Kohler COMMAND CV17-745 User manual

SERVICE MANUAL
VERTICAL CRANKSHAFT
COMMAND CV17-745
Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
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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...........................................................................................................
2
1
4
5
3
5B
8
9
10
11
6
7
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1.1
Section 1
Safety and General Information
Section 1
Safety and General Information
Safety Precautions
To ensure safe operation please read the following statements and understand their meaning.Also
refer to your equipment manufacturer's manual for other important safety information.This manual
contains safety precautions which are explained below. Please read carefully.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow 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, and
clothing away from all moving
parts to prevent injury. Never
operate the engine with covers,
shrouds, or guards removed.
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
WARNING
Hot Parts!
Engine components can get
extremely hot from operation. To
prevent severe burns, do not
touch these areas while the
engine is running—or immediately
after it is turned off. Never operate
the engine with heat shields or
guards removed.
Accidental Starts can cause
severe injury or death.
Disconnect and ground spark plug
leads before servicing.
WARNING
Accidental Starts!
Disabling engine. Accidental
starting can cause severe injury
or death. Before working on the
engine or equipment, disable the
engine as follows: 1) Disconnect the
spark plug lead(s). 2) Disconnect
negative (-) battery cable from
battery.
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1.2
Section 1
Safety and General Information
Carbon Monoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
WARNING WARNING
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
CAUTION
Uncoiling Spring can cause severe
injury.
Wear safety goggles or face
protection when servicing retractable
starter.
WARNING
Explosive Gas can cause fires and
severe acid burns.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.
Lethal Exhaust Gases!
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.Avoid inhaling exhaust
fumes, and never run the engine
in a closed building or confined
area.
Spring Under Tension!
Retractable starters contain a
powerful, recoil spring that is under
tension. Always wear safety
goggles when servicing retractable
starters and carefully follow
instructions in "Retractable Starter"
Section 7 for relieving spring
tension.
Explosive Gas!
Batteries produce explosive
hydrogen gas while being
charged. To prevent a fire or
explosion, charge batteries only in
well ventilated areas. Keep
sparks, open flames, and other
sources of ignition away from the
battery at 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 at the ground cable
terminal which could cause an
explosion if hydrogen gas or
gasoline vapors are present.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
WARNING
Explosive Fuel!
Gasoline is extremely flammable
and its vapors can explode if
ignited. Store gasoline only in
approved 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
with hot parts or sparks from
ignition. Do not start the engine
near spilled fuel. Never use
gasoline as a cleaning agent.
Cleaning Solvents can cause
severe injury or death.
Use only in well ventilated areas
away from ignition sources.
WARNING
Flammable Solvents!
Carburetor cleaners and solvents
are extremely flammable. Keep
sparks, flames, and other sources
of ignition away from the area.
Follow the cleaner manufacturer’s
warnings and instructions on its
proper and safe use. Never use
gasoline as a cleaning agent.
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1.3
Section 1
Safety and General Information
Engine Identification Numbers
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification and Serial Numbers, including letter
suffixes if there are any.
The engine identification numbers appear on a decal,
or decals, affixed to the engine shrouding. See Figure
1-1.An explanation of these numbers is shown in
Figure 1-2.
Figure 1-1. Engine Identification Decal Location.
Figure 1-2. Explanation of Engine Identification Numbers.
A. Model No.
Version Code
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
Variation of
Basic Engine
B. Spec. No. 61500
Engine Model Code
Code Model
72 CV17
61 CV18
65 CV20
67 CV22 (624 cc)
69 CV25
75 CV22/23 (674 cc)
79 CV26
CV730-0001
CV740-0001
CV745-0001
Complete Spec Number
(IncorporatingModel
No. with Variation No. of
Basic Spec.)
or
C. Serial No.
Year Manufactured Code
Code Model
21 1991
22 1992
23 1993
24 1994
25 1995
26 1996
27 1997
28 1998
Factory Code
3305810334
Code Model
29 1999
30 2000
31 2001
32 2002
33 2003
34 2004
35 2005
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1.4
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
daily and changing oil regularly. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure.
