Kohler CV11-16 Service Manual Download Page 3

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

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

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

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

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

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

Summary of Contents for CV11-16

Page 1: ...1 SERVICE MANUAL VERTICAL CRANKSHAFT CV11 16 CV460 465 CV490 495...

Page 2: ......

Page 3: ...ting Section 4 Air Cleaner and Air Intake System Section 5 Fuel System and Governor Section 6 Lubrication System Section 7 Retractable Starter Section 8 Electrical System and Components Section 9 Disa...

Page 4: ......

Page 5: ...ed at all times Failure to follow these precautions could result in injury to yourself and others Rotating Parts can cause severe injury Stay away while engine is in operation WARNING Rotating Parts K...

Page 6: ...s Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors...

Page 7: ...mbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers of the engine The engine identification numbers appear a on decal or decals...

Page 8: ...s Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle...

Page 9: ...the system run the engine until the tank and system are empty 4 Remove the spark plug Add one tablespoon of engine oil into the spark plug hole Install the plug but do not connect the plug lead Crank...

Page 10: ...16 40 M8x1 25 2 Studs Exhaust Flange Mounting Surface Engine Mounting Surface 35 35 Rotation 254 10 0 Cylinder 4xM8x1 25 296 11 65 321 12 64 Cylinder 137 5 5 41 411 16 18 Air Cleaner Cover Removal 62...

Page 11: ...5 37 8 N m 27 9 ft lb 38 1 N m 28 1 ft lb 2400 Bore CV11 14 CV460 465 87 mm 3 43 in CV15 CV16 CV490 495 90 mm 3 60 in Stroke CV11 16 67 mm 2 64 in CV460 465 CV490 495 77 mm 3 03 in Displacement CV11 1...

Page 12: ...0 7864 in Max Wear Limit 19 959 mm 0 7858 in Carburetor Preliminary Low Idle Fuel Needle Setting 1 Turn Fuel Bowl Retaining Screw Torque 5 1 6 2 N m 45 55 in lb Connecting Rod Cap Fastener Torque torq...

Page 13: ...691 in O D Max Wear Limit 44 84 mm 1 765 in Max Taper 0 022 mm 0 0009 in Max Out of Round 0 025 mm 0 0010 in Oil Pan End Main Bearing Journal O D New 41 915 41 935 mm 1 6502 1 6510 in O D Max Wear Lim...

Page 14: ...0 12 0 N m 71 106 in lb Delco Remy Starter 6 0 9 0 N m 53 79 in lb Fan Flywheel Fan Fastener Torque 9 9 N m 88 in lb Flywheel Retaining Screw Torque 66 4 N m 49 ft lb Fuel Pump Fuel Pump Fastener Tor...

Page 15: ...ton Pin Piston to Piston Pin selective fit 0 006 0 017 mm 0 0002 0 0007 in Piston Pin Bore I D New 19 006 19 012 mm 0 7483 0 7485 in Max Wear Limit 19 025 mm 0 7490 in Piston Pin O D New 18 995 19 000...

Page 16: ...CV460 465 0 041 0 044 mm 0 0016 0 0017 in CV15 CV16 CV490 495 0 031 0 043 mm 0 0012 0 0016 in Retractable Starter Center Screw Torque 7 4 8 5 N m 65 75 in lb Stator Stator Mounting Screw Torque 6 2 N...

Page 17: ...lve Stem to Valve Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D New 7 038 7 058 mm 0 2771 0 2779 in Max Wear Limit 7 134 mm 0 2809 in Exhaust Valve Guide I D New 7 038...

Page 18: ...47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 58 3 43 76 4 55 131 5 97 184 4 136 219 7 162 94 9 70 Noncritical Fasteners Into Aluminum Noncritical Fasteners Into Aluminum Tightening Torque N m in lb...

Page 19: ...res 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 down time T...

Page 20: ...nking circuits KO3218 Cylinder Leakdown Tester Used for checking combustion retention and if cylinder piston rings or valves are worn KO3219 Oil Pressure Test Kit Used to test verify oil pressure on p...

