JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER

EQUIPMENT DIVISION

1975
AUG 2002

Lawn Tractors
LT150, 160, 170, 180

TM1975 AUG 2002

TECHNICAL MANUAL

North American Version

Litho in U.S.A.
 INTRODUCTION
Manual Description
This technical manual is written for an experienced Safety
technician and contains sections that are specifically for
this product. It is a part of a total product support program.
The manual is organized so that all the information on a Specifications and Information
particular system is kept together. The order of grouping is
as follows:
• Table of Contents Engine (Kohler)
• Specifications and Information
• Identification Numbers
• Tools and Materials Engine (Briggs & Stratton)
• Component Location
• Schematics and Harnesses
Engine (Kawasaki)
• Theory of Operation
• Operation and Diagnostics
• Diagnostics Electrical
• Tests and Adjustments
• Repair
• Other Power Train (Gear)
NOTE: Depending on the particular section or system
being covered, not all of the above groups may be
used. Power Train (Hydro)
The bleed tabs for the pages of each section will align with
the sections listed on this page. Page numbering is
consecutive from the beginning of the Safety section Steering
through the last section.
We appreciate your input on this manual. If you find any
errors or want to comment on the layout of the manual Brakes
please contact us.

Attachments

Miscellaneous
All information, illustrations and
specifications in this manual are based
on the latest information at the time of
publication. The right is reserved to
make changes at any time without
notice.
COPYRIGHT© 2002
Deere & Co.
John Deere Worldwide Commercial and
Consumer Equipment Division
All rights reserved
Previous Editions
COPYRIGHT©

Introduction
 SAFETY
Be Prepared for Emergencies
Safety

Recognize Safety Information

This is the safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe servicing
practices.

• When you work around fuel, do not smoke or work near

Understand Signal Words
heaters or other fire hazards.
A signal word - DANGER, WARNING, or CAUTION - is • Store flammable fluids away from fire hazards. Do not
used with the safety-alert symbol. DANGER identifies the incinerate or puncture pressurized containers.
most serious hazards.
• Make sure machine is clean of trash, grease, and
DANGER or WARNING safety signs are located near debris.
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to • Do not store oily rags; they can ignite and burn
safety messages in this manual. spontaneously.
• Be prepared if a fire starts.
Replace Safety Signs • Keep a first aid kit and fire extinguisher handy.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your telephone.

Use Care In Handling and Servicing Batteries

Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement.

Safety -1
 SAFETY
Prevent Battery Explosions Prolonged exposure to loud noise can cause impairment or
loss of hearing. Wear a suitable hearing protective device
• Keep sparks, lighted matches, and open flame away such as earmuffs or earplugs to protect against
from the top of battery. Battery gas can explode. objectionable or uncomfortable loud noises.
• Never check battery charge by placing a metal object Operating equipment safely requires the full attention of the
across the posts. Use a volt-meter or hydrometer. operator. Do not wear radio or music headphones while
• Do not charge a frozen battery; it may explode. Warm operating machine.
battery to 16°C (60°F).
Service Machines Safely
Prevent Acid Burns
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.

Avoid acid burns by:

1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte. Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
5. Use proper jump start procedure. machine tools or moving parts. If these items were to get
caught, severe injury could result.
If you spill acid on yourself:
Remove rings and other jewelry to prevent electrical shorts
1. Flush your skin with water.
and entanglement in moving parts.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 10-15 minutes. Use Proper Tools
4. Get medical attention immediately. Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
If acid is swallowed:
only to loosen threaded parts and fasteners. For loosening
1. Drink large amounts of water or milk. and tightening hardware, use the correct size tools. DO
2. Then drink milk of magnesia, beaten eggs, or vegetable NOT use U.S. measurement tools on metric fasteners.
oil. Avoid bodily injury caused by slipping wrenches. Use only
service parts meeting John Deere specifications.
3. Get medical attention immediately.
Park Machine Safely
Wear Protective Clothing

Before working on the machine:

1. Lower all equipment to the ground.
2. Stop the engine and remove the key.
Wear close fitting clothing and safety equipment
appropriate to the job. 3. Disconnect the battery ground strap.
4. Hang a “DO NOT OPERATE” tag in operator station.

