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Kohler COMMAND CV17-745, Service Manual

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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 ....................................................................................

Section 5B. Electronic Fuel Injection (EFI) Fuel System ......................................................

Section 6. Lubrication System ................................................................................................

Section 7. Retractable Starter .................................................................................................

Section 8. Electrical System and Components .....................................................................

Section 9. Disassembly ...........................................................................................................

Section 10. Inspection and Reconditioning ...........................................................................

Section 11. Reassembly ...........................................................................................................

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Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983

www.mymowerparts.com

Summary of Contents for COMMAND CV17-745

Page 1: ...SERVICE MANUAL VERTICAL CRANKSHAFT COMMAND CV17 745 Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 2: ...tem and Governor Section 5B Electronic Fuel Injection EFI Fuel System Section 6 Lubrication System Section 7 Retractable Starter Section 8 Electrical System and Components Section 9 Disassembly Sectio...

Page 3: ...ow these precautions could result in injury to yourself and others CV17 745 Rotating Parts can cause severe injury Stay away while engine is in operation WARNING Rotating Parts Keep hands feet hair an...

Page 4: ...all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur...

Page 5: ...S Electric Start C V 18 S Command Engine Vertical Crankshaft Horsepower 17 17 HP 18 18 HP 20 20 HP 22 22 HP 23 23 HP 25 25 HP 26 26 HP Numerical Designation 730 740 745 or Identification Decal Variati...

Page 6: ...Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should...

Page 7: ...disconnect the battery or use a battery minder to keep the battery charged during storage 6 Store the engine in a clean dry place Periodic Maintenance Instructions WARNING Accidental Starts Disabling...

Page 8: ...Safety and General Information Figure 1 4 Typical Engine Dimensions CV Series with Standard Flat Air Cleaner Base engine illustrated Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymo...

Page 9: ...Safety and General Information Figure 1 5 Typical Engine Dimensions CV Series with Commercial Mower Air Cleaner Base engine illustrated Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www my...

Page 10: ...neral Information Figure 1 6 Typical Engine Dimensions CV EFI Series with Heavy Duty Air Cleaner Dimensions in millimeters Inch equivalents shown in Kohler Engine Parts Call K T 606 678 9623 or 606 56...

Page 11: ...mm 3 03 in CV22 23 674 cc 80 mm 3 15 in CV25 CV26 CV730 745 83 mm 3 27 in Stroke 67 mm 2 64 in Displacement CV17 561 cc 34 cu in CV18 CV20 CV22 624 cc 624 cc 38 cu in CV22 23 674 cc 674 cc 41 cu in C...

Page 12: ...65 in lb Connecting Rod Cap Fastener Torque torque in increments 8 mm straight shank 22 7 N m 200 in lb 8 mm step down 14 7 N m 130 in lb 6 mm straight shank 11 3 N m 100 in lb Connecting Rod to Crank...

Page 13: ...6107 1 6116 in O D Max Wear Limit 40 84 mm 1 608 in Max Taper 0 022 mm 0 0009 in Max Out of Round 0 025 mm 0 0010 in Connecting Rod Journal O D New 35 955 35 973 mm 1 4156 1 4163 in O D Max Wear Limi...

Page 14: ...126 mm 0 0009 0 0049 in Governor Cross Shaft O D 6 mm Shaft New 5 975 6 012 mm 0 2352 0 2367 in Max Wear Limit 5 962 mm 0 2347 in 8 mm Shaft New 7 949 8 000 mm 0 3129 3149 in Max Wear Limit 7 936 mm...

Page 15: ...0012 0 0031 in CV18 CV20 CV22 624 cc 0 040 0 080 mm 0 0016 0 0031 in CV22 23 674 cc 0 030 0 076 mm 0 0012 0 0030 in CV25 CV26 CV730 745 0 015 0 037 mm 0 0006 0 0015 in Oil Control Ring to Groove Side...

Page 16: ...n Electric Eaton 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 Torque All 15 3 N m 135 in lb...

Page 17: ...dard 7 048 mm 0 2775 in 0 25 mm O S 7 298 mm 0 2873 in Intake Valve Minimum Lift 8 07 mm 0 3177 in Exhaust Valve Minimum Lift 8 07 mm 0 3177 in Nominal Valve Seat Angle 45 Tightening Torque N m in lb...

Page 18: ...5 35 74 6 55 108 5 80 7 16 20 61 0 45 101 7 75 142 4 105 1 2 13 67 8 50 108 5 80 155 9 115 1 2 20 94 9 70 142 4 105 223 7 165 9 16 12 101 7 75 169 5 125 237 3 175 9 16 18 135 6 100 223 7 165 311 9 23...

