Kohler Command CV730 User Manual

SERVICE MANUALVERTICAL CRANKSHAFTCOMMAND CV17-750

1.8Section 1Safety and General InformationFigure 1-6. Typical Engine Dimensions CV EFI Series with Heavy-Duty Air Cleaner.Dimensions in millimeters.In

5B.33Section 5BEFI Fuel System5BCode: 21Source: Engine Speed SensorExplanation: ECU receiving inconsistent toothcount signals from speed sensor.Expect

5B.34Section 5BEFI Fuel SystemCode: 23Source: ECUExplanation: ECU is unable to recognize or processsignals from its memory.Expected EngineResponse: En

5B.35Section 5BEFI Fuel System5BCode: 33Source: Oxygen Sensor/Fuel SystemExplanation: “System too Rich” Temporary fueladaptation control is at the upp

5B.36Section 5BEFI Fuel SystemCode: 42Source: Engine (Oil) Temperature SensorExplanation: Not sending proper signal to ECU.Expected EngineResponse: En

5B.37Section 5BEFI Fuel System5B3. Fuel Pump Relay Relateda. Bad fuel pump relay.Primary side functional but pin 30 to pin 87remains open. Primary sid

5B.38Section 5BEFI Fuel SystemCode: 61Source:Explanation: Denotes the end of fault codes. Ifsignaled first, no other fault codesare present.Troublesho

5B.39Section 5BEFI Fuel System5BFigure 5B-41.*Operate for an appropriate period of time based upon original fault codes.

5B.40Section 5BEFI Fuel SystemFlow Chart Diagnostic AidsDiagnostic Aid #1 “SYSTEM POWER” (MIL does notilluminate when key is turned “on”)Possible caus

5B.41Section 5BEFI Fuel System5BDiagnostic Aid #5 “FUEL PUMP” (fuel pump notturning on)Possible causes:1. Fuel pump fuse2. Fuel pump circuit problem“2

6.1Section 6Lubrication System6Section 6Lubrication SystemGeneralThis engine uses a full pressure lubrication system,delivering oil under pressure to

1.9Section 1Safety and General Information1General Specifications1Power (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J19

6.2Section 6Lubrication SystemFigure 6-2. Oil Fill Cap/Dipstick.4. Remove dipstick and check oil level. The levelshould be between the FULL and ADD ma

6.3Section 6Lubrication System6Change the oil as follows:1. A drain plug is located on either side of the oilsump; one is near the starter, the other

6.4Section 6Lubrication SystemTo service the blower housing mounted oil cooler,clean the outside of the fins with a brush (see Figure6-7). Remove the

7.1Section 7Retractable Starter7Section 7Retractable StarterWARNING: Spring Under Tension!Retractable starters contain a powerful, recoil spring that

7.2Section 7Retractable Starter6. Tie a single knot in one end of the new rope.7. Rotate the pulley counterclockwise (whenviewed from pawl side of pul

7.3Section 7Retractable Starter7Figure 7-6. Removing Pulley from Housing.8. Note the position of the spring and keeperassembly in the pulley. See Figu

7.4Section 7Retractable StarterFigure 7-8. Installing Pulley and Spring intoHousing.3. Install the pawl springs and pawls into thestarter pulley. See

8.18Section 8Electrical System and ComponentsSection 8Electrical System and ComponentsThis section covers the operation, service, and repair ofthe ele

8.2Section 8Electrical System and ComponentsNormal: A plug taken from an engine operating undernormal conditions will have light tan or gray coloredde

8.38Section 8Electrical System and Components2. Keep the cables, terminals, and external surfacesof the battery clean. A build-up of corrosive acidor

1.10Section 1Safety and General InformationGeneral Specifications1 cont.Oil Capacity (w/filter) - approximate,determined by oil filter and oil cooler

8.4Section 8Electrical System and ComponentsThe SMART-SPARK™ ignition system used on somemodels is an advanced version of the CD ignitionsystem used o

8.58Section 8Electrical System and ComponentsKill Switch or‘‘Off’’ Position ofKey SwitchIgnitionModulesSpark PlugMagnetFlywheel0.28/0.33 mm(0.011/0.01

8.6Section 8Electrical System and ComponentsB. Capacitive Discharge with Electronic SparkAdvance (SMART-SPARK™)SMART-SPARK™equipped engines utilize an

