Simplicity 490 Service Manual

1COMMANDSERVICE MANUALVERTICAL CRANKSHAFTCV11-16,CV460-465,CV490-495

1.8Section 1Safety and General InformationBalance ShaftEnd Play ...

9.6Section 9Disassembly3. Remove the hex. flange nut on stud securing thecarburetor side baffle,* if not removed previouslyduring carburetor removal.

9.7Section 9Disassembly9Figure 9-24. Removing Cylinder Head.Figure 9-22. Removing Fuel Line (not on allmodels).Remove Valve Cover and Cylinder Head1.

9.8Section 9DisassemblyRocker ShaftHex.FlangeScrewBreather Reed Retainerand Breather ReedRocker ArmsSpark PlugFigure 9-26. Removing Spark Plug, Breath

9.9Section 9Disassembly9Figure 9-29. Removing Valves. (Bridge Type Head.)Remove Drive Cup, Grass Screen,Flywheel and FanNOTE: Always use a flywheel st

9.10Section 9Disassembly1. Check if the extra retaining clips are present. If so,cut the clips, so they can be removed and discard.Mark the tops of th

9.11Section 9Disassembly9Oil PanHex. FlangeScrews (12)Figure 9-36. Removing Oil Pan.3. Locate the splitting tabs on the oil pan andcrankcase. Insert t

9.12Section 9DisassemblyFigure 9-42. Original Style - Removing Oil PumpCovers and Rotors.ShimCamshaftOil Pump CoverHex. Flange ScrewsO-RingOilPumpRoto

9.13Section 9Disassembly9Figure 9-45. Removing Balance Shaft.Figure 9-46.Remove Connecting Rod and Piston1. Remove the two hex. flange screws andconne

9.14Section 9DisassemblyFigure 9-50. Removing Crankshaft.Remove Flywheel End Oil Seal1. Remove the oil seal from the crankcase.Remove Governor Cross S

9.15Section 9Disassembly9Regulating PinGovernor GearFigure 9-53. Removing Governor Gear.

1.9Section 1Safety and General Information1CrankshaftEnd Play (free)...

9.16Section 9Disassembly

10.1Section 10Inspection and Reconditioning10Section 10Inspection and ReconditioningCV11-16CV460-465, CV490-495This section covers the operation, insp

10.2Section 10Inspection and Reconditioning4. The choke control setting is less critical with ACR.In the event of flooding, excess fuel is blown outth

10.3Section 10Inspection and Reconditioning10Figure 10-2. Removing Plug.CrankcaseInspection and ServiceCheck all gasket surfaces to make sure they are

10.4Section 10Inspection and ReconditioningFigure 10-3. Cylinder Bore Crosshatch afterHoning.4. After resizing, check the bore for roundness,taper, an

10.5Section 10Inspection and Reconditioning10Cylinder Head and ValvesInspection and ServiceCarefully inspect the valve mechanism parts. Inspectthe val

10.6Section 10Inspection and ReconditioningNormal: Even after long hours of operation a valvecan be reconditioned and reused if the face andmargin are

10.7Section 10Inspection and Reconditioning10Excessive Combustion Temperatures: The whitedeposits seen here indicate very high combustiontemperatures,

10.8Section 10Inspection and ReconditioningValve GuidesIf a valve guide is worn beyond specifications, it will notguide the valve in a straight line.

10.9Section 10Inspection and Reconditioning10Ring failure is usually indicated by excessive oilconsumption and blue exhaust smoke. When rings fail,oil

1.10Section 1Safety and General InformationCylinder HeadCylinder Head Fastener Torque (torque in 2 increments)... 20, 40.7 N·m (15, 30 ft. lb.)M

10.10Section 10Inspection and ReconditioningSome important points to remember when servicingpiston rings:1. If the cylinder bore does not need reborin

10.11Section 10Inspection and Reconditioning101. Oil Control Ring (Bottom Groove): Install theexpander and then the rails. Make sure the endsof the ex

10.12Section 10Inspection and ReconditioningFigure 10-13. Governor Shaft.2. Install new governor regulating pin, Part No.12 380 01-S, and governor gea

11.1Section 11Reassembly11Section 11ReassemblyCV11-16CV460-465, CV490-495The following sequence is suggested for completeengine reassembly. This proce

11.2Section 11Reassembly3. Using the KO1030 oil seal installer, install a newgovernor cross shaft oil seal into the crankcase.See Figure 11-2.Figure 1

11.3Section 11Reassembly11On CV460-495 models the offset of the connecting rodand cap must be oriented to the left, with the partnumber up. The arrow

