Kohler CV11-16 User manual

1
SERVICE MANUAL
VERTICAL CRANKSHAFT
CV11-16, CV460-465, CV490-495

Contents
Section 1. Safety and General Information.............................................................................
Section 2. Special Tools............................................................................................................
Section 3. Troubleshooting ......................................................................................................
Section 4. Air Cleaner and Air Intake System.........................................................................
Section 5. Fuel System and Governor.....................................................................................
Section 6. Lubrication System.................................................................................................
Section 7. Retractable Starter ..................................................................................................
Section 8. Electrical System and Components ......................................................................
Section 9. Disassembly.............................................................................................................
Section 10. Inspection and Reconditioning............................................................................
Section 11. Reassembly............................................................................................................
1
2
3
4
5
6
7
8
9
10
11

1.1
Section 1
Safety and General Information
1
Section 1
Safety and General Information
Safety Precautions
To insure safe operations 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.
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.
CV11-16
CV460-465, CV490-495

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
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
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.
WARNING
Explosive Gas can cause fires and
severe acid burns.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.

1.3
Section 1
Safety and General Information
1
A. Model No.
Command Engine
Vertical Crankshaft
Displacement (cc)
460 = 460 cc
490 = 490 cc
Version Code
S = Electric Start
T = Retractable Start
ST = Electric/Retractable Start
Variation of
Basic Engine
B. Spec. No.
Engine Model Code
Code Model
11 CV11
12 CV12.5
22 CV13
14 CV14
41 CV15
43 CV16
265 CV460-465
275 CV490-495
C. Serial No.
Year Manufactured Code
Code Model
21 1991
22 1992
23 1993
24 1994
25 1995
26 1996
27 1997
28 1998
29 1999
30 2000
31 2001
32 2002
Factory Code
2105810334
Engine Identification Numbers
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification, and Serial Numbers of the engine.
The engine identification numbers appear a on decal
(or decals) affixed to the engine shrouding. See Figure
1-1. An explanation of these numbers is shown in
Figure 1-2.
Figure 1-2. Explanation of Engine Identification Numbers.
C V 12.5 ST
1203
Figure 1-1. Engine Identification Decal Location.
or Horsepower
11 = 11 HP
12.5 = 12.5 HP
13 = 13 HP
14 = 14 HP
15 = 15 HP
16 = 16 HP
Identification Decal
MODEL NO.
SPEC. NO.
SERIAL NO.
REFER TO OWNER'S MANUAL FOR
SAFETY, MAINTENANCE SPECS
AND ADJUSTMENTS. FOR SALES
AND SERVICE IN US/CANADA
CALL: 1-800-544-2444.
www.kohlerengines.com
KOHLER CO. KOHLER, WI USA
CV12.5ST
1203
2105810334
A
B
C

1.4
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important, as is checking oil
daily, and changing oil regularly. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure. Synthetic oil is recommended for
use in LPG-fueled engines because there is less
oxidation or thickening, and deposit accumulation on
intake valves is substantially reduced.
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 below.
NOTE: Using other than service class SG, SH, SJ or
higher oil, or extending oil change intervals
longer than recommended, can cause engine
damage.
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 1-3.
Fuel Recommendations
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.
General Recommendations
Purchase gasoline in small quantities and store
in clean, approved containers. A container with a
capacity of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
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 insure easy 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. Leaded gasoline may
be used in areas where unleaded is not available
and exhaust emissions are not regulated. Be aware
however, that the cylinder head will require more
frequent service.
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 maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
Figure 1-3. Oil Container Logo.
Refer to Section 6 - “Lubrication System” for detailed
oil check, oil change, and oil filter change procedures.
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 4°C (40°F).
**Synthetic oils will provide better starting in extreme cold
below -23°C (-10°F).
** *