8.78Section 8Electrical System and ComponentsOperation: The ignition module for this systemoperates in the same fashion as the fixed timingmodule, exc

8.8Section 8Electrical System and Componentsa. If one side is not firing, check all wiring,connections, and terminations on that side. Ifwiring is oka

8.98Section 8Electrical System and ComponentsFigure 8-8.1. Make a line near the edge of the flywheel screenwith a marking pen or narrow tape.2. Connec

8.10Section 8Electrical System and ComponentsIgnition Module Resistance Table 4) Position a 0.30 mm (0.012 in.) feelergauge between the magnet and all

8.118Section 8Electrical System and Componentsa. If correct voltage is not measured, connectblack voltmeter lead directly to the negative(-) post of t

8.12Section 8Electrical System and ComponentsFigure 8-12.2. Check the SAM part number stamped on the sideof the housing. Verify that you have an analo

8.138Section 8Electrical System and ComponentsFigure 8-14. Connected Tester Leads.The test procedure for twin cylinder SAMs will varyslightly, dependi

1.11Section 1Safety and General Information1CrankcaseGovernor Cross Shaft Bore I.D.6 mm ShaftNew ...

8.14Section 8Electrical System and ComponentsFigure 8-16. “Pass” Indicator.**The tester is powered by a 9-volt battery. MostSAMs are designed to opera

8.158Section 8Electrical System and Components15/20/25 Amp Regulated Charging SystemFigure 8-17. Wiring Diagram - 15/20/25 Amp Regulated Battery Charg

8.16Section 8Electrical System and ComponentsFigure 8-19. 15 Amp Stator and Rectifier-Regulator.Figure 8-20. 20 Amp Stator and Rectifier-Regulator.Fig

8.178Section 8Electrical System and ComponentsGround-To-Kill Lead (White)DiodeKeyswitchOptionalOil SentryTMSwitch(Indicator Light)OptionalOil SentryTM

8.18Section 8Electrical System and ComponentsFigure 8-23. 3 Amp/70 Watt Stator.StatorThe stator is mounted on the crankcase behind theflywheel. Follow

8.198Section 8Electrical System and Components3. Plug the tester into the proper AC outlet/powersupply for tester being used. Turn on the powerswitch.

8.20Section 8Electrical System and Components6. Press the ‘‘TEST’’ button until a ‘‘click’’ is heardand then release. See Figure 8-27. Momentarilyone

8.218Section 8Electrical System and ComponentsFigure 8-33. Connections for Testing Charging System.Figure 8-32.3. Plug the tester into the proper AC o

8.22Section 8Electrical System and ComponentsProblem Test Conclusion1. Trace B+ lead from rectifier-regulator to key switch, or otheraccessible connec

8.238Section 8Electrical System and ComponentsTroubleshooting Guide3 Amp Battery Charging System with 70 Watt Lighting StatorNOTE: Zero ohmmeters on e

1.12Section 1Safety and General InformationCylinder BoreCylinder Bore I.D.New - CV17 ...

8.24Section 8Electrical System and ComponentsElectric Starting MotorsSome engines in this series use inertia drive startingmotors while most use solen

8.258Section 8Electrical System and ComponentsOperation - Inertia Drive StartersWhen power is applied to the starter, the armaturerotates. As the arma

8.26Section 8Electrical System and ComponentsFigure 8-36. Assembling Inner Half of Tool AroundArmature Shaft and Retaining Ring.5. Thread the center s

8.278Section 8Electrical System and ComponentsRetaining Ring Installation1. Position the retaining ring in the groove in one ofthe inner halves. Assem

8.28Section 8Electrical System and ComponentsNOTE: Use a brush holder tool to keep thebrushes in the pockets. A brush holdertool can easily be made fr

8.298Section 8Electrical System and ComponentsFigure 8-42. Style ‘‘B’’ Commutator End Cap withBrushes.6. Install the thru bolts and tighten securely.7

8.30Section 8Electrical System and ComponentsStarter Disassembly1. Disconnect the lead wire from the solenoid.2. Remove the hex nuts securing the sole

8.318Section 8Electrical System and ComponentsFigure 8-45. Removing Solenoid Screws.3. If the solenoid was mounted with Phillips headscrews, separate

8.32Section 8Electrical System and ComponentsFigure 8-48. Removing Thru Bolts.5. Remove the commutator end plate assembly,containing the brush holder,