Oil Type
Use high-quality detergent oil of API (American
Petroleum Institute) Service Class SG, SH, SJ or
higher. Select the viscosity based on the air
temperature at the time of operation as shown in the
followingtable.
Refer to Section 6 - “Lubrication System” for detailed
procedures on checking the oil, changing the oil and
changing the oil filter.
Fuel Recommendations
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can
explode if ignited. Before servicing the fuel system,
make sure there are no sparks, open flames or other
sources of ignition nearby as these can ignite gasoline
vapors. Disconnect and ground the spark plug leads to
prevent the possibility of sparks from the ignition system.
General Recommendations
Purchase gasoline in small quantities and store in clean,
approved containers.Acontainer with a capacity of 2
gallons or less with a pouring spout is recommended.
Such a container is easier to handle and helps eliminate
spillage during refueling.
Do not use gasoline left over from the previous season,
to minimize gum deposits in your fuel system and to
ensureeasy starting.
Do not add oil to the gasoline.
Do not overfill the fuel tank. 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 be 90 octane minimum.
Unleaded gasoline is recommended as it leaves less
combustion chamber deposits and reduces harmful
exhaust emissions. Leaded gasoline is not
recommended and must not be used on EFI engines,
or on other models where exhaust emissions are
regulated.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
NOTE: Using other than service class SG, SH, SJ or
higher oil or extending oil change intervals
longer than recommended can cause engine
damage.
NOTE: Synthetic oils meeting the listed
classifications may be used with oil changes
performed at the recommended intervals.
However to allow piston rings to properly seat,
a new or rebuilt engine should be operated for
at least 50 hours using standard petroleum
based oil before switching to synthetic oil.
Alogo or symbol on oil containers identifies theAPI
service class and SAE viscosity grade. See Figure 1-3.
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 40°F.
**Synthetic oils will provide better starting in extreme cold
(below -10°F).
*
**
Figure 1-3. Oil Container Logo.
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1.5
Section 1
Safety and General Information
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
²Have a Kohler Engine Service Dealer perform this service.
³Cleanout Kits 25 755 20-S (black) or 25 755 21-S (gold) allow cooling areas to be cleaned without removing shrouds.
Storage
If the engine will be out of service for two months or
more, use the following storage procedure.
1. Clean the exterior surfaces of the engine. On
Electronic Fuel Injected (EFI) engines, avoid
spraying water at the wiring harness or any of the
electrical components.
2. Change the oil and oil filter while the engine is still
warm from operation. See “Change Oil and Oil
Filter” in Section 6.
3. The fuel system must be completely emptied, or
the gasoline must be treated with a stabilizer to
prevent deterioration. If you choose to use a
stabilizer, follow the manufacturer’s
recommendations, and add the correct amount
for the capacity of the fuel system.
Fill the fuel tank with clean, fresh gasoline. Run
the engine for 2 to 3 minutes to get stabilized fuel
into the rest of the system. Close the fuel shut-off
valve when the unit is being stored or transported.
To empty the system, run the engine until the tank
and the system is empty.
4. Remove the spark plugs and add one tablespoon
of engine oil into each spark plug hole. Install the
spark plugs, but do not connect the plug leads.
Crank the engine two or three revolutions.
5. On equipment with an EFI engine, 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 engine. Accidental starting can cause severe injury or death. Before working on the engine or
equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-)
battery cable from battery.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table.They should
also be included as part of any seasonal tune-up.
• Replace fuel filter1(EFI engines). Section 5B
Daily or Before
Starting Engine
Maintenance Required Refer to:Frequency • Fill fuel tank. Section 5
• Check oil level. Section 6
• Check air cleaner for dirty1, loose, or damaged parts. Section 4
• Check air intake and cooling areas, clean as necessary1. Section 4
• Service precleaner element1. Section 4
Every 25 Hours • Replace air cleaner element1. Section 4
• Change oil. (More frequently under severe conditions.) Section 6
• Remove cooling shrouds and clean cooling areas1,3. Section 4
• Check oil cooler fins, clean as necessary (if equipped). Section 6
• Check spark plug condition and gap. Section 8
• Change oil filter. Section 6
Annually or
Every 500 Hours • Have bendix starter drive serviced2. Section 8
• Have solenoid shift starter disassembled and cleaned2. Section 8
Every 100 Hours
Every 200 Hours
Every 1500 Hours • Have crankshaft spline lubricated2. Section 2
Every 500 Hours
Every 250 Hours • Replace heavy-duty air cleaner element and check inner element1. Section 4
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1.6
Section 1
Safety and General Information
Figure 1-4. Typical Engine Dimensions CV Series with Standard Flat Air Cleaner.
