1990–1995 Kohler Command 11 / 12.5 / 14 HP Engine Service Manual (TP-2402)

Kohler service manual TP-2402 covers the 1990–1995 Command 11, 12.5, and 14 HP horizontal-crankshaft engines (CH11, CH12.5, and CH14). Coverage includes electric, retractable, and combined electric/retractable start versions, identified by the S, T, and ST suffixes.

Text search and diagram detail: This PDF has no text search or embedded bookmarks. Its printed contents page lists the 11 sections; wiring labels and terminal markings in the ignition and charging diagrams are legible.

• Internal engine repair: Complete disassembly and reassembly, cylinder bore honing, piston and ring inspection, crankshaft service, and camshaft end-play adjustment.

• Cylinder head and valves: Valve-guide reconditioning, valve-seat cutting and lapping, hydraulic lifter installation, rocker-arm inspection, and valve-train specifications.

• Fuel system and governor: Adjustable-main-jet carburetor repair, fuel delivery diagnosis, mechanical pump replacement, and governor sensitivity and remote-control adjustments.

• Lubrication and cooling: Gerotor oil pump service, pressure-relief components, Oil Sentry switch testing, air-cleaner maintenance, and air-intake and cooling-system cleaning.

• Electrical troubleshooting: Electronic magneto tests, regulated charging-system diagnostics, battery checks, and wiring diagrams showing optional Oil Sentry connections.

• Starting systems: Retractable starter rope and pawl replacement, recoil spring handling, and repair of Bendix-drive and solenoid-shift electric starters.

The repair procedures suit mechanics familiar with engine rebuilding and equipped to measure cylinder bores, crankshaft journals, and valve guides.

Troubleshooting and Internal Engine Repair

The troubleshooting guide addresses starting problems, stalling, misfire, overheating, power loss, and oil consumption. Because Automatic Compression Release (ACR) affects compression readings, the manual explains the limitations of compression testing and provides crankcase-vacuum checks and physical inspection guidance to help assess internal condition.

Internal work includes crankpin inspection and undersize connecting-rod selection, cylinder resizing, and piston-to-bore measurement. Reassembly covers balance-shaft and camshaft timing, plus shim selection with camshaft end-play tool KO-1031.

Valve-guide reconditioning uses reamer KO-1026. The guides and valve-seat inserts are nonreplaceable; the manual covers reconditioning, seat cutting, and valve lapping.

Incorrect sleeve-bearing oil-hole alignment can interrupt lubrication and cause engine failure; the assembly illustrations show its relationship to the crankcase oil gallery.

Fuel Delivery, Governor, and Lubrication

Fuel delivery differs between gravity-fed engines and those with the optional mechanical pump. The nylon-bodied pump is replaced as a unit; the carburetor section covers the float, inlet needle and seat, throttle and choke shafts, and welch plugs.

Preliminary carburetor settings distinguish CH14 from CH11/CH12.5. High-altitude jet guidance, governor-spring position charts, and remote throttle/choke adjustments address application differences.

Incorrect fuel-pump lever positioning can damage the pump and engine.

The lubrication section explains service access to the balance-shaft-driven gerotor pump and why pickup or relief-valve work requires closure-plate removal. Oil Sentry testing covers its use for engine shutdown or a warning light.

Ignition, Charging, and Starter Repair

Fault charts for the 15-amp regulated charging system distinguish stator, rectifier-regulator, battery, and wiring problems. Magneto ignition coverage includes plug-condition diagnosis, module-secondary resistance testing, and the ground-to-kill circuit.

Electric-starter repair includes drive service, brush replacement, commutator inspection, and assembly alignment. The retractable-starter section separates rope replacement from the full disassembly needed for pawl service and describes recoil spring handling.

Follow the manual's precautions for accidental starting, rotating parts, fuel vapors, and recoil spring tension.

Specifications and Illustrated References

Factory tables cover oil capacity, piston-ring end gaps, valve-stem and guide clearances, minimum valve lift, crankshaft journal tolerances, and camshaft end play. Metric and inch-series fastener charts accompany torque specifications for the closure plate, cylinder head, and connecting rod.

Performance curves and fuel-consumption charts appear in Power, Torque, and Fuel Data, alongside Typical Engine Dimensions. Repair illustrations include Carburetor — Exploded View and Cylinder Bore Crosshatch After Honing, while Electronic Magneto Ignition System and the electric-start charging-system wiring diagram cover the electrical circuits.

PDF Contents and Page Breakdown

Supplied as one printable English-language PDF. The 110-page PDF comprises 106 technical pages, one contents page, two cover pages, and one otherwise blank section page; all are included in the total.