8.338Section 8Electrical System and ComponentsFigure 8-54. Removing Retaining Ring.12. Remove the drive pinion assembly from thearmature.13. Clean the

1.13Section 1Safety and General Information1IgnitionSpark Plug Type (Champion® or Equivalent) ... RC12YC, XC

8.34Section 8Electrical System and ComponentsFigure 8-56. Checking Brushes.Armature1. Clean and inspect the commutator (outersurface). The mica insula

8.358Section 8Electrical System and ComponentsFigure 8-60. Service Brush Kit.5. Perform Steps 10-13 in the “Starter Reassembly”sequence. Installation

8.36Section 8Electrical System and ComponentsFigure 8-62. Installing Thrust Washer.4. Apply a small amount of oil to the bearing in thedrive end cap,

8.378Section 8Electrical System and ComponentsFigure 8-66. Installing Thrust Washer.10. Starter reassembly when replacing the Brushes/Brush Holder Ass

8.38Section 8Electrical System and ComponentsFigure 8-70. Installing Brush Holder Assemblyusing Tool with Extension.11. Install the end cap onto the a

8.398Section 8Electrical System and Components12 volt Test LeadsMomentaryConnection Only12 volt Test LeadsMomentaryConnection OnlyVOM LeadsManually Pu

8.40Section 8Electrical System and ComponentsPlungerPushed “In”VOM MeterLeads12 volt Test LeadsTest 4. Solenoid Hold-In Coil/Contact ContinuityTest.Us

9.1Section 9Disassembly9Section 9Disassembly WARNING: Accidental Starts!Disabling engine. Accidental starting can cause severeinjury or death. Befor

9.2Section 9DisassemblyFigure 9-2. Removing Oil Fill Cap/Dipstick.3. Remove the mounting screw and detach the oilfill tube. See Figure 9-3.4. Remove a

9.3Section 9Disassembly9Figure 9-8. Removing Commercial Mower Elementand Precleaner.Figure 9-6. Removing Standard Element andPrecleaner.3. Remove the

1.14Section 1Safety and General InformationPiston, Piston Rings, and Piston Pin cont.Top and Middle Compression Ring End GapNew Bore - CV17Top Ring ..

9.4Section 9DisassemblyFigure 9-11. Air Cleaner Bracket/Valve CoverMounting Screws (Two-Barrel Model Pictured).Heavy Duty Air Cleaner1. Disconnect the

9.5Section 9Disassembly9Figure 9-14. Removing Throttle Control Bracket.Figure 9-15. Removing Control Panel.Remove Fuel PumpWARNING: Explosive Fuel!Gas

9.6Section 9DisassemblyFigure 9-18. Removing Control Bracket.Figure 9-19. Removing Control Bracket and AirCleaner Bracket (Some Models).2. Disconnect

9.7Section 9Disassembly93. Remove the carburetor, throttle linkage andgovernor lever as an assembly.Figure 9-22. Removing Carburetor and Linkage(Two-B

9.8Section 9DisassemblyFigure 9-29. Removing Outer Baffles.5. If the flywheel screen overlaps the blowerhousing, remove the fasteners and screen. If i

9.9Section 9Disassembly9Figure 9-30. Removing Flywheel Screen.6. Remove the remaining hex flange screws securingthe blower housing. Note the one silve

9.10Section 9DisassemblyFigure 9-37. Removing Valve Cover.Remove Ignition Modules1. Disconnect the lead(s) from each ignition module.See Figure 9-38.F

9.11Section 9Disassembly9Figure 9-39. Position of Ignition Modules.3. Remove the mounting screws and ignitionmodules. Note the position of the ignitio

9.12Section 9DisassemblyFigure 9-43. Removing Cylinder Head.4. Remove the lifters from the lifter bores. Use ahydraulic lifter tool. Do not use a magn

9.13Section 9Disassembly9Figure 9-45. Removing Rocker Arm.2. Compress the valve springs using a valve springcompressor. See Figure 9-46.Figure 9-46. R

1.15Section 1Safety and General Information1StatorMounting Screw Torque ...

9.14Section 9DisassemblyFigure 9-51. Removing Flywheel Fastener UsingStrap Wrench.2. Remove the hex flange screw and washer.3. Use a puller to remove

9.15Section 9Disassembly9Figure 9-54. Removing Stator.Remove Oil Pan Assembly1. Remove the ten hex flange screws securing the oilpan to the crankcase.