Page 19: ...ug Blue for plastic cased ECU KO3217 9 Some of the specialty tools are shown and mentioned at various points in this manual A complete catalog of available tools may be ordered under Kohler Part No TP...

Page 20: ...an old junk connecting rod Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod...

Page 21: ...lifters are installed for proper break in upon initial startup Lubricant is included with each replacement camshaft and lifter or may also be obtained separately in a 1 8 oz handy dispensing tube See...

Page 22: ...2 4 Section 2 Special Tools Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 23: ...l of ignition module to ground 5 Faulty cylinder head gasket 6 Faulty carburetor 7 Vacuum fuel pump malfunction or oil in vacuum hose 8 Leaking cracked vacuum hose to fuel pump 9 Intake system leak 10...

Page 24: ...e overfilled 8 Blown head gasket overheated Oil Leaks from Oil Seals Gaskets 1 Crankcase breather is clogged or inoperative 2 Breather reed broken 3 Loose or improperly torqued fasteners 4 Piston blow...

Page 25: ...vailable spots Crankcase vacuum is best measured with either a water manometer SPX Part No KO1048 formerly Kohler Part No 25 761 02 S or a vacuum gauge SPX Part No KO3223 formerly Kohler Part No 25 76...

Page 26: ...s 1 Run the engine for 3 5 minutes to warm it up 2 Remove the spark plug s and the air filter from engine 3 Rotate the crankshaft until the piston of cylinder being tested is at top dead center of the...

Page 27: ...en zone Piston rings and cylinder in good condition Gauge reading in moderate yellow zone Engine is still usable but there is some wear present Customer should start planning for overhaul or replaceme...

Page 28: ...3 6 Section 3 Troubleshooting Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 29: ...premature wear and failure Precleaner Service Standard and Commercial Mower Types If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty con...

Page 30: ...the precleaner if so equipped from the paper element Service the precleaner as described in Precleaner Service 4 Do not wash the paper element or use pressurized air as this will damage the element R...

Page 31: ...Seal Stud Plenum air cleaner system does not use a precleaner Knob Knob Seal Air Cleaner Cover Element Cover Nut Rubber Seal Precleaner Element Cover Element Spitback Cup Gasket Spitback Cup Air Clean...

Page 32: ...uts securing the bracket or spitback cup with seal and baffle if equipped to base If a plastic intake manifold is used remove the two lower base mounting screws See Figure 4 7 3 Pinch the sealing coll...

Page 33: ...using See Figure 4 10 Figure 4 10 Removing Elements 3 After the element is removed check the condition of the inner element It should be replaced whenever it appears dirty typically every other time t...

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 inspe...

Page 35: ...l is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved...

Page 36: ...Hold the line below the bottom of the tank Open the shut off valve if so equipped and observe flow 3 If fuel does flow from the line check for faulty fuel pump Test 4 If fuel does not flow from the li...

Page 37: ...the float stops fuel flow when the engine is at rest When fuel is being consumed the float will drop and fuel pressure will push the inlet needle away from the seat allowing more fuel to enter the bo...

Page 38: ...ed 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 Air and fuel are mixed in the body of the slow jet and exit to the...

Page 39: ...Float Main Emulsion Hole Idle Speed RPM Adjustment Screw Air Fuel Mixture 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...

Page 40: ...off solenoid The solenoid is installed in place of the bowl retaining screw The solenoid has a spring loaded pin that retracts when 12 volt current is applied to the lead When it is extended the main...

Page 41: ...M by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application Refer to the equipment manufacturer s recommendat...

Page 42: ...placement parts are used Disassemble carburetor as follows after removal from the engine See Figure 5 7 1 Remove the fuel bowl retaining screw or solenoid assembly then remove the bowl and bowl gasket...

Page 43: ...ar or damage Inspect the tip of the low idle fuel adjusting needle if equipped for wear or grooves The choke plate is spring loaded Check to make sure it moves freely 1 Carburetor Body 2 Idle Fuel Adj...

Page 44: ...connect the accelerator pump hose if so equipped from the upper fitting Remove the four fuel bowl screws and carefully separate the fuel bowl from the carburetor Do not damage the O Ring s Transfer an...

Page 45: ...cure with the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in lb Reattach the accelerator pump hose if so equipped and secure with the clip See Figure 5 13 Figure 5 12 Checking Float H...

Page 46: ...parts in the overhaul kit Further disassembly is not necessary The throttle shaft assembly fuel inlet seat and bowl chamber baffle are non serviceable items and should not be removed The choke shaft a...

Page 47: ...21 Figure 5 21 Installing Float Assembly 12 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but...

Page 48: ...nd install it into the carburetor As an initial adjustment set to 1 turn out from lightly seated See Figure 5 25 Figure 5 25 Installing Idle Fuel Adjusting Screw and Spring 18 Place the shorter new sp...