11.4Section 11Reassembly4. Lubricate the crankshaft journal and connectingrod bearing surfaces with engine oil. Install the rodcap to connecting rod.5

11.5Section 11Reassembly11Installing Camshaft1. Lubricate the camshaft lobes and bearingsurfaces with engine oil.2. Align the timing marks on the cams

11.6Section 11ReassemblyFigure 11-16. Installing Oil Pressure Relief ValveBracket.Later (One-Piece) Style Oil Pressure Relief Valve1. If this style re

11.7Section 11Reassembly11Figure 11-20. Installing Oil Pickup Components.Install Oil Pan to CrankcaseRTV silicone sealant is used as a gasket between

1.11Section 1Safety and General Information1Ignition (Cont'd)Spark Plug Torque ...

11.8Section 11ReassemblyFigure 11-24. Installing Oil Pump Cover.Torque the screws as follows:Into new as-cast hole–6.2 N·m (55 in. lb.).Into used hole

11.9Section 11Reassembly11Figure 11-25. Installing Oil Seals.Install Stator and Wiring Harness1. Push the stator leads through the hole to theoutside

11.10Section 11Reassembly2. Reattach the fan to the flywheel, using thespacers and hex. flange screws, or shoulderscrews. See Figure 11-28. Torque the

11.11Section 11Reassembly11Figure 11-32. Torquing Flywheel Fastener (ElectricStart Models).5. Install the grass screen onto the fan assembly(electric

11.12Section 11ReassemblyReassemble Cylinder HeadRefer to Figure 11-37 for cylinder head differences. Assemble the components accordingly, based on he

11.13Section 11Reassembly11Figure 11-39. Installing Valve Keepers.4. Rocker Bridge Heads–Figure 11-40a. Position the rocker arms over the valve stemsa

11.14Section 11ReassemblyFigure 11-42. Installing Adjustment Nut.5. Install breather reed and reed retainer, securewith the M5 hex. flange screw. Torq

11.15Section 11Reassembly11Heads with Separate Pivots/Rocker Arms–Figure 11-37• Non-Adjustable Valve Lash Configurationa. Seat the push rods into sock

11.16Section 11ReassemblyInstall Ignition Module1. Rotate the flywheel so the magnet is away from theignition module bosses. Install the ignition modu

11.17Section 11Reassembly11Figure 11-52. Installing Cylinder Head Baffle.5. Install the grommet around the high tension lead(metal blower housings onl

1.12Section 1Safety and General InformationPiston, Piston Rings, and Piston Pin (Cont'd.)Center Compression Ring End GapNew Bore CV11-14, CV460-

11.18Section 11Reassembly2. Apply a 1/16" bead of RTV sealant to the cylinderhead as shown in Figure 11-55.NOTE: To ensure proper adhesion of the

11.19Section 11Reassembly11Install Carburetor and ExternalGovernor Components1. Install the rubber fuel line and secure the rubberfuel line to the met

11.20Section 11ReassemblyFigure 11-63. Attaching the Ground Lead.5. Install the governor lever onto the cross shaft, butDO NOT tighten at this time. A

11.21Section 11Reassembly11b. Grasp the cross shaft with a pliers and turn theshaft couterclockwise as far as it will go, thentighten the hex. nut sec

11.22Section 11ReassemblyFigure 11-68. Installing Air Cleaner Cover.Install Electric StarterElectric Starter (Bendix Drive or Solenoid Shift)1. Instal

11.23Section 11Reassembly11Figure 11-72. Installing Muffler.Prepare the Engine for OperationThe engine is now completely reassembled. Beforestarting o

1COMMANDSERVICE MANUALVERTICAL CRANKSHAFTCV11-16,CV460-465,CV490-495

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044FOR SALES AND SERVICE INFORMATIONIN U.S. AND CANADA, CALL1-800-544-2444LITHO IN U.S.A.FORM NO.: TP

1.13Section 1Safety and General Information1Valves and Valve LiftersHydraulic Valve Lifter to Crankcase Running Clearance ... 0.0124/0.0501 mm

1.14Section 1Safety and General InformationGeneral Torque ValuesMetric Fastener Torque Recommendations for Standard ApplicationsSizeM4 1.2 (11) 1.7 (1

2.1Section 2Special Tools2Section 2Special ToolsCV11-16CV460-465, CV490-495Kohler Special Service ToolsKohler Co. has made an agreement with the Servi

2.2Section 2Special ToolsDiagnostic and Repair ToolsThe tools listed in the following table are used for specific diagnosis or repair procedures, as d