Page 21: ...r Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool If you don t have a spanner wrench to lift the rocker arms or to turn the crankshaft you can make a tool for doing this out of an old junk...

Page 22: ...2 4 Section 2 Special Tools...

Page 23: ...5 Faulty choke or throttle controls 6 Faulty spark plug 7 Low compression 8 Faulty ACR mechanism Engine Will Not Crank 1 PTO drive is engaged 2 Battery if equipped is discharged 3 Safety interlock sw...

Page 24: ...if the element is dirty or clogged These could indicate that the engine has been underserviced Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner is no...

Page 25: ...ould be a minimum of 10 2 cm 4 in above the level in the open side If the level in the engine side is the same as the open side no vacuum or the level in the engine side is lower than the level in the...

Page 26: ...and crankshaft PTO or insert a shoulder bolt through the slot and thread it into the mounting hole If the flywheel end is more accessible you can use a breaker bar and socket on the flywheel nut scre...

Page 27: ...through a duct from the blower housing and from the outside slot The later type uses a flat base plate with the enclosure provided by the cover Figure 4 1 Original Air Cleaner Assembly Exploded View F...

Page 28: ...nd tighten the retaining knob Paper Element Service Every 100 hours of operation more often under extremely dusty or dirty conditions check the paper element Clean or replace the element as necessary...

Page 29: ...curely Air Intake Cooling System Clean Air Intake Cooling Areas To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times E...

Page 30: ...4 4 Section 4 Air Cleaner and Air Intake System...

Page 31: ...y clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves le...

Page 32: ...lines 4 Check the operation of fuel pump a Remove the fuel line from the inlet fitting of the carburetor b Crank the engine several times and observe flow 4 If fuel does flow from the line check for...

Page 33: ...flange screws as follows Into new as cast hole 9 0 N m 80 in lb Into used hole 4 2 5 1 N m 37 45 in lb 4 Connect the fuel lines to the inlet and outlet fittings Carburetor Gasoline These engines are e...

Page 34: ...e fuel bowl low idle fuel adjusting needle and welch plugs Clean vent ports and air bleeds Blow out all passages with compressed air f Fuel bowl gasket leaks Remove fuel bowl and replace gasket g Leak...

Page 35: ...t is possible Low Idle Speed Setting 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before doing step 2 2 Low Idle Speed Setting Place the throttle...

Page 36: ...al Walbro Carburetors In order to clean the idle ports and bowl vent thoroughly remove the welch plugs covering these areas Use Tool No KO1018 and the following procedure to remove the welch plugs See...

Page 37: ...See Figure 5 8 Also take note of the choke plate position in bore and the position of the choke lever and choke return spring Figure 5 8 Marking Choke Plate and Carburetor Body 2 Some carburetors have...

Page 38: ...amaged float tabs Check the float hinge and pin for wear or damage Inspect the fuel inlet needle and seat for wear or damage Inspect the tip of the low idle fuel adjusting needle for wear or grooves I...

Page 39: ...ver over the lever stop pin To ensure the proper alignment of the upper bushing and the lower shaft hole use a 3 16 diameter drill blank to align the bushing as it is pressed into the casting 3 Instal...

Page 40: ...he solenoid Also check to see that the ground lead from the carburetor body to the air cleaner base mounting stud is properly connected Figure 5 13 Installing Welch Plugs 4 After the plugs are install...

Page 41: ...hand truck when moving or tilt the tank on its footring in a position slightly off vertical and roll it Avoid personal contact with LPG fuel to prevent frostbite See a physician if frostbite occurs W...

Page 42: ...checking the items listed above adjust or service the carburetor as follows Adjust Carburetor 1 With the engine stopped reset the main fuel setting by closing the adjusting screw until it bottoms the...

Page 43: ...arm up period of about sixty seconds to allow the oxygen sensor to heat up and the fuel metering valve to stabilize When first started the engine will be running rich and may sound rough As the oxygen...

