SERVICE MANUALVERTICAL CRANKSHAFTCOMMAND PRO CV940-CV1000
1.6Section 1Safety and General InformationDimensions in millimeters. Inch equivalents shown in [ ].411.64[16.206]14.7[.58]130.00[5.118]152.36[5.999]23
Section 9Inspection and Reconditioning9.8Valve Seat Cutter PilotValve Guidesȱȱȱȱȱȱ¢ȱęǰȱȱȱnot guide the valve
Section 9Inspection and Reconditioning99.9Overheated or Deteriorated OilScored Piston and RingsAbrasive Scratched RingsStuck, Broken RingsRing failure
Section 9Inspection and Reconditioning9.10Replacement pistons are available in STD bore size, and in 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) over
Section 9Inspection and Reconditioning99.11Figure 9-12. Piston Ring Installation.ȱ ŗǯȱ ȱȱȱǻĴȱǼDZȱȱȱexpander and then
Section 9Inspection and Reconditioning9.12Oil Pan AssemblyInspectionInspect the oil seal in the oil pan and remove it if it is worn or damaged. Refer
Section 9Inspection and Reconditioning99.13O-Ring32144. Install the O-Ring in the groove of the oil pump housing. Use a small quantity of grease to ho
9.14
10.110Section 10ReassemblyGeneralNOTE: Make sure the engine is assembled usingȱęȱȱǰȱȱǰȱȱǯȱ
10.2Section 10Reassemblyȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱǯȱ řǯȱ ȱȱȱȱȱȱ
10.3Section 10Reassembly10Oil SealSeal depth1.5 - 2.0 mm (0.059 - 0.078 in)CrankcaseSurface12.66 mm(0.498 in.)Crankcase SurfaceGovernorGear ShaftFigu
1.7Section 1Safety and General Information1¹Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine o
10.4Section 10ReassemblyŚǯȱ Ĵȱȱȱ¢ȱȱȱȱĞȱȱȱȱȱȱȃȄȱȱǯȱȱȱȱȱǯȱȱȱ
10.5Section 10Reassembly10No. 1 SideNo. 2 SideInstall Connecting Rods with Pistons and RingsDZȱ ȱ¢ȱȱȱȱȱǯȱȱ
10.6Section 10ReassemblyFigure 10-20. Torquing Connecting Rod End Cap Screws.ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱȱ
10.7Section 10Reassembly10OilSeal3 mm (0.118 in.)ȱ śǯȱ ȱȱȱ¢ȱȱȱȱȱȱȱ¢ǯInstall Oil Pan Seal and Main Bea
10.8Section 10ReassemblyO-Ring1081143512791164213Install Oil Pan Assemblyŗǯȱ ȱȱȱȱȱȱȱȱȱȱȱȱǰȱ
10.9Section 10Reassembly10CrankcaseFilterBreather HoseFlange Nuts (4)GasketCheck Crankshaft End playȱ ŗǯȱ ȱȱȱȱǰȱȱȱȱȱ
10.10Section 10Reassembly1342ȱ řǯȱ ȱȱȱ¡ȱĚȱǰȱȱȱȱȱȱȱȱȱŗŖȬřśȱȱ5.7 N·m (51 in. lb.)ǯFigu
10.11Section 10Reassembly10DZȱ ¢ȱĞȱȱ¢ȱȱȱȱȱȱȱȱȱ¢ǯȱȱ¡ȱĞȱȱ
10.12Section 10ReassemblySpacerWashers2245541331No. 1 No. 2Figure 10-43. Installing Valves with Valve Spring Compressor.Install Cylinder He
10.13Section 10Reassembly10ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱ¢ȱȱȱȱȱ¢ǯȱȱȱȱȱȱ¢ȱ
1.8Section 1Safety and General InformationCarburetor, Intake Manifold, and Air CleanerȱȱȱȱTorque Using Sequence in
10.14Section 10ReassemblyȱȱDZȱ ȱ ǯȱ ȱȱȱȱȱȱȱȱȱ ȱǯȱ ȱ ǯȱ ¢¢ȱȱĞȱȱȱȱȱǛ
10.15Section 10Reassembly10Figure 10-53. Establishing the "0" Lash Point.Śǯȱ ȱȱȱȱĴȱȱȱȱǰȱȱȱǻ
10.16Section 10ReassemblySpringInstall Spark Plugsȱ ŗǯȱ ȱȱ®ȱŗŖȱǻȱǼȱȱǯȱ Řǯȱ ȱȱȱȱ0.76 mm (0.030 in.)ǯ
10.17Section 10Reassembly10O-Rings AroundDowel PinsFigure 10-62. Installing Nipple into Cup and Oil Filter Housing.Figure 10-63. Torquing Nipple into
10.18Section 10Reassembly12Cylinder 1Cylinder 234Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱȱȱȱȱȱȱȱȱ
10.19Section 10Reassembly10Figure 10-71. Installing Stator.śǯȱ ȱȱȱȱȱȱȱȱȱƸȱȱȱȱȱȱȱȱ
10.20Section 10ReassemblyFigure 10-76. Clean and Dry Flywheel Hub.Figure 10-77. Installed Flywheel Key.DZȱ ȱȱȱĚ¢ȱ¢ȱȱȱ
10.21Section 10Reassembly10śǯȱ ȱȱ0.30 mm (0.012 in.)ȱĚȱȱȱȱȱȱȱȱȱǯȱȱȱŗŖȬŞŖǯȱȱ
10.22Section 10ReassemblyInstall Oil Coolerŗǯȱ ȱȱȱȱȱȱȱȱȱęȱȱȱȱȱǯȱȱȱȱ
10.23Section 10Reassembly10ȱ řǯȱ ȱȱȱȱȱǯȱȱȱŗŖȬŞŞǯFigure 10-88. Connecting Leads to Starting Motor.,QVWDOO9DOOH\%
1.9Section 1Safety and General Information1ĞȱȱȱȱǻȱȱǼRunning Clearance - New ...
10.24Section 10Reassembly1, 5432MountingScrewsInstall Control Bracket and Air Cleaner Assemblyȱ ŗǯȱ ȱȱȱȱ¢ȱȱȱ
10.25Section 10Reassembly10Fuel PumpOutlet HosePulseHoseInletHoseFigure 10-96. Installing Choke Link and Push-On Nut.Install Throttle and Choke Linkag
10.26Section 10ReassemblyOil PanAdjusting Governorȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱȱ¢ȱȱȱȱ
10.27Section 10Reassembly10Oil FillTubeLiftBracketLowerMountingScrewCylinder ShroudsMountingScrewsȱ Řǯȱ ȱȱȱȱȱȱȱȱ¢™
10.28Section 10ReassemblyInstall Oil Filter and Add Oil to Crankcaseȱ ŗǯȱ ȱȱȱȱǯȱȱȱŗŖȬŗŖşǯȱȱȱȱȱŘŗǯŚȱȉ
10.29Section 10Reassembly10Testing the Engineȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱ
10.30
LITHO IN U.S.A.FORM NO.: TP-2581ISSUED: 1/09REVISED: ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044FOR SALES AND SERVICE INFORMATION IN U.S. AN
1.10Section 1Safety and General InformationGrass Screen Hex Stud Torque ...
1.11Section 1Safety and General Information1ŶȱȱŗŗȱȱǻŖǯŚřřȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯTop Comp
1.12Section 1Safety and General InformationTightening Torque: N·m (in. lb.) + or - 10%Property ClassNoncriticalFastenersInto AluminumSizeM4 1.2 (11) 1
1.13Section 1Safety and General Information1English Fastener Torque Recommendations for Standard ApplicationsGrade 2 or 5Fasteners IntoAluminumSize8-3
1.14
2.1Section 2Tools & Aids2Section 2Tools & AidsToolsDescription Source/Part No.Ğȱ¢ȱȱȱĞȱ¢ǯȱȱȬŞ
2.2Section 2Tools & AidsTools (Continued)Description Source/Part No.¢ȱȱĞȱȱȱȱȱ¢ȱĞǯȱŘśȱŝŜŗ
2.3Section 2Tools & Aids2AidsDescription Source/Part No.ĞȱȱǻȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬȱȱǻȦȱŜŜŗǼ
2.4Section 2Tools & AidsSpecial Tools You Can MakeFlywheel Holding ToolȱĚ¢ȱȱȱȱȱȱȱȱȱȱȱĚ¢ȱȱȱȱ
3.13Section 3TroubleshootingTroubleshooting GuideWhen troubles occur, be sure to check the simple ȱǰȱȱęǰȱ¢ȱȱȱȱȱȱco
3.2Section 3TroubleshootingEngine Overheatsȱ ŗǯȱ ȱȦȱǰȱȱęǰȱȱȱshrouds clogged.ȱ Řǯȱ ¡ȱȱǯȱ řǯȱ
3.3Section 3Troubleshooting3ȱȱȱȱȱȱȱȱȱȱthe engine is reassembled and placed into operation. ȱȱ
3.4Section 3TroubleshootingLeakdown Test Resultsȱȱȱȱ ...ȱȱ
4.14Section 4Air Cleaner and Air Intake SystemPaper ElementInnerElementInlet ScreenAir CleanersGeneralThese engines utilize a Heavy-Duty style air cle
4.2Section 4Air Cleaner and Air Intake SystemEjectorAreaCylinderShroud4. Do not wash the paper element and inner element or use compressed air, this w