2.3Section 2Special Tools2Special Tools You Can MakeFlywheel Holding ToolFlywheel removal and reinstallation becomes a “snap”using a handy holding too

ContentsSection 1. Safety and General Information ...Section 2. Special Tools

2.4Section 2Special Tools

3.1Section 3Troubleshooting3Section 3TroubleshootingCV11-16CV460-465, CV490-495Troubleshooting GuideWhen troubles occur, be sure to check the simpleca

3.2Section 3TroubleshootingEngine Loses Power1. Low crankcase oil level.2. High crankcase oil level.3. Dirty air cleaner element.4. Dirt or water in t

3.3Section 3Troubleshooting3Basic Engine TestsCrankcase Vacuum TestA partial vacuum should be present in the crankcasewhen the engine is operating at

3.4Section 3TroubleshootingCompression TestThese engines are equipped with an automaticcompression release (ACR) mechanism. Because ofthe ACR mechanis

4.1Section 4Air Cleaner and Air Intake System4Section 4Air Cleaner and Air Intake SystemCV11-16CV460-465, CV490-495Air CleanerThese engines are equipp

4.2Section 4Air Cleaner and Air Intake SystemOn these, air is drawn in around the bottom of thecover, or from the blower housing, rather than fromslot

4.3Section 4Air Cleaner and Air Intake System4NOTE: Damaged, worn, or loose air cleanercomponents can allow unfiltered air into theengine causing prem

4.4Section 4Air Cleaner and Air Intake System

5.1Section 5Fuel System and Governor5Section 5Fuel System and GovernorCV11-16CV460-465, CV490-495Gasoline fuel systems are covered in the first part o

1.1Section 1Safety and General Information1Section 1Safety and General InformationCV11-16CV460-465, CV490-495Safety PrecautionsTo insure safe operatio

5.2Section 5Fuel System and GovernorFuel System Troubleshooting Guide (Gasoline)Test Conclusion1. Check for the following:a. Make sure the fuel tank c

5.3Section 5Fuel System and Governor5RepairNylon-bodied fuel pumps are not serviceable and mustbe replaced when faulty. Replacement pumps areavailable

5.4Section 5Fuel System and GovernorTroubleshooting - Gasoline SystemsIf engine troubles are experienced that appear to befuel system related, check t

5.5Section 5Fuel System and Governor5Now turn the adjusting needle in (clockwise). Theengine speed may increase, then it will decreaseas the needle is

5.6Section 5Fuel System and GovernorDisassemblyFigure 5-6. Carburetor - Exploded View.1. Remove the bowl retaining screw, retaining screwgasket, and f

5.7Section 5Fuel System and Governor5Figure 5-7. Removing Welch Plug.Main Fuel Jet RemovalThe main jet on Walbro carburetors is pressed into theside o

5.8Section 5Fuel System and GovernorCleaningWARNING: Flammable Solvents!Carburetor cleaners and solvents are extremelyflammable. Keep sparks, flames,

5.9Section 5Fuel System and Governor5RepairAlways use new gaskets when servicing or reinstallingcarburetors. Repair kits are available which includene

5.10Section 5Fuel System and GovernorFigure 5-14. Installing Float and Fuel Inlet Needle.5. Install the bowl gasket, fuel bowl, bowl retainingscrew ga

5.11Section 5Fuel System and Governor5If these check out, the solenoid should be removed forbench testing. Remember to shut off fuel supply andcatch a

1.2Section 1Safety and General InformationCarbon Monoxide can causesevere nausea, fainting or death.Do not operate engine in closed orconfined area.WA

5.12Section 5Fuel System and GovernorTroubleshooting - LPG SystemsIf engine troubles are experienced that appear to becaused by the carburetor, check

5.13Section 5Fuel System and Governor5Kohler Emission Sentry™ SystemSome Kohler Command engines are equipped with theEmission Sentry™ System. Emission

5.14Section 5Fuel System and Governor2. The stepper motor, electronic control unit(ECU) and oxygen sensor can all be checked withthe Kohler Emission S

5.15Section 5Fuel System and Governor5When the engine is at rest, and the throttle is in the‘‘fast’’ position, the tension of the governor spring hold

5.16Section 5Fuel System and GovernorFigure 5-20. Typical Throttle/Choke Controls.3. Align the hole in the throttle lever with the hole inthe speed co

5.17Section 5Fuel System and Governor5Choke AdjustmentThis procedure must follow the "High Idle SpeedAdjustment" just described. If not alre

5.18Section 5Fuel System and Governor2. Position the choke cable under the cable clamp.3. Push the choke (knob/handle) in the applicationpanel until i

5.19Section 5Fuel System and Governor5Starting an Engine Equipped with SeparateControl Cables1. Place the throttle control midway between the"slo

5.20Section 5Fuel System and GovernorGoverned IdleAdjusting ScrewFigure 5-26. Location of Governed Idle AdjustingScrew.