Page 49: ...elivery chamber Secure with the new retaining ring See Figure 5 29 Figure 5 29 Check Valve and Retaining Ring Installed 6 Notice the small alignment tab and the small bead on one side of the outer dia...

Page 50: ...iscard the removed parts Figure 5 32 Choke Details 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...

Page 51: ...overnor It is designed to hold the engine speed constant under changing load conditions The governor gear flyweight mechanism is mounted inside the crankcase on the oil pan and is driven off the gear...

Page 52: ...ity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes of the governor lever If speed surging occurs with a change in engine load the governor is set too sen...

Page 53: ...hrottle Control Lever 2 Choke Control Lever 1 Kill Switch Choke Control Cable Throttle Control Cable Kill Switch Adjusting Screw Dual Control High Speed Lever Stop Screw Do Not Remove High Speed Contr...

Page 54: ...ing 180 until hooked as shown in Figure 5 38 3 Hook the short end of the spring into the appropriate hole in the governor lever Refer to the appropriate chart in Section 11 Reassembly of this manual f...

Page 55: ...rical Relay 5B 12 5B 13 Fuel Injectors 5B 13 5B 16 Ignition System 5B 17 Spark Plugs 5B 18 Wiring Harness 5B 18 Battery Charging System 5B 18 Fuel Components Fuel Pump 5B 18 5B 19 Fuel Pressure Regula...

Page 56: ...the system can be primed by manually cycling the fuel pump a Turn the key switch to the on run position The fuel pump will run for about three seconds and stop Turn the switch off and back on to rest...

Page 57: ...ntrols the amount of fuel by varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The controlled injection of the fuel occurs ea...

Page 58: ...open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installati...

Page 59: ...or limp home operation slowed speed richer running may be initiated A technician can access the stored fault code using a blink code diagnosis flashed out through the MIL An optional computer softwar...

Page 60: ...sure the engine has resistor type spark plugs 4 Disconnect the main harness connector from the ECU 5 Connect an ohmmeter between the 9 and 10 pin terminals See chart on page 5B 26 or 5B 29 according...

Page 61: ...ted to the throttle body manifold 3 a Use an ohmmeter and connect the ohmmeter leads as follows to test See chart on page 5B 26 or 5B 29 24 Pin MSE 1 0 Plastic Cased ECU Red positive ohmmeter lead to...

Page 62: ...connector plugs start engine and retest system operation 7 Remove the two mounting screws from the TPS Save the screws for reuse Remove and discard the faulty TPS Install the replacement TPS and secu...

Page 63: ...atch the MIL When the light starts blinking rapidly 5 blinks per second move the throttle lever to the low idle speed position Check and adjust the idle speed to 1500 RPM using a tachometer The lamp s...

Page 64: ...hould again be 2375 2625 a If the resistance is out of specifications replace the temperature sensor b If it is within specifications proceed to Step 6 6 Check the circuits input ground from the main...

Page 65: ...indicates the oxygen sensor is functioning normally and fuel delivery is within prescribed parameters If the voltage readings show a steady decline rev the engine and check the indicated reading again...

Page 66: ...as specified move the black voltmeter lead to the negative post of the battery to be certain of a good ground If the voltage is still not correct the ECU is probably bad b If the voltage readings are...

Page 67: ...e Terminal 87A Not used Figure 5B 14 Style 1 Fuel Injector 2 Connect the black lead of VOA meter to a chassis ground location Connect the red lead to the 86 terminal in relay connector see Figure 5B 1...

Page 68: ...of the injector see inset contains a series of calibrated openings which directs the fuel into the manifold in a cone shaped spray pattern Figure 5B 16 Fuel Injector Details The injector is opened and...

Page 69: ...E 1 1 Plastic Cased ECU Check the resistance between relay terminal 87 and pin 14 in the main connector Then check the resistance between relay terminal 87 and pin 15 Resistance should be 4 15 for eac...

Page 70: ...ogged injectors include rough idle hesitation stumble during acceleration or triggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the dire...

Page 71: ...Rx1 scale check the resistance in circuits as follows 24 Pin MSE 1 0 Plastic Cased ECU Check between terminal 87 and pin 22 for coil 1 Repeat the test between terminal 87 and pin 23 for coil 2 32 Pin...

Page 72: ...ded in Section 8 Fuel Components Fuel Pump Internal External Figure 5B 21 24 Pin MSE 1 0 Plastic Cased ECU Connector Figure 5B 22 32 Pin MSE 1 1 Plastic Cased ECU Connector Figure 5B 23 Fuel Pump Styl...