(Baseengineillustrated)
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1.7
Section 1
Safety and General Information
Figure 1-5. Typical Engine Dimensions CV Series with Commercial Mower Air Cleaner.
(Baseengineillustrated)
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1.8
Section 1
Safety and General Information
Figure 1-6. Typical Engine Dimensions CV EFI Series with Heavy-Duty Air Cleaner.
Dimensions in millimeters.
Inch equivalents shown in ().
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1.9
Section 1
Safety and General Information
General Specifications1
Power (@ 3600 RPM, corrected to SAE J1995)
CV17............................................................................................................................12.7 kW (17 HP)
CV18............................................................................................................................13.4 kW (18 HP)
CV20............................................................................................................................14.9 kW (20 HP)
CV22/23 .......................................................................................................................16.4 kW (22 HP)
CV25, CV730 ...............................................................................................................18.4 kW (25 HP)
CV26............................................................................................................................19.4 kW (26 HP)
CV740 ..........................................................................................................................20.1 kW (27 HP)
CV745 ..........................................................................................................................20.9 kW (28 HP)
Peak Torque
CV17 - @ 2000 RPM ...................................................................................................42.9 N·m (31.7 ft. lb.)
CV18 - @ 2200 RPM ...................................................................................................44.4 N·m (32.8 ft. lb.
CV20 - @ 2600 RPM ...................................................................................................44.2 N·m (32.6 ft. lb.)
CV22/23 - @ 2200 RPM ..............................................................................................51.7 N·m (38.2 ft. lb.)
CV25, CV730 - @ 2800 RPM.......................................................................................54.1 N·m (39.9 ft. lb.)
CV26 - @ 2800 RPM ...................................................................................................54.2 N·m (40.0 ft. lb.)
CV740 - @ 3000 RPM .................................................................................................57.9 N·m (42.7 ft. lb.)
CV745 - @ 2200 RPM .................................................................................................60.7 N·m (44.8 ft. lb.)
Bore
CV17............................................................................................................................73 mm (2.87 in.)
CV18, CV20, CV22 (624 cc) ........................................................................................77 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.)
CV25, CV26, CV730-745 .............................................................................................725 cc (44 cu. in.)
CompressionRatio
CV17 ............................................................................................................................8.2:1
CV18, CV20,CV22/23 ..................................................................................................8.5:1
CV25, CV26, CV730-745 .............................................................................................9.0:1
Dry Weight
CV17, CV18, CV20, CV22/23 ......................................................................................41 kg (90 lb.)
CV25, CV26, CV730-745 .............................................................................................43 kg (94 lb.)
Oil Capacity (with filter)
CV17, CV18, CV20, CV22/23
CV25, CV26, CV730-745 .............................................................................................1.9 L (2.0 U.S. qt.)
Angle of Operation - Maximum (At Full Oil Level)All Directions .........................................25°
Blower Housing and Sheet Metal
M5FastenersTorque ..................................................................................4.0 N·m (35 in. lb.)
1Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior
to assembly.
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1.10
Section 1
Safety and General Information
Blower Housing and Sheet Metal cont.
M6FastenersTorque ..................................................................................6.8 N·m (60 in. lb.)
Rectifier-Regulator Fastener Torque ...........................................................4.0 N·m (35 in. lb.)
Camshaft
End Play (With Shim) .................................................................................0.076/0.127 mm (0.0030/0.0050 in.)
Running Clearance .....................................................................................0.025/0.063 mm (0.0010/0.0025 in.)
Bore I.D.
New......................................................................................................20.000/20.025 mm (0.7874/0.7884 in.)
Max. Wear Limit ...................................................................................20.038 mm (0.7889 in.)