Safety -2
 SAFETY
Support Machine Properly and Use Proper Work In Ventilated Area
Lifting Equipment

Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
If you must work on a lifted machine or attachment, extension.
securely support the machine or attachment. If you do not have an exhaust pipe extension, open the
Do not support the machine on cinder blocks, hollow tiles, doors and get outside air into the area.
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack. Warning: California Proposition 65 Warning
Follow recommended procedures in this manual.
Gasoline engine exhaust from this product contains
Lifting heavy components incorrectly can cause severe chemicals known to the State of California to cause cancer,
injury or machine damage. Follow recommended birth defects, or other reproductive harm.
procedure for removal and installation of components in the
manual. Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust. Hazardous fumes
Work In Clean Area can be generated when paint is heated by welding,
soldering, or using a torch. Do all work outside or in a well
Before starting a job:
ventilated area. Dispose of paint and solvent properly.
1. Clean work area and machine. Remove paint before welding or heating: If you sand or
2. Make sure you have all necessary tools to do your job. grind paint, avoid breathing the dust. Wear an approved
respirator. If you use solvent or paint stripper, remove
3. Have the right parts on hand. stripper with soap and water before welding. Remove
4. Read all instructions thoroughly; do not attempt solvent or paint stripper containers and other flammable
shortcuts. material from area. Allow fumes to disperse at least 15
minutes before welding or heating.
Using High Pressure Washers
Avoid Harmful Asbestos Dust
Directing pressurized water at electronic/electrical Avoid breathing dust that may be generated when
components or connectors, bearings, hydraulic seals, fuel handling components containing asbestos fibers.
injection pumps or other sensitive parts and components Inhaled asbestos fibers may cause lung cancer.
may cause product malfunctions. Reduce pressure and
spray at a 45 to 90 degree angle. Components in products that may contain asbestos
fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in
Illuminate Work Area Safely these components is usually found in a resin or sealed in
Illuminate your work area adequately but safely. Use a some way. Normal handling is not hazardous as long as
portable safety light for working inside or under the airborne dust containing asbestos is not
machine. Make sure the bulb is enclosed by a wire cage. generated.
The hot filament of an accidentally broken bulb can ignite Avoid creating dust. Never use compressed air for cleaning.
spilled fuel or oil. Avoid brushing or grinding material containing asbestos.
When servicing, wear an approved respirator. A special
vacuum cleaner is recommended to clean asbestos. If not
available, apply a mist of oil or water on the material
containing asbestos. Keep bystanders away from the area.

Safety -3
 SAFETY
Service Tires Safely Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause serious

injury. Potentially hazardous chemicals used with John
Explosive separation of a tire and rim parts can cause Deere equipment include such items as lubricants,
serious injury or death. coolants, paints, and adhesives.
Do not attempt to mount a tire unless you have the proper A Material Safety Data Sheet (MSDS) provides specific
equipment and experience to perform the job. details on chemical products: physical and health hazards,
Always maintain the correct tire pressure. Do not inflate the safety procedures, and emergency response techniques.
tires above the recommended pressure. Never weld or heat Check the MSDS before you start any job using a
a wheel and tire assembly. The heat can cause an increase hazardous chemical. That way you will know exactly what
in air pressure resulting in a tire explosion. Welding can the risks are and how to do the job safely. Then follow
structurally weaken or deform the wheel. procedures and recommended equipment.

When inflating tires, use a clip-on chuck and extension

hose long enough to allow you to stand to one side and Dispose Of Waste Properly
NOT in front of or over the tire assembly. Use a safety cage Improperly disposing of waste can threaten the
if available. environment and ecology. Potentially harmful waste used
Check wheels for low pressure, cuts, bubbles, damaged with John Deere equipment include such items as oil, fuel,
rims or missing lug bolts and nuts. coolant, brake fluid, filters, and batteries. Use leakproof
containers when draining fluids. Do not use food or
beverage containers that may mislead someone into
Avoid Injury From Rotating Blades, Augers drinking from them. Do not pour waste onto the ground,
and PTO Shafts down a drain, or into any water source. Inquire on the
proper way to recycle or dispose of waste from your local
environmental or recycling center, or from your John Deere
dealer.

Live With Safety

Keep hands and feet away while machine is running. Shut

off power to service, lubricate or remove mower blades,
augers or PTO shafts.

Before returning machine to customer, make sure machine

is functioning properly, especially the safety systems. Install
all guards and shields.

