Kohler Command PRO EFI Series User manual

ECV940 & ECV980
Service Manual
KohlerEngines.com
IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.
62 690 05 Rev. E 1
2 Safety
3Maintenance
5Specifi cations
17 Tools and Aids
20 Troubleshooting
24 Air Cleaner/Intake
25 Electronic Fuel Injection (EFI) System
54 Governor System
80 Lubrication System
82 Electrical System
87 Starter System
91 Disassembly/Inspection and Service
112 Reassembly

Safety
2 62 690 05 Rev. EKohlerEngines.com
SAFETY PRECAUTIONS
WARNING: A hazard that could result in death, serious injury, or substantial property damage.
CAUTION: A hazard that could result in minor personal injury or property damage.
NOTE: is used to notify people of important installation, operation, or maintenance information.
WARNING
Explosive Fuel can cause
fi res and severe burns.
Do not fi ll fuel tank while
engine is hot or running.
Gasoline is extremely fl ammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or fl ames.
Spilled fuel could ignite if it comes
in contact with hot parts or sparks
from ignition. Never use gasoline
as a cleaning agent.
WARNING
Rotating Parts can cause
severe injury.
Stay away while engine
is in operation.
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate engine with covers,
shrouds, or guards removed.
WARNING
Carbon Monoxide can
cause severe nausea,
fainting or death.
Avoid inhaling exhaust
fumes. Never run engine
indoors or in enclosed
spaces.
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.
WARNING
Accidental Starts can
cause severe injury or
death.
Disconnect and ground
spark plug lead(s) before
servicing.
Before working on engine or
equipment, disable engine as
follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative (–)
battery cable from battery.
WARNING
Hot Parts can cause
severe burns.
Do not touch engine
while operating or just
after stopping.
Never operate engine with heat
shields or guards removed.
WARNING
Cleaning Solvents can
cause severe injury or
death.
Use only in well
ventilated areas away
from ignition sources.
Carburetor cleaners and solvents
are extremely fl ammable. Follow
cleaner manufacturer’s warnings
and instructions on its proper and
safe use. Never use gasoline as a
cleaning agent.
CAUTION
Electrical Shock can
cause injury.
Do not touch wires while
engine is running.
CAUTION
Damaging Crankshaft
and Flywheel can cause
personal injury.
Using improper procedures can
lead to broken fragments. Broken
fragments could be thrown from
engine. Always observe and use
precautions and procedures when
installing fl ywheel.
CAUTION
Failure to utilize or
reassemble debris
screen as designed could
result in debris screen
failure and serious
personal injury.
WARNING
High Pressure Fluids can
puncture skin and cause
severe injury or death.
Do not work on fuel
system without proper
training or safety
equipment.
Fluid puncture injuries are highly
toxic and hazardous. If an injury
occurs, seek immediate medical
attention.
WARNING
Explosive Fuel can
cause fi res and severe
burns.
Fuel system ALWAYS
remains under HIGH
PRESSURE.
Wrap a shop towel completely
around fuel pump module
connector. Press release button(s)
and slowly pull connector away
from fuel pump module allowing
shop towel to absorb any residual
fuel in high pressure fuel line. Any
spilled fuel must be completely
wiped up immediately.

Maintenance
362 690 05 Rev. E KohlerEngines.com
MAINTENANCE INSTRUCTIONS
WARNING
Before working on engine or equipment, disable engine as
follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark plug lead(s)
before servicing.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.
MAINTENANCE SCHEDULE
Every 100 Hours or Annually¹
● Change oil. Oil fi lter is recommended. Lubrication System
● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake
Every 150 Hours¹
● Check air cleaner element. Air Cleaner/Intake
● Replace unique Electronic Fuel Injection (EFI) fuel fi lter.
● Check oil cooler fi ns, clean as necessary. Lubrication System
Every 200 Hours
● Change oil fi lter. Lubrication System
Every 300 Hours
● Replace air cleaner element and check inner element. Air Cleaner/Intake
Every 500 Hours or Annually¹
● Replace spark plugs and set gap. Electrical System
Every 600 Hours
● Replace air cleaner inner element. Air Cleaner/Intake
1 Perform these procedures more frequently under severe, dusty, dirty conditions.
REPAIRS/SERVICE PARTS
Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized
dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance
462 690 05 Rev. EKohlerEngines.com
OIL RECOMMENDATIONS
We recommend use of Kohler oils for best performance.
Other high-quality detergent oils (including synthetic)
of API (American Petroleum Institute) service class SJ
or higher are acceptable. Select viscosity based on
air temperature at time of operation as shown in table
below.
°F -20 020324060
50 80 100
°C -30 -20 -10 0 10 20 30 40
10W-30
5W-30
SAE 30
20W-50
FUEL RECOMMENDATIONS
WARNING
Explosive Fuel can cause fi res and severe
burns.
Do not fi ll fuel tank while engine is hot or
running.
Gasoline is extremely fl ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or fl ames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
NOTE: E15, E20 and E85 are NOT approved and
should NOT be used; eff ects of old, stale or
contaminated fuel are not warrantable.
Fuel must meet these requirements:
● Clean, fresh, unleaded gasoline.
● Octane rating of 87 (R+M)/2 or higher.
● Research Octane Number (RON) 90 octane minimum.
● Gasoline up to 10% ethyl alcohol, 90% unleaded is
acceptable.
● Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blend (max 15% MTBE by volume) are
approved.
● Do not add oil to gasoline.
● Do not overfi ll fuel tank.
● Do not use gasoline older than 30 days.
STORAGE
If engine will be out of service for 2 months or more
follow procedure below.
1. Add Kohler PRO Series fuel treatment or equivalent
to fuel tank. Run engine 2-3 minutes to get stabilized
fuel into fuel system (failures due to untreated fuel
are not warrantable).
2. Change oil while engine is still warm from operation.
Remove spark plug(s) and pour about 1 oz. of
engine oil into cylinder(s). Replace spark plug(s) and
crank engine slowly to distribute oil.
3. Disconnect negative (-) battery cable.
4. Store engine in a clean, dry place.