Camshaft Bearing Surface O.D.
New......................................................................................................19.962/19.975 mm (0.7859/0.7864 in.)
Max. Wear Limit ...................................................................................19.959 mm (0.7858 in.)
Carburetor and Intake Manifold
Intake Manifold Mounting Fastener Torque
Torque in Two Stages ...........................................................................initially to 7.4 N·m (66 in. lb.)
finally to 9.9 N·m (88 in. lb.)
Carburetor Mounting Nut Torque ................................................................6.2-7.3 N·m (55-65 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-Crankpin Running Clearance
New......................................................................................................0.030/0.055 mm (0.0012/0.0022 in.)
Max. Wear Limit ...................................................................................0.070 mm (0.0028 in.)
Connecting Rod-to-Crankpin Side Clearance .............................................0.26/0.63 mm (0.0102/0.0248 in.)
Connecting Rod-to-Piston Pin Running Clearance .....................................0.015/0.028 mm (0.0006/0.0011 in.)
Piston Pin End I.D.
New......................................................................................................17.015/17.023 mm (0.6699/0.6702 in.)
Max. Wear Limit ...................................................................................17.036 mm (0.6707 in.)
Crankcase
Governor Cross Shaft Bore I.D.
6 mm Shaft
New ..................................................................................................6.025/6.050 mm (0.2372/0.2382 in.)
Max. Wear Limit................................................................................6.063 mm (0.2387 in.)
8 mm Shaft
New ..................................................................................................8.025/8.075 mm (0.3159/0.3179 in.)
Max. Wear Limit................................................................................8.088 mm (0.3184 in.)
BreatherCoverFastenerTorque ..................................................................7.3 N·m (65 in. lb.)
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1.11
Section 1
Safety and General Information
Crankcase cont.
OilDrainPlugTorque ..................................................................................13.6 N·m (10 ft. lb.)
Oil Pan
Oil Pan Fastener Torque.............................................................................24.4 N·m (216 in. lb.)
Crankshaft
End Play (Free) ..........................................................................................0.070/0.590 mm (0.0028/0.0230 in.)
Crankshaft Bore (In Crankcase)
New......................................................................................................40.965/41.003 mm (1.6128/1.6143 in.)
Max. Wear Limit ...................................................................................41.016 mm (1.6148 in.)
Crankshaft to Sleeve Bearing (Crankcase)
Running Clearance - New ....................................................................0.03/0.09 mm (0.0012/0.0035 in.)
Crankshaft Bore (In Oil Pan) - New ............................................................40.987/40.974 mm (1.6136/1.6131 in.)
Crankshaft Bore (In Oil Pan)-to-Crankshaft
Running Clearance - New ....................................................................0.039/0.074 mm (0.0015/0.0029 in.)
Flywheel End Main Bearing Journal
O.D. - New ...........................................................................................40.913/40.935 mm (1.6107/1.6116 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.)
Oil Pan End Main Bearing Journal
O.D. - New ...........................................................................................40.913/40.935 mm (1.6107/1.6116 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 Limit ........................................................................35.94 mm (1.415 in.)
Max. Taper ...........................................................................................0.018 mm (0.0007 in.)
Max. Out-of-Round ..............................................................................0.025 mm (0.0010 in.)
Crankshaft T.I.R.
PTO End, Crank in Engine...................................................................0.279 mm (0.0110 in.)
Entire Crank, in V-Blocks .....................................................................0.10 mm (0.0039 in.)
Cylinder Bore
CylinderBoreI.D.
New-CV17 ..........................................................................................73.006/73.031mm(2.8742/2.8752in.)
New - CV18, CV20, CV22 (624 cc) .......................................................77.000/77.025mm(3.0315/3.0325in.)
New - CV22/23 (674 cc).......................................................................80.000/80.025 mm (3.1496/3.1506 in.)
New-CV25,CV26, CV730-745 ............................................................82.988/83.013mm(3.2672/3.2682in.)
Max. Wear Limit - CV17 .......................................................................73.070mm(2.8757in.)
Max. Wear Limit - CV18, CV20, CV22 (624 cc) ....................................77.063 mm (3.0340 in.)