Safety -4
 SPECIFICATIONS & INFORMATION TABLE OF CONTENTS
Specifications & Information

Table of Contents

Fastener Torques..............................................7
Metric Fastener Torque Values ......................7
Metric Fastener Torque Value - Grade 7........8
Inch Fastener Torque Values .........................9
General Information........................................10
Gasoline .......................................................10
Gasoline Storage..........................................10
Engine Oil.....................................................10
Engine Break-In Oil ......................................11
Anti-corrosion Grease .................................12
Alternative Lubricants...................................12
Synthetic Lubricants .....................................12
Lubricant Storage .........................................12

Specifications & Information Table of Contents - 5

SPECIFICATIONS & INFORMATION TABLE OF CONTENTS

Specifications & Information Table of Contents - 6

 SPECIFICATIONS & INFORMATION FASTENER TORQUES
Fastener Torques

Metric Fastener Torque Values

4.8 8.8 9.8 10.9 12.9

Property
Class
and 4.8 8.8 9.8 10.9 12.9
Head
Markings 4.8 8.8 9.8 10.9 12.9 12.9

Property 5 10 10 12
Class
and

10
10

12
5

Nut 5 10 10 12
Markings

MIF

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Lubricated Dry a Lubricated a Dry a Lubricated a Dry a Lubricated Dry a

a a
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500

DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application.
Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically.
DO NOT use air powered wrenches.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Specifications & Information Fastener Torques - 7

 SPECIFICATIONS & INFORMATION FASTENER TORQUES
Fasteners should be replaced with the same class. Make sure fastener threads are clean and that you properly start thread
engagement. This will prevent them from failing when tightening.
When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head.
Tighten toothed or serrated-type lock nuts to the full torque value.
a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means
plain or zinc plated (Yellow Dichromate - Specification JDS117) without any lubrication.
Reference: JDS - G200

Metric Fastener Torque Value - Grade 7

Size Steel or Gray Iron Aluminum Torque

Torque
N•m lb-ft N•m lb-ft
M6 11 8 8 6

M8 24 18 19 14
M10 52 38 41 30
M12 88 65 70 52
M14 138 102 111 82
M16 224 165 179 132

Specifications & Information Fastener Torques - 8

 SPECIFICATIONS & INFORMATION FASTENER TORQUES
Inch Fastener Torque Values
1 or 2b 5 5.1 5.2 8 8.2
SAE
Grade
and Head No Marks
Markings

2 5 8
SAE
Grade No Marks
and Nut
Markings
MIF

Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Lubricated Dry a Lubricated Dry a Lubricated a Dry a Lubricated a Dry a
a a
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft

1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46

7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115

9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160

5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400

7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350

1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

DO NOT use these hand torque values if a different torque Tighten toothed or serrated-type lock nuts to the full torque
value or tightening procedure is given for a specific value.
application. Torque values listed are for general use only
and include a ±10% variance factor. Check tightness of a “Lubricated” means coated with a lubricant such as
fasteners periodically. DO NOT use air powered wrenches. engine oil, or fasteners with phosphate and oil coatings.
Shear bolts are designed to fail under predetermined loads. “Dry” means plain or zinc plated (yellow dichromate -
Always replace shear bolts with identical grade. Specification JDS117) without any lubrication.
Fasteners should be replaced with the same grade. Make b “Grade 2” applies for hex cap screws (Not Hex Bolts) up
sure fastener threads are clean and that you properly start to 152 mm (6 in.) long. “Grade 1” applies for hex cap
thread engagement. This will prevent them from failing
when tightening. screws over 152 mm (6 in.) long, and for all other types of
bolts and screws of any length.
When bolt and nut combination fasteners are used, torque
values should be applied to the NUT instead of the bolt Reference: JDS-G200
head.

Specifications & Information Fastener Torques - 9

 SPECIFICATIONS & INFORMATION GENERAL INFORMATION
General Information

Gasoline

c CAUTION: Avoid injury! Gasoline is HIGHLY

FLAMMABLE, handle it with care.DO NOT
refuel machine while:
indoors, always fill gas tank outdoors
machine is near an open flame or sparks
engine is running, STOP engine MIF
engine is hot, allow it to cool sufficiently first • methyl tertiary butyl ether (MTBE) blends DO NOT
smoking exceed 15% by volume
Help prevent fires:
IMPORTANT: Avoid damage! DO NOT use
fill gas tank to bottom of filler neck only METHANOL gasolines because METHANOL is
be sure fill cap is tight after fueling harmful to the environment and to your health.