Page 44: ...assembly from the engine Remove the four small socket head screws and separate the fuel metering valve from the stepper motor Try to turn the load adjusting screw with the blade of a small screwdrive...

Page 45: ...re proper setting make sure the throttle linkage is connected to the governor arm and the throttle lever on the carburetor See Figure 5 18 1 With the governor lever loose on the cross shaft pull the l...

Page 46: ...able to remove any slack Tighten the cable clamp securely High Idle Speed Adjustment The recommended maximum no load high idle speed for most of these engines is 3750 RPM The actual high idle speed de...

Page 47: ...ensitive If a big drop in speed occurs when normal load is applied the governor should be set for greater sensitivity The position of the governor spring in the governor arm depends on the high idle n...

Page 48: ...ol in the full fast throttle position Then move the throttle lever back 3 16 or 4 75 mm Insert the cable boden wire into the throttle control lever on the control plate 3 Position the throttle cable u...

Page 49: ...n the high idle stop screw inward clockwise until it stops against the throttle control lever Then tighten the stop screw retaining nut 8 Recheck high idle RPM to assure the required RPM has been obta...

Page 50: ...5 20 Section 5 Fuel System and Governor Governed Idle Adjusting Screw Figure 5 26 Location of Governed Idle Adjusting Screw...

Page 51: ...J or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure...

Page 52: ...oil as follows see Figure 6 5 Figure 6 5 Oil Drain Plugs Oil Filter Oil Filter Drain Plug and Optional Oil Sentry Switch 1 Remove the oil drain plug and oil fill cap dipstick Be sure to allow ample t...

Page 53: ...wise until the rubber gasket contacts the filter adapter then tighten the filter an additional 2 3 to 1 turn 7 Fill the crankcase with new oil of the proper type to the F mark on the dipstick 8 Test r...

Page 54: ...close On stationary or unattended applications pumps generators etc the pressure switch can be used to ground the ignition module to stop the engine On vehicular applications lawn tractors mowers etc...

Page 55: ...ressure gauge and a continuity tester are required to test the switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the swit...

Page 56: ...6 6 Section 6 Lubrication System...

Page 57: ...using 2 Remove the starter To Install Starter 1 Install the retractable starter and five hex flange screws to blower housing Leave the screws slightly loose 2 Pull the starter handle out until the paw...

Page 58: ...ring to unwind Enlist the aid of a helper if necessary or use a C clamp to hold the pulley in position 9 Insert the new rope through the rope hole in starter pulley and rope guide bushing of housing S...

Page 59: ...starter pulley 5 Rotate the pulley clockwise 2 full turns This will ensure the spring is disengaged from the starter housing 6 Hold the pulley into the starter housing Invert the pulley housing so th...

Page 60: ...the pulley and spring into the starter housing See Figure 7 9 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 Installi...

Page 61: ...le Equivalent alternate brand plugs can also be used Gap CV11 15 CV460 465 490 495 1 02 mm 0 040 in CV11 14 LP CV16 0 76 mm 0 030 in Thread Size 14 mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in Spar...

Page 62: ...a worn plug the center electrode will be rounded and the gap will be eroded 010 or more beyond the correct gap Replace a worn spark plug immediately Chalky White Deposits Chalky white colored deposits...

Page 63: ...combustion chamber The timing of the spark is automatically controlled by the module Therefore other than periodically checking replacing the spark plug no maintenance timing or adjustments are neces...

Page 64: ...g terminal C of high terminal lead With the ohmmeter leads connected in this manner the resistance of secondary should be 7 900 to 18 400 ohms NOTE This test cannot be performed unless module has been...

Page 65: ...el An electronic capacitive discharge ignition module which mounts on the engine crankcase A spark advance module which mounts to the engine shrouding A 12 volt battery which supplies current to the s...

Page 66: ...eeds the charge pump capacitor the comparator changes state and activates the pulse generator The generated pulse returns to the ignition module through the yellow lead and turns on the semiconductor...