1.5
Section 1
Safety and General Information
1
Periodic Maintenance
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.
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.
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 manufacturers
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 2-3 minutes to get stabilized fuel into the
carburetor.
To empty the system, run the engine until the tank
and system are empty.
4. Remove the spark plug. Add one tablespoon of
engine oil into the spark plug hole. Install the
plug, but do not connect the plug lead. Crank the
engine two or three revolutions.
5. Remove the spark plug. Cover the spark plug
hole with your thumb, and turn the engine
over until the piston is at the top of its stroke.
(Pressure against thumb is greatest.) Reinstall
the plug, but do not connect the plug lead.
6. Store the engine in a clean, dry place.
Frequency Maintenance Required Refer to:
• Fill fuel tank.
• Check oil level.
• Check air cleaner for dirty1, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary1.
Daily or Before
Starting Engine
Section 5
Section 6
Section 4
Section 4
• Service precleaner element1.
Every 25 Hours Section 4
• Replace air cleaner element1.
• Change oil1.
• Remove cooling shrouds and clean cooling areas1.
Every
100 Hours Section 4
Section 6
Section 4
• Change oil filter1.
• Check spark plug condition and gap.
Every
200 Hours Section 6
Section 8
1
Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
2Have a Kohler Engine Service Dealer perform this service. Not necessary on Delco Starters.
Annually or
Every
500 Hours
• Have bendix starter drive serviced2.
• Have solenoid shift starter disassembled and cleaned2.Section 8
Section 8

1.6
Section 1
Safety and General Information
Figure 1-4. Typical Engine Dimensions.
Air Filter
and Cover
Cylinder
Carburetor
Fuel Shut-off
Solenoid Carburetor
Fuel Inlet
Oil Drain Plug
3/8 NPT Inch
Oil Filter Side
17
(.67)
Engine Mounting
Surface
Oil Filter
Cylinder
262
(10.31)
47
(1.85)
24.0
(9.4)
Valve Cover End 25.4
(1.00)
6.34
(.250)Keyway Width
220.2
(8.67)
45° 45°
60.0
(2.36)
4.0
(.16)
40°
M8x1.25
2 Studs
Exhaust Flange
Mounting Surface
Engine Mounting Surface
35° 35°
Rotation
254
(10.0)
Cylinder
4xM8x1.25
296
(11.65)
321
(12.64)
Cylinder
137.5
(5.41)
411
(16.18)
Air Cleaner
Cover Removal
62.5
(2.46)
19
(.74)
Exhaust Flange
Mounting Surface
25.4
(1.00)
6.34
(.250) Keyway Width
Starter Side
Starter Motor
Engine Mounting
Surface
26.5
(1.04) Throttle Cable
207
(80.16)
176.6
(6.95)
Oil Level
Dipstick & Fill
328*
(12.91)
463*
(18.23)
108
(4.25)
135.0
(5.31)
Flywheel End
372
(14.66)
204
(8.04)
124
(4.88)
Dimensions in () are inch equivalents.
*CV11-16 10 mm shorter
C
L
C
L
C
L
Cylinder
C
L
C
L
C
L