5.15Section 5Fuel System and GovernorDescriptionThis section covers the carbureted fuel system used on these engines. The governor system is covered a
ContentsSection 1. Safety and General Information...Section 2. Tools & A
5.2Section 5Fuel System and GovernorFuel System TestsWhen the engine starts hard, or turns over but will not start, it is possible that the problem is
5.3Section 5Fuel System and Governor5Self-RelievingChokeFuel Shut-OffSolenoidBowl Drain ScrewSlow JetsBowl VentLow Idle Fuel Adjustments(With Limiters
5.4Section 5Fuel System and GovernorTroubleshooting ChecklistWhen the engine starts hard, runs roughly or stalls at low idle speed, check the followin
5.5Section 5Fuel System and Governor5Fuel Shut-OffSolenoidHigh Altitude OperationȱȱȱȱȱȱȱŗśŖŖȱȱǻśŖŖŖȱĞǯǼȱȱǰ
5.6Section 5Fuel System and GovernorLeanRichAdjust to MidpointLeanRichAdjust to MidpointLeft SideRight SideCarburetor AdjustmentsAdjustmentDZȱ
5.7Section 5Fuel System and Governor5Governed Idle Systemȱȱȱȱ¢ȱȱȱȱȱȱdesired idle speed regardless of ambient
5.8Section 5Fuel System and GovernorFigure 5-11. Setting High Speed RPM (Air Cleaner Removed for Clarity).Carburetor ServicingThe following section co
5.9Section 5Fuel System and Governor5Figure 5-14. Float and Inlet Needle Details. ȱ Ŝǯȱ ȱȱĚȱȱȱȱȱȱȱseat and carbu
5.10Section 5Fuel System and GovernorFigure 5-18. Fuel Bowl Removed From Carburetor.DZȱ ȱ¢ȱȱȱȱȱis not necessary unles
5.11Section 5Fuel System and Governor5śǯȱ ȱȱȱȱǻǼȱȱȱand spring from the carburetor. Discard the parts.DZȱ ȱ
5.12Section 5Fuel System and GovernorFigure 5-26. Installing Float Assembly.ŗŚǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱhangs vertically and re
5.13Section 5Fuel System and Governor5śǯȱ ȱȱȱ¡ȱǻ¢ȬǼȱȱȱȱȱȱĞȱȱȱȱȱȱlever from th
5.14Section 5Fuel System and GovernorȱŗŘǯȱ ȬȱǻȱȱȬȱǼ 13. Drain Screw 14. Bowl Screw (4)ȱŗśǯȱ ȱȱŗŜǯȱ ȱ 17. Fl
5.15Section 5Fuel System and Governor5GovernorLeverGovernorCross ShaftGovernedIdle SpringLinkageGovernorSpringGovernorGeneralThe governor is designed
5.16Section 5Fuel System and GovernorHold Lever in"Full Throttle"PositionHigh Speed (RPM)Adjustment Screw3. Stop when the desired RPM speed
6.16Section 6Lubrication SystemSAE10W30APISERVICESJ5W-20, 5W-30RECOMMENDED SAE VISCOSITY GRADES10W-30Kohler 10W-30°F-200203240 6080100°C-30 -20-10 010
6.2Section 6Lubrication SystemOil Drain PlugDrain PlugOperating RangeChecking Oil LevelThe importance of checking and maintaining the proper oil lev
6.3Section 6Lubrication System6ȱ řǯȱ ȱȱȱȱȱȱȱ21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ.ȱ Śǯȱ ȱȱǰȱȱȱȱȱȱ
6.4Section 6Lubrication SystemPressureSwitchService Oil CoolerȱȱȱȱȱȱȱȱȱȱȱǯȱŘȱȱ¢ȱ
6.5Section 6Lubrication System6Installationȱȱ¢ȜȱȱȱȱȱȱȱȱȱȱǯȱȱȱŜȬŗŘǯȱȱȱȱ
1.11Rotating Parts!Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, o
6.6
7.17Section 7Electrical System and ComponentsThis section covers the operation, service, and repair of the electrical system components. Systems and c
7.2Section 7Electrical System and ComponentsDZȱȱȱȱȱȱȱȱȱnormal conditions will have light tan or gray colored
7.3Section 7Electrical System and Components7DC VoltmeterBatteryBatteryGeneralȱŗŘȬȱĴ¢ȱȱŚŖŖȱȱȱȱǻǼȱȱgenerally recommen