6.1Section 6Lubrication System6Section 6Lubrication SystemCV11-16CV460-465, CV490-495Oil RecommendationsUsing the proper type and weight of oil in the

1.3Section 1Safety and General Information1A. Model No.Command EngineVertical CrankshaftDisplacement (cc)460 = 460 cc490 = 490 ccVersion CodeS = Elect

6.2Section 6Lubrication SystemFigure 6-4. Oil Level Dipstick.5. If the level is low, add oil of the proper type, up tothe ‘‘F’’ mark on the dipstick.

6.3Section 6Lubrication System64. Reinstall the oil fill cap/dipstick and tightensecurely.NOTE: To prevent extensive engine wear ordamage, always main

6.4Section 6Lubrication SystemFigure 6-9. Engine Mounted Oil Filter.Oil Sentry™Some engines are equipped with an optional OilSentry™ oil pressure moni

6.5Section 6Lubrication System6InstallationThe pressure switch is installed in the oil filter adapter,in one of the main oil galleries of the oil pan.

6.6Section 6Lubrication System

7.1Section 7Retractable Starter7Section 7Retractable StarterCV11-16CV460-465, CV490-495WARNING: Spring Under Tension!Retractable starters contain a po

7.2Section 7Retractable StarterRope ReplacementThe rope can be replaced without complete starterdisassembly.1. Remove the starter from the engine blow

7.3Section 7Retractable Starter7DisassemblyCAUTION: Spring Under Tension!Do not remove the center screw from the starter untilthe spring tension is re

7.4Section 7Retractable StarterInspection and Service1. Carefully inspect the rope, pawls, housing, centerscrew, and other components for wear ordamag

8.1Section 8Electrical System and Components8Section 8Electrical System and ComponentsCV11-16CV460-465, CV490-495This section covers the operation, se

1.4Section 1Safety and General InformationOil RecommendationsUsing the proper type and weight of oil in thecrankcase is extremely important, as is che

8.2Section 8Electrical System and Components4. Reinstall the spark plug into the cylinder head.Torque the spark plug to 24.4-29.8 N·m(18-22 ft. lb.).I

8.3Section 8Electrical System and Components8Figure 8-2. Electronic Magneto Ignition System, CV11-15, CV460-465, CV490-495 Engines.Electronic Magneto

8.4Section 8Electrical System and ComponentsMagneto Ignition System Troubleshooting GuideThe following guide will help locate and correct ignition sys

8.5Section 8Electrical System and Components8Electronic Ignition System with Spark Advance (Smart Spark™), CV16 EnginesThe CV16 engines are equipped w

8.6Section 8Electrical System and ComponentsOperationAs the flywheel rotates, the magnet grouping passesthe input coil (L1) of the ignition module, in

8.7Section 8Electrical System and Components8Troubleshooting CD Ignition SystemsThe CD ignition system is designed to be trouble-freefor the life of t

8.8Section 8Electrical System and Components4. Remove the blower housing from the engine.a. Trace the black ground lead from the SAMand check that the

8.9Section 8Electrical System and Components8Figure 8-8. Checking Battery Voltage.Electrical Systems Wiring Diagrams andBattery Charging SystemsMost e

8.10Section 8Electrical System and ComponentsFigure 8-10. CV11-15, CV460-465, CV490-495 3 amp Unregulated Battery Charging System.Ground-To-Kill Lead

8.11Section 8Electrical System and Components8Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting StatorNOTE: Zero ohmmeters on

1.5Section 1Safety and General Information1Periodic MaintenanceWARNING: Accidental Starts!Disabling engine. Accidental starting can cause severe injur

8.12Section 8Electrical System and Components2. If voltage is 13 volts or more, stator is OK.Check for loose connections or shorts inwiring harness.If

8.13Section 8Electrical System and Components8NoLightsOr BatteryCharging(BrakingSystemTest)Test1. Replace burned out lights.2. If voltage is 35 volts

8.14Section 8Electrical System and ComponentsCV11-15, CV460-465, CV490-495 Electric Start Engines 15 amp Battery Charging SystemFigure 8-12. CV11-15,

