1991–2005 Kohler Command CV17, CV18, CV20, CV22, CV23, CV25, CV26, CV730, CV740, CV745 V-Twin Engine Service & Repair Manual (P/N TP-2450-B)

This PDF service manual details the disassembly, inspection, and reassembly processes for the listed 1991–2005 Kohler Command V-twin engines with vertical crankshaft configurations. Form No. TP-2450-B, revised 6/04, covers carbureted models and CV26/CV745 EFI.

Printable PDF and Included Pages

Text search, bookmarks, and wiring detail: Main text is searchable, with 13 bookmarks for the contents and service sections. EFI wiring pages 5B.27–5B.28 and some diagram content are not text-searchable. Small wiring labels require zooming; fine print on 5B.27 remains somewhat soft.

This printable, English-language manual is supplied as one 199-page PDF: 191 service-section content pages, one main contents page, two cover pages, and five section-end blank pages, all included in the total.

V-Twin Overhaul, Fuel Systems, and Electrical Testing

These selected topics focus on workshop repairs and diagnosis. The manual also includes storage procedures and crankshaft spline-drive lubrication guidance.

• Internal engine repair: Disassembly, hydraulic lifter bleeding, valve seat reconditioning, crankshaft and piston inspection, camshaft installation, and engine reassembly.

• Carburetors and governor: Nikki and Keihin carburetor overhaul, float servicing, accelerator-pump and choke repair, fuel-pump testing, and mechanical governor adjustments.

• EFI diagnosis: Fuel-pressure and injector tests, oxygen-sensor checks, Throttle Position Sensor (TPS) initialization, and ECU blink code analysis.

• Ignition and charging: Standard CD and SMART-SPARK ignition diagnosis, ignition-module testing, stator checks, rectifier-regulator evaluations, and electrical wiring diagrams.

• Starting systems: Retractable starter servicing, rope and pawl replacement, and inertia-drive or solenoid-shift electric starter disassembly, inspection, and repair.

• Lubrication and air intake: Oil-pump and pressure-relief valve inspection, Oil Sentry testing, crankcase vacuum tests, oil-cooler maintenance, and air-cleaner servicing.

This manual is suited to mechanics familiar with engine rebuilding and electrical testing, with access to precision measuring tools and the specified diagnostic equipment.

Internal Engine Inspection and Reassembly

Internal repair coverage includes connecting-rod and crankshaft inspection, camshaft timing and endplay, cylinder honing, and piston-ring installation. Reference tables provide valve stem-to-guide clearances, piston-to-cylinder tolerances, wear limits, spark-plug torque, and general fastener torques from M4 to M14.

Rebuild differences: Bolted cylinder heads and heads secured by studs and nuts have different machining and tightening requirements. Some CV25 engines have POWER-BORE plated cylinders; the cast-iron-sleeve honing and resizing procedures do not apply to those bores.

Step-by-step procedures cover hydraulic lifter bleeding and engine reassembly. Excess oil retained in a lifter can bend a push rod or break a rocker arm during assembly.

For engines with Automatic Compression Release (ACR), the cylinder leakdown test helps distinguish valve leakage from ring or cylinder wear when compression readings are unreliable. The specified tester is KO3219.

Nikki and Keihin Fuel-System Service

Separate carburetor procedures explain float circuits, fuel shut-off solenoid checks, and disassembly and reassembly. The Typical Carburetor – Exploded View supports component identification; the text distinguishes repairable parts from nonserviceable jets, seats, and shaft assemblies by carburetor type.

Fuel-pump performance data accompanies the delivery tests. Governor setup differs between carbureted and EFI engines, with reassembly charts identifying spring colors and attachment holes for the applicable engine and throttle-control configuration.

CV26 and CV745 EFI Diagnostics

The plastic-cased 24-pin MSE 1.0 and 32-pin MSE 1.1 Electronic Control Units (ECUs) are not interchangeable. Connector assignments and TPS initialization procedures differ; auto-learn applies to MSE 1.1.

Engine-speed and oil-temperature sensor tests accompany the Cutaway of Oxygen Sensor. The Bosch EFI Diagnostic Flow Diagram connects troubleshooting to ten diagnostic aids, MIL blink-code explanations, injector leakage tests, and fuel-pump, relay, and pressure-regulator checks. EFI service tools are listed under kit KO3217.

ECU service covers diagnosis and replacement rather than internal repair. Clogged injectors are replaced rather than cleaned. Safety guidance addresses retained fuel pressure after shutdown; disconnecting electrical components with the ignition on can damage the ECU.

Ignition, Charging, and Starter Repair

SMART-SPARK testing distinguishes analog and digital spark advance modules and references ignition tester KO1046. Supporting illustrations include the Capacitive Discharge Ignition Module Schematic and Wiring Diagram – 15/20/25 amp Regulated Battery Charging System, alongside the separate 3-amp system with 70-watt lighting.

Electric starter procedures distinguish inertia-drive units from Nippondenso and Delco-Remy solenoid-shift designs. They cover brush replacement, commutator servicing, and mica-undercut inspection. The Retractable Starter – Exploded View supports spring-and-keeper replacement; a spring that has escaped its keeper is replaced rather than rewound.

Oil-Pump and Air-Cleaner Variants

The lubrication sections explain gerotor oil-pump inspection, crankcase breather operation, and serviceable versus one-piece pressure-relief valves. An internal fault in the later nonserviceable valve requires oil-pump replacement.

Oil-cooler maintenance covers crankcase-mounted and blower-housing-mounted units. Air-cleaner instructions and dimensional views distinguish standard, commercial-mower, and heavy-duty configurations.

Examples of Valve Clearances and EFI Sensor Test Data

Intake valve stem-to-guide running clearance is 0.038–0.076 mm; the exhaust specification is 0.050–0.088 mm. These are guide clearances for cylinder-head inspection, rather than adjustable valve lash.

For CV26/CV745 EFI diagnosis, engine-speed sensor resistance is 750–1000 Ω at 20°C (68°F). Separate sensor and harness checks help distinguish a component fault from a wiring problem.