Kohler CV490-495 Generator Set

⚠ Overspeed is Hazardous! Do not tamper with the governor setting.

Tools: Tachometer, 6.35 mm (1/4 in.) drill bit

1. Make sure throttle cable is adjusted properly.
2. Start engine and warm up; place throttle control to fast or high idle.
3. Align hole in throttle lever with hole in speed control bracket using a pencil or 6.35 mm drill bit.
4. Loosen bracket mounting screws and move bracket up or down until desired high idle speed is reached.
5. Tighten mounting screws: new as-cast hole 10.7 N·m; used hole 7.3 N·m.
6. Recheck speed with tachometer and readjust if necessary.
7. Adjust the choke.

Tools: Pliers, Torque wrench

1. With governor lever loose on cross shaft, pull lever towards carburetor (wide open throttle).
2. Grasp cross shaft with pliers or insert a nail into the hole in cross shaft end.
3. Rotate the shaft counterclockwise as far as it will turn.
4. Tighten the hex. nut securely and torque to 9.9 N·m (88 in. lb.).

⚠ Certified engines have the idle mixture preset and sealed at the factory.

Tools: Tachometer

1. Start the engine and run at half throttle 5 to 10 minutes to warm up.
2. Place throttle control into the "idle" or "slow" position.
3. Set the low idle speed to 1200 RPM (±75 RPM) by turning the low idle speed adjusting screw in or out.
4. Check the speed using a tachometer.

⚠ Certified engines may have a fixed idle or limiter cap on the idle fuel adjusting needle.

1. Start the engine and run at half throttle 5 to 10 minutes to warm up.
2. Place throttle in "idle" or "slow" position. Turn the low idle fuel adjusting needle out (counterclockwise) until engine speed decreases (rich); note position.
3. Turn the adjusting needle in (clockwise); engine speed increases then decreases as it goes lean; note position.
4. Set the adjusting needle midway between the rich and lean settings.

Tools: Water manometer or vacuum/pressure test gauge (KO1048/KO3223)

1. Insert rubber stopper into oil fill hole; connect hose between stopper and manometer tube; check water level at 0 line.
2. Start engine and run at no-load high idle (3200 to 3750 RPM).
3. Open clamp and note water level; engine side should be minimum 10.2 cm (4 in.) above open side.
4. Close shut-off clamp before stopping the engine.

Tools: Cylinder Leakdown Tester (KO3219), Holding tool

1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter.
3. Rotate crankshaft until piston is at TDC of compression stroke and hold in position.
4. Install adapter into spark plug hole but do not attach to tester yet.
5. Connect adequate air source to tester.
6. Turn regulator knob clockwise until gauge needle is in the yellow set area.
7. Connect tester quick-disconnect to adapter and note gauge reading.
8. Listen for escaping air at carburetor, exhaust, and crankcase breather.

Tools: Compressed air, Pressure regulator, Pressure gauge, Continuity tester

1. Connect the continuity tester across the blade terminal and the metal case of the switch. At 0 psi the tester should indicate continuity (switch closed).
2. Gradually increase pressure; the tester should indicate no continuity (switch open) as pressure increases through 2.0/5.0 psi.
3. The switch should remain open as pressure increases to 90 psi maximum.
4. Gradually decrease pressure; the tester should indicate continuity (switch closed) as pressure decreases through 2.0/5.0 psi.

1. Remove the oil drain plug and oil fill cap/dipstick and allow complete drainage.
2. Reinstall the drain plug and tighten to 13.6 N·m (10 ft. lb.).
3. Fill crankcase with new oil of the proper type to the F mark on the dipstick.
4. Reinstall oil fill cap/dipstick and tighten securely.

1. Drain oil from the engine crankcase.
2. Remove the oil filter drain plug where applicable and allow filter to drain.
3. Remove old filter and wipe off filter adapter; reinstall drain plug to 7.3-9.0 N·m.
4. Pour new oil into new filter through threaded center hole until oil reaches bottom of threads.
5. Wipe a drop of oil on the new filter rubber gasket.
6. Install filter; turn until gasket contacts adapter, then tighten additional 2/3 to 1 turn.
7. Fill crankcase with new oil to the F mark.
8. Test run engine, check for leaks, stop and recheck oil level.

⚠ Never operate engine with oil below the L mark or over the F mark.

1. Make sure engine is stopped, level, and cool so oil has drained into sump.
2. Clean area around oil fill cap/dipstick before removing it.
3. Remove oil fill cap/dipstick and wipe oil off.
4. Reinsert dipstick and rest cap on tube; do not thread the cap on.
5. Check oil level; add proper oil up to but not over the F mark.

⚠ Accidental starting can cause severe injury or death.

1. Disconnect the spark plug lead(s).
2. Disconnect negative (-) battery cable from battery.

1. Disconnect the fuel lines from the inlet and outlet fittings of the pump.
2. Remove the hex. flange screws, fuel pump, and gasket.
3. If necessary, remove the fittings from the pump body.