1.7
Section 1
Safety and General Information
1
General Specifications¹
Power (@ 3600 RPM, corrected to SAE J1995)
CV11 .................................................................................. 8.2 kW (11 HP)
CV12.5............................................................................... 9.33 kW (12.5 HP)
CV13.................................................................................. 9.75 kW (13 HP)
CV14.................................................................................. 10.5 kW (14 HP)
CV15.................................................................................. 11.19 kW (15 HP)
CV16.................................................................................. 11.9 kW (16 HP)
CV460-465......................................................................... 11.9 kW (16 HP)-13.0 kW (16.5 HP)
CV490-495......................................................................... 12.7 kW (17 HP)-13.4 kW (18 HP)
Max Torque (@ RPM indicated)
CV11 .................................................................................. 27.4 N·m (20.2 ft. lb.) @ 2000
CV12.5............................................................................... 27.8 N·m (20.5 ft. lb.) @ 2500
CV13.................................................................................. 27.8 N·m (20.5 ft. lb.) @ 2500
CV14.................................................................................. 28.9 N·m (21.3 ft. lb.) @ 2500
CV15.................................................................................. 33.2 N·m (24.5 ft. lb.) @ 2400
CV16.................................................................................. 35.3 N·m (26.0 ft. lb.) @ 2400
CV460-465......................................................................... 36.3 N·m (26.8 ft. lb.) @ 2400
CV490-495......................................................................... 37.8 N·m (27.9 ft. lb.)-38.1 N·m (28.1 ft. lb.) @ 2400
Bore
CV11-14, CV460-465......................................................... 87 mm (3.43 in.)
CV15, CV16, CV490-495................................................... 90 mm (3.60 in.)
Stroke
CV11-16.............................................................................67 mm (2.64 in.)
CV460-465, CV490-495..................................................... 77 mm (3.03 in.)
Displacement
CV11-14.............................................................................398 cc (24.3 cu. in.3)
CV15, CV16....................................................................... 426 cc (26.0 cu. in.3)
CV460-465......................................................................... 460 cc (27.9 cu. in.3)
CV490-495......................................................................... 490 cc (29.9 cu. in.3)
Compression Ratio................................................................... 8.5:1
Weight (approx.)
CV11-16.............................................................................39.54 kg (87 lb.)
CV460-465, CV490-495..................................................... 41.9 kg (90 lb.)
Oil Capacity (approx.)............................................................... 1.9 L (2.0 U.S. qt.)
Air Cleaner
Base Nut Torque....................................................................... 9.9 N·m (88 in. lb.)
Wing Nut Torque....................................................................... 1.5 N·m (12 in. lb.)
Angle of Operation - Maximum (at full oil level)
Intermittent - All Directions........................................................ 35°
Continuous - All Directions ....................................................... 20°
1Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior
to assembly.

1.8
Section 1
Safety and General Information
Balance Shaft
End Play........................................................................................................0.0575/0.3625 mm (0.0027/0.0137 in.)
Running Clearance........................................................................................0.0250/0.1520 mm (0.0009/0.0059 in.)
Bore I.D.
New.........................................................................................................20.000/20.025 mm (0.7874/0.7884 in.)
Max. Wear Limit......................................................................................20.038 mm (0.7889 in.)
Balance Shaft Bearing Surface O.D.
New.........................................................................................................19.962/19.975 mm (0.7859/0.7864 in.)
Max. Wear Limit......................................................................................19.959 mm (0.7858 in.)
Camshaft
End Play (free)...............................................................................................0.088/0.393 mm (0.003/0.015 in.)
End Play (with shims)....................................................................................0.076/0.127 mm (0.003/0.005 in.)
Running Clearance........................................................................................0.025/0.105 mm (0.0010/0.0041 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
Preliminary Low Idle Fuel Needle Setting.....................................................1 Turn
Fuel Bowl Retaining Screw Torque...............................................................5.1-6.2 N·m (45-55 in. lb.)
Connecting Rod
Cap Fastener Torque (torque in increments)
6 mm straight shank bolt.........................................................................11.3 N·m (100 in. lb.)
8 mm step-down bolt...............................................................................14.7 N·m (130 in. lb.)
8 mm straight shank bolt.........................................................................22.7 N·m (200 in. lb.)
Connecting Rod-to-Crankpin Running Clearance at 21°C (70°F)
New.........................................................................................................0.030/0.055 mm (0.0012/0.0022 in.)
Max. Wear Limit......................................................................................0.07 mm (0.0025 in.)
Connecting Rod-to-Crankpin Side Clearance ...............................................0.18/0.41 mm (0.007/0.016 in.)
Connecting Rod-to-Piston Pin Running Clearance at 21°C (70°F)...............0.015/0.028 mm (0.0006/0.0011 in.)
Piston Pin End I.D.
New........................................................................................................19.015/19.023 mm (0.7486/0.7489 in.)
Max. Wear Limit.....................................................................................19.036 mm (0.7495 in.)
Crankcase
Governor Cross Shaft Bore I.D.
New........................................................................................................6.025/6.050 mm (0.2372/0.2382 in.)
Max. Wear Limit.....................................................................................6.063 mm (0.2387 in.)