Specifi cations
562 690 05 Rev. E KohlerEngines.com
A
B
CD
E
F
G
I
J
K
L
M
N
O
P
H
Q
A484.6 mm (19.08 in.) B
503.4 mm (19.82 in.)
Air Filter Element
Removal
C267.4 mm (10.53 in.) D152.5 mm (6.00 in.)
E99.6 mm (3.92 in.) F17.3 mm (0.68 in.)
Spark Plug Lead GCylinder #1 Shroud H
30.0 mm (1.18 in.)
Cylinder #1 Shroud
Removal
IOil Level Dipstick
and Fill JMounting Hole "A" K89.8 mm (3.54 in.) Oil Filter LCenterline Engine
M62.7 mm (2.47 in.) N20.7 mm (0.82 in.)
Spark Plug Lead O325.3 mm (12.81 in.) Oil Filter P560.3 mm (22.06 in.)
Q
93.5 mm (3.68 in.)
Air Filter Cover
Assembly Removal
Engine Dimensions - Flywheel Side

Specifi cations
662 690 05 Rev. EKohlerEngines.com
N
A
P
B
D
C
D
B
BE
F
G
H
I
B
C
B
K
J
L
M
O
A428.1 mm (16.86 in.) B45° C55° D35°
E2X Ø 35 mm (1.38 in.)
Muffl er Gasket F60 mm (2.36 in.) Exhaust Port #2 GM8 X 1.25 mm 4 Studs HØ 254.0 mm (10.0 in.)
I
M8 X 1.25-6H 25 mm
(0.98 in.) Deep 7
Holes
JRotation Direction K89.8 mm (3.54 in.) LMounting Hole "A"
M89.8 mm (3.54 in.) N275.2 mm (10.84 in.) O60.0 mm (2.36 in.)
Exhaust Port #1 P124.2 mm (4.89 in.)
Engine Dimensions - PTO Side (Earlier Design)

Specifi cations
762 690 05 Rev. E KohlerEngines.com
M
A
O
CC
B
BD
E
F
G
H
B
B
J
I
K
L
N
A428.1 mm (16.86 in.) B45° C35° D2X Ø 35 mm (1.38 in.)
Muffl er Gasket
E60 mm (2.36 in.)
Exhaust Port #2 FM8 X 1.25 mm 4 Studs GØ 254.0 mm (10.0 in.) H
3/8-16 UNF-2B Inch
30 mm (1.18 in.)
Deep 4 Holes
IRotation Direction J89.8 mm (3.54 in.) KMounting Hole "A" L89.8 mm (3.54 in.)
M275.2 mm (10.84 in.) N60.0 mm (2.36 in.)
Exhaust Port #1 O124.2 mm (4.89 in.)
Engine Dimensions - PTO Side (Later Design)

Specifi cations
862 690 05 Rev. EKohlerEngines.com
A
L K
O
N
M
J
I
H
G
F
E
D
C
B
A680.8 mm (26.80 in.) B93.5 mm (3.68 in.)
Exhaust Port #1 COil Pressure Switch DEngine Mounting Surface
E80.2 mm (3.16 in.) F6.4 mm (0.25 in.)
Square Keyway G
7/16-20 UNF-2B Inch
38.1 mm (1.50 in.)
Deep
HØ 28.6 mm (1.13 in.)
IMounting Hole "A" J
156.2 mm (6.15 in.)
Cylinder #1 Shroud
Removal
K389.8 mm (15.35 in.) L423.2 mm (16.66 in.)
MGrass Screen NCylinder #1 Shroud O50.0 mm (1.97 in.)
Oil Filter Removal
Engine Dimensions - Starter Side

