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.

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.

• 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.

Engine Specification and Testing Data

Internal repair coverage includes connecting-rod and crankshaft inspection, camshaft timing and endplay, cylinder honing, and piston-ring installation. Specifications provided include valve stem-to-guide running clearances and piston-to-cylinder bore tolerances.

The manual lists torque settings for fasteners ranging from M4 to M14, component tightening sequences, wear limits, and spark-plug torque.

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

The hydraulic lifter bleeding procedure addresses trapped oil that can bend push rods or break rocker arms during reassembly.

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 manual identifies leakdown tester KO3219 for this work.

Nikki and Keihin Fuel-System Service

It details float circuits for Nikki and Keihin carburetors, fuel pump performance data, fuel shut-off solenoid checks, and separate carburetor disassembly and reassembly procedures. The Typical Carburetor – Exploded View supports component identification, while the service text distinguishes repairable parts from nonserviceable jets, seats, and shaft assemblies by carburetor type.

Governor setup differs between carbureted and EFI engines. Reassembly charts identify governor spring colors and attachment holes for the applicable engine and throttle-control configuration.

CV26 and CV745 EFI Diagnostics

The two plastic-cased Electronic Control Units (ECUs), 24-pin MSE 1.0 and 32-pin MSE 1.1, are not interchangeable. Each has its own connector assignments and TPS initialization procedure; auto-learn applies to MSE 1.1.

Engine-speed sensor air-gap checks, oil-temperature sensor tests, and the Cutaway of Oxygen Sensor support sensor diagnosis. The Bosch EFI Diagnostic Flow Diagram links to ten diagnostic aids, alongside MIL blink-code explanations, injector leakage tests, and fuel-pump, relay, and pressure-regulator checks. The procedures reference EFI service kit KO3217.

ECU coverage concerns diagnosis and replacement, not internal repair. Clogged injectors are replaced rather than cleaned. Safety guidance addresses retained fuel pressure after shutdown and the risk of ECU damage from disconnecting electrical components with the ignition on.

Ignition, Charging, and Starter Repair

SMART-SPARK coverage distinguishes analog and digital spark advance modules. Ignition testing references KO1046, with circuit explanations supported by the Capacitive Discharge Ignition Module Schematic.

Charging-system documentation includes the Wiring Diagram – 15/20/25 amp Regulated Battery Charging System and the separate 3-amp system with 70-watt lighting.

Electric starter procedures distinguish inertia-drive units from Nippondenso and Delco-Remy solenoid-shift designs. Coverage includes brush replacement, commutator servicing, and inspection of the mica undercut. The Retractable Starter – Exploded View supports spring-and-keeper replacement; the manual excludes rewinding a spring that has escaped its keeper.

Oil-Pump and Air-Cleaner Variants

The lubrication sections cover the gerotor oil pump, crankcase breather, and serviceable versus one-piece pressure-relief valves. The later one-piece valve is nonserviceable; an internal fault requires oil-pump replacement.

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

Printable PDF and Included Pages

This printable, English-language 199-page PDF contains 191 pages across the service sections, one main contents page, two cover pages, and five section-end blank pages, all included in the total.