7.4Section 7Electrical System and ComponentsMolex Plug(Some Models)ȱȱȱěȱ¢ȱȱȱ¢ȱȱȱǯȱȱ¢ȱ
7.5Section 7Electrical System and Components7Kill Switch or ‘‘Off’’ Position of Key SwitchIgnitionModulesSpark PlugMagnetFlywheel(0.28/0.33 mm)0.011/0
7.6Section 7Electrical System and Componentsǯȱ ȱȱȱȱǰȱȱȱ¢ȱȱȱȱȱǯȱȱȱ¢ȱǰȱwires, con
7.7Section 7Electrical System and Components7Troubleshooting DSAI Ignition Systemsȱȱȱ¢ȱȱȱȱȱȱȱȱȱ
7.8Section 7Electrical System and Componentsȱ Řǯȱ ȱȱȱǰȱȱȱȱȱśśŖȬŜŖŖȱǰȱȱȱǻǼȱȱǯȱ řǯȱ
7.9Section 7Electrical System and Components7Battery Charging SystemGeneralMost engines are equipped with a 15, 20, or 25 ampȱȱ¢
1.2Section 1Safety and General Information¡ȱȱȱȱęȱȱsevere burns.ȱȱęȱȱȱȱȱȱengine is hot or running.W
7.10Section 7Electrical System and Components15/20/25 Amp Regulated Charging SystemFigure 7-11. Wiring Diagram - 15/20/25 Amp Regulated Battery Chargi
7.11Section 7Electrical System and Components7Figure 7-12. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four
7.12Section 7Electrical System and ComponentsFigure 7-13. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five
7.13Section 7Electrical System and Components7StatorȱȱȱȱȱȱȱȱȱĚ¢ǯȱȱȱȱȱȱŞȱȬȱȃ
7.14Section 7Electrical System and Componentsśǯȱ ȱȱȱȱȱȱȱȦȱȱȱȱǯȱȱȱȱȱǯȱȱ
7.15Section 7Electrical System and Components7Troubleshooting Guide15/20/25 Amp Battery Charging SystemsȱȱȱȱȱȱĴ¢ȱ
7.16Section 7Electrical System and ComponentsDC Voltmeter5HFWL¿HU5HJXODWRUFlywheelStatorAmmeterBattery(-)(+)Figure 7-20. Connections for Testing Char
7.17Section 7Electrical System and Components7Torx Head Screws7URXEOHVKRRWLQJ*XLGH±6WDUWLQJ'LI¿FXOWLHVDelco-Remy StartersFigure 7-21. Delco-R
7.18Section 7Electrical System and ComponentsFigure 7-23. Solenoid Removed from Starter. Figure 7-24. Removing Plunger.ȱ Śǯȱ ȱȱȱȱǻ
7.19Section 7Electrical System and Components7DriveEnd CapScrewPlungerSpringLeverPlatePlugSolenoidFrame & FieldBrush HolderNutCommutatorEnd PlateS
1.3Section 1Safety and General Information1A. Model No.C V 980 SB. Spec. No.Command EngineVersion CodeS = Electric StartC. Serial No.Year Manufactured
7.20Section 7Electrical System and ComponentsWear Limit Length7.6 mm (0.300 in.)Mica InsulationCommutator O.D.InspectionDrive Pinionȱȱȱ
7.21Section 7Electrical System and Components7Brush ReplacementȱȱȱȱȱȱȱȱȱǻŚǼǯȱȱȱȱȱȱȱȱ
7.22Section 7Electrical System and Componentsřǯȱ ȱȱěȱȱǻǼȱȱȱȱȱȃěȄȱȱȱȱȱȱȦ
7.23Section 7Electrical System and Components7Figure 7-43. Installing Thrust Washer.ȱŗŖǯȱ ȱ¢ȱȱȱȱȦȱȱ
7.24Section 7Electrical System and ComponentsExtension.ǯȱ ȱȱȱ¢ȱ¢ȱȱȱend housing, and carefully place the tool ǻ
7.25Section 7Electrical System and Components7VOM Leads12 volt Test LeadsMomentaryConnection OnlySolenoid Test ProcedureSolenoid Shift Style Starters
7.26Section 7Electrical System and ComponentsTest 4. Solenoid Hold-In Coil/Contact Continuity Test.ȱȱȱȱȱȱȱȱ¡Řȱǰȱ
8.18Section 8DisassemblyWARNING: Accidental Starts!Disabling engine. Accidental starting can cause severe injury or death. Before working on the engin