clean up any gas spills IMMEDIATELY

keep machine clean and in good repair-free of
excess grease, oil, debris, and faulty or
c CAUTION: Avoid injury! California Proposition
65 Warning: Gasoline engine exhaust from this
damaged parts product contains chemicals known to the State
any storage of machines with gas left in tank of California to cause cancer, birth defects, or
should be in an area that is well ventilated to other reproductive harm.
prevent possible igniting of fumes by an open
flame or spark, this includes any appliance Gasoline Storage
with a pilot light
To prevent fire or explosion caused by STATIC IMPORTANT: Avoid damage! Keep all dirt, scale,
ELECTRIC DISCHARGE during fueling: water or other foreign material out of gasoline.
ONLY use a clean, approved POLYETHYLENE Keep gasoline stored in a safe, protected area. Storage of
PLASTIC fuel container and funnel WITHOUT gasoline in a clean, properly marked (“UNLEADED
any metal screen or filter GASOLINE”) POLYETHYLENE PLASTIC container
To avoid engine damage: WITHOUT any metal screen or filter is recommended. DO
NOT use de-icers to attempt to remove water from gasoline
• DO NOT mix oil with gasoline or depend on fuel filters to remove water from gasoline.
• ONLY use clean, fresh unleaded gasoline with an Use a water separator installed in the storage tank outlet.
octane rating (anti-knock index) of 87 or higher BE SURE to properly discard unstable or contaminated
gasoline. When storing machine or gasoline, it is
• fill gas tank at the end of each day's operation to help
recommended that you add John Deere Gasoline
prevent condensation from forming inside a partially filled
Conditioner and Stabilizer (TY15977) or an equivalent to
tank
the gasoline. BE SURE to follow directions on container
• keep up with specified service intervals and to properly discard empty container.
Use of alternative oxygenated, gasohol blended, unleaded
gasoline is acceptable as long as: Engine Oil
• the ethyl or grain alcohol blends DO NOT exceed 10% Use the appropriate oil viscosity based on the expected air
by volume or temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oil is PREFERRED:

Specifications & Information General Information - 10

 SPECIFICATIONS & INFORMATION GENERAL INFORMATION
• PLUS-4® - SAE 10W-40 • BREAK-IN ENGINE OIL.
• TURF-GARD® - SAE 10W-30 John Deere BREAK-IN ENGINE OIL is formulated with
special additives for aluminum and cast iron type engines
The following John Deere oils are also recommended,
to allow the power cylinder components (pistons, rings, and
based on their specified temperature range:
liners as well) to “wear-in” while protecting other engine
• TORQ-GARD SUPREME® - 5W-30 components, valve train and gears, from abnormal wear.
Other oils may be used if above John Deere oils are not Engine rebuild instructions should be followed closely to
available, provided they meet one of the following determine if special requirements are necessary.
specifications: John Deere BREAK-IN ENGINE OIL is also recommended
• SAE 5W-30 - API Service Classification SJ or higher; for non-John Deere engines, both aluminum and cast iron
types.
• SAE 10W-30 - API Service Classification SJ or higher;
The following John Deere oil is also recommended as a
• SAE 30 - API Service Classification SJ or higher. break-in engine oil:
• CCMC Specification G4 or higher. • TORQ-GARD SUPREME® - SAE 5W-30.
SAE 10W-40

SAE 5W-30

BREAK-IN OIL
SAE 5W-30

SAE 5W-30
AIR TEMPERATURE PREFERRED
AIR TEMPERATURE
MIF

John Deere Dealers: You may want to cross-reference the MIF

following publications to recommend the proper oil for your If the above recommended John Deere oils are not
customers: available, use a break-in engine oil meeting the following
• Module DX,ENOIL2 in JDS-G135; specification during the first 5 hours (maximum) of
operation:
• Section 530, Lubricants & Hydraulics, of the John Deere
Merchandise Sales Guide; • SAE 5W-30 - API Service Classification SJ or higher.

• Lubrication Sales Manual PI7032. • SAE 5W-30 - CCMC Specification G4 or higher.

IMPORTANT: Avoid damage! After the break-in

Engine Break-In Oil period, use the John Deere oil that is recommended
for this engine.
IMPORTANT: Avoid damage! ONLY use a quality
break-in oil in rebuilt or remanufactured engines for John Deere Dealers: You may want to cross-reference the
the first 5 hours (maximum) of operation. DO NOT following publications to recommend the proper oil for your
use oils with heavier viscosity weights than SAE 5W- customers:
30 or oils meeting specifications API SG or SH, • Module DX,ENOIL4 in JDS-G135;
these oils will not allow rebuilt or remanufactured
• Section 530, Lubricants & Hydraulics, of the John Deere
engines to break-in properly.
Merchandise Sales Guide;
The following John Deere oil is PREFERRED: • Lubrication Sales Manual PI7032.