1.9
Section 1
Safety and General Information
1
Crankshaft
End Play (free)..........................................................................................0.0575/0.4925 mm (0.0022/0.0193 in.)
End Play (thrust bearing with shims)........................................................0.050/0.530 mm (0.0020/0.0209 in.)
Crankshaft Bore in Crankcase I.D.
New....................................................................................................44.965/44.990 mm (1.7702/1.7712 in.)
Max. Wear Limit.................................................................................44.9758/45.0012 mm (1.7707/1.7717 in.)
Crankshaft Bore in Crankcase Running Clearance
New....................................................................................................0.0300/0.0770 mm (0.0011/0.0030 in.)
Crankshaft Bore in Oil Pan I.D.
New....................................................................................................41.965/42.003 mm (1.6521/1.6536 in.)
Max. Wear Limit.................................................................................41.9760/42.0141 mm (1.6526/1.6541 in.)
Crankshaft Bore in Oil Pan Running Clearance
New....................................................................................................0.0300/0.0880 mm (0.0011/0.0034 in.)
Flywheel End Main Bearing Journal
O.D. - New.........................................................................................44.913/44.935 mm (1.7682/1.7691 in.)
O.D. - Max. Wear Limit.......................................................................44.84 mm (1.765 in.)
Max. Taper .........................................................................................0.022 mm (0.0009 in.)
Max. Out-of-Round ............................................................................0.025 mm (0.0010 in.)
Oil Pan End Main Bearing Journal
O.D. - New.........................................................................................41.915/41.935 mm (1.6502/1.6510 in.)
O.D. - Max. Wear Limit.......................................................................41.86 mm (1.648 in.)
Max. Taper .........................................................................................0.020 mm (0.0008 in.)
Max. Out-of-Round ............................................................................0.025 mm (0.0010 in.)
Connecting Rod Journal
O.D. - New.........................................................................................38.958/30.970 mm (1.5338/1.5343 in.)
O.D. - Max. Wear Limit.......................................................................38.94 mm (1.5328 in.)
Max. Taper .........................................................................................0.012 mm (0.0005 in.)
Max. Out-of-Round ............................................................................0.025 mm (0.0010 in.)
Crankshaft T.I.R.
PTO End, Crank in Engine.................................................................0.30 mm (0.012 in.)
Entire Crank, in V-Blocks...................................................................0.10 mm (0.0039 in.)
Cylinder Bore
Cylinder Bore I.D.
New
CV11-14, CV460-465.......................................................................87.000/87.025 mm (3.4252/3.4262 in.)
CV15, CV16, CV490-495.................................................................90.000/90.025 mm (3.5433/3.5443 in.)
Max. Wear Limit
CV11-14, CV460-465.......................................................................87.063 mm (3.4277 in.)
CV15, CV16, CV490-495.................................................................90.063 mm (3.5458 in.)
Max. Out-of-Round ............................................................................0.12 mm (0.0047 in.)
Max. Taper .........................................................................................0.05 mm (0.0020 in.)