Page 67: ...ications Required Spark plug gap 0 030 Ignition module air gap 0 008 0 012 0 010 NOTE Ignition tester KO1046 must be used to test Smart Spark ignition Use of any other tester can result in inaccurate...

Page 68: ...a minimum current rating of 250 cold cranking amps is recommended The requirement depends on engine size applications and starting temperatures Cranking requirements increase as temperatures decrease...

Page 69: ...omponents Figure 8 9 3 amp 70 Watt Stator 1 Make sure the battery polarity is correct A negative ground system is used 2 Disconnect the battery cables negative cable first before doing electric weldin...

Page 70: ...2 V Battery Solenoid Starter Optional 70 Watt Lighting Stator Yellow Black Flywheel Stator Ignition Module Spark Plug Red Blue R A S GND Light Optional Fuse Optional Ammeter B Safety Switch Optional S...

Page 71: ...the leads reversed some resistance should be measured about midscale on Rx1 range 3 If resistance is low in both directions the diode is shorted Replace the diode If resistance is high in both directi...

Page 72: ...re the resistance from the lighting lead to ground using an ohmmeter 3 If resistance is low in both directions the diode is shorted Replace the diode If resistance is high in both directions the diode...

Page 73: ...3 With the engine stopped measure the resistance from braking lead to ground using an ohmmeter 3 If resistance is approximately 0 2 0 4 ohms stator is OK If resistance is 0 ohms stator is shorted Repl...

Page 74: ...Optional Oil Sentry Switch Shutdown Battery _ Solenoid Starter Fuel Solenoid Auto Choke Diodes Optional Fuse Optional Ammeter B Rectifier Regulator AC AC Ignition Module Spark Plug Flywheel Stator CV1...

Page 75: ...ents 8 Figure 8 14 15 amp Stator and Rectifier Regulator Figure 8 15 Proper Connection to Test 15 amp Charging System DC Volt Meter Battery Ammeter Flywheel Stator Rectifier Regulator AC B AC Rectifie...

Page 76: ...rease when load is applied test stator Tests 2 and 3 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter 2 If volta...

Page 77: ...ly and Reassembly Sections for starter removal and installation procedures Inertia Drive Electric Starters This subsection covers the operation troubleshooting and repair of the inertia drive permanen...

Page 78: ...e components Style A Drive Service 1 Remove the starter from the engine and remove the dust cover 2 Hold the drive pinion in a vice with soft jaws when removing and installing the stop nut The armatur...

Page 79: ...r over the inner halves to hold them in position Dust Cover Spring Retainer Retaining Ring Anti Drift Spring Dust Cover Spacer Drive Pinion Drive Nut Collar Figure 8 18 Assembling Inner Half of Tool A...

Page 80: ...he small raised line on the edge of the drive end cap On starters with Style A commutator end caps it will be aligned with a premarked line on the starter frame The frame is not premarked on starters...

Page 81: ...from the end cap Replacement brushes come preassembled in the carrier housing retained with two carton staples Commutator Service Clean the commutator with a coarse lint free cloth Do not use emery c...

Page 82: ...nstall the drive components following the instructions for servicing the drive Figure 8 25 110 Volt UL Approved Electric Starter 110 Volt AC Starter Some engines on floor care equipment are equipped w...

Page 83: ...embly and assembly procedure of the UTE solenoid shift starter The Nippendenso solenoid shift starter is covered starting on page 8 24 The Delco solenoid shift starter starts on page 8 28 Hex Flange S...

Page 84: ...d cap in position Hold in position temporarily with tape NOTE Be sure alignment marks on caps and frame are in proper position 2 Place drive pinion with seal thrust washer and retainer on drive shaft...

Page 85: ...lder from frame 2 Cut the brush lead wire at the edge of the post with a pair of nippers 3 File off burrs on the post Starter Assembly Armature Nut Drive Lever Dust Cover Solenoid Nut Drive Pinion Dri...