Specifications & Information General Information - 11

 SPECIFICATIONS & INFORMATION GENERAL INFORMATION
Anti-corrosion Grease Alternative Lubricants
This anti-corrosion grease is formulated to provide the best Conditions in certain geographical areas outside the United
protection against absorbing moisture, which is one of the States and Canada may require different lubricant
major causes of corrosion. This grease is also superior in recommendations than the ones printed in this technical
its resistance to separation and migration. manual or the operator's manual. Consult with your John
The following anti-corrosion grease is PREFERRED: Deere Dealer, or Sales Branch, to obtain the alternative
lubricant recommendations.
• DuBois MPG-2® Multi-Purpose Polymer Grease -
M79292. IMPORTANT: Avoid damage! Use of alternative
Other greases may be used if they meet or exceed the lubricants could cause reduced life of the
following specifications: component
• John Deere Standard JDM J13A2, NLGI Grade 1. If alternative lubricants are to be used, it is recommended
that the factory fill be thoroughly removed before switching
to any alternative lubricant.

Synthetic Lubricants
Synthetic lubricants may be used in John Deere equipment
if they meet the applicable performance requirements
NLGI Grade 1
JDM J13A2

(industry classification and/or military specification) as

shown in this manual.
The recommended air temperature limits and service or
lubricant change intervals should be maintained as shown
in the operator’s manual.
Avoid mixing different brands, grades, or types of oil. Oil
manufacturers blend additives in their oils to meet certain
specifications and performance requirements. Mixing
different oils can interfere with the proper functioning of
AIR TEMPERATURE these additives and degrade lubricant performance.
MIF

John Deere Dealers: You may want to cross-reference the

Lubricant Storage
following publications to recommend the proper grease for All machines operate at top efficiency only when clean
your customers: lubricants are used. Use clean storage containers to
• Module DX,GREA1 in JDS-G135; handle all lubricants. Store them in an area protected from
dust, moisture, and other contamination. Store drums on
• Section 530, Lubricants & Hydraulics, of the John Deere their sides. Make sure all containers are properly marked
Merchandise Sales Guide; as to their contents. Dispose of all old, used containers and
• Lubrication Sales Manual PI7032. their contents properly.

Specifications & Information General Information - 12

 ENGINE - KOHLER TABLE OF CONTENTS
Hydraulic Valve Lifters
Engine - Kohler

Table of Contents
Removal and Installation ............................. 41
Hydraulic Valve Lifters Inspection ............... 41
Balancer Shaft Removal and Installation..... 42
Specifications .................................................15 Balancer Shaft Inspection............................ 42
General Specifications .................................15 Governor Removal and Installation ............. 43
Tests and Adjustments Specifications..........16 Governor Inspection .................................... 44
Repair Specifications....................................16 Piston Assembly Removal ........................... 44
Torque Specifications (Alphabetical)............19 Piston Assembly Disassemble .................... 45
Special or Required Tools ............................20 Piston Inspection ......................................... 45
Troubleshooting .............................................21 Piston Ring End Gap Measurement ............ 45
Engine Troubleshooting: Piston Ring Side Clearance Measurement.. 46
Engine Will Not Crank ..................................21 Connecting Rod Measurement .................... 46
Engine Cranks But Will Not Start .................22 Piston Measurement.................................... 47
Engine Runs Erratically/Loss Of Power .......23 Piston Assembly .......................................... 47
Tests and Adjustments ..................................23 Piston Installation......................................... 48
Throttle Cable Adjustment............................23 Crankshaft Removal and Installation ........... 48
Choke Adjustment ........................................24 Crankshaft and Main Bearing Inspection..... 49
Governor Adjustment ...................................24 Crankshaft Alignment .................................. 50
Fast Idle Speed Adjustment .........................24 Oil Pan Removal and Installation................. 50
Slow Idle Speed Adjustment ........................25 Oil Pan Seal Removal and Installation ........ 51
Cylinder Leakdown Test...............................26 Crankcase Oil Seal
Automatic Compression Release (ACR) Removal and Installation ............................. 51
Check ...........................................................26 Oil Pickup Inspection ................................... 51
Crankcase Vacuum Test ..............................27 Oil Pump Relief Valve Inspection ................ 52
Fuel Flow Test..............................................28 Oil Pump Installation.................................... 52
Oil Pressure Test..........................................29 Cylinder Block Inspection ............................ 52
Fuel and Air Repair.........................................30 Cylinder Bore Deglazing .............................. 53
Air Intake System Components....................30 Stator and Ignition Module
Carburetor Removal and Installation............31 Removal and Installation ............................. 53
Carburetor Inspection...................................31 Starting Motor Removal and Installation...... 54
Engine Repair..................................................32 Starting Motor Drive Replacement............... 55
Fuel Pump Removal and Installation............32 Starting Motor Brush Replacement and
Engine Removal and Installation..................33 Armature Test .............................................. 55
Rocker Arms Removal and Installation ........35
Cylinder Head Removal and Installation ......35
Valves and Springs
Removal and Installation ..............................36
Cylinder Head Inspection .............................36
Valves Inspection .........................................36
Valve Guides Inspection ..............................37
Valve Seats Recondition ..............................37
Valves Lap....................................................38
Breather Inspection ......................................38
Flywheel Removal and Installation...............38
Camshaft Removal and Installation .............39
Camshaft Inspection ....................................40
Camshaft End Play Measurement ...............41

