts (2)
  • Page 144 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Fuel Pump Inlet Hose Outlet Hose (To Carburetor) Pulse Hose Mounting Screws the in-line fuel filter. See Figure 9-12. Figure 9-10. Removing Throttle Control Bracket. Figure 9-12. Pulse Fuel Pump Details.
  • Page 145 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Governor Lever Control Bracket Figure 9-14. Removing Control Bracket. Figure 9-16. Removing Governor Lever. Remove Carburetor Air Cleaner Brackets (Some Models) WARNING: Explosive Fuel! Gasoline may be present in the carburetor and fuel system.
  • Page 146 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove Outer Baffles and Blower Housing 1. Disconnect the wire leads from the start switch on the blower housing (if so equipped). Disconnect the plug from the rectifier-regulator. Use the tip of...
  • Page 147 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-21. Loosening Spark Advance Module Figure 9-24. Removing Flywheel Screen. (Applicable Models). 6. Remove the remaining hex. flange screws securing the blower housing. Note the one silver plated screw used for the rectifier-regulator ground strap or lead.
  • Page 148 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove Oil Sentry™ 1. Disconnect the lead from the Oil Sentry™ switch. 2. Remove the Oil Sentry™ switch from the breather cover (see Figure 9-27). Figure 9-29. Break Breather Cover Seal.
  • Page 149 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-31. Removing Valve Cover. Figure 9-33. Position of Ignition Modules. Remove Ignition Modules 3. Remove the mounting screws and ignition 1. Disconnect the lead(s) from each ignition module.
  • Page 150 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove Cylinder Heads and Hydraulic Lifters NOTE: Cylinder heads are retained using either hex. flange screws or hex. flange nuts and washers on studs. Do not interchange or mix...
  • Page 151 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-37. Removing Cylinder Head. Figure 9-39. Removing Rocker Arm. 4. Remove the lifters from the lifter bores. Use 2. Compress the valve springs using a valve spring hydraulic lifter tool (SPX Part No. KO1044). Do compressor.

  • Page 152: Flywheel Strap Wrench

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Valve Keepers Retainer Spring Figure 9-41. Valve Components. Figure 9-43. Removing Plastic Grass Screen. 2. Remove the four hex. flange screws or hex. studs and washers. Remove the plastic fan from the flywheel.
  • Page 153 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-47. Removing Backing Plates and Stator Figure 9-45. Removing Flywheel Fastener Using Wire Bracket. Strap Wrench. 2. Remove the two hex. flange screws and the 2. Remove the hex. flange screw and washer.
  • Page 154 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 2. Locate the splitting tabs cast into the perimeter of the oil pan. Insert the drive end of a 1/2" breaker bar between the splitting tab and the crankcase and turn it to break the RTV seal.
  • Page 155 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 3. Repeat the above procedure for the other Remove Connecting Rods with Pistons connecting rod and piston assembly. and Rings 1. Remove the two hex. flange screws securing the Remove Crankshaft closest connecting rod end cap.
  • Page 156 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 9.16 www.mymowerparts.com...
  • Page 157 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 CV17-745 Inspection and Reconditioning Section 10 Inspection and Reconditioning This section covers the operation, inspection, and Operation repair/reconditioning of major internal engine The ACR mechanism consists of a flyweight, spring components.