8.2Section 8DisassemblyCylinder ShroudShut Off Fuel SupplyDrain Oil from Crankcase and Remove Oil Filterȱ ŗǯȱ ȱȱȱęȱȱȱǯȱ
8.3Section 8Disassembly83. Remove the lower mounting screw and pull the ȱęȱȱȱȱȱǯFigure 8-7. Removing Oil Fill Tube.Remove El
1.4Section 1Safety and General InformationSAE10W30APISERVICESJ5W-20, 5W-30RECOMMENDED SAE VISCOSITY GRADES10W-30Kohler 10W-30°F-200203240 6080100°C-30
8.4Section 8DisassemblyRemove Fuel PumpWARNING: Explosive Fuel!ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱȱǯȱȱȱ
8.5Section 8Disassembly8Figure 8-15. Removing Control Bracket.ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱȱȱȱȱĞǯȱȱ
8.6Section 8DisassemblyNOTE: New clamps are recommended any time disassembly is performed, or if clamps have been loosened (expanded) several times.)L
8.7Section 8Disassembly8Figure 8-24. Removing Oil Filter Housing.ȱȱȱ¢ȱȱȱȱęȱȱassembly requires individual serv
8.8Section 8DisassemblyRemove Grass Screen and Cooling Fanȱ ŗǯȱ ȱȱǰȱĴȱǰȱȱ¡ȱȱȱȱȱǰȱě
8.9Section 8Disassembly8Wiring HarnessMoldedClips2. Remove the mounting screws securing the ęȬȱȱȱȱȱassembly. Note th
8.10Section 8DisassemblyRemove Valve Covers1. Remove the screw and grommet securing each valve cover. 2. Remove the valve cover and gasket from each c
8.11Section 8Disassembly8Figure 8-42. Removing Hydraulic Lifters. Figure 8-43. Match Numbers on Cylinder Barrel and Heads.Disassemble Cylinder Heads1.
8.12Section 8DisassemblyFigure 8-47. Valve Stem Seals.NOTE: These engines use valve stem seals on the intake and exhaust valves. Use a new seal whenev
8.13Section 8Disassembly8Figure 8-52. Removing Oil Pan.Oil Pump AssemblyThe oil pump is mounted to the inside of the oil pan. If service is required,
1.5Section 1Safety and General Information1¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.2Have a Kohle
8.14Section 8Disassembly2. Carefully remove the connecting rod and piston ¢ȱȱȱ¢ȱǯȱȱȱŞȬśŜǯFigure 8-56. Removing Pisto
8.15Section 8Disassembly8Remove Lifter Feed Chamber Cover and Gasketsȱ ŗǯȱ ȱȱȱȱȱȱĞȱȱchamber cover, and gaskets.
8.16
99.1Section 9Inspection and ReconditioningThis section covers the operation, inspection, and repair/reconditioning of major internal engine components
Section 9Inspection and Reconditioning9.245°High Point from Fillet IntersectionsThis Fillet AreaMust Be Completely SmoothMinimumThe Fillet Must Blend
Section 9Inspection and Reconditioning99.311 mm (0.433 in.)Measure 11 mm above the Bottom of Piston Skirt at Right Angles to Piston Pinaccomplished at
Section 9Inspection and Reconditioning9.4Feeler Gauge2. Use an inside micrometer, telescoping gauge, or bore gauge and measure the cylinder bore. Take
Section 9Inspection and Reconditioning99.5EXHAUST VALVEINTAKE VALVEABCDDFEGHFEGHINTEXHFigure 9-6. Valve Details.ȱȱȱȱȱȱ
Section 9Inspection and Reconditioning9.6Normal:ȱȱĞȱȱȱȱȱȱȱcan be reconditioned and reused if the face and margin are
Section 9Inspection and Reconditioning99.7Excessive Combustion Temperatures: The white deposits seen here indicate very high combustion temperatures,
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