Max. Wear Limit - CV22/23 (674 cc) ....................................................80.065 mm (3.1522 in.)
Max. Wear Limit - CV25, CV26, CV730-745 .........................................83.051 mm (3.2697 in.)
Max. Out-of-RoundCV17 ......................................................................0.13mm (0.0051 in.)
Max.Out-of-RoundCV18-745 ...............................................................0.12 mm(0.0047 in.)
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1.12
Section 1
Safety and General Information
Cylinder Bore cont.
Max.Taper............................................................................................0.05 mm(0.0020 in.)
Cylinder Head
CylinderHead FastenerTorque
Hex.Flange Nut -Torque in TwoStages.......................................... initially to 16.9 N·m (150 in. lb.)
finally to 33.9 N·m (300 in. lb.)
Head Bolt - Torque in Two Stages .................................................. initially to 22.6 N·m (200 in. lb.)
finally to 41.8 N·m (370 in. lb.)
Max. Out-of-Flatness............................................................................ 0.076 mm (0.003 in.)
Rocker Arm Screw Torque.................................................................... 11.3 N·m (100 in. lb.)
Fan/Flywheel
Fan Fastener Torque ............................................................................ 9.9 N·m (88 in. lb.)
Flywheel Retaining ScrewTorque......................................................... 66.4 N·m (49 ft. lb.)
Governor
Governor Cross Shaft-to-Crankcase Running Clearance
6 mm Shaft .................................................................................... 0.013/0.075 mm (0.0005/0.0030 in.)
8 mm Shaft .................................................................................... 0.025/0.126 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 (0.3124 in.)
Governor Gear Shaft-to-Governor
Gear Running Clearance................................................................ 0.015/0.140 mm (0.0006/0.0055 in.)
Governor Gear Shaft O.D.
New................................................................................................ 5.990/6.000 mm (0.2358/0.2362 in.)
Max. Wear Limit ............................................................................. 5.977 mm (0.2353 in.)
Governor Lever Nut Torque .................................................................. 6.8 N·m (60 in. lb.)
Ignition
Spark Plug Type (Champion®or Equivalent)......................................... RC12YC or Platinum 3071
Spark Plug Gap .................................................................................... 0.76 mm (0.030 in.)
Spark Plug Torque ................................................................................ 24.4-29.8 N·m (18-22 ft. lb.)
Ignition ModuleAir Gap ........................................................................ 0.28/0.33 mm (0.011/0.013 in.)
IgnitionModule FastenerTorque............................................................ 4.0-6.2N·m(35-55 in. lb.)
Speed SensorAir Gap(EFI engines) ..................................................... 1.250/1.750mm (0.049/0.068 in.)
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1.13
Section 1
Safety and General Information
Muffler
MufflerRetainingNutsTorque................................................................ 24.4 N·m (216 in. lb.)
Oil Filter
OilFilterTorque..................................................................................... 10.4-12.7N·m (90-110in.lb.)
Oil Cooler
Oil Cooler/Adapter Nipple Torque ......................................................... 27 N·m (20 ft. lb.)
Piston, Piston Rings, and Piston Pin
Piston-to-Piston Pin Running Clearance............................................... 0.006/0.017 mm (0.0002/0.0007 in.)
Piston Pin Bore I.D.
New................................................................................................ 17.006/17.012 mm (0.6695/0.6698 in.)
Max. Wear Limit............................................................................. 17.025 mm (0.6703 in.)
Piston Pin O.D.
New................................................................................................ 16.995/17.000 mm (0.6691/0.6693 in.)
Max. Wear Limit............................................................................. 16.994 mm (0.6691 in.)
TopCompressionRing-to-GrooveSide Clearance
CV17 .............................................................................................. 0.040/0.085mm(0.0016/0.0033in.)
CV18,CV20, CV22 (624 cc) ........................................................... 0.040/0.080mm(0.0016/0.0031in.)
CV22/23(674cc)............................................................................ 0.030/0.076mm(0.0012/0.0030in.)
CV25,CV26, CV730-745 ................................................................ 0.025/0.048 mm (0.0010/0.0019 in.)