Page 86: ...See Figure 8 28 Figure 8 28 Lock Collar around Retaining Ring 5 Install the thrust washer onto the armature shaft and lightly lubricate the end of the shaft with drive lubricant 6 Position the lubric...

Page 87: ...armature and drive end cap aligning the cutout with lever section on top The rubber insulating grommet should also be up See Figure 8 33 NOTE Maintain pressure on the insulator while installing so th...

Page 88: ...elco Remy Starters Figure 8 37 Starter Disassembly 1 Remove the hex nut and disconnect the positive brush lead bracket from the solenoid terminal 2 Remove the three screws securing the solenoid to the...

Page 89: ...e 8 41 Removing Thru Bolts 5 Remove the commutator end plate assembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 8...

Page 90: ...10 Push the stop collar down to expose the retaining ring See Figure 8 46 Figure 8 46 Retaining Ring Detail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the ol...

Page 91: ...e clutch housing and rotating the pinion Pinion should rotate in one direction only Solenoid Drive Armature Plug Lever Ring Stop Frame Field Screw Plunger Spring Plate Collar Brush Holder Nut CE Frame...

Page 92: ...he armature is bad 4 Check the armature windings insulation for shorting Shift Fork Check that the shift fork is complete and the pivot and contact areas are not excessively worn cracked or broken Bru...

Page 93: ...If necessary rotate the pinion outward on the armature splines against the retainer to help seat the collar around the retainer Figure 8 54 Installing Stop Collar and Retainer NOTE Always use a new re...

Page 94: ...f the armature shaft See Figure 8 59 Figure 8 59 Installing Thrust Washer 10 Starter reassembly when replacing the Brushes Brush Holder Assembly a Hold the starter assembly vertically on the end housi...

Page 95: ...on the end housing and carefully place the tool w extension and assembled original brush holder assembly onto the end of the armature shaft Slide the brush holder assembly down into place around the...

Page 96: ...end cap Use these to hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in lb See Figure 8 66 Figure 8 66 Installing Solenoid Screws 14 Connect the pos...

Page 97: ...5 Remove retractable starter 6 Remove electric starter 7 Remove air cleaner 8 Remove external governor components and carburetor 9 Remove fuel pump 10 Remove rectifier regulator 11 Remove extended oil...

Page 98: ...and retractable starter See Figure 9 4 Figure 9 4 Removing Retractable Starter Remove Electric Starter Electric Starter Bendix Drive or Solenoid Shift 1 Disconnect the lead from the stud terminal on...

Page 99: ...proved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact...

Page 100: ...7 Remove the baffle screw and internal tooth washer securing the ground lead for the fuel solenoid if so equipped See Figure 9 11 Figure 9 11 Removing Baffle Screw and Washer 8 Remove the carburetor a...

Page 101: ...flange valve cover screws and any loose spacers stamped steel valve covers which also attach the muffler and or lift bracket Note the assembly orientation for proper reassembly later Oil Fill Tube He...

Page 102: ...ee Figure 9 19 Figure 9 19 Removing Heat Deflector 5 Remove the two hex flange screws and starter side cylinder barrel baffle 6 Remove the two hex flange screws and blower housing back plate See Figur...

Page 103: ...Screw and Spacer Figure 9 23 Removing Valve Cover 2 Remove the hex flange screws spacer from the screw between the intake and exhaust ports cylinder head push rods and cylinder head gasket Cylinder H...

Page 104: ...nfiguration a Loosen the set screws and remove the adjustment nuts on the rocker arm pivot studs b Remove the rocker arm pivot assemblies Figure 9 27 Separate Rocker Arm Pivot Assembly Style Head 4 Re...

Page 105: ...ressor Strap Wrench Figure 9 30 Removing Flywheel Retaining Screw and Drive Cup Recoil Start Models Figure 9 31 Loosening Flywheel Fastener 2 Remove the grass screen from fan See Figure 9 32 Electric...