1.10
Section 1
Safety and General Information
Cylinder Head
Cylinder Head Fastener Torque (torque in 2 increments)......... 24, 48.9 N·m (18, 36 ft. lb.)
Max. Out-of-Flatness................................................................ 0.076 mm (0.003 in.)
Rocker Pedestal Fastener Torque............................................ 11.3 N·m (100 in. lb.)
Electric Starter
Starter Thru Bolt Torque
UTE/Johnson Electric, Eaton (Inertia Drive)...................... 4.5-5.7 N·m (40-50 in. lb.)
Nippendenso (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.)
Starter Mounting Screw Torque (All).........................................15.3 N·m (135 in. lb.)
Solenoid Mounting Hardware (Nut/Screw) Torque
Nippendenso Starter.......................................................... 6.0-9.0 N·m (53-79 in. lb.)
Delco-Remy Starter ...........................................................4.0-6.0 N·m (35-53 in. lb.)
Brush Holder Mounting Screw Torque
Delco-Remy Starter ...........................................................2.5-3.3 N·m (22-29 in. lb.)
Nut, Positive (+) Brush Lead Torque
Nippendenso Starter.................................................... 8.0-12.0 N·m (71-106 in. lb.)
Delco-Remy Starter..................................................... 6.0-9.0 N·m (53-79 in. lb.)
Fan/Flywheel
Fan Fastener Torque................................................................ 9.9 N·m (88 in. lb.)
Flywheel Retaining Screw Torque............................................ 66.4 N·m (49 ft. lb.)
Fuel Pump
Fuel Pump Fastener Torque..................................................... 9.0 N·m (80 in. lb.) Into new as-cast hole
4.2-5.1 N·m (37-45 in. lb.) Into used hole
Fuel Pump Pad Cover Fastener Torque................................... 10.7 N·m (95 in. lb.) Into new as-cast hole
7.3 N·m (65 in. lb.) Into used hole
Governor
Governor Cross Shaft to Crankcase Running Clearance......... 0.025/0.075 mm (0.0010/0.0030 in.)
Governor Cross Shaft O.D.
New.................................................................................... 5.975/6.000 mm (0.2352/0.2362 in.)
Max. Wear Limit................................................................. 5.962 mm (0.2347 in.)
Governor Gear Shaft-to-Governor Gear Running Clearance... 0.050/0.160 mm (0.0019/0.0063 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.)
Ignition
Spark Plug Type (Champion® or equivalent)............................. RC12YC (Standard) or
Premium Gold 2071 (Pro Series)
Spark Plug Gap
CV11-15, CV460-465, CV490-495..................................... 1.02 mm (0.040 in.)
CV11-14 LP, CV16............................................................. 0.76 mm (0.030 in.)

1.11
Section 1
Safety and General Information
1
Ignition (Cont'd)
Spark Plug Torque.................................................................... 24.4-29.8 N·m (18-22 ft. lb.)
Ignition Module Air Gap............................................................0.200/0.300 mm (0.0078/0.0118 in.)
Ignition Module Fastener Torque.............................................. 6.2 N·m (55 in. lb.) Into new as-cast hole
4.0 N·m (35 in. lb.) Into used hole
Muffler
Muffler Retaining Nuts.............................................................. 24.4 N·m (216 in. lb.)
Oil Filter/Oil Pan
Oil Filter Torque........................................................................ 10.4-12.7 N·m (90-110 in. lb.)
Oil Filter Drain Plug (1/8" NPT) Torque..................................... 7.3-9.0 N·m (65-80 in. lb.)
Oil Pan Fastener Torque........................................................... 24.4 N·m (216 in. lb.)
Oil Sentry™Pressure Switch Torque......................................... 6.8 N·m (60 in. lb.)
Oil Pump Cover Fastener Torque............................................. 6.2 N·m (55 in. lb.) Into new as-cast hole
4.0 N·m (35 in. lb.) Into used hole
Piston, Piston Rings, and Piston Pin
Piston-to-Piston Pin (selective fit)............................................. 0.006/0.017 mm (0.0002/0.0007 in.)
Piston Pin Bore I.D.
New.................................................................................... 19.006/19.012 mm (0.7483/0.7485 in.)
Max. Wear Limit................................................................. 19.025 mm (0.7490 in.)
Piston Pin O.D.
New.................................................................................... 18.995/19.000 mm (0.7478/0.7480 in.)
Max. Wear Limit................................................................. 18.994 mm (0.74779 in.)
Top Compression Ring-to-Groove Side Clearance
CV11-14, CV460-465......................................................... 0.034/0.100 mm (0.0013/0.0039 in.)
CV15, CV16, CV490-495................................................... 0.060/0.105 mm (0.0023/0.0041 in.)
Middle Compression Ring-to-Groove Side Clearance
CV11-14, CV460-465......................................................... 0.040/0.080 mm (0.0016/0.0032 in.)
CV15, CV16, CV490-495................................................... 0.040/0.085 mm (0.0015/0.0033 in.)
Oil Control Ring-to-Groove Side Clearance
CV11-14, CV460-465......................................................... 0.036/0.186 mm (0.0014/0.0073 in.)
CV15, CV16, CV490-495................................................... 0.036/0.186 mm (0.0014/0.0073 in.)
Top Compression Ring End Gap
New Bore
CV11-14, CV460-465....................................................... 0.250/0.500 mm (0.010/0.020 in.)
CV15, CV16, CV490-495................................................. 0.28/0.51 mm (0.011/0.020 in.)
Used Bore (max.)............................................................... 0.79 mm (0.031 in.)