MiddleCompression Ring-to-GrooveSideClearance
CV17 .............................................................................................. 0.030/0.080mm(0.0012/0.0031in.)
CV18,CV20, CV22 (624 cc) ........................................................... 0.040/0.080mm(0.0016/0.0031in.)
CV22/23(674cc)............................................................................ 0.030/0.076mm(0.0012/0.0030in.)
CV25,CV26, CV730-745 ................................................................ 0.015/0.037 mm (0.0006/0.0015 in.)
OilControl Ring-to-GrooveSideClearance
CV17 .............................................................................................. 0.046/0.201mm(0.0018/0.0079in.)
CV18,CV20, CV22 (624 cc) ........................................................... 0.060/0.202mm(0.0024/0.0080in.)
CV22/23(674cc)............................................................................ 0.046/0.196mm(0.0018/0.0077in.)
CV25,CV26, CV730-745 ................................................................ 0.026/0.176 mm (0.0010/0.0070 in.)
Top and Middle Compression RingEnd Gap
NewBore-CV17
TopRing ..................................................................................... 0.180/0.380mm(0.0071/0.0150in.)
MiddleRing ................................................................................ 0.180/0.440 mm (0.0071/0.0173 in.)
New Bore - CV18, CV20, CV22 (624 cc)......................................... 0.25/0.45 mm (0.0098/0.0177 in.)
NewBore - CV22 (674cc) .............................................................. 0.18/0.46mm(0.0071/0.0181in.)
New Bore- CV25,CV26, CV730-745 .............................................. 0.25/0.56mm (0.0100/0.0224 in.)
UsedBore (Max.) - CV17
TopRing ..................................................................................... 0.70mm (0.028 in.)
MiddleRing ................................................................................ 0.90 mm(0.035 in.)
Used Bore (Max.) - CV18, CV20, CV22 (624 cc)............................. 0.77 mm (0.030 in.)
Used Bore (Max.) - CV22/23 (674 cc) ............................................. 0.80 mm(0.0315in.)
UsedBore(Max.)- CV25, CV26, CV730-745.................................. 0.94 mm (0.037 in.)
Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
www.mymowerparts.com

1.14
Section 1
Safety and General Information
Piston, Piston Rings, and Piston Pin cont.
Piston Thrust Face O.D.²
New-CV17 .................................................................................... 72.966/72.984 mm (2.8727/2.8734 in.)
New - CV18, CV20, CV22 (624 cc) ................................................. 76.967/76.985 mm (3.0302/3.0309 in.)
New-CV22/23 (674 cc).................................................................. 79.963/79.979mm (3.1481/3.1488 in.)
New-CV25,CV26, CV730-745 ...................................................... 82.986 mm (3.3194in.)
Max. Wear Limit - CV17 ................................................................. 72.839 mm (2.8677in.)
Max. Wear Limit - CV18, CV20, CV22 (624 cc) .............................. 76.840 mm (3.0252 in.)
Max. Wear Limit - CV22 (674 cc).................................................... 79.831mm(3.1430in.)
Max. Wear Limit - CV25, CV26, CV730-745 ................................... 82.841 mm (3.3136 in.)
PistonThrustFace-to-Cylinder Bore² Running Clearance
New-CV17 .................................................................................... 0.022/0.065 mm (0.0009/0.0026 in.)
New - CV18, CV20, CV22 (624 cc) ................................................. 0.014/0.057 mm (0.0005/0.0022 in.)
New-CV22/23 (674 cc).................................................................. 0.021/0.062mm(0.0008/0.0024in.)
New-CV25,CV26, CV730-745 ...................................................... 0.001/0.045 mm (0.039/0.0018 in.)
Speed Control Bracket
Fastener Torque ................................................................................... 7.3-10.7 N·m (65-95 in. lb.)
Starter Assembly
Thru Bolt Torque
UTE/Johnson 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.)
Brush Holder Mounting Screw Torque
Delco-Remy Starter........................................................................ 2.5-3.3 N·m (22-29 in. lb.)
Solenoid (Starter)
Mounting Hardware Torque
NippondensoStarter .......................................................................6.0-9.0 N·m (53-79 in. lb.)