Page 106: ...ller to remove the flywheel from the crankshaft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged Flywheel Puller Strap Wrench Figure 9 34 Removing Fan from Flywh...

Page 107: ...Early Style Figure 9 37 Splitting the Oil Pan Crankcase Remove Oil Pickup Oil Pressure Relief Valve and Oil Pump 1 Remove the oil seal from the oil pan 2 Remove the hex flange screw oil pickup cover...

Page 108: ...identify the hydraulic lifters as either intake or exhaust The exhaust lifter is nearest to the PTO side of the crankcase 3 Remove the camshaft and shim not on all models See Figure 9 44 Figure 9 41...

Page 109: ...ut of the cylinder bore Remove Piston from Connecting Rod 1 Remove the wrist pin retainer and wrist pin Separate the piston from the connecting rod See Figure 9 48 Figure 9 48 Separating Piston from C...

Page 110: ...Seal Piston Ring Piston Ring Expander Plain Washer Hitch Pin Governor Cross Shaft Plain Washer Crankshaft Figure 9 49 Removing Piston Rings 2 Remove the oil control ring rails then remove the spacer...

Page 111: ...9 15 Section 9 Disassembly 9 Regulating Pin Regulating Pin Governor Gear Governor Gear Figure 9 53 Removing Governor Gear...

Page 112: ...9 16 Section 9 Disassembly...

Page 113: ...ipped with an Automatic Compression Release ACR mechanism The ACR lowers compression at cranking speeds to make starting easier Operation The ACR mechanism consist of a flyweight spring and pivoting c...

Page 114: ...eplace 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 Measur...

Page 115: ...0 020 in the initial resizing should be done with a boring bar until the cylinder is within 0 08 0 12 mm 0 003 0 005 in of the desired size Then use the following procedures for honing to the final di...

Page 116: ...is necessary that the clearance be accurately checked This step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gaug...

Page 117: ...and check the valves first After removal clean the valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion burned fac...

Page 118: ...1000 hours under controlled test conditions Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and too narrow These conditions could be attributed to excessi...

Page 119: ...to ream the valve guides and clean or replace the valves depending on their condition Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensat...

Page 120: ...with an 89 cutter as specified for the valve seat angle in Figure 10 5 With the proper 45 valve face angle as specified in Figure 10 4 and the valve seat cut properly 44 5 as measured from centerline...

Page 121: ...ures on a specific area of the piston Detonation generally occurs from using low octane fuels Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation P...

Page 122: ...d with new ring sets Follow instructions carefully Use a piston ring expander to install rings Install the bottom oil control ring first and the top compression ring last Refer to Figure 10 10 Figure...

Page 123: ...elief valve body piston and spring is used see Figure 10 11 Check that piston and body are free of nicks or burrs Check the spring for any wear or distortion The free length of the spring should be ap...

Page 124: ...lled so that it protrudes 1 289 plus or minus 004 in above the crankcase boss See Figure 10 13 Stamped Steel Valve Cover If the engine has stamped steel valve cover the sealing surface must be checked...

Page 125: ...kup 9 Install oil pan to crankcase 10 Install oil pump 11 Install oil seals 12 Install stator and wiring harness 13 Install fuel line 14 Install fan flywheel grass screen and drive cup 15 Reassemble c...

Page 126: ...Install Crankshaft 1 Lubricate the flywheel end bearing surfaces of the crankshaft and crankcase with engine oil 2 Insert the crankshaft through the flywheel end bearing See Figure 11 4 Figure 11 4 In...

Page 127: ...gs using a piston ring compressor See Figure 11 8 Push the piston through the compressor so the oil control bottom ring is just above the lower edge of the compressor Figure 11 8 Installing Piston and...

Page 128: ...ne oil 2 Align the timing marks on the balance shaft gear and the larger gear on the crankshaft Lower the balance shaft into the bearing surface in the crankcase On CV460 495 models the crankshaft and...