Page 73: ...k is not kinked or blocked If the return line is good replace the regulator see Regulator Service on page 5B 20 b If the pressure is too low install in line T SPX Part No KO3217 8 between the pump and...

Page 74: ...essing the valve against the valve seat The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the...

Page 75: ...ce and safety can be affected Relieve system pressure through the safety valve in the fuel rail before servicing Figure 5B 30 Throttle Body Intake Manifold General The fuel rail is a formed tube assem...

Page 76: ...dard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting Check the equipment manufacturer s recommendation For starting and warm up the ECU will a...

Page 77: ...initial adjustment A Checking the Initial Adjustment 1 Unsnap the plastic linkage bushing attaching the throttle linkage to the governor lever See Figure 5B 34 Unhook the damper spring from the lever...

Page 78: ...ng Split of Clamp 2 Follow the instructions in Step 2 of Checking the Initial Adjustment then reattach the throttle linkage to the governor lever with the bushing clip It is not necessary to reattach...

Page 79: ...pump not running 3 Fuel pressure low 4 Insufficient fuel delivery 5 TPS offset incorrect Initialization 6 Speed sensor loose or faulty 7 TPS faulty 8 Engine temp sensor faulty 9 Faulty injectors Engi...

Page 80: ...or each style of ECU connector is provided on pages 5B 26 and 5B 29 NOTE When performing voltage or continuity tests avoid putting excessive pressure on or against the connector pins Flat pin probes a...

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: ...osition Sensor TPS Input Speed Sensor Input Speed Sensor Ground Not Used Not Used Not Used Injector 1 Output Injector 2 Output Not Used Diagnostic Line Throttle Position Temperature Sensor Supply Volt...

Page 84: ...en 6 Test fuel pump and relay operation as described earlier under Fuel Pump Service Fault Codes The ECU continuously monitors engine operation against preset performance limits If the operation is ou...

Page 85: ...codes with an explanation of what triggers them what symptoms might be expected and the probable causes Diagnostic Code Summary Example of Diagnostic Display Long Pause 3 4 5 6 7 k n i l B e d o C 2 D...

Page 86: ...1 6 2 0 P d n u o r G o t t i u c r i C t r o h S 1 r o t c e j n I A N Y 1 5 2 6 2 0 P y r e t t a B o t t i u c r i C t r o h S 1 r o t c e j n I A N Y 2 5 3 6 2 1 P t i u c r i C n e p O 2 r o t c...

Page 87: ...ss connection problem 5 Ignition System Related a Non resistor spark plug s used Code 22 Source Throttle Position Sensor TPS Explanation Unrecognizable signal is being sent from sensor too high too lo...

Page 88: ...gine will run rich if oxygen sensor is shorted to ground or lean if it is shorted to battery voltage After fault is detected performance can vary depending on cause If performance is pretty good the p...

Page 89: ...tion air air cleaner dirty restricted intake leak throttle bores d Base engine problem rings valves e Exhaust system leak f Fuel in the crankcase oil g Blocked or restricted fuel return circuit to tan...

Page 90: ...ossible Causes 1 TPS Related a TPS rotated on throttle shaft assembly out of allowable range b TPS bad 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin 18 to TPS pin 1 ECU p...

Page 91: ...uel pump relay pin 87 to injector pin 1 b Opened main fuse F1 3 Fuel Pump Relay Related a Bad fuel pump relay Primary side functional but pin 30 to pin 87 remains open Primary side pin 85 to pin 86 is...

Page 92: ...rnally 3 Engine Wiring Harness related a Fuel pump fuse F1 open b Broken or shorted wire in harness ECU pin 28 to fuel pump relay pin 86 Ignition switch to fuel pump relay pin 85 4 ECU Related a Circu...

Page 93: ...5B 39 Section 5B EFI Fuel System Figure 5B 41 Operate for an appropriate period of time based upon original fault codes Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 94: ...ECU only 13 Code 55 MIL Light 32 Pin MSE 1 1 Plastic Cased ECU only 14 Code 56 Pump Relay 32 Pin MSE 1 1 Plastic Cased ECU only 15 Code 61 End of Fault Blink Code Transmission Diagnostic Aid 3 RUN ON...

Page 95: ...ts 22 23 65 66 30 and relay 32 Pin MSE 1 1 Plastic Cased ECU Circuits 30 31 65 66 relay and relay circuit 30 5 ECU grounds 6 ECU Diagnostic Aid 8 FUEL SYSTEM ELECTRICAL no fuel delivery Possible cause...

Page 96: ...5B 42 Section 5B EFI Fuel System Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 97: ...re at the time of operation as shown in the following table Figure 6 1 Oil Container Logo The top position of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional...