Delco-Remy Starter.........................................................................4.0-6.0 N·m (35-53 in. lb.)
Nut, Positive (+) Brush Lead Torque
NippondensoStarter ........................................................................8.0-12.0N·m (71-106 in. lb.)
Delco-RemyStarter .........................................................................8.0-11.0 N·m (71-97in.lb.)
Stator
Mounting Screw Torque ........................................................................ 6.2 N·m (55 in. lb.)
Throttle/Choke Controls
Governor Control Lever Fastener Torque ............................................. 9.9 N·m (88 in. lb.)
Valve Cover
ValveCoverFastenerTorque
Gasket Style Cover ........................................................................ 3.4 N·m (30 in. lb.)
BlackO-RingStyle Cover
w/ShoulderScrews .................................................................... 5.6 N·m (50 in. lb.)
w/FlangeScrewsandSpacers ................................................... 9.9 N·m (88 in. lb.)
BrownO-RingStyleCoverw/IntegralMetalSpacers........................ 9.9 N·m (88 in. lb.)
²Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.
Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
www.mymowerparts.com

1.15
Section 1
Safety and General Information
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications
Valves and Valve Lifters
HydraulicValveLiftertoCrankcaseRunningClearance ..........................0.0241/0.0501mm (0.0009/0.0020 in.)
IntakeValveStem-to-Valve GuideRunningClearance ............................ 0.038/0.076mm(0.0015/0.0030in.)
ExhaustValveStem-to-ValveGuide Running Clearance ........................ 0.050/0.088 mm (0.0020/0.0035in.)
IntakeValveGuide I.D.
New................................................................................................ 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit............................................................................. 7.135 mm (0.2809 in.)
ExhaustValveGuideI.D.
New ................................................................................................ 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit ............................................................................. 7.159mm (0.2819 in.)
ValveGuide ReamerSize
Standard ......................................................................................... 7.048 mm (0.2775in.)
0.25 mm O.S.................................................................................. 7.298 mm (0.2873 in.)
IntakeValve Minimum Lift...................................................................... 8.07mm(0.3177 in.)
ExhaustValveMinimum Lift .................................................................. 8.07mm(0.3177 in.)
Nominal Valve SeatAngle..................................................................... 45°
Tightening Torque: N·m (in. lb.) + or - 10%
Property Class Noncritical
Fasteners
IntoAluminum
Size
M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
Tightening Torque: N·m (ft. lb.) + or - 10%
Property Class Noncritical
Fasteners
IntoAluminum
M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 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)
5.8 8.8 10.9 12.9
4.8 5.8 10.9 12.9
4.8
8.8
Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
www.mymowerparts.com

1.16
Section 1
Safety and General Information
English Fastener Torque Recommendations for Standard Applications
Grade 2 or 5
Fasteners Into
Aluminum
Size
8-32 2.3 (20) 2.8 (25) --------- 2.3 (20)
10-24 3.6 (32) 4.5 (40) --------- 3.6 (32)
10-32 3.6 (32) 4.5 (40) --------- ---------
1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)
1/4-28 9.6 (85) 15.8 (140) 22.6 (200) ---------
5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)
5/16-24 18.7 (165) 30.5 (270) --------- ---------
3/8-16 29.4 (260) --------- --------- ---------
3/8-24 33.9 (300) --------- --------- ---------
Size
5/16-24 --------- ---------- 40.7 (30) ---------
3/8-16 --------- 47.5 (35) 67.8 (50) ---------
3/8-24 --------- 54.2 (40) 81.4 (60) ---------
7/16-14 47.5 (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 (230) ---------
5/8-11 149.2 (110) 244.1 (180) 352.6 (260) ---------
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) ---------
3/4-10 199.3 (150) 332.2 (245) 474.6 (350) ---------
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) ---------
Tightening Torque: N·m (ft. lb.) + or - 20%
Tightening Torque: N·m (in. lb.) + or - 20%
Grade 2 Grade 5 Grade 8
Bolts, Screws, Nuts and Fasteners
Assembled Into Cast Iron or Steel
N·m = in. lb. x 0.113
N·m = ft. lb. x 1.356
in. lb. = N·m x 8.85
ft. lb. = N·m x 0.737
Torque
Conversions
Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
www.mymowerparts.com

2.1
Section 2
Special Tools
Section 2
Special Tools
CV17-745
Some special tools for this engine are:
Camshaft Endplay Plate........................................................................................ KO1031
Flywheel Strap Wrench ......................................................................................... NU10357