Specifi cations
962 690 05 Rev. E KohlerEngines.com
A
B
C
D
E
F
G
H
I
J
K
L
M
ALifting Point BCylinder #2 Shroud CAccess to Oil Cooler D
156.2 mm (6.15 in.)
Cylinder #2 Shroud
Removal
ELifting Point F
Fuel Filter
Fits 6.4 mm (0.25 in.)
Fuel Line
G70.5 mm (2.78 in.)
Exhaust Port #2 HMounting Hole "A"
I652.3 mm (25.68 in.) JOil Drain Plug
1/2 NPT Inch KEngine Mounting Surface L2.6 mm (0.10 in.)
MMuffl er (optional)
Engine Dimensions - Opposite Starter Side

Specifi cations
10 62 690 05 Rev. EKohlerEngines.com
TORQUE SPECIFICATIONS3,5 ECV940 ECV980
Blower Housing and Sheet Metal
M6 Screw
New, Untapped Hole (casting)
Used, Tapped Hole (casting)
New, Extruded Hole (sheet metal)
Used, Extruded Hole (sheet metal)
Mounting Clip (valley baffl e)
10.7 N·m (95 in. lb.)
7.3 N·m (65 in. lb.)
2.5 N·m (22 in. lb.)
2.0 N·m (18 in. lb.)
2.5 N·m (22 in. lb.)
Intake Manifold and Air Cleaner
Intake Manifold Mounting Fastener (torque in 2 increments) fi rst to 16.9 N·m (150 in. lb.)
fi nally to 22.6 N·m (200 in. lb.)
Air Cleaner Elbow to Throttle Body Mounting Nut 7.9 N·m (70 in. lb.)
Air Cleaner Bracket Mounting Screw (into intake manifold) 11.3 N·m (100 in. lb.)
GCU Bracket to Intake Manifold & Air Cleaner Bracket 11.3 N·m (100 in. lb.)
Ground Lead to Air Cleaner Bracket 5.6 N·m (50 in. lb.)
Fuel Injector Cap Fastener 7.3 N·m (65 in. lb.)
Manifold Absolute Pressure (MAP) Sensor Fastener (Engines with
Separate MAP and Intake Air Temperature Sensors)
7.3 N·m (65 in. lb.)
Temperature/Manifold Absolute Pressure (TMAP) Sensor Fastener
(Engines with Combined Sensor)
7.3 N·m (65 in. lb.)
GENERAL SPECIFICATIONS3,6 ECV940 ECV980
Bore 90 mm (3.54 in.)
Stroke 78.5 mm (3.1 in.)
Displacement 999 cc (61 cu. in.)
Oil Capacity (refi ll) 1.9-2.6 L (2.0-2.7 U.S. qt.)
Maximum Angle of Operation (@ full oil level)425°
Model . . . . . . . . . . . . . . . . . . . . . ECV940
EFI Command Engine
Vertical Shaft
Numerical Designation
Specifi cation . . . . . . . . . . . . . . . ECV940-0001
Serial . . . . . . . . . . . . . . . . . . . . . 4623500328
Year Manufactured Code Factory Code
Code Year
46 2016
47 2017
48 2018
ENGINE IDENTIFICATION NUMBERS
Kohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair,
ordering correct parts, and engine replacement.
3 Values are in Metric units. Values in parentheses are English equivalents.
4 Exceeding maximum angle of operation may cause engine damage from insuffi cient lubrication.
5 Lubricate threads with engine oil prior to assembly.
6 Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.