Page 98: ...rest the oil fill cap on the tube Do not thread the cap onto the tube See Figure 6 2 NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate...

Page 99: ...en end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter...

Page 100: ...ter should indicate a change to no continuity switch open The switch should remain open as the pressure is increased to 90 psi maximum 3 Gradually decrease the pressure through the range of 3 0 5 0 ps...

Page 101: ...ower housing leaving the five hex flange screws slightly loose Figure 7 2 Removing Starter Handle 3 Remove the rope retainer from inside the starter handle Untie the single knot and remove the rope re...

Page 102: ...n the spring is properly tensioned the rope will retract fully and the handle will stop against the starter housing Pawls Dogs Replacement To replace the pawls follow disassembly steps 1 4 and reassem...

Page 103: ...ce and away from others in the area 7 Rotate the pulley slightly from side to side and carefully separate the pulley from the housing See Figure 7 6 If the pulley and the housing do not separate easil...

Page 104: ...Make sure the pulley is fully seated against the starter housing Do not wind the pulley and recoil spring at this time Figure 7 9 Installing Pawls and Pawl Springs 4 Place the brake washer in the rece...

Page 105: ...their condition and either reset the gap or replace with new plugs as necessary To service the plugs perform the following steps 1 Before removing a spark plug clean the area around the base of the pl...

Page 106: ...ir cleaner a breather problem or worn piston rings cylinder walls or valve guides Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich fu...

Page 107: ...ranking requirements increase as temperatures decrease and battery capacity shrinks Refer also to the operating instructions for the piece of equipment for specific battery requirements Battery Size R...

Page 108: ...the following components A magnet assembly which is permanently affixed to the flywheel Two electronic capacitive discharge ignition modules which mount on the engine crankcase Figure 8 4 A kill swit...

Page 109: ...coil L1 The resultant pulse is rectified by D1 and charges capacitor C1 As the magnet assembly completes its pass it activates the triggering device L2 which causes the semiconductor switch SCS to tu...

Page 110: ...8 7 A 12 volt battery which supplies current to the spark advance module A kill switch or key switch which grounds the spark advance module to stop the engine Two spark plugs Figure 8 7 Block Diagram...

Page 111: ...ems produce a high energy electric spark but the spark must be discharged or damage to the system can result Do not crank or run an engine with a spark plug lead disconnected Always provide a path for...

Page 112: ...cannot touch ground Try to start the engine to verify whether the reported problem is still present a If the problem is gone the electrical system on the unit is suspect Check the key switch wires co...

Page 113: ...2B Kohler Part No 24 584 03 should be replaced with 24 584 11 or 24 584 15 S For small modules with vendor numbers MA 2C or MA 2D Kohler Part No 24 584 11 or the larger style modules 24 584 15 S and...

Page 114: ...steady spark is now present both sides on a twin your problem should be corrected Go to step 4 of Test 5 b If there is still a spark problem perform all of Test 5 5 Check and or adjust the ignition mo...

Page 115: ...SAM leads verifying a snug fit at the ignition module terminals If any connections do not feel snug disconnect the lead lightly pinch the female terminal with a pliers and recheck the fit 4 Seal the...

Page 116: ...iring points are different and testing can only determine if the DSAM is working not the actual firing points Connect the tester in the same manner and start the test If the numbers start advancing th...

Page 117: ...am Some engines utilize a 3 amp unregulated system with optional 70 watt lighting circuit Refer to Figure 8 18 NOTE Observe the following guidelines to avoid damage to the electrical system and compon...

Page 118: ...8 Electrical System and Components Figure 8 15 15 amp Stator and Rectifier Regulator Figure 8 16 20 amp Stator and Rectifier Regulator Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mym...

Page 119: ...Black 3 Amp 70 Watt Flywheel Stator Ignition Modules Spark Plug Red Blue R A S B GND Light Optional Fuse Optional Ammeter Spark Plug Figure 8 17 25 Amp Stator and Rectifier Regulators 3 amp Unregulat...

Page 120: ...er Regulator Tester SPX Part No KO3221 formerly Kohler Part No 25 761 20 S To Test NOTE Disconnect all electrical connections attached to the rectifier regulator Testing may be performed with the rect...

Page 121: ...lluminate indicating the condition of the part 20 25 Amp Rectifier Regulators 1 Connect the single lead adapter in between the B center terminal of the rectifier regulator being tested and the squared...

Page 122: ...t the remaining black lead from tester to one of the black AC outside leads from rectifier regulator See Figure 8 27 Figure 8 27 5 Plug the tester into a 110 volt AC outlet power supply and turn on th...

Page 123: ...on until a click is heard and then release See Figure 8 23 Momentarily either the HIGH LOW or SHORT light will flash a If the HIGH light flashes on off the part is good and may be used b If any other...