1.12
Section 1
Safety and General Information
Piston, Piston Rings, and Piston Pin (Cont'd.)
Center Compression Ring End Gap
New Bore
CV11-14, CV460-465....................................................... 0.250/0.510 mm (0.0010/0.020 in.)
CV15, CV16, CV490-495................................................. 0.22/0.48 mm (0.008/0.018 in.)
Used Bore (max.)............................................................... 0.76 mm (0.030 in.)
Oil Control Ring End Gap
CV11-14, CV460-465......................................................... 0.250/1.020 mm (0.010/0.040 in.)
CV15, CV16, CV490-495................................................... 0.250/0.760 mm (0.0098/0.0299 in.)
Piston Thrust Face O.D. (See Figure 10-4)
New
CV11-14, CV460-465....................................................... 86.941/86.959 mm (3.4229/3.4236 in.)
CV15, CV16, CV490-495................................................. 89.951/89.969 mm (3.5413/3.5420 in.)
Max. Wear Limit
CV11-14, CV460-465....................................................... 86.814 mm (3.4179 in.)
CV15, CV16, CV490-495................................................. 89.824 mm (3.5363 in.)
Piston Thrust Face (See Figure 10-4)-to-Cylinder Bore Running Clearance - New
CV11-14, CV460-465......................................................... 0.041/0.044 mm (0.0016/0.0017 in.)
CV15, CV16, CV490-495 .................................................. 0.031/0.043 mm (0.0012/0.0016 in.)
Retractable Starter
Center Screw Torque................................................................ 7.4-8.5 N·m (65-75 in. lb.)
Stator
Stator Mounting Screw Torque................................................. 6.2 N·m (55 in. lb.)
Throttle/Choke Controls
Governor Control Lever Fastener Torque................................. 9.9 N·m (88 in. lb.)
Speed Control Bracket Assembly Fastener Torque.................. 10.7 N·m (95 in. lb.) Into new as-cast hole
7.3 N·m (65 in. lb.) Into used hole
Valve Cover/Rocker Arms
Valve Cover Fastener Torque................................................... 10.7 N·m (95 in. lb.) Into new as-cast hole
7.3 N·m (65 in. lb.) Into used hole
Rocker Arm I.D.
New.................................................................................... 15.837/16.127 mm (0.63/0.64 in.)
Max. Wear Limit................................................................. 16.13 mm (0.640 in.)
Rocker Shaft O.D.
New.................................................................................... 15.90/15.85 mm (0.63 in.)
Max. Wear Limit................................................................. 15.727 mm (0.619 in.)
Non-Adjustable Valve Lash Configuration
Rocker Arm Screw Torque................................................. 11.3 N·m (100 in. lb.)
Adjustable Valve Lash Configuration
Rocker Arm Pivot Stud Torque........................................... 11.3 N·m (100 in. lb.)
Adjustment Set Screw Torque............................................ 7.3 N·m (65 in. lb.)

1.13
Section 1
Safety and General Information
1
Valves and Valve Lifters
Hydraulic Valve Lifter to Crankcase Running Clearance.......... 0.0124/0.0501 mm (0.0005/0.0020 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.................................................................................... 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit................................................................. 7.134 mm (0.2809 in.)
Exhaust Valve Guide I.D.
New.................................................................................... 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit................................................................. 7.159 mm (0.2819 in.)
Valve Guide Reamer Size
STD.................................................................................... 7.048 mm (0.2775 in.)
0.25 mm O.S...................................................................... 7.298 mm (0.2873 in.)
Intake Valve Minimum Lift......................................................... 8.96 mm (0.353 in.)
Exhaust Valve Minimum Lift .....................................................9.14 mm (0.360 in.)
Nominal Valve Seat Angle........................................................45°