Specifi cations
1162 690 05 Rev. E KohlerEngines.com
TORQUE SPECIFICATIONS3,5 ECV940 ECV980
Connecting Rod
Cap Fastener (torque in increments) 11.6 N·m (103 in. lb.)
Crankcase
Breather Cover Fastener 12.4 N·m (110 in. lb.)
Oil Drain Plug 21.4 N·m (16 ft. lb.)
Oil Temperature Sensor 7.3 N·m (65 in. lb.)
Dipstick Tube Screw 7.7 N·m (68 in. lb.)
Cylinder Head
Fastener (torque in 2 increments)
Head Bolt fi rst to 23.7 N·m (210 in. lb.)
fi nally to 46.9 N·m (415 in. lb.)
Pipe Plug 3/4 in. 28.5 N·m (252 in. lb.)
Rocker Arm Stud (AVT) 11.3 N·m (100 in. lb.)
Rocker Arm Screw (Non-AVT) 15.5 N·m (137 in. lb.)
Setscrew, AVT pivot locking 7.7 N·m (69 in. lb.)
Debris Screen
Fastener 9.9 N·m (88 in. lb.)
Hex Stud 21.5 N·m (190 in. lb.)
Mounting Screw - Hex Flange Screw 20.3 N·m (180 in. lb.)
Mounting Screw - Button Head Cap Screw 9.9 N·m (88 in. lb.)
Front Drive Shaft Screw (into fl ywheel) 24.4 N·m (216 in. lb.)
Flywheel
Fan Fastener Screw - Truss Head 10.4 N·m (92 in. lb.)
Fan Fastener Screw - Hex Head 9.9 N·m (88 in. lb.)
Flywheel Retaining Screw 69.8 N·m (51 ft. lb.)
Fuel Pump
Module Baffl e to Crankcase Fastener 11.9 N·m (105 in. lb.)
Module to Baffl e Fastener 9.2 N·m (81 in. lb.)
Pulse Pump Screw (to blower housing) 2.8 N·m (25 in. lb.)
Governor (Electronic)
Governor Control Unit (GCU) to GCU Bracket 2.1 N·m (19 in. lb.)
Digital Linear Actuator (DLA) Bracket to GCU Bracket 10.2 N·m (90 in. lb.)
DLA to DLA Bracket Screw 7.3 N·m (65 in. lb.)
Governor (Mechanical)
Lever Nut 7.1 N·m (63 in. lb.)
Yoke Mounting Screw 2.2 N·m (20 in. lb.)
Ignition
Spark Plug 27 N·m (20 ft. lb.)
Coil Fastener 5.1 N·m (45 in. lb.)
Electronic Control Unit (ECU) to Bracket Screw 6.2 N·m (55 in. lb.)
Rectifi er-Regulator Fastener 2.5 N·m (22 in. lb.)
3 Values are in Metric units. Values in parentheses are English equivalents.
5 Lubricate threads with engine oil prior to assembly.

Specifi cations
12 62 690 05 Rev. EKohlerEngines.com
TORQUE SPECIFICATIONS3,5 ECV940 ECV980
Igniton Continued
Crankshaft Position Sensor
Earlier Design Bracket
Crankshaft Position Sensor to Bracket Screw 11.3 N·m (100 in. lb.)
Crankshaft Position Sensor Bracket to Crankcase Screw 9.7 N·m (86 in. lb.)
Crankshaft Position Sensor
Later Design Bracket
Crankshaft Position Sensor to Bracket Screw 6.8 N·m (60 in. lb.)
Crankshaft Position Sensor Bracket to Crankcase Screw 7.3 N·m (65 in. lb.)
Lifter Feed Chamber Cover
Screw 6.6 N·m (58 in. lb.)
Muffl er
Retaining Nut 24.4 N·m (216 in. lb.)
Screw, intermittent bracket (into weld nut) 13.6 N·m (120 in. lb.)
M6 Screw 9.9 N·m (88 in. lb.)
M8 Screw 24.4 N·m (216 in. lb.)
Oil Cooler
Mounting Screw 2.3 N·m (21 in. lb.)
Oil Filter Adapter/Housing
Mounting Screw 23.7 N·m (210 in. lb.)
Oil Filter Nipple 17.8 N·m (158 in. lb.)
Oil Pan
Fastener 25.6 N·m (227 in. lb.)
Oil Temperature Sensor 13.6 N·m (120 in. lb.)
Oil Temperature Sensor Reducer Bushing 17.6 N·m (156 in. lb.)
Oil Temperature Sensor Nut 2.3 N·m (20 in. lb.)
Oil Pickup Screen
Mounting Screw 11.3 N·m (100 in. lb.) into a new hole
7.7 N·m (68 in. lb.) into a used hole
Oil Pump
Mounting Screw 9.9 N·m (88 in. lb.)
Oil SentryTM
Pressure Switch 10.7 N·m (95 in. lb.)
Solenoid (starter)
Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.)
Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.)
3 Values are in Metric units. Values in parentheses are English equivalents.
5 Lubricate threads with engine oil prior to assembly.