Page 124: ...roblem can usually be found somewhere in the charging system or with the battery NOTE Always zero ohmmeter on each scale before testing to ensure accurate readings Voltage tests should be made with th...

Page 125: ...harness With engine running at 3000 RPM measure voltage from lighting lead to ground using an AC voltmeter 3 With engine stopped measure the resistance of stator from lighting lead to ground using an...

Page 126: ...y replace the faulty components 1 Check the specific gravity of battery If low recharge or replace battery as necessary 1 Check for excessively dirty or worn brushes and commutator Clean using a coars...

Page 127: ...ove the starter from the engine and remove the dust cover 2 Hold the drive pinion in a vice with soft jaws when removing or installing the stop nut The armature will rotate with the nut until the driv...

Page 128: ...Dust Cover Spacer Spring Retainer Figure 8 31 Drive Components Bonded Inertia Drive Starter 2 Disassemble the snap ring removal tool SPX Part No KO1049 formerly Kohler Part No 25 761 18 S 3 Again refe...

Page 129: ...the drive end cap On starters with Style A commutator end caps it will be aligned with a pre marked line on the starter frame The frame is not pre marked on starters with Style B end caps Place a pie...

Page 130: ...e into the starter frame Make sure the magnets are closer to the drive shaft end of the armature The magnets will hold the armature inside the frame 3 Install the drive end cap over the drive shaft Ma...

Page 131: ...starter servicing follows Operation Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel r...

Page 132: ...a solid portion which should be crimped on the post 5 Solder the crimped portion to the post 6 Replace the brush holder in the frame and place the brushes in the brush holder Reinstall the springs Sta...

Page 133: ...nted with external Torx head screws the plunger is part of the solenoid unhook the plunger pin from the drive lever Remove the gasket from the recess in the housing See Figures 8 42 and 8 43 Figure 8...

Page 134: ...the armature and drive end cap See Figure 8 46 Figure 8 48 Armature and Lever Removed 10 Push the stop collar down to expose the retaining ring See Figure 8 49 Figure 8 46 Starter Frame Removed 7 Remo...

Page 135: ...clean using a soft cloth or use compressed air Figure 8 49 Retaining Ring Detail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Lever Solenoid...

Page 136: ...e b The surface between the pinion and the clutch mechanism for nicks or irregularities which could cause seal damage c Check the drive clutch by holding the clutch housing and rotating the pinion The...

Page 137: ...ve lubricant Part No 52 357 02 S Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the other starter parts for wear or damage as required Starter Reassembly 1 Apply drive lub...

Page 138: ...ing which receives the backup washer See Figure 8 59 Figure 8 59 Installing Armature and Pivot Lever Figure 8 60 Installing Backup Washer and Grommet 8 Install the frame with the small notch forward o...

Page 139: ...Brush Installation Tool SPX Part No KO3226 1 with extension or use the tube described above from a prior brush installation through the brush holder assembly so the holes in the metal mounting clips a...

Page 140: ...ee Figures 8 67 and 8 68 Figure 8 68 Torquing Brush Holder Screws 13 Hook the plunger behind the upper end of the drive lever and install the spring into the solenoid Insert the three mounting screws...

Page 141: ...ct spark plug leads 2 Shut off fuel supply 3 Drain oil from crankcase and remove oil filter 4 Remove oil cooler 5 Remove muffler 6 Remove air cleaner assembly 7 Remove control panel 8 Remove fuel pump...

Page 142: ...oil pan leaving the oil lines attached Remove the two hex flange screws mounting the oil cooler to the blower housing Remove the cooler lines and filter adapter as an assembly Remove Muffler 1 Remove...

Page 143: ...and air cleaner base See Figure 9 7 Two additional lower screws must be removed if the engine contains a lower air cleaner support bracket Figure 9 9 Disconnect Breather Hose from Base 5 Disconnect th...

Page 144: ...the engine 1 Disconnect the fuel lines at the carburetor and at Figure 9 10 Removing Throttle Control Bracket Figure 9 12 Pulse Fuel Pump Details Figure 9 13 Disconnecting Pulse Line from Crankcase 2...

Page 145: ...emove Carburetor WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks and other sources of...

Page 146: ...ion in the plug See Figure 9 20 This will allow the blower housing to be removed without disturbing the wiring harness Figure 9 19 Removing Electric Starter Motor 3 Remove the starter assembly and lif...

Page 147: ...screws securing the blower housing Note the one silver plated screw used for the rectifier regulator ground strap or lead Remove the blower housing See Figures 9 25 and 9 26 Figure 9 21 Loosening Spar...

Page 148: ...holes The latest design uses a brown O Ring and the bolt hole spacers are molded in place 1 Remove the four hex flange screws securing each valve cover Note valve cover differences for proper locatio...

Page 149: ...ing the intake manifold to the cylinder heads Note which screws hold the wiring clamps 2 Remove the intake manifold and the intake manifold gaskets aluminum intake manifolds or O Ring plastic intake m...

Page 150: ...removed if damaged or if cylinder reconditioning is necessary Once removed they must be replaced 2 Mark the location of the push rods as either intake or exhaust and cylinder 1 or 2 Push rods should...

Page 151: ...1 Remove the two hex flange screws rocker arm pivots and rocker arms from the cylinder head See Figure 9 39 Figure 9 39 Removing Rocker Arm 2 Compress the valve springs using a valve spring compresso...

Page 152: ...tal retainers Then unsnap the screen from the mounting posts See Figure 9 43 Figure 9 41 Valve Components Valve Keepers Cap Spring Retainer Figure 9 43 Removing Plastic Grass Screen 2 Remove the four...

Page 153: ...Stator Remove Oil Pan Assembly 1 Remove the ten hex flange screws securing the oil pan to the crankcase See Figure 9 49 Figure 9 46 Removing Flywheel with a Puller 4 Remove the woodruff key Remove Sta...

Page 154: ...rankcase and turn it to break the RTV seal See Figure 9 49 Do not pry on the sealing surfaces as this can cause leaks Governor Gear Assembly The governor gear assembly is located inside the oil pan If...

Page 155: ...not mix end caps and connecting rods Remove Connecting Rods with Pistons and Rings 1 Remove the two hex flange screws securing the closest connecting rod end cap Remove the end cap See Figure 9 54 Fi...

Page 156: ...9 16 Section 9 Disassembly Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 157: ...ion Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR Some engines are equipped with the optional Automatic Compression Release ACR mechan...

Page 158: ...ter to measure the outside diameter of the crankshaft main bearing journals Subtract the journal diameters from their respective bore diameters to get the running clearances Check the results against...

Page 159: ...off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot s...

Page 160: ...her at each of the three locations Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left i...

Page 161: ...wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition...

Page 162: ...ions Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and too narrow These conditions could be attributed to excessive hours or a combination of poor operat...

Page 163: ...ture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a...

Page 164: ...r the valve seat angle in Figure 10 6 Cutting the proper 45 valve face angle as specified in Figure 10 6 and the proper valve seat angle 44 5 half of the full 89 angle will achieve the desired 0 5 1 0...

Page 165: ...ces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to...

Page 166: ...ortant points to remember when servicing piston rings 1 The cylinder bore must be deglazed before service ring sets are used 2 If the cylinder bore does not need reboring and if the old piston is with...

Page 167: ...fters for wear or damage If the lifters need to be replaced apply a liberal coating of Kohler lubricant 25 357 14 S to the base of each new lifter before it is installed Bleeding the Lifters To preven...

Page 168: ...r is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary 1 Remove the regulating pin and governor gear assembly See Fig...

Page 169: ...gure 10 18 Oil Pressure Relief Valve Piston and Spring Reassembly 1 Install the pressure relief valve piston and spring 2 Install the oil pickup to the oil pump body Lubricate the O Ring with oil and...

Page 170: ...he upper end of the head is completely sealed by the rocker cover so a low positive pressure is created in the head cavity The 1 rocker cover has a hole in it for venting The bottom nipple of an oil s...

Page 171: ...ross shaft 3 Install crankshaft 4 Install connecting rods with pistons and rings 5 Install camshaft 6 Install oil pan assembly 7 Install stator and backing plates 8 Install flywheel 9 Install fan and...

Page 172: ...8 mm Governor Shaft Install the nylon washer onto the governor cross shaft then start the push on retaining ring Hold the cross shaft up in position place a 0 50 mm 0 020 in feeler gauge on top of th...

Page 173: ...ston into the cylinder as shown in Figure 11 9 Be careful that the oil ring rails do not spring free between the bottom of the ring compressor and the top of the cylinder Install Crankshaft 1 Carefull...

Page 174: ...e 12 o clock position 3 Turn the governor cross shaft clockwise until the lower end of the shaft contacts the cylinder Make sure the cross shaft remains in this position while installing the camshaft...

Page 175: ...unted inside the oil pan If service was required and the oil pump was removed refer to the assembly procedures under Oil Pump Assembly in Section 10 Determining Camshaft End Play 1 Install the shim re...

Page 176: ...Using outdated sealant can result in leakage 1 Be sure the sealing surfaces have been cleaned and prepared as described at the beginning of Section 10 or in Service Bulletin 252 2 Check to make sure t...

