12 690 01 Rev Lawn Mower Parts Riding Lawn Mower Parts

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15 15 hp 16 16 hp identi cation 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

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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,Safety and CV490 495,General Information. 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 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 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 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,WARNING WARNING WARNING.
Accidental Starts can cause Rotating Parts can cause severe Hot Parts can cause severe burns. severe injury or death injury,Do not touch engine while operating. Disconnect and ground spark plug Stay away while engine is in or just after stopping. leads before servicing operation,Accidental Starts Rotating Parts Hot Parts. Disabling engine Accidental Keep hands feet hair and clothing Engine components can get. starting can cause severe away from all moving parts to extremely hot from operation To. injury or death Before working prevent injury Never operate the prevent severe burns do not touch. on the engine or equipment engine with covers shrouds or these areas while the engine is. disable the engine as follows 1 guards removed running or immediately after it. Disconnect the spark plug lead s is turned off Never operate the. 2 Disconnect negative battery engine with heat shields or guards. cable from battery removed,Safety and General Information. WARNING WARNING WARNING, Explosive Fuel can cause fires and Carbon Monoxide can cause Explosive Gas can cause fires and. severe burns severe nausea fainting or death severe acid burns. Charge battery only in a well, Stop engine before filling fuel tank Do not operate engine in closed or ventilated area Keep sources of.
confined area ignition away,Explosive Fuel Lethal Exhaust Gases Explosive Gas. Gasoline is extremely flammable Engine exhaust gases contain Batteries produce explosive. and its vapors can explode if poisonous carbon monoxide hydrogen gas while being. ignited Store gasoline only in Carbon monoxide is odorless charged To prevent a fire or. approved containers in well colorless and can cause death explosion charge batteries only in. ventilated unoccupied buildings if inhaled Avoid inhaling exhaust well ventilated areas Keep. away from sparks or flames Do fumes and never run the engine sparks open flames and other. not fill the fuel tank while the in a closed building or confined sources of ignition away from the. engine is hot or running since area battery at all times Keep batteries. spilled fuel could ignite if it comes out of the reach of children. in contact with hot parts or sparks Remove all jewelry when servicing. from ignition Do not start the WARNING batteries,engine near spilled fuel Never use. gasoline as a cleaning agent Before disconnecting the negative. ground cable make sure all,switches are OFF If ON a spark. WARNING Uncoiling Spring can cause severe will occur at the ground cable. injury terminal which could cause an, Wear safety goggles or face explosion if hydrogen gas or. protection when servicing retractable gasoline vapors are present. Cleaning Solvents can cause,severe injury or death.
Spring Under Tension CAUTION,Retractable starters contain a. powerful recoil spring that is,Use only in well ventilated areas away. from ignition sources under tension Always wear safety. goggles when servicing retractable,Flammable Solvents starters and carefully follow. Electrical Shock can cause injury, Carburetor cleaners and solvents instructions in Retractable Starter. are extremely flammable Keep Section 7 for relieving spring Do not touch wires while engine is. sparks flames and other sources tension running,of ignition away from the area.
Follow the cleaner manufacturer s,warnings and instructions on its Electrical Shock. proper and safe use Never use Never touch electrical wires or. gasoline as a cleaning agent components while the engine is. running They can be sources of,electrical shock,Safety and General Information. Engine Identification Numbers,When ordering parts or in any communication. involving an engine always give the Model 1,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.
Identification Decal,Figure 1 1 Engine Identification Decal Location. A Model No C V 12 5 ST,Command Engine Version Code. Vertical Crankshaft S Electric Start,Displacement cc T Retractable Start. or Horsepower,460 460 cc ST Electric Retractable Start. 490 490 cc 12 5 12 5 HP,B Spec No 1203,MODEL NO CV12 5ST A.
Engine Model Code Variation of,Code Model Basic Engine SPEC NO 1203 B. 11 CV11 SERIAL NO 2105810334 C,12 CV12 5 REFER TO OWNER S MANUAL FOR. SAFETY MAINTENANCE SPECS,22 CV13 AND ADJUSTMENTS FOR SALES. 14 CV14 AND SERVICE IN US CANADA,41 CV15 CALL 1 800 544 2444. 43 CV16 www kohlerengines com,265 CV460 465,275 CV490 495.
KOHLER CO KOHLER WI USA,C Serial No 2105810334,Year Manufactured Code Factory Code. Code Model, Figure 1 2 Explanation of Engine Identification Numbers. Safety and General Information,Oil Recommendations Fuel Recommendations. Using the proper type and weight of oil in the, crankcase is extremely important as is checking oil WARNING Explosive Fuel. daily and changing oil regularly Failure to use the Gasoline is extremely flammable and its vapors can. correct oil or using dirty oil causes premature engine explode if ignited Store gasoline only in approved. wear and failure Synthetic oil is recommended for containers in well ventilated unoccupied buildings. use in LPG fueled engines because there is less away from sparks or flames Do not fill the fuel tank. oxidation or thickening and deposit accumulation on while the engine is hot or running since spilled fuel. intake valves is substantially reduced could ignite if it comes in contact with hot parts or. sparks from ignition Do not start the engine near, Oil Type spilled fuel Never use gasoline as a cleaning agent.