Specifi cations
1362 690 05 Rev. E KohlerEngines.com
TORQUE SPECIFICATIONS3,5 ECV940 ECV980
Starter Assembly
Thru Bolt 5.6-9.0 N·m (49-79 in. lb.)
Mounting Screw 16 N·m (142 in. lb.)
Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.)
Stator
Mounting Screw 9.3 N·m (82 in. lb.)
Throttle Control Bracket
Fastener 9.9 N·m (88 in. lb.)
Valve Cover
Fastener 13.6 N·m (120 in. lb.)
CLEARANCE SPECIFICATIONS3ECV940 ECV980
Camshaft
End Play 0.3/1.3 mm (0.011/0.051 in.)
Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.)
Bore I.D.
New
Max. Wear Limit
20.000/20.025 mm (0.7874/0.7884 in.)
20.038 mm (0.7889 in.)
Bearing Surface O.D.
New
Max. Wear Limit
19.962/19.975 mm (0.7859/0.7864 in.)
19.959 mm (0.7858 in.)
Cam Lobe Profi le (minimum dimension, measured from base circle
to top of lobe)
Exhaust 35 mm (1.3779 in.)
Intake 34.1 mm (1.3425 in.) 35 mm (1.3779 in.)
Connecting Rod
Crankpin End I.D. @ 70°F
New
Max. Wear Limit
44.030/44.037 mm (1.7334/1.7337 in.)
0.070 mm (0.0028 in.)
Connecting Rod-to-Crankpin Running Clearance
New
Max. Wear Limit
0.030/0.055 mm (0.0012/0.0022 in.)
0.070 mm (0.0028 in.)
Connecting Rod-to-Crankpin Side Clearance 0.30/0.59 mm (0.0118/0.0232 in.)
Connecting Rod-to-Piston Pin Running Clearance 0.015/0.028 mm (0.0006/0.0011 in.)
Piston Pin End I.D. @ 70°F
New
Max. Wear Limit
19.015/19.023 mm (0.7486/0.7489 in.)
19.036 mm (0.7494 in.)
Crankcase
Governor Cross Shaft Bore I.D. (Mechanical Governor)
New
Max. Wear Limit
8.025/8.050 mm (0.3159/0.3169 in.)
8.088 mm (0.3184 in.)
Crankshaft
End Play (free)
Thrust Bearing (Flange)
Non-Thrust Bearing
0.30/1.50 mm (0.011/0.059 in.)
0.20/0.94 mm (0.008/0.037 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.

Specifi cations
14 62 690 05 Rev. EKohlerEngines.com
CLEARANCE SPECIFICATIONS3ECV940 ECV980
Crankshaft Continued
Bore (in crankcase)
New 45.043/45.068 mm (1.7733/1.7743 in.)
Crankshaft Bore (in crankcase)-to-Crankshaft Running Clearance
New 0.043/0.090 mm (0.0017/0.0035 in.)
Bore (in oil pan)
New, Without Bearing 50.025/50.00 mm (1.9694/1.9685 in.)
Crankshaft to Sleeve Bearing (in oil pan) Running Clearance
New 0.040/0.167 mm (0.0015/0.0065 in.)
Oil Pan End Main Bearing Journal
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
44.978/45.00 mm (1.770/1.771 in.)
44.90 mm (1.767 in.)
0.022 mm (0.0009 in.)
0.025 mm (0.0010 in.)
Connecting Rod Journal
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
Width
43.982/44.000 mm (1.731/1.732 in.)
43.97 mm (1.731 in.)
0.018 mm (0.0007 in.)
0.025 mm (0.0010 in.)
53.00/53.09 mm (2.0866/2.0901 in.)
T.I.R.
PTO End, Crank in Engine
Entire Crank, in V-Blocks
0.279 mm (0.0110 in.)
0.10 mm (0.0039 in.)
Flywheel End Main Bearing Journal
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
44.978/45.00 mm (1.770/1.771 in.)
44.90 mm (1.767 in.)
0.022 mm (0.0009 in.)
0.025 mm (0.0010 in.)
Crankshaft Bearing (PTO)
New (installed)
Max. Wear Limit
45.040/45.145 mm (1.773.1.777 in.)
45.158 mm
Cylinder Bore
I.D.
New
Max. Wear Limit
Max. Taper
Max. Out-of-Round
90.000/90.025 mm (3.543/3.544 in.)
90.075 mm (3.546 in.)
0.013 mm (0.00051 in.)
0.013 mm (0.00051 in.)
Cylinder Head
Max. Out-of-Flatness 0.076 mm (0.003 in.)
Governor (Mechanical)
Governor Cross Shaft-to-Crankcase Running Clearance 0.025/0.087 mm (0.0009/0.0034 in.)
Cross Shaft O.D.
New
Max. Wear Limit
7.963/8.000 mm (0.3135/.3149 in.)
7.936 mm (0.3124 in.)
Governor Gear Shaft-to-Governor Gear Running Clearance 0.070/0.160 mm (0.0027/0.0063 in.)
Gear Shaft O.D.
New
Max. Wear Limit
5.990/6.000 mm (0.2358/0.2362 in.)
5.977 mm (0.2353 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.