9.16Section 9DisassemblyFigure 9-60. Removing Connecting Rod End Cap.NOTE: If a carbon ridge is present at the top ofeither cylinder bore, use a ridge

9.17Section 9Disassembly93. Repeat the above procedure for the otherconnecting rod and piston assembly.Remove Crankshaft1. Carefully pull the cranksha

10.1Section 10Inspection and Reconditioning10Section 10Inspection and ReconditioningThis section covers the operation, inspection, andrepair/reconditi

10.2Section 10Inspection and ReconditioningThe connecting rod journal can be ground one sizeunder. When grinding the crankshaft, grinding stonedeposit

10.3Section 10Inspection and Reconditioning101. Lower hone into bore and after centering, adjustso that the stones are in contact with the cylinderwal

10.4Section 10Inspection and ReconditioningFigure 10-4. Measuring Piston Diameter.2. Use an inside micrometer, telescoping gauge, orbore gauge and mea

10.5Section 10Inspection and Reconditioning10Figure 10-5. Checking Cylinder Head Flatness.Carefully inspect the valve mechanism parts. Inspectthe valv

10.6Section 10Inspection and ReconditioningNormal: Even after long hours of operation a valvecan be reconditioned and reused if the face andmargin are

1.16Section 1Safety and General InformationGeneral Torque ValuesMetric Fastener Torque Recommendations for Standard ApplicationsTightening Torque: N·m

10.7Section 10Inspection and Reconditioning10Excessive Combustion Temperatures: The whitedeposits seen here indicate very high combustiontemperatures,

10.8Section 10Inspection and ReconditioningValve GuidesIf a valve guide is worn beyond specifications, it willnot guide the valve in a straight line.

10.9Section 10Inspection and Reconditioning10Ring failure is usually indicated by excessive oilconsumption and blue exhaust smoke. When ringsfail, oil

10.10Section 10Inspection and ReconditioningFigure 10-10. Measuring Piston Ring SideClearance.Install New Piston RingsTo install new piston rings, pro

10.11Section 10Inspection and Reconditioning10Figure 10-12. Piston Ring Installation.1. Oil Control Ring (Bottom Groove): Install theexpander and then

10.12Section 10Inspection and ReconditioningFigure 10-13. Removing Governor Gear.2. Remove the locking tab thrust washer locatedunder the governor gea

10.13Section 10Inspection and Reconditioning10Figure 10-16. Oil Pump, Oil Pickup, and ReliefValve (Original Style).Figure 10-17. Oil Pump, Plastic Oil

10.14Section 10Inspection and Reconditioning5. After torquing, rotate the gear and check forfreedom of movement. Make sure there is nobinding. If bind

11.1Section 11Reassembly11Section 11ReassemblyGeneralNOTE: Make sure the engine is assembled using allspecified torque values, tightening sequences,an

11.2Section 11ReassemblyFigure 11-2. Installing Oil Seal in Crankcase.Install Governor Cross Shaft1. Lubricate the governor cross shaft bearingsurface

1.17Section 1Safety and General Information1English Fastener Torque Recommendations for Standard ApplicationsGrade 2 or 5Fasteners IntoAluminumSize8-3

11.3Section 11Reassembly11Figure 11-7. Installing Crankshaft.Install Connecting Rods with Pistons andRingsNOTE: The cylinders are numbered on the cran

11.4Section 11ReassemblyFigure 11-13. Aligning Crankshaft and CamshaftTiming Marks.Figure 11-11. Torquing Connecting Rod End Cap.6. Repeat the above p

11.5Section 11Reassembly11Figure 11-14. Checking Camshaft End Play.3. Apply pressure on the camshaft end playchecking tool (pushing camshaft towardcra

11.6Section 11Reassembly6. Install the ten hex flange screws securing the oilpan to the crankcase. Torque the fasteners in thesequence shown in Figure

11.7Section 11Reassembly11Figure 11-23. Clean and Dry Taper of Crankshaft.Install FlywheelWARNING: Damaging Crankshaft andFlywheel Can Cause Personal

11.8Section 11ReassemblyFigure 11-26. Installing Fan.3. If the engine has a plastic grass screen, snap thescreen onto the fan. See Figure 11-27. Due t

11.9Section 11Reassembly11Figure 11-28. Installing Supports for Metal GrassScreen.2. Tighten the supports with a torque wrench to9.9 N·m (99 in. lb.).