1.14
Section 1
Safety and General Information
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications
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
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)
Noncritical
Fasteners
Into Aluminum
Noncritical
Fasteners
Into Aluminum
Tightening Torque: N·m (in. lb.) + or - 10%
Property Class
4.8 5.8 8.8 10.9 12.9
4.8 5.8 8.8 10.9 12.9
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
Oil Drain Plugs Tightening Torque: N•m (English Equiv.)
Size
1/8" NPT
1/4"
3/8"
1/2"
3/4"
X-708-1
Into Cast Iron
–
17.0 (150 in. lb.)
20.3 (180 in. lb.)
27.1 (20 ft. lb.)
33.9 (25 ft. lb.)
27.1/33.9 (20/25 ft. lb.)
Into Aluminum
4.5 (40 in. lb.)
11.3 (100 in. lb.)
13.6 (120 in. lb.)
17.6 (13 ft. lb.)
21.7 (16 ft. lb.)
27.1/33.9 (20/25 ft. lb.)

2.1
Section 2
Special Tools
2
Section 2
Special Tools
Kohler Special Service Tools
Kohler Co. has made an agreement with the Service
Tools Div. of SPX Corp. (a subsidiary of Owatonna
Tool Corp.) to handle our special service tools. The
intent of this program is to provide you with a single
source for all Kohler special tools, and to make it easy
and convenient to obtain those tools, at reasonable
cost. Tool orders can be placed with SPX by any of
three methods. Mail orders should be sent to:
OTC/SPX Corp., 655 Eisenhower Dr., Owatonna, MN
55060. You can also fax the order to [phone]
(USA and Canada) or [phone] (International).
Finally, you can order by phone at [phone]
(USA and Canada) or [phone] (International).
Repair Tools
These 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 down
time.
Tool Kit No. KO3211A–This basic tool kit includes
tools necessary to service Kohler K-Series and
Magnum engines.
COMMAND Tool Kit No. KO3213–This kit is
designed for the current Kohler Engine Service Dealer
already having the KO3211A basic tool kit. This kit
includes all additional tools necessary to service
current Command series engines.
COMMAND Tool Kit No. KO3214–This kit is for the
new Kohler Dealer servicing the Command series
engines only.
RTV Silicone Sealant
RTV silicone sealant is used as a gasket between the
crankcase and closure plate, and between the valve
cover and head. The recommended sealant is Loctite®
5900, available under Kohler Part No. 25 597 07-S.
Prepare the sealing surfaces of the crankcase and
closure plate as directed by the sealant manufacturer
or refer to Service Bulletin 252.
CV11-16
CV460-465, CV490-495

2.2
Section 2
Special Tools
Diagnostic and Repair Tools
The tools listed in the following table are used for specific diagnosis or repair procedures, as described. Order
from SPX Corp.
Description SPX Part No.
Hydraulic Lifter Tool
Designed to remove and install hydraulic lifters KO1044
Ignition Tester
Used for testing output on capacitive discharge (CD) ignition systems KO1046
Ignition Tester
Used for testing ouput on all other systems, except CD KO1047
Water Manometer
Used for testing crankcase vacuum and exhaust back pressure KO1048
Inductive Tachometer
Used for checking the operating speed (RPM) of an engine KO3216
Ammeter Set
Used for checking current flow in charging and cranking circuits KO3218
Cylinder Leakdown Tester
Used for checking combustion retention and if cylinder, piston, rings, or valves are worn KO3219
Oil Pressure Test Kit
Used to test/verify oil pressure on pressure lubricated engines KO3220
Electric Starter Service Kit
Used to service all electric starters, including solenoid shift KO3226
Electric Starter Service Kit
Used to remove and reinstall drive retainers on most inertia drive starters KO1049
Rectifier-Regulator Tester
Used for testing rectifier-regulators KO3221
Spark Advance Module Tester
Used to test the SAM on engines with Smart Spark KO3222
Vacuum/Pressure Tester
Used like the water manometer but easier to operate, transport, and maintain KO3223
Spanner Wrench
Used for installing push rods or rotating crankshaft OEM6200
Engine Analysis Kit
Used for testing running conditions of Kohler engines in applications KO1000A