Specifi cations
1562 690 05 Rev. E KohlerEngines.com
3 Values are in Metric units. Values in parentheses are English equivalents.
7 Measure 11 mm (0.4331 in.) above bottom of piston skirt at right angles to piston pin.
CLEARANCE SPECIFICATIONS3ECV940 ECV980
Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Crankshaft Position Sensor Air Gap (only on earlier design sensor
bracket)
0.2/0.7 mm (0.008/0.027 in.)
Crankshaft Position Sensor Max. Air Gap (only on later design
sensor bracket)
2.794 mm (0.110 in.)
Piston, Piston Rings, and Piston Pin
Piston-to-Piston Pin Running Clearance 0.006/0.018 mm (0.0002/0.0007 in.)
Pin Bore I.D.
New
Max. Wear Limit
19.006/17.013 mm (0.7482/0.7485 in.)
19.025 mm (0.7490 in.)
Pin O.D.
New
Max. Wear Limit
18.995/19.000 mm (0.7478/0.7480 in.)
18.994 mm (0.7478 in.)
Top Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.)
Middle Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.)
Oil Control Ring-to-Groove Side Clearance 0.03/0.19 mm (0.0011/0.0074 in.)
Top and Center Compression Ring End Gap
New Bore
Used Bore (max.)
0.30/0.55 mm (0.011/0.021 in.)
0.94 mm (0.037 in.)
Thrust Face O.D.7
New
Max. Wear Limit
89.953/89.967 mm (3.5414/3.5420 in.)
89.925 mm (3.540 in.)
Piston Thrust Face-to-Cylinder Bore7 Running Clearance
New 0.033/0.071 mm (0.0013/0.0028 in.)
Valves and Valve Lifters
Hydraulic Valve Lifter to Crankcase Running Clearance 0.012/0.050 mm (0.0004/0.0019 in.)
Intake Valve Stem-to-Valve Guide Running Clearance 0.038/0.076 mm (0.0015/0.0030 in.)
Exhaust Valve Stem-to-Valve Guide Running Clearance 0.050/0.088 mm (0.0020/0.0035 in.)
Intake Valve Guide I.D.
New
Max. Wear Limit
7.038/7.058 mm (0.2771/0.2779 in.)
7.135 mm (0.2809 in.)
Exhaust Valve Guide I.D.
New
Max. Wear Limit
7.038/7.058 mm (0.2771/0.2779 in.)
7.159 mm (0.2819 in.)
Guide Reamer Size
Standard
0.25 mm O.S.
7.048 mm (0.2775 in.)
7.298 mm (0.2873 in.)
Nominal Valve Face Angle 45°

Specifi cations
16 62 690 05 Rev. EKohlerEngines.com
GENERAL TORQUE VALUES
Metric Fastener Torque Recommendations for Standard Applications
Property Class Noncritical
Fasteners
Into Aluminum
Size 4.8 5.8 8.8 10.9 12.9
Tightening Torque: N·m (in. lb.) ± 10%
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.) ± 10%
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 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
Torque Conversions
N·m = in. lb. x 0.113 in. lb. = N·m x 8.85
N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737
English Fastener Torque Recommendations for Standard Applications
Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners
Into Aluminum
Size Grade 2 Grade 5 Grade 8
Tightening Torque: N·m (in. lb.) ± 20%
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) — — —
Tightening Torque: N·m (ft. lb.) ± 20%
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) 142.5 (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) —
5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —
3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Tools and Aids
1762 690 05 Rev. E KohlerEngines.com
Certain quality tools are designed to help you perform specifi c disassembly, repair, and reassembly procedures. By
using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service
capabilities and customer satisfaction by decreasing engine downtime.
Here is a list of tools and their source.
NOTE: Not all tools listed are required to service this engine.
SEPARATE TOOL SUPPLIERS
Kohler Tools
Contact your local Kohler source of
supply.
SE Tools
415 Howard St.
Lapeer, MI 48446
Phone [phone]
Toll Free 800-664-2981
Fax [phone]
Design Technology Inc.
768 Burr Oak Drive
Westmont, IL 60559
Phone [phone]
Fax [phone]
TOOLS
Description Source/Part No.
Alcohol Content Tester
For testing alcohol content (%) in reformulated/oxygenated fuels.
Kohler 25 455 11-S
Camshaft Endplay Plate
For checking camshaft endplay.
SE Tools KLR-82405
Camshaft Seal Protector (Aegis)
For protecting seal during camshaft installation.
SE Tools KLR-82417
Cylinder Leakdown Tester
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available:
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)
Kohler 25 761 05-S
Design Technology Inc.
DTI-731-03
Dealer Tool Kit (Domestic)
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester
Cylinder Leakdown Tester
Oil Pressure Test Kit
Rectifi er-Regulator Tester (120 V AC/60Hz)
Kohler 25 761 39-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 20-S
Dealer Tool Kit (International)
Complete kit of Kohler required tools.
Components of 25 761 42-S
Ignition System Tester
Cylinder Leakdown Tester
Oil Pressure Test Kit
Rectifi er-Regulator Tester (240 V AC/50Hz)
Kohler 25 761 42-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 41-S
Digital Vacuum/Pressure Tester
For checking crankcase vacuum.
Individual component available:
Rubber Adapter Plug
Design Technology Inc.
DTI-721-01
Design Technology Inc.
DTI-721-10
Electronic Fuel Injection (EFI) Diagnostic Software
For Laptop or Desktop PC.
Kohler 25 761 23-S
EFI Service Kit
For troubleshooting and setting up an EFI engine.
Components of 24 761 01-S
Fuel Pressure Tester
Noid Light
90° Adapter
Code Plug, Red Wire
Code Plug, Blue Wire
Shrader Valve Adapter Hose
Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire)
Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool)
K-Line Adapter Jumper Lead Wiring Harness
Kohler 24 761 01-S
Design Technology Inc.
DTI-019
DTI-021
DTI-023
DTI-027
DTI-029
DTI-037
DTI-031
DTI-033
Kohler 25 176 23-S
Kohler Wireless Diagnostic System Module (Bluetooth®)
For wireless Android EFI diagnostics.
Individual component available:
Wireless Diagnostic System Interface Cable
Kohler 25 761 45-S
Kohler 25 761 44-S