Use high quality detergent oil of API American, Petroleum Institute service class SG SH SJ General Recommendations. or higher Select the viscosity based on the air Purchase gasoline in small quantities and store. temperature at the time of operation as shown below 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. Use of synthetic oil having 5W 20 or 5W 30 rating is Do not overfill the fuel tank Leave room for the fuel to. acceptable up to 4 C 40 F expand, Synthetic oils will provide better starting in extreme cold.
below 23 C 10 F,For best results use only clean fresh unleaded. NOTE Using other than service class SG SH SJ or gasoline with a pump sticker octane rating of 87 or. higher oil or extending oil change intervals higher In countries using the Research method it. longer than recommended can cause engine should be 90 octane minimum. Unleaded gasoline is recommended as it leaves less. A logo or symbol on oil containers identifies the API combustion chamber deposits Leaded gasoline may. service class and SAE viscosity grade See Figure 1 3 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,Gasoline Ether blends. Figure 1 3 Oil Container Logo Methyl Tertiary Butyl Ether MTBE and unleaded. gasoline blends up to maximum of 15 MTBE by, Refer to Section 6 Lubrication System for detailed volume are approved as a fuel for Kohler engines.
oil check oil change and oil filter change procedures Other gasoline ether blends are not approved. Safety and General Information,Periodic Maintenance. WARNING Accidental Starts 1, 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,Frequency Maintenance Required Refer to. Fill fuel tank Section 5,Daily or Before Check oil level Section 6.
Starting Engine Check air cleaner for dirty1 loose or damaged parts Section 4. Check air intake and cooling areas clean as necessary1 Section 4. Every 25 Hours Service precleaner element1 Section 4. Every Replace air cleaner element1 Section 4,100 Hours Change oil1 Section 6. Remove cooling shrouds and clean cooling areas1 Section 4. Every Change oil filter1 Section 6, 200 Hours Check spark plug condition and gap Section 8. Annually or Have bendix starter drive serviced2 Section 8. Every Have solenoid shift starter disassembled and cleaned2 Section 8. Perform these maintenance procedures more frequently under extremely dusty dirty conditions. Have a Kohler Engine Service Dealer perform this service Not necessary on Delco Starters. Storage To empty the system run the engine until the tank. If the engine will be out of service for two months or and system are empty. more use the following storage procedure,4 Remove the spark plug Add one tablespoon of. 1 Clean the exterior surfaces of the engine engine oil into the spark plug hole Install the. plug but do not connect the plug lead Crank the, 2 Change the oil and oil filter while the engine is engine two or three revolutions. still warm from operation See Change Oil and, Oil Filter in Section 6 5 Remove the spark plug Cover the spark plug.
hole with your thumb and turn the engine, 3 The fuel system must be completely emptied over until the piston is at the top of its stroke. or the gasoline must be treated with a stabilizer Pressure against thumb is greatest Reinstall. to prevent deterioration If you choose to the plug but do not connect the plug lead. use a stabilizer follow the manufacturers, recommendations and add the correct amount 6 Store the engine in a clean dry place. 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. Safety and General Information,Air Filter,CL Cylinder.
Oil Filter,Carburetor,Fuel Shut off,Carburetor 47,Fuel Inlet Engine Mounting. Oil Drain Plug,3 8 NPT Inch 17,CL Cylinder,Oil Filter Side. Valve Cover End 1 00,16 18 6 34 Keyway Width,Air Cleaner 250. Cover Removal,321 CL Cylinder,62 5 1 04 CL Throttle Cable. Exhaust Flange,Engine Mounting 2 46,Mounting Surface.
Surface 19,Starter Motor 25 4 74,6 34 80 16,Keyway Width 204. Starter Side 8 04 176 6,CL Cylinder,220 2 4 88,60 0 Oil Level. 2 36 135 0 108 Dipstick Fill,254 4 0 328,10 0 16 12 91. CL Cylinder,Rotation Flywheel End,CV11 16 10 mm shorter. 35 35 Exhaust Flange,Mounting Surface,Engine Mounting Surface.
Dimensions in are inch equivalents,Figure 1 4 Typical Engine Dimensions. Safety and General Information,General Specifications. Power 3600 RPM corrected to SAE J1995,CV11 8 2 kW 11 HP 1. 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.
CV11 14 CV460 465 87 mm 3 43 in,CV15 CV16 CV490 495 90 mm 3 60 in. 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, Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior. to assembly,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. 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,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.
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,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.
Safety and General Information,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 1. 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, 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,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 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 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, 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,Safety and General Information.
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 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,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.

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