11.10Section 11ReassemblyFigure 11-34. Intake Valve Seal Location.Assemble Cylinder HeadsPrior to installation, lubricate all components withengine oi

11.11Section 11Reassembly11Figure 11-36. Installing Valves with Valve SpringCompressor.Install Cylinder HeadsNOTE: Cylinder heads must be attached wit

11.12Section 11ReassemblyFigure 11-41. Install Push Rods in Their OriginalPosition.2. Apply grease to the contact surfaces of the rockerarms and rocke

ContentsSection 1. Safety and General Information ...Section 2. Tools & A

2.1Section 2Tools & Aids2Section 2Tools & AidsCertain quality tools are designed to help you perform specific disassembly, repair, and reassem

11.13Section 11Reassembly11Figure 11-43. Using Spanner Wrench to Lift RockerArm Over Push Rod.5. Repeat the above steps for the remainingcylinder. Do

11.14Section 11ReassemblyFigure 11-46. Setting Ignition Module Air Gap.6. Torque the screws to 4.0-6.2 N·m (35-55 in. lb.).7. Repeat steps 4 through 6

11.15Section 11Reassembly11NOTE: If the wires were disconnected from theignition modules on engines with SMART-SPARK™, reattach the leads and seal the

11.16Section 11ReassemblyInstall Blower Housing and Outer BafflesNOTE: Do not completely tighten screws until allitems are installed to allow shifting

11.17Section 11Reassembly11Figure 11-59. Installing Blower Housing.3. Position the outer baffles and secure using thefour hex flange screws (two long,

11.18Section 11ReassemblyFigure 11-64. Rectifier-Regulator Ground Details.2. Install the B+ terminal/lead into the centerposition of the rectifier-reg

11.19Section 11Reassembly11Install Valve CoversThree valve cover designs have been used. The earliesttype used a gasket and RTV sealant between the co

11.20Section 11ReassemblyFigure 11-70. Install Governor Lever to Shaft.2. Make sure the throttle linkage is connected to thegovernor lever and the thr

11.21Section 11Reassembly11Figure 11-73. Throttle Linkage Details.3. Move the governor lever toward the carburetor asfar as it will go (wide-open thro

11.22Section 11ReassemblyFigure 11-76. Connecting Governor Spring toGovernor Lever.Install Throttle and Choke Controls1. One-Barrel Carburetor Models:

2.2Section 2Tools & Aids).tnoc(slooTnoitpircseD .oNtraP/ecruoShcnerWpartSleehwylF.lavomergnirudleehwylfdlohoT90428-RLKslooTESlooTretfiLevlaVciluar

11.23Section 11Reassembly113. Connect the governor spring from the throttlecontrol bracket to the appropriate hole in thegovernor lever, as indicated

11.24Section 11Reassembly8 mm Governor Lever and Hole Position/RPM ChartCV18 EnginesEngine Mounted Throttle ControlPivot ShaftSpring Color Hole No.Sta

11.25Section 11Reassembly11Install Electric Starter Motor1. Install the starter motor using the two hex flangescrews. Position the lift bracket as sho

11.26Section 11ReassemblyFigure 11-81. Reinstalled Fuel Pump.2. Install the fuel pump using the two hex flangescrews. Torque the screws to 2.3 N·m (20

11.27Section 11Reassembly11Figure 11-85. Torquing Base and Spitback CupMounting Nuts.Figure 11-84. Breather Hose and Separator Details.2. Position a n

11.28Section 11ReassemblyFigure 11-89. Securing Air Cleaner MountingBracket.6. Two-Barrel Carburetor Models Only: Attach thechoke return spring to the

11.29Section 11Reassembly11Figure 11-92. Install Oil Drain Plug(s).Prepare the Engine for OperationThe engine is now completely reassembled. Beforesta

LITHO IN U.S.A.FORM NO.: TP-2450-CISSUED: 3/94REVISED: 3/06ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044FOR SALES AND SERVICE INFORMATIONIN U.S

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2.4Section 2Tools & AidsSpecial Tools You Can MakeFlywheel Holding ToolA flywheel holding tool can be made out of an oldjunk flywheel ring gear as

3.1Section 3Troubleshooting3Section 3TroubleshootingTroubleshooting GuideWhen troubles occur, be sure to check the simplecauses which, at first, may s

3.2Section 3TroubleshootingEngine Will Not Idle1. Dirt or water in the fuel system.2. Stale fuel and/or gum in carburetor.3. Faulty spark plugs.4. Fue