Tools and Aids
18 62 690 05 Rev. EKohlerEngines.com
TOOLS
Description Source/Part No.
E-Gov Jumper Test Tool
Used to test sealed GCU/wiring harness module on ECV940, ECV980 E-Gov
engines.
Kohler 25 761 51-S
Flywheel Puller
For properly removing fl ywheel from engine.
SE Tools KLR-82408
Flywheel Anchor Bolts, Washers, Nuts Tool
Used with Flywheel Puller for properly removing fl ywheel from 5400 Series engine.
Kohler 25 086 753-S
Hose Removal Tool, Dual Size/End (also available in EFI Service Kit)
Used to properly remove fuel hose from engine components.
Kohler 25 455 20-S
Hydraulic Valve Lifter Tool
For removing and installing hydraulic lifters.
Kohler 25 761 38-S
Ignition System Tester
For testing output on all systems, including CD.
Kohler 25 455 01-S
Inductive Tachometer (Digital)
For checking operating speed (RPM) of an engine.
Design Technology Inc.
DTI-110
Off set Wrench (K and M Series)
For removing and reinstalling cylinder barrel retaining nuts.
Kohler 52 455 04-S
Oil Pressure Test Kit
For testing/verifying oil pressure on pressure lubricated engines.
Kohler 25 761 06-S
Rectifi er-Regulator Tester (120 volt current)
Rectifi er-Regulator Tester (240 volt current)
For testing rectifi er-regulators.
Components of 25 761 20-S and 25 761 41-S
CS-PRO Regulator Test Harness
Special Regulator Test Harness with Diode
Kohler 25 761 20-S
Kohler 25 761 41-S
Design Technology Inc.
DTI-031R
DTI-033R
Spark Advance Module (SAM) Tester
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Kohler 25 761 40-S
Starter Servicing Kit (All Starters)
For removing and reinstalling drive retaining rings and brushes.
Individual component available:
Starter Brush Holding Tool (Solenoid Shift)
SE Tools KLR-82411
SE Tools KLR-82416
Stepper Motor Controller Tool
For testing operation of stepper motor/Digital Linear Actuator (DLA).
Kohler 25 455 21-S
Jumper Lead Tool
For use with Stepper Motor Controller Tool to test rotary stepper motor.
Kohler 25 518 43-S
Triad/OHC Timing Tool Set
For holding cam gears and crankshaft in timed position while installing timing belt.
Kohler 28 761 01-S
Valve Guide Reamer (K and M Series)
For properly sizing valve guides after installation.
Design Technology Inc.
DTI-K828
Valve Guide Reamer O.S. (Command Series)
For reaming worn valve guides to accept replacement oversize valves. Can be used
in low-speed drill press or with handle below for hand reaming.
Kohler 25 455 12-S
Reamer Handle
For hand reaming using Kohler 25 455 12-S reamer.
Design Technology Inc.
DTI-K830

