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Kohler Command Pro CV940

Kohler Command Pro CV940
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CV940-CV1000
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 02 Rev. D 1
2 Safety
3 Maintenance
5 Speci cations
13 Tools and Aids
16 Troubleshooting
20 Air Cleaner/Intake
21 Fuel System
27 Governor System
28 Lubrication System
30 Electrical System
38 Starter System
42 Disassembly/Inspection and Service
56 Reassembly

Table of Contents

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Kohler Command Pro CV940 Specifications

General IconGeneral
Compression Ratio8.5:1
Cooling SystemAir-cooled
Starting SystemElectric start
Spark Plug Gap0.030 in (0.76 mm)
Oil Capacity2.0 qt (1.9 L)
Ignition SystemElectronic
Fuel SystemCarburetor

Summary

Safety

Safety Precautions

WARNING and CAUTION statements to prevent death, serious injury, or property damage.

Maintenance

Maintenance Instructions

Guidelines for performing maintenance and safety warnings.

Maintenance Schedule

Routine maintenance intervals and tasks for the engine.

Specifications

Engine Dimensions

Detailed diagrams with measurements of engine components.

Engine Identification Numbers

Details on locating and reading engine identification numbers.

Torque Specifications

Torque values for various fasteners and components.

Clearance Specifications

Tolerances and measurements for engine parts.

General Torque Values

Standard torque recommendations for fasteners.

Tools and Aids

Separate Tool Suppliers

List of suppliers for specialized engine service tools.

Tools

Descriptions and part numbers for required service tools.

Aids

Descriptions and part numbers for service aids.

Troubleshooting

Troubleshooting Guide

General guide to diagnosing common engine problems.

Engine Cranks But Will Not Start

Troubleshooting steps for no-start conditions.

Engine Will Not Crank

Troubleshooting steps for when the engine won't turn over.

Engine Starts But Does Not Keep Running

Troubleshooting steps for engines that stall.

Engine Starts Hard

Troubleshooting steps for difficult starting.

Engine Runs But Misses

Troubleshooting steps for engine misfires.

Engine Will Not Idle

Troubleshooting steps for idle speed issues.

Engine Overheats

Troubleshooting steps for engine overheating.

Engine Knocks

Troubleshooting steps for engine knocking sounds.

Engine Loses Power

Troubleshooting steps for loss of engine power.

Air CleanerIntake

Air Cleaner

Components and service for the air cleaner system.

Breather Tube

Inspection and maintenance of the breather tube.

Fuel System

Fuel Pump

Details and replacement of the fuel pump.

Fuel System Tests

Procedures for testing fuel system components.

Carburetor

Components and description of the two-barrel carburetor.

Troubleshooting-Carburetor Related Causes

Common carburetor issues and their solutions.

Carburetor Adjustments

Procedures for adjusting carburetor settings.

Carburetor Servicing

Detailed steps for carburetor disassembly and cleaning.

Governor System

Governor

Explanation of governor function and types.

Governor Components

Identification of governor system parts.

Governor Adjustments

Procedures for adjusting governor settings.

Lubrication System

Oil Recommendations

Recommended engine oil types and viscosity.

Check Oil Level

Procedure for checking the engine oil level.

Change Oil and Filter

Steps for draining oil and replacing the oil filter.

Electrical System

Spark Plugs

Inspection, service, and specifications for spark plugs.

Battery

Recommendations and maintenance for the engine battery.

Electronic Ignition Systems

Description and troubleshooting for ignition systems.

Electronic Ignition Systems Tests

Procedures for testing electronic ignition components.

Test for Spark

Procedures for testing spark output and ignition timing.

Battery Charging System

Testing and maintenance of the battery charging system.

Starter System

Troubleshooting-Starting Difficulties

Common issues and solutions for starting problems.

Solenoid Shift Starters

Description of solenoid shift starter operation.

Starter Disassembly

Steps for disassembling the starter motor.

Inspection

Inspection of starter components like armature and brushes.

Solenoid Tests

Procedures for testing starter solenoid functionality.

DisassemblyInspection and Service

External Engine Components

Diagram and list of external engine components.

Remove Carburetor

Steps for safely removing the carburetor.

Remove Fuel Pump

Steps for removing the fuel pump.

Remove Oil Cooler

Steps for removing the oil cooler.

Remove Flywheel

Procedures for safely removing the flywheel.

Remove Valve Covers

Steps for removing valve covers and related components.

Disassemble Cylinder Heads

Procedures for disassembling cylinder heads.

Valve Seat Inserts

Information on valve seat inserts and their service.

Remove Connecting Rods with Pistons and Rings

Steps for removing connecting rods and pistons.

Piston and Rings

Inspection and service of pistons and rings.

Remove Crankshaft

Procedure for removing the crankshaft.

Crankcase

Inspection and service of the crankcase.

Measuring Piston-to-Bore Clearance

Procedure for accurately measuring piston-to-bore clearance.

Reassembly

Crankcase Components

Reassembly of crankcase internal components.

Install Flywheel End Oil Seal

Procedure for installing the flywheel end oil seal.

Install Crankshaft

Steps for installing the crankshaft into the crankcase.

Install Camshaft

Procedure for installing the camshaft and checking end play.

Install Oil Pan Assembly

Steps for installing the oil pan and related components.

Install Breather

Procedure for installing the breather assembly.

Install Cylinder Heads

Steps for installing the cylinder heads and adjusting valve clearance.

Install Valve Covers

Procedure for installing valve covers and spark plugs.

Install Oil Filter Housing Assembly

Steps for installing the oil filter housing.

Install Stator, Wiring Harness, and Rectifier-Regulator

Procedure for installing stator and related electrical components.

Install Outer Cylinder Baffles

Steps for installing outer cylinder baffles.

Install Cooling Fan and Debris Screen

Procedure for installing cooling fan and debris screen.

Install Carburetor

Steps for installing the carburetor and connecting linkages.

Governor SpringRPM Chart

Chart detailing governor spring colors and corresponding RPM settings.

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