3.3Section 3Troubleshooting3• Check the condition of the oil. Drain the oil into acontainer - the oil should flow freely. Check formetal chips and oth

3.4Section 3TroubleshootingPossible Cause Solution1. Disassemble breather, clean parts thoroughly,reassemble, and recheck pressure.2. Replace all worn

3.5Section 3Troubleshooting3Air escaping from crankcase breather ... Rings or cylinder worn.Air esc

4.1Section 4Air Cleaner and Air Intake System4Section 4Air Cleaner and Air Intake SystemAir CleanersGeneralThese engines are equipped with a replaceab

1.1Section 1Safety and General Information1Section 1Safety and General InformationSafety PrecautionsTo ensure safe operation please read the following

4.2Section 4Air Cleaner and Air Intake SystemFigure 4-4. Precleaner on Commercial Mower TypeAir Cleaner.Figure 4-3. Precleaner on Standard Air Cleaner

4.3Section 4Air Cleaner and Air Intake System4Wing NutAir CleanerCover(Plenum*)CoverRetainingKnobAir CleanerCover (Std.)Element Cover NutElement Cover

4.4Section 4Air Cleaner and Air Intake SystemAir Cleaner ComponentsWhenever the air cleaner cover is removed, or thepaper element or precleaner are se

4.5Section 4Air Cleaner and Air Intake System4Heavy-Duty Air CleanerGeneralThe heavy-duty air cleaner consists of a cylindricalhousing, typically moun

4.6Section 4Air Cleaner and Air Intake SystemAir Intake/Cooling SystemTo ensure proper cooling, make sure the grass screen,cooling fan fins, and other

5.1Section 5Fuel System and Governor5Section 5Fuel System and GovernorDescriptionThe Command vertical twins use two different typesof fuel systems; ca

5.2Section 5Fuel System and GovernorFuel FilterMost engines are equipped with an in-line filter.Periodically inspect the filter and replace with agenu

5.3Section 5Fuel System and Governor5Troubleshooting – Fuel System Related CausesTest Conclusion1. Check the following:a. Make sure the fuel tank cont

5.4Section 5Fuel System and Governor3. Remove the pulse line that connects the pump tothe crankcase.4. Install a new pump using the hex flange screws.

5.5Section 5Fuel System and Governor5Figure 5-3. Slow Circuit.Fuel InletFloat Valve SeatFloat ValveMain JetFloatMain EmulsionHoleIdle Speed(RPM)Adjust

1.2Section 1Safety and General InformationCarbon Monoxide can cause severenausea, fainting or death.Avoid inhaling exhaust fumes, andnever run the eng

5.6Section 5Fuel System and GovernorFigure 5-4. Main Circuit.Check Valve SpringOutlet Check ValveLeak JetAdjustment ScrewDiaphragm SpringPump Diaphrag

5.7Section 5Fuel System and Governor5Troubleshooting ChecklistWhen the engine starts hard, runs roughly or stalls atlow idle speed, check the followin

5.8Section 5Fuel System and GovernorHigh Altitude OperationWhen operating the engine at altitudes of 1500 m(5000 ft.) and above, the fuel mixture tend

5.9Section 5Fuel System and Governor5Figure 5-6. Carburetor Adjustments.2. Preliminary Settings: Turn the adjusting needleout (counterclockwise) from

5.10Section 5Fuel System and Governor16.5 mm(0.65 in.)Turn CarburetorUpside DownFigure 5-7. Governed Idle Spring Location.Figure 5-8. Holding Throttle

5.11Section 5Fuel System and Governor5DisassemblyUse the carburetor repair kit (and the float repair kit iffloat components are to be replaced). Refer

5.12Section 5Fuel System and GovernorFigure 5-10. Typical Carburetor - Exploded View.Inspection/RepairTo clean vent ports, seats etc., use a goodcomme

5.13Section 5Fuel System and Governor5Always use new gaskets when servicing or reinstallingcarburetors. Repair kits are available which includenew gas

5.14Section 5Fuel System and GovernorFigure 5-14. Installing Float Assembly.6. Hold the carburetor body so the float assemblyhangs vertically and rest

5.15Section 5Fuel System and Governor5Figure 5-19. Main Jet and Slow Jet Removed.4. Remove the two screws securing the top cover,gasket, and ground le