  • Page 158: Section 10 Inspection And Reconditioning

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Inspect the crankshaft bearing surfaces for scoring, The connecting rod journal can be ground one size grooving, etc. Measure the running clearance between under. When grinding the crankshaft, grinding stone...
  • Page 159 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Crankcase 1. Lower hone into bore and after centering, adjust so that the stones are in contact with the cylinder Inspection and Service wall. Use of a commercial cutting-cooling agent is Check all gasket surfaces to make sure they are free recommended.
  • Page 160 NOTE: Do not use a feeler gauge to measure piston- to-bore clearance–it will yield inaccurate measurements. Always use a micrometer. Inspect the ring gear for cracks or damage. Kohler does not provide ring gears as a serviceable part. Replace the flywheel if the ring gear is damaged.
  • Page 161 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Carefully inspect the valve mechanism parts. Inspect the valve springs and related hardware for excessive wear or distortion. Check the valves and valve seat area or inserts for evidence of deep pitting, cracks, or distortion.
  • Page 162 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Normal: Even after long hours of operation a valve can Leakage: A poor grind on face or seat of valve will be reconditioned and reused if the face and margin are allow leakage resulting in a burned valve on one side in good shape.
  • Page 163 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Excessive Combustion Temperatures: The white Stem Corrosion: Moisture in fuel or from condensation deposits seen here indicate very high combustion are the most common causes of valve stem corrosion.
  • Page 164 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications, it will not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and Valve Seat excessive oil consumption.
  • Page 165 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Ring failure is usually indicated by excessive oil Detonation damage occurs when a portion of the fuel consumption and blue exhaust smoke. When rings fail, charge ignites spontaneously from heat and pressure oil is allowed to enter the combustion chamber where it shortly after ignition.
  • Page 166 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Replacement pistons are available in STD bore size, and 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize. Replacement pistons include new piston ring sets and new piston pins.
  • Page 167 Check the base surface of the hydraulic lifters for wear or damage. If the lifters need to be replaced, apply a Piston liberal coating of Kohler lubricant 25 357 14-S to the base of each new lifter before it is installed. “Bleeding” the Lifters...
  • Page 168 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Disassembly Reassembly The governor gear must be replaced once it is removed 1. Install the locking tab thrust washer on the from the oil pan. governor gear shaft with the tab down.
  • Page 169 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Piston Spring Roll Pin Figure 10-16. Oil Pump, Oil Pickup, and Relief Figure 10-18. Oil Pressure Relief Valve Piston and Valve (Original Style). Spring. Reassembly 1. Install the pressure relief valve piston and spring.
  • Page 170 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Crankcase Breather System The breather system is designed to control the amount of oil in the head area and still maintain the necessary vacuum in the crankcase.
  • Page 171 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly CV17-745 Section 11 Reassembly General 16. Install blower housing and outer baffles. NOTE: Make sure the engine is assembled using all 17. Install Oil Sentry specified torque values, tightening 18.
  • Page 172 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-4. Installing Governor Cross Shaft Hitch Figure 11-2. Installing Oil Seal in Crankcase. Pin (6 mm Shaft). Install Governor Cross Shaft 1. Lubricate the governor cross shaft bearing surfaces in the crankcase with engine oil.
  • Page 173 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Crankshaft 1. Stagger the piston rings in the grooves until the end gaps are 120° apart. The oil ring rails should 1. Carefully slide the flywheel end of the crankshaft also be staggered.
  • Page 174 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Torque these to 22.7 N·m (200 in. lb.) 8 mm Straight Shank Torque these to 14.7 N·m (130 in. lb.) 8 mm Step-Down Torque these to 11.3 N·m (100 in. lb.) Figure 11-12.
  • Page 175 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Determining Camshaft End Play Governor Gear Assembly 1. Install the shim removed during disassembly onto The governor gear assembly is located inside the oil the camshaft. pan. If service was required, and the governor was removed, refer to the assembly procedures under 2.
  • Page 176 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Oil Pan Assembly 6. Install the ten hex. flange screws securing the oil pan to the crankcase. Torque the fasteners in the RTV sealant is used as a gasket between the oil pan sequence shown in Figure 11-18 to 24.4 N·m...
  • Page 177 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Flywheel WARNING: Damaging Crankshaft and Flywheel Can Cause Personal Injury! Using improper procedures to install the flywheel can crack or damage the crankshaft and/or flywheel. This not only causes extensive engine damage, but can also cause personal injury, since broken fragments could be thrown from the engine.
  • Page 178 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly NOTE: Make sure the flywheel key is installed properly in the keyway. The flywheel can become cracked or damaged if the key is not properly installed. 2. Install the flywheel onto the crankshaft being careful not to shift the woodruff key.
  • Page 179 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-28. Installing Supports for Metal Grass Figure 11-30. Applying Camshaft Lubricant to Screen. Bottom of Lifters. 2. Tighten the supports with a torque wrench to 9.9 3. Note the mark or tag identifying the hydraulic N·m (99 in.
  • Page 180 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Intake Valve Seal Figure 11-32. Match Numbers on Cylinder Barrel Figure 11-34. Intake Valve Seal Location. and Head. Assemble Cylinder Heads 3. If the breather reeds and stops were removed...
  • Page 181 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-36. Installing Valves with Valve Spring Figure 11-37. Torquing Cylinder Head Fasteners. Compressor. 4. Torque the hex. flange screws in two stages; first to 22.6 N·m (200 in. lb.), then finally to 41.8 N·m Install Cylinder Heads (370 in.
  • Page 182 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly b. Thread the opposite end of the stud, with the preapplied locking compound, into the crankcase, until the specified height from the crankcase surface is achieved. See Figure 11-39. When threading in the studs, use a steady tightening motion without interruption until the proper height is obtained.
  • Page 183 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-44. Installing Spark Plugs. Figure 11-42. Torquing Rocker Arm Screws. Install Ignition Modules 4. Use a spanner wrench or rocker arm lifting tool (see Section 2), to lift the rocker arms and 1.
  • Page 184 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 4. Rotate the flywheel to position the magnet directly under one ignition module. 5. Insert a 0.30 mm (0.012 in.) flat feeler gauge between the magnet and the ignition module (see Figure 11-46).
  • Page 185 ™ reattach the leads and seal the base of the terminal connectors with GE/Novaguard G661 (Kohler Part No. 25 357 11-S) or Fel-Pro Lubri- Sel dielectric compound. The beads should overlap between the terminals* to form a solid bridge of compound. See Figure 11-50. Do not put any compound inside the terminals.
  • Page 186 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Blower Housing and Outer Baffles NOTE: Do not completely tighten screws until all items are installed to allow shifting for hole alignment. 1. Pull the wire harness and spark plug leads out through the appropriate openings in the shrouding.
  • Page 187 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-59. Installing Blower Housing. Figure 11-61. Tightening Short Screws for Outer Baffles. 3. Position the outer baffles and secure using the 4. Tighten all of the shrouding fasteners. Torque the four hex.
  • Page 188 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Oil Sentry™ (If So Equipped) ® ® 1. Apply pipe sealant with Teflon (Loctite No. 59241 ™ or equivalent) to the threads of the Oil Sentry switch and install it into the breather cover. See Figure 11-63.
  • Page 189 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Valve Covers Brown O-Ring style cover w/integral spacers ....... 9.9 N·m (88 in. lb.) Three valve cover designs have been used. The earliest type used a gasket and RTV sealant between the cover and sealing surface of the cylinder head.
  • Page 190 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 5. Reconnect the lead wire to the fuel shut-off Install External Governor Controls solenoid if so equipped. 1. Install the governor lever onto the governor cross shaft. See Figure 11-68.
  • Page 191 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Throttle and Choke Controls 1. Connect the choke linkage to the carburetor and choke actuator lever. 2. Install the standard throttle control bracket and the air cleaner support bracket (if used) to the cylinder heads using the four hex.
  • Page 192 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 3. Connect the governor spring from the throttle 6 mm Governor Lever and Hole Position/ control bracket to the appropriate hole in the RPM Chart governor lever, as indicated in the applicable chart.
  • Page 193 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 8 mm Governor Lever and Hole Position/RPM Chart Governor Lever CV18 Engines Intended Standard Engine Mounted Throttle Control Maximum RPM Throttle Control Pivot Shaft High Idle Spring Color Hole No.
  • Page 194 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 8 mm Governor Lever and Hole Position/RPM Charts cont. CV26, CV745 EFI Engines Intended With WAWB (Wide Area Walk Standard Throttle Control Governor Shaft Maximum RPM Behind) Throttle Control...
  • Page 195 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Metal-Cased Pulse Fuel Pump Figure 11-79. Installing Fuel Line (Commercial Plastic-Cased Mower Shown). Pulse Fuel Pump Install Air Cleaner Assembly Refer to Section 4 for the air cleaner reassembly procedure.
  • Page 196 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 3. Secure the air cleaner base and bracket, or spit- Install Oil Cooler back cup with baffle, using the hex. flange nuts. If If so equipped, the oil cooler can now be installed to the a lower air cleaner bracket is used, install the two engine.
  • Page 197 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Prepare the Engine for Operation The engine is now completely reassembled. Before starting or operating the engine, be sure to do the following. 1. Make sure all hardware is tightened securely.
  • Page 198 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 11.28 www.mymowerparts.com...
  • Page 199 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 FORM NO.: TP-2450-B ISSUED: 3/94 REVISED: 6/04 MAILED: 7/04 LITHO IN U.S.A. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 www.mymowerparts.com...

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