8.15Section 8Electrical System and Components8Figure 8-14. 15 amp Stator and Rectifier-Regulator.Figure 8-15. Proper Connection to Test 15 amp Chargin

8.16Section 8Electrical System and ComponentsTroubleshooting Guide 15 amp Regulated Battery Charging System.NOTE: Zero ohmmeters on each scale to ensu

8.17Section 8Electrical System and Components8Electric StartersSome engines in this series use inertia drive startingmotors while others use solenoid

8.18Section 8Electrical System and ComponentsOperation - Inertia Drive StartersWhen power is applied to the starter, the armaturerotates. As the armat

8.19Section 8Electrical System and Components8Style "B" Drive Service1. The rubber dust cover has a molded lip on theinside that snaps into

8.20Section 8Electrical System and ComponentsRetaining Ring Installation1. Position the retaining ring in the groove in one ofthe inner halves. Assemb

8.21Section 8Electrical System and Components8NOTE: Use a brush holder tool to keep thebrushes in the pockets. A brush holdertool can easily be made f

1.6Section 1Safety and General InformationFigure 1-4. Typical Engine Dimensions.Air Filterand CoverCylinderCarburetorFuel Shut-offSolenoidCarburetorFu

8.22Section 8Electrical System and ComponentsFigure 8-24. Style "B" Commutator End Cap withBrushes.6. Install the thru bolts and tighten sec

8.23Section 8Electrical System and Components8Solenoid Shift Electric StartersThe following subsection covers the solenoid shift electric starters. Mu

8.24Section 8Electrical System and ComponentsOperation (Solenoid Shift Starters)When power is applied to the starter the electricsolenoid moves the dr

8.25Section 8Electrical System and Components8Figure 8-27. Nippendenso Solenoid Shift Starter.9. When the stop collars are removed, the retainercan be

8.26Section 8Electrical System and ComponentsStarter Reassembly1. Install the drive pinion onto the armature shaft.2. Slide the stop collar onto the a

8.27Section 8Electrical System and Components88. Position the insulator over the brushes andsprings. Hold it firmly in place so the springs donot come

8.28Section 8Electrical System and ComponentsFigure 8-35. Installing Thru Bolts.14. Connect the braided (brush) lead to lower mainsolenoid terminal an

8.29Section 8Electrical System and Components83. Lift and unhook the plunger assembly from thedrive lever. Remove the gasket from the recess inthe hou

8.30Section 8Electrical System and Components8. Take out the drive lever and pull the armature outfrom the drive end cap. See Figure 8-45.9. Remove th

8.31Section 8Electrical System and Components8Figure 8-48. Delco-Remy Solenoid Shift Starter.InspectionDrive PinionCheck and inspect the following are

1.7Section 1Safety and General Information1General Specifications¹Power (@ 3600 RPM, corrected to SAE J1995)CV11 ...

8.32Section 8Electrical System and ComponentsContinuity CheckArmatureCoilInsulation CheckCommutator O.D.Mica InsulationArmature1. Clean and inspect th

8.33Section 8Electrical System and Components8Starter ServiceClean the drive lever and armature shaft. Apply Kohlerelectric starter drive lubricant, P

8.34Section 8Electrical System and Components7. Install the backup washer, followed by the rubbergrommet, into the matching recess of the driveend cap

8.35Section 8Electrical System and Components8Figure 8-61. Removing Retaining Caps.b. Position each of the brushes back in their slots sothey are flus

8.36Section 8Electrical System and ComponentsFigure 8-65. Torquing Brush Holder Screws.13. Hook the plunger behind the upper end of thedrive lever, an

9.1Section 9Disassembly9Section 9DisassemblyCV11-16CV460-465, CV490-495WARNING: Accidental Starts!Disabling engine. Accidental starting can cause seve

9.2Section 9DisassemblyFigure 9-1. Removing Spark Plug Lead, Oil Drains,Oil Filter, and Oil Sentry™ Switch (oil filter drainplug not on all models).Re

9.3Section 9Disassembly9Figure 9-5. Removing Bendix Drive Starter.Remove Air Cleaner1. Loosen the knob and remove the air cleaner cover.See Figure 9-6

9.4Section 9Disassembly3. Remove the two hex. flange screws and speedcontrol bracket. See Figure 9-9.MountingScrewsChokeControlLeverChoke LinkageSpeed

9.5Section 9Disassembly9Figure 9-14. Removing Oil Fill Tube.Remove Blower Housing and Baffles1. See Figure 9-15, 9-16, and 9-17. Remove the sixscrews