1.3Section 1Safety and General Information1Engine Identification NumbersWhen ordering parts, or in any communicationinvolving an engine, always give t

5.16Section 5Fuel System and GovernorFigure 5-22. Installing Plug into Slow Jet Tube.10. Attach the inlet needle to the metal tang of thefloat with th

5.17Section 5Fuel System and Governor5Figure 5-26. Installing Fuel Bowl O-Rings.15. Install the fuel bowl onto the carburetor. Securewith the four ori

5.18Section 5Fuel System and Governor2. Remove the three screws securing the cover to theaccelerator pump housing. Remove the cover,spring, and diaphr

5.19Section 5Fuel System and Governor5Figure 5-34. Installing Accelerator Pump HousingScrews and Hose.8. Install the new clips onto each end of the ne

5.20Section 5Fuel System and GovernorFigure 5-38. Choke Shaft and Spring Details.10. Slide the choke shaft and spring, into thecarburetor. Pivot (prel

5.21Section 5Fuel System and Governor5AdjustmentNOTE: Carburetor adjustments should be made onlyafter the engine has warmed up.The carburetor is desig

5.22Section 5Fuel System and GovernorFigure 5-41. Governed Idle Spring Location.Figure 5-40. Optimum Low Idle Fuel Settings.Models with Governed Idle

5.23Section 5Fuel System and Governor5Figure 5-45. Float and Inlet Needle Details.6. Install the float and inlet needle down into theseat and carburet

5.24Section 5Fuel System and GovernorFigure 5-50. Removing Float and Inlet Needle.3. Use an appropriate size flat screwdriver, andcarefully remove the

5.25Section 5Fuel System and Governor5Figure 5-53. Slow Jets and O-Ring Detail.5. Remove the idle speed (RPM) adjustment screwand spring from the carb

1.4Section 1Safety and General InformationOil RecommendationsUsing the proper type and weight of oil in thecrankcase is extremely important. So is che

5.26Section 5Fuel System and GovernorFigure 5-57. Installing Float Assembly.14. Hold the carburetor body so the float assemblyhangs vertically and res

5.27Section 5Fuel System and Governor5Figure 5-58. Checking Float Height.NOTE: Be sure to measure from the casting surface,not the rubber gasket, if s

5.28Section 5Fuel System and GovernorFigure 5-63. Choke Shaft and Spring Details.10. Slide the choke shaft and spring into thecarburetor. Pivot (prelo

5.29Section 5Fuel System and Governor51. Carburetor Body Subassembly2. Idle Speed Screw3. Idle Speed Spring4. Screw5. Ground Lead6. Retaining Washer7.

5.30Section 5Fuel System and GovernorFigure 5-66. Governor Controls and Linkage(External).Initial AdjustmentNOTE: EFI engines require a special initia

5.31Section 5Fuel System and Governor5Sensitivity AdjustmentGovernor sensitivity is adjusted by repositioning thegovernor spring in the holes of the g

5.32Section 5Fuel System and GovernorChoke Lever DetailFigure 5-68. Governor Used with Commercial Mower Air Cleaner (CV17-745).Commercial Mower Govern

5.33Section 5Fuel System and Governor5WasherLock NutChoke LinkageBushingSpacerSpringWasherChokeCableClampand ScrewControlBracketScrewSpringWasherHex N

5B.1Section 5BEFI Fuel System5BSection 5BElectronic Fuel Injection (EFI)Fuel SystemContents Page(s)DescriptionInitial Starting/Priming Procedure ...

5B.2Section 5BEFI Fuel SystemWARNING: Explosive Fuel!Gasoline is extremely flammable and its vapors can explodeif ignited. Store gasoline only in appr

1.5Section 1Safety and General Information1¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.²Only require

5B.3Section 5BEFI Fuel System5BGasoline/Alcohol blendsGasohol (up to 10% ethyl alcohol, 90% unleadedgasoline by volume) is approved as a fuel for Kohl

5B.4Section 5BEFI Fuel SystemDuring certain operating periods such as cold starts,warm up, acceleration, etc., an air/fuel ratio richerthan 14.7:1 is

5B.5Section 5BEFI Fuel System5BTwo different ECU styles have been used in CV EFIproduction. Each has a plastic case, but they differ inhaving a 24 pin

5B.6Section 5BEFI Fuel SystemGeneralThe engine speed sensor is essential to engineoperation; constantly monitoring the rotational speed(RPM) of the cr