Tools and Aids
1962 690 05 Rev. E KohlerEngines.com
FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL
A fl ywheel holding tool can be made out of an old junk
fl ywheel ring gear and used in place of a strap wrench.
1. Using an abrasive cut-off wheel, cut out a six tooth
segment of ring gear as shown.
2. Grind off any burrs or sharp edges.
3. Invert segment and place it between ignition bosses
on crankcase so tool teeth engage fl ywheel ring
gear teeth. Bosses will lock tool and fl ywheel in
position for loosening, tightening, or removing with a
puller.
A spanner wrench to lift rocker arms or turn crankshaft
may be made out of an old junk connecting rod.
1. Find a used connecting rod from a 10 HP or larger
engine. Remove and discard rod cap.
2. Remove studs of a Posi-Lock rod or grind off
aligning steps of a Command rod, so joint surface is
fl at.
3. Find a 1 in. long capscrew with correct thread size to
match threads in connecting rod.
4. Use a fl at washer with correct I.D. to slip on
capscrew and approximately 1 in. O.D. Assemble
capscrew and washer to joint surface of rod.
AIDS
Description Source/Part No.
Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S
Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S
Dielectric Grease Loctite® 51360
Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S
RTV Silicone Sealant
Loctite® 5900® Heavy Body in 4 oz. aerosol dispenser.
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved
for use. Permatex® the Right Stuff ® 1 Minute Gasket™ or Loctite® Nos. 5900® or
5910® are recommended for best sealing characteristics.
Kohler 25 597 07-S
Loctite® 5910®
Loctite® Ultra Black 598™
Loctite® Ultra Blue 587™
Loctite® Ultra Copper 5920™
Permatex® the Right Stuff ® 1
Minute Gasket™
Spline Drive Lubricant Kohler 25 357 12-S

Troubleshooting
20 62 690 05 Rev. EKohlerEngines.com
Engine Cranks But Will Not Start
● Battery connected backwards.
● Blown fuse.
● Clogged fuel line or fuel fi lter.
● Empty fuel tank.
● Faulty electronic control unit.
● Faulty ignition coil(s).
● Faulty spark plug(s).
● Fuel pump malfunction-vacuum hose clogged or
leaking.
● Fuel shut-off valve closed.
● Insuffi cient voltage to electronic control unit.
● Interlock switch is engaged or faulty.
● Key switch or kill switch in OFF position.
● Low oil level.
● Quality of fuel (dirt, water, stale, mixture).
● Spark plug lead(s) disconnected.
Engine Starts But Does Not Keep Running
● Faulty cylinder head gasket.
● Faulty or misadjusted throttle controls.
● Fuel pump malfunction-vacuum hose clogged or
leaking.
● Intake system leak.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Quality of fuel (dirt, water, stale, mixture).
● Restricted fuel tank cap vent.
Engine Starts Hard
● Clogged fuel line or fuel fi lter.
● Engine overheated.
● Faulty ACR mechanism (Retractable Start).
● Faulty or misadjusted throttle controls.
● Faulty spark plug(s).
● Flywheel key sheared.
● Fuel pump malfunction-vacuum hose clogged or
leaking.
● Interlock switch is engaged or faulty.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Low compression.
● Quality of fuel (dirt, water, stale, mixture).
● Weak spark.
TROUBLESHOOTING GUIDE
When troubles occur, be sure to check simple causes which, at fi rst, may seem too obvious to be considered. For
example, a starting problem could be caused by an empty fuel tank.
Some general common causes of EFI engine troubles are listed below and vary by engine specifi cation. Use these to
locate causing factors.
Engine Will Not Crank
● Battery is discharged.
● Faulty electric starter or solenoid.
● Faulty key switch or ignition switch.
● Interlock switch is engaged or faulty.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Pawls not engaging in drive cup (Retractable Start).
● Seized internal engine components.
Engine Runs But Misses
● Engine overheated.
● Faulty spark plug(s).
● Ignition coil(s) faulty.
● Incorrect crankshaft position sensor air gap.
● Interlock switch is engaged or faulty.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Quality of fuel (dirt, water, stale, mixture).
● Spark plug lead(s) disconnected.
● Spark plug lead boot loose on plug.
● Spark plug lead loose.
Engine Will Not Idle
● Engine overheated.
● Faulty spark plug(s).
● Idle speed adjusting screw improperly set.
● Inadequate fuel supply.
● Low compression.
● Quality of fuel (dirt, water, stale, mixture).
● Restricted fuel tank cap vent.
Engine Overheats
● Cooling fan broken.
● Excessive engine load.
● High crankcase oil level.
● Lean fuel mixture.
● Low crankcase oil level.
Engine Knocks
● Excessive engine load.
● Hydraulic lifter malfunction.
● Incorrect oil viscosity/type.
● Internal wear or damage.
● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture).