Kohler CV11-16, Service Manual

Page: 114 / 150

10.2
Section 10
Inspection and Reconditioning
4. The choke control setting is less critical with ACR.
In the event of fl ooding, excess fuel is blown out
the opened exhaust valve and does not hamper
starting.
5. Engines with ACR start much faster in cold
weather than engines without ACR.
6. Engines with ACR can be started with spark plugs
that are worn or fouled. Engines without ACR
probably could not be started with those same
spark plugs.
Camshaft
Inspection and Service
Inspect the gear teeth of the camshaft. If the teeth
are badly worn, chipped, or some are missing,
replacement of the camshaft will be necessary.
Crankshaft
Inspection and Service
Inspect the gear teeth of the crankshaft. If the teeth
are badly worn, chipped, or some are missing,
replacement of the crankshaft will be necessary.
Some engines have replaceable crankshaft bearings,
most do not. Inspect the crankshaft bearing and/
or journal surface for scoring, grooving, etc. Do not
replace bearings unless they show signs of damage
or are out of running clearance specifi cations. If the
crankshaft turns easily and noiselessly, and there is
no evidence of scoring, grooving, etc., on the races or
bearing surfaces, the bearings can be reused.
Inspect the crankshaft keyways. If worn or chipped,
replacement of the crankshaft will be necessary.
Inspect the crankpin for score marks or metallic
pickup. Slight score marks can be cleaned with
crocus cloth soaked in oil. If wear limits, as stated
in “Specifi cations and Tolerances” are exceeded, it
will be necessary to either replace the crankshaft or
regrind the crankpin to
0.25 mm (0.010 in.) undersize.
If reground, a 0.25 mm (0.010 in.) undersize
connecting rod (big end) must then be used to achieve
proper running clearance. Measure the crankpin for
size, taper, and out-of-round.
NOTE: If the crankpin is reground, visually check to
insure that the fi llet blends smoothly with the
crankpin surface. See Figure 10-1.
Figure 10-1. Crankpin Fillets.
On engines with a replaceable bearing insert on
the fl ywheel end, the crankshaft fl ywheel end main
bearing journal can be ground two sizes under. The
connecting rod journal can be ground one size under.
When grinding a crankshaft on a CV11-16, CV460-
465, CV490-495 engine, grinding stone deposits can
get caught in the oil passages, which could cause
severe engine damage. Removing the plug each time
the crankshaft is ground provides easy access for
cleaning any grinding deposits that may collect in the
oil passages.
Use the following procedure to remove and replace
the plug.
Procedures to Remove Plug:
1. Drill a 3/16" hole through the plug in the
crankshaft.
2. Thread a 3/4" or 1" long self-tapping screw
with a fl at washer into the drilled hole. The fl at
washer must be large enough to seat against the
shoulder of the plug bore. See Figure 10-2.
3. Tighten the self-tapping screw until it draws the
plug out of the crankshaft.
Procedure to Install New Plug:
1. Use a single cylinder camshaft pin Part No.
47 380 09-S as a driver and tap the plug into the
plug bore until it seats at the bottom of the bore.
Make sure the plug is tapped in evenly to prevent
leakage.
High Point From
Fillet Intersections
The Fillet Must
Blend Smoothly
With The Bearing
Journal Surface
45°
Minimum
This Fillet Area
Must Be
Completely Smooth