Page 129: ...5 0 03075 in Red 0 79375 0 83185 mm 0 03125 0 03275 in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gray 0 94615 0 98425 mm 0 03725 0 03875 in Black 0 99695...

Page 130: ...relief valve into place See Figure 11 19 Do not use Loctite Figure 11 17 Later Style Oil Pressure Relief Valve 2 Use a piece of thin wall metal tubing or deep socket with a slightly smaller O D than...

Page 131: ...ult in leaks The use of a gasket removing solvent is recommended 2 Apply a 1 16 bead of sealant to the oil pan as shown in Figure 11 21 Apply a second bead to the section between point A and point B 3...

Page 132: ...it No KO1027 Install the seals until the driver bottoms against the crankcase or oil pan See Figure 11 25 Install Oil Pump 1 Lubricate the oil pump cavity and oil pump rotors with engine oil Install t...

Page 133: ...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 inj...

Page 134: ...Grass Screen Plain Washer Figure 11 29 Installing Flywheel Retractable Starter Models Electric Start Models Install the plain washer and the hex flange screw See Figure 11 30 Figure 11 30 Installing...

Page 135: ...old cutoff push rod mounted in a drill press arbor press or vice and slowly apply pressure two or three times to bleed the lifters See Figure 11 34 If a vice is used in bleeding the lifters be sure to...

Page 136: ...valve spring retainer exhaust valve spring and valve spring cap Compress the valve spring using a valve spring compressor and install the keepers See following NOTE regarding exhaust valve rotator us...

Page 137: ...tighten only at this time Adjustable Valve Lash Configuration a Position the guide plate on the head with the formed lips down and install the two pivot studs Torque the pivot studs to 11 3 N m 100 in...

Page 138: ...switch insert a long 90 mm 3 5 in head bolt through the special washer flat on one edge and the cutout switch Install it in position 1 d Determine the correct length head bolt for position 5 based upo...

Page 139: ...installed for all applications which do not have a metal vacuum line at this location Use pipe sealant with Teflon on the threads 6 Install the spark plug into the cylinder head Torque the spark plug...

Page 140: ...all the silver screw if the screw also attaches the fuel solenoid ground lead See Figure 11 51 Figure 11 49 Installing Blower Housing Back Plate 2 Install the starter side cylinder barrel baffle and o...

Page 141: ...r and crankcase Refer to page 2 1 for the approved sealant NOTE Always use fresh sealant Using outdated sealant can result in leakage 1 Prepare the sealing surfaces of the cylinder head and valve cove...

Page 142: ...oil fill cap are in place 2 Install the oil fill tube into the hole in the crankcase See Figure 11 58 2 4 1 3 5 Figure 11 58 Installing Oil Fill Tube 3 Secure the oil fill tube to the crankcase with...

Page 143: ...0 Installing Fuel Pump 2 Install the gasket fuel pump and two hex flange screws Torque the screws as follows Into new as cast hole 9 0 N m 80 in lb Into used hole 4 2 5 1 N m 37 45 in lb 3 Install the...

Page 144: ...ure 11 64 Installing Choke Linkage and Speed Control Bracket Install Air Cleaner and Make Initial Governor Adjustment 1 Make sure the metal bushings in the air cleaner base mounting flange are in plac...

Page 145: ...ng the Governor 5 Be sure the rubber sleeve seal is installed on the air cleaner base stud Install the air cleaner element and precleaner Secure the element with the wing nut See Figure 11 67 Figure 1...

Page 146: ...r housing Leave the screws slightly loose Figure 11 70 Installing Retractable Starter Install Muffler 1 Install the gasket muffler and hex flange nuts to the exhaust port studs Leave the nuts slightly...

Page 147: ...d the engine can be test run If however it cannot be turned over completely locks up at some point return the piston to TDC between the intake and exhaust strokes and wait ten minutes to allow the lif...

Page 148: ...11 24 Section 11 Reassembly...

Page 149: ......

Page 150: ...AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2011 by Kohler Co All rights reserved FORM NO 12 690 01 Rev ISSUED 4 1...

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