Page 177: ...completely free of any lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the hex flange screw is torqued to specifications Figure 11 22 Installing Back...

Page 178: ...w and washer 4 Use a flywheel strap wrench or holding tool to hold the flywheel Torque the hex flange screw securing the flywheel to the crankshaft to 66 4 N m 49 ft lb See Figure 11 25 Figure 11 25 I...

Page 179: ...talled in the same position as before disassembly The exhaust lifters are located on the output shaft oil pan side of the engine while the intake lifters are located on the fan side of the engine The...

Page 180: ...Valve Components Figure 11 33 Installed Breather Reed Valve Stem Seals These engines use valve stem seals on the intake valves and occasionally on the exhaust valves Use a new seal whenever the valve...

Page 181: ...ylinder heads and crankcase See Figure 11 32 3 Install the cylinder head and start the four new hex flange screws NOTE When installing cylinder heads new screws should always be used Figure 11 37 Torq...

Page 182: ...e Figure 11 39 When threading in the studs use a steady tightening motion without interruption until the proper height is obtained Otherwise the frictional heat from the engaging threads may cause the...

Page 183: ...5 Installing Ignition Modules 2 On engines equipped with SMART SPARK both modules are installed the same way with the two tabs out See Figure 11 46 On engines not equipped with SMART SPARK the modules...

Page 184: ...lips onto the appropriate bolts before installing Make sure the gaskets are in the proper orientation See Figures 11 47 and 11 48 Using the sequence shown in Figure 11 49 torque the four screws in two...

Page 185: ...ard ignition modules See Figure 11 51 Figure 11 53 Breather Cover and Gasket RTV sealant was used on early models between the breather cover and the crankcase A gasket with imprinted sealant beads is...

Page 186: ...Installing Screws Locations 3 and 4 4 Install the inner baffles using the remaining two hex flange screws see Figures 11 55 and 11 56 and finger tighten Do not torque the screws at this time they will...

Page 187: ...ing fasteners Torque the blower housing screws to 6 2 N m 55 in lb in a new hole or to 4 0 N m 35 in lb in a used hole Torque the shorter M5 side baffle screws to 4 0 N m 35 in lb See Figure 11 61 Tor...

Page 188: ...emoved previously then connect the rectifier regulator ground lead with the washer and the silver screw through the eyelet as shown If a grounding bracket is used secure with the mounting screw and wa...

Page 189: ...eads install a new cover gasket on each then apply a second bead of sealant on the top surface of the gaskets For O Ring type covers install a new O Ring in the groove of each cover Do not use gaskets...

Page 190: ...r lever and the throttle lever on the carburetor See Figure 11 69 Figure 11 71 Installing Control Panel 8 Assemble the throttle control shaft to the control bracket 9 Assemble the choke control to the...

Page 191: ...rews to 10 7 N m 95 in lb into new holes or 7 3 N m 65 in lb into used holes Figure 11 73 Standard Control Bracket Figure 11 74 Throttle Choke Control Bracket Detail Item Description 1 Bracket speed c...

Page 192: ...oint of the governor lever Governor Lever Governor Spring High Idle RPM Hole No Color Code 3801 4000 6 Clear 3601 3800 5 Clear 3451 3600 4 Clear 3301 3450 3 Clear 3101 3300 5 Purple 2951 3100 4 Purple...

Page 193: ...e Control High Idle WOT Intended Maximum RPM Spring Color Hole No Purple Black Red Purple Black Red Clear Red Green 4 4 4 3 3 3 3 2 1 3888 3780 3672 3564 3456 3348 3240 3132 3024 3600 3500 3400 3300 3...

Page 194: ...ear 3 3 3 2 2 1 1 1 1 8 mm Governor Lever and Hole Position RPM Charts cont Figure 11 75 Installing Starter and Lift Bracket 4 Install the dipstick tube and align the mounting hole with the threaded h...

Page 195: ...nd of the rubber breather hose through the base until properly seated collars sealed against each side of the base See Figure 11 81 Metal Cased Pulse Fuel Pump Plastic Cased Pulse Fuel Pump Figure 11...

Page 196: ...rn 3 Secure the air cleaner base and bracket or spit back cup with baffle using the hex flange nuts If a lower air cleaner bracket is used install the two M5 screws through the lower section of the ba...

Page 197: ...tions and procedures in the Safety and General Information and Lubrication System sections 4 Adjust the carburetor idle fuel needle or idle speed adjusting screw as necessary Refer to Section 5 Fuel S...

Page 198: ...11 28 Section 11 Reassembly Kohler Engine Parts Call K T 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 199: ...SUED 3 94 REVISED 6 04 MAILED 7 04 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALESAND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 Kohler Engine Parts Call K T 606 678 9623 or...

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