Engine - Kohler Table of Contents - 13

ENGINE - KOHLER TABLE OF CONTENTS

Engine - Kohler Table of Contents - 14

 ENGINE - KOHLER SPECIFICATIONS
Specifications

General Specifications
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Model Number 15 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV15S
Model Number 16 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV460S
Power:
15 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 kW
16 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9 kW
Displacement:
15 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 cm3 (26.0 cu-in.)
16 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 cm3 (28.1 cu-in.)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Bore:
15 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 mm (3.55 in.)
16 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 mm (3.43 in.)
Stroke:
15 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.)
16 hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 mm (3.03 in.)
Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1 Cranking - 8.5:1 Running
Compression Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic/Centrifugal
Crankshaft Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vertical (Counterbalanced)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressurized Gerotor Pump
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 413 kPa (0 - 60 psi)
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter
Crankcase Capacity:
With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (1.5 qt)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper With Outer Foam Element
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal, Discharge Below Frame
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1700 ± 100 rpm
Fast Idle (Domestic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm
Maximum Angle of Operation (With Full Crankcase):
Continuous (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20°
Intermittent (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35°
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type)
Fuel Shut-Off Solenoid (Optional): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replaceable (Below Carburetor Float Bowl)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.5 kg (87 lbs)

Engine - Kohler Specifications - 15

 ENGINE - KOHLER SPECIFICATIONS
Tests and Adjustments Specifications
Engine
Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.)
Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None (Hydraulic Lifters)
Oil Pressure (Minimum at 1250 rpm): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 kPa (18 psi)
Crankcase Vacuum (Minimum At Operating Temp.): . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 cm (4 in.) Water Movement
Automatic Compression Release Minimum Lift (Engine Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)

Fuel/Air System:
Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1700 ± 100 rpm
Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm

Repair Specifications
Cylinder Head:
Cylinder Head Flatness (Maximum Warpage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.076 mm (0.003 in.)
Valves and Valve Lifters:
Hydraulic Lifter Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0124 - 0.0501 mm (0.0005 - 0.0020 in.)
Intake Valve-to-Guide Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.076 mm (0.0015 - 0.0030 in.)
Intake Valve Stem OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.982 - 7.000 mm (0.2749 - 0.2756 in.)
Exhaust Valve Stem OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.970 - 6.988 mm (0.2744 - 0.2751 in.)
Exhaust Valve-to-Guide Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.088 mm (0.0020 - 0.0035 in.)
Intake Valve Guide ID:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.038 - 7.058 mm (0.2771 - 0.2779 in.)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.134 mm (0.2809 in.)
Exhaust Valve Guide ID:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.038 - 7.058 mm (0.2771 - 0.2779 in.)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.159 mm (0.2819 in.)
Valve Guide Reamer:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.048 mm (0.2775 in.)
Oversize (0.25 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.298 mm (0.2873 in.)
Intake Valve Lift (Minimum - Engine Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.96 mm (0.353 in.)
Intake Valve Lift (Minimum - Engine Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.96 mm (0.353 in.)
Exhaust Valve Lift (Minimum - Engine Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14 mm (0.360 in.)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45°
Valve Seat Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5°
Rocker Arms:
Rocker Arm ID:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.837 - 16.127 mm (0.63 - 0.64 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.727 mm (0.619 in.)
Rocker Shaft:
Rocker Shaft OD:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.837 - 16.127 mm (0.63 - 0.64 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.727 mm (0.619 in.)

Engine - Kohler Specifications - 16

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