5B.7Section 5BEFI Fuel System5BGeneralThe throttle position sensor (TPS) is used to indicatethrottle plate angle to the ECU. Since the throttle (byway

5B.8Section 5BEFI Fuel SystemFigure 5B-7. Service Connector Plug, PlasticCased ECU Harness.8. Hold the throttle against the idle speed stopscrew, turn

5B.9Section 5BEFI Fuel System5B11. Reconnect the battery cable and all external loads.Remove the rubber band from the throttle lever.Readjust the idle

5B.10Section 5BEFI Fuel SystemOxygen SensorGeneralThe engine (oil) temperature sensor (Figure 5B-8) isused by the system to help determine fuelrequire

5B.11Section 5BEFI Fuel System5BThe oxygen sensor can function only after beingheated by exhaust temperatures to a minimum of375°C (709°F). A cold oxy

5B.12Section 5BEFI Fuel Systemb. If the resistance is less than 1.0 MΩΩΩΩΩ, thesensor is bad, replace it.5. With the oxygen sensor disconnected andeng

1.6Section 1Safety and General InformationFigure 1-4. Typical Engine Dimensions CV Series with Standard Flat Air Cleaner.Dimensions in millimeters.Inc

5B.13Section 5BEFI Fuel System5BFigure 5B-12. Relay Connector.3. Set meter for DC voltage. Touch red tester leadto the #30 terminal in relay connector

5B.14Section 5BEFI Fuel System1. Filter Strainer InFuel Supply2. Electrical Connection3. Solenoid WindingMulti-OrificeDirector Plate WithCalibrated Op

5B.15Section 5BEFI Fuel System5BFigure 5B-18. Volt Noid Light.1. Disconnect the electrical connector from bothinjectors. Plug a 12 volt noid light (pa

5B.16Section 5BEFI Fuel System10. Remove the manifold mounting bolts and separatethe throttle body/manifold from the engineleaving the TPS, fuel rail,

5B.17Section 5BEFI Fuel System5BIgnition SystemGeneralA high-voltage, solid-state, battery ignition system isused with the EFI system. The ECU control

5B.18Section 5BEFI Fuel SystemSpark PlugsEFI engines are equipped with Champion® RC12YC(Kohler Part No. 12 132 02-S) resistor spark plugs.Equivalent a

5B.19Section 5BEFI Fuel System5Bpump preventing the continued delivery of fuel. Inthis situation, the MIL will go on, but it will go backoff after 4 c

5B.20Section 5BEFI Fuel SystemFigure 5B-26. Fuel Pressure Regulator Details.ServiceDepending on the application, the regulator may belocated in the fu

5B.21Section 5BEFI Fuel System5BFuel Rail6. Install the new regulator by carefully pushingand rotating it slightly into the base or housing.a. Externa

5B.22Section 5BEFI Fuel SystemGeneralSpecial low permeation high-pressure fuel line withan SAE 30 R9 rating is required for safe and reliableoperation

1.7Section 1Safety and General Information1Figure 1-5. Typical Engine Dimensions CV Series with Commercial Mower Air Cleaner.Dimensions in millimeters

5B.23Section 5BEFI Fuel System5BFigure 5B-33. Idle Speed Screw Details.Initial Governor AdjustmentThe initial governor adjustment is especially critic

5B.24Section 5BEFI Fuel SystemFigure 5B-37. Throttle Link in Center of Hole.Figure 5B-36. Inserting Feeler Gauge (EnginesWithout Stop Screw).b. On eng

5B.25Section 5BEFI Fuel System5B4. Verify that the governor has been set correctly.With the linkage still retained in the “FullThrottle” position (Ste

5B.26Section 5BEFI Fuel SystemElectrical SystemThe EFI system is a 12 VDC negative ground system,designed to operate down to a minimum of 7.0 volts.If

5B.29Section 5BEFI Fuel System5B“32 Pin” (MSE 1.1) Plastic-Cased ECU SystemsPin #1234567891011121314151617181920212223242526272829303132FunctionPerman

5B.30Section 5BEFI Fuel SystemFuel SystemWARNING: Fuel System Under Pressure!The fuel system operates under high pressure. Systempressure must be reli

5B.31Section 5BEFI Fuel System5BLong PauseShort PauseCode 3232Code 6116Long PauseLight remains on at end of transmission1. Diagnostic display initiate

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