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Kohler CV11-16 User Manual

Kohler CV11-16
148 pages
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1
COMMAND
SERVICE MANUAL
VERTICAL CRANKSHAFT
CV11-16,
CV460-465,
CV490-495

Table of Contents

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Kohler CV11-16 Specifications

General IconGeneral
Horsepower11 HP at 3600 RPM
Fuel SystemCarburetor
Lubrication SystemSplash
Cooling SystemAir Cooled
Dry Weight60 lbs
Fuel TypeGasoline

Summary

Section 1 Safety and General Information

Safety Precautions

Important safety statements and warnings for engine operation and maintenance.

Fuel Recommendations (Gasoline)

Advice on using clean, fresh, unleaded gasoline and safe storage practices.

Engine Identification Numbers

Explains model, spec, and serial numbers for engine identification and parts ordering.

Oil Recommendations

Guidance on selecting the correct type and viscosity of engine oil based on temperature.

Periodic Maintenance

Schedule of required maintenance procedures at specified intervals for optimal engine performance.

General Specifications

Key technical specifications for the engine models, including power and displacement.

Section 2 Special Tools

Kohler Special Service Tools

Information on obtaining specialized tools for servicing Kohler engines.

Diagnostic and Repair Tools

Table of tools used for specific engine diagnosis and repair procedures.

Special Tools You Can Make

Instructions for creating custom tools for flywheel and crankshaft servicing.

Section 3 Troubleshooting

Troubleshooting Guide

General guide to identifying and resolving common engine problems by checking simple causes first.

Engine Cranks But Will Not Start

Lists potential causes and checks for engines that crank but fail to start.

Engine Overheats

Identifies common causes of engine overheating, such as clogged cooling areas or improper load.

Engine Loses Power

Outlines reasons for engine power loss, including oil level, air cleaner, and compression issues.

Cylinder Leakdown Test

Procedure for performing a leakdown test to assess cylinder sealing and component wear.

Section 4 Air Cleaner and Air Intake System

Air Cleaner

Details on the engine's air cleaner system, including paper and optional foam precleaners.

Service

Instructions for daily checks, precleaner, and paper element servicing for the air cleaner.

Air Intake/Cooling System

Emphasizes the importance of keeping air intake and cooling areas clean to prevent overheating.

Section 5 Fuel System and Governor

Fuel Recommendations (Gasoline)

Safety warnings and recommendations for using gasoline, including fuel type and storage.

Fuel System (Gasoline)

Overview of the typical gasoline fuel system components and operation.

Carburetor (Gasoline)

Information on Walbro and Nikki carburetors, including adjustment procedures.

Troubleshooting - Gasoline Systems

Steps to check fuel system components before carburetor adjustment or disassembly.

Governor

Explanation of the centrifugal flyweight mechanical governor's function and operation.

High Idle Speed Adjustment

Procedure for setting the engine's maximum no-load high idle speed.

Section 6 Lubrication System

Oil Recommendations

Guidance on using the correct type and weight of oil for engine longevity.

Check Oil Level

Step-by-step instructions for checking the engine oil level before each use.

Change Oil and Oil Filter

Procedures for changing engine oil and oil filter at recommended intervals.

Full-Pressure Lubrication System

Details on the engine's full-pressure oil system, including pump operation and service.

Testing Oil Pressure

Method for testing engine oil pressure using an oil pressure tester.

Section 7 Retractable Starter

WARNING: Spring Under Tension!

Critical safety warning about the tension of the recoil spring in retractable starters.

Rope Replacement

Step-by-step instructions for replacing the starter rope without full disassembly.

Pawls (Dogs) Replacement

Information on replacing starter pawls, including available repair kits.

Disassembly

Detailed procedure for disassembling the retractable starter, with safety precautions.

Section 8 Electrical System and Components

WARNING: Electrical Shock

Essential safety warning about touching electrical wires or components while the engine is running.

Spark Plug

Information on spark plug types, gap settings, and common causes of misfire.

Electronic Magneto Ignition System

Overview of the magneto ignition system components and their basic operation.

Magneto Ignition System Troubleshooting Guide

Guide to diagnosing and correcting ignition system problems, including spark and module testing.

Battery

Recommended battery specifications and maintenance guidelines for reliable starting.

Electric Starters

Information on inertia drive and solenoid shift electric starters, including precautions.

Inertia Drive Electric Starters

Details on the operation, service, and troubleshooting of inertia drive starters.

Solenoid Shift Electric Starters

Covers UTE, Nippendenso, and Delco solenoid shift starter disassembly and service.

Section 9 Disassembly

Typical Disassembly Sequence

A suggested step-by-step procedure for complete engine disassembly.

Drain Oil from Crankcase and Remove Oil Filter

Instructions for draining engine oil and removing the oil filter before further disassembly.

Remove External Governor Components and Carburetor

Steps for removing governor linkage and the carburetor assembly.

Remove Valve Cover and Cylinder Head

Procedure for removing the valve cover and cylinder head assembly.

Remove Flywheel and Fan

Steps for removing components related to the flywheel and fan assembly.

Remove Oil Pan

Instructions for removing the oil pan from the crankcase.

Remove Hydraulic Lifters and Camshaft

Steps for removing the hydraulic lifters and camshaft.

Remove Connecting Rod and Piston

Procedure for separating the connecting rod and piston from the crankshaft.

Section 10 Inspection and Reconditioning

Automatic Compression Release (ACR)

Explanation of the ACR mechanism, its operation, and benefits for easier starting.

Crankshaft

Inspection procedures for crankshaft journals, keyways, and crankpin for wear or damage.

Cylinder Bore

Guidance on checking cylinder bore for scoring, wear, and proper resizing procedures.

Pistons and Rings

Inspection of pistons and rings for damage, wear, and proper installation techniques.

Valve Guides

Procedures for checking valve guide-to-stem clearance and reaming guides if necessary.

Section 11 Reassembly

Typical Reassembly Sequence

A suggested step-by-step procedure for complete engine reassembly.

Install Governor Gear and Cross Shaft

Instructions for installing the governor gear and cross shaft assembly.

Install Crankshaft

Procedure for lubricating and installing the crankshaft into the crankcase.

Install Piston and Connecting Rod

Steps for installing the piston and connecting rod assembly into the cylinder bore.

Installing Camshaft

Guidance on lubricating and timing the installation of the camshaft.

Reassemble Cylinder Head

Procedures for assembling the cylinder head components based on valve train configuration.

Install Fan and Flywheel

Precautions and steps for correctly installing the flywheel and fan assembly.

Prepare the Engine for Operation

Final checks and preparations before starting the engine after reassembly.

Testing the Engine

Recommended procedure for testing the engine on a stand after reassembly.

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