Flywheel Puller Kit................................................................................................. NU3226
Rocker Arm Spanner Wrench................................................................................ OEM6200
Valve Guide Reamer ............................................................................................. KO1026
Water Manometer ................................................................................................. KO1048
Cylinder Leakdown Tester ..................................................................................... KO3219
Ignition System Tester ........................................................................................... KO1046
Hydraulic Lifter Removal/Reinstallation Tool.......................................................... KO1044
Starter Service Kit ................................................................................................. KO3226
Starter Retaining Ring Tool.................................................................................... 25 761 18-S
Vacuum Gauge ..................................................................................................... KO3223
Tachometer (Digital Inductive)............................................................................... KO3216
SparkAdvance Module (SAM) Tester.................................................................... KO3222
Rectifier-RegulatorTester ..................................................................................... KO3221
Electronic Fuel Injection (EFI) Service Tools
EFI Service Kit ...................................................................................................... KO3217
GaugeAssembly ............................................................................................... KO3217-4
Pliers................................................................................................................. KO3217-5
Circuit Tester ..................................................................................................... KO3217-6
Jumper Plug, Red (for metal cased ECU) ......................................................... KO3217-7
Tee Valve Assembly .......................................................................................... KO3217-8
Jumper Plug, 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-2546. The tool price list is available under Kohler Part
No. TP-2547.
Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures.
By using tools designed for the job, you can service engines easier, faster, and safer! In addition, you’ll increase
your service capabilities and customer satisfaction by decreasing engine downtime.
Kohler special tools are handled by SPX Corp., a division of Owatonna Tool Corp. (OTC). The tools are easy to
purchase by contacting SPX/OTC by phone, fax, or mail.
Phone: [phone]
International:1-507-455-7223
8:00 am – 8:00 pm EST
Fax: [phone]
1-586-578-7375
International:1-507-455-7063
Mail: SPX Corp., OTC
28635 Mound Rd.
Warren, MI 48092-3499
Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
www.mymowerparts.com

2.2
Section 2
Special Tools
Figure 2-1. Tool Catalog and Price List.
Special Tools You Can Make
Flywheel Holding Tool
Flywheel removal and reinstallation becomes a “snap”
using a handy holding tool which can be made out of
an old “junk” flywheel ring gear as shown in Figure 2-2.
Using an abrasive cut-off wheel, cut out a six tooth
segment of the ring gear as shown. Grind off any burrs
or sharp edges. The segment can be used in place of
a strap wrench. Invert the segment and place it
between the ignition bosses on the crankcase so that
the tool teeth engage the flywheel ring gear teeth. The
bosses will “lock” the tool and flywheel in position for
loosening, tightening or removing with a puller.
Figure 2-2. Flywheel Holding Tool.
RockerArm/Crankshaft Tool
If a spanner wrench to lift the rocker arms or turn the
crankshaft is not available, a tool may be made for
doing this out of 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, so the joint surface is flat. Find a 1
in. long capscrew with the correct thread size to match
the threads in the connecting rod. Obtain a flat washer
with the correct I.D. to slip on the capscrew and an
O.D. of approximately 1 in. or use Kohler Part No.
12 468 05.Assemble the capscrew and washer to the
joint surface of the rod, as shown in Figure 2-3.
Figure 2-3. Rocker Arm/Crankshaft Tool.
Cylinder Leakdown Tester
ACylinder Leakdown Tester (SPX Part No. KO3219,
formerly Kohler 25 761 05-S) is a valuable alternate to
a compression test on these engines. See Figure 2-4.
By pressurizing the combustion chamber from an
external air source, this tool can determine if valves or
rings are leaking. Instructions for using this tester are
found in Section 3 of this manual.
Figure 2-4. Cylinder Leakdown Tester.
Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
www.mymowerparts.com