Kohler CH940-CH1000

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Electrical System

3962 690 01 Rev. C KohlerEngines.com

Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector

(LP-NG Kohler Power Systems Application)

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Contents1
Safety2
Safety Precautions2
Maintenance3
Maintenance Schedule3
Repairs/Service Parts3
Weekly3
Oil Recommendations4
Storage4
Fuel Recommendations4
Specifications5
Engine Dimensions with Heavy-Duty Air Cleaner5
Engine Dimensions with Low-Proﬁ Le Air Cleaner6
Engine Identification Numbers7
General Specifications7
Torques7
Blower Housing and Steel Metal7
Wear Limits9
Connecting Rod-To-Piston Pin Running Clearance10
Connecting Rod Journal10
Crankshaft T.I.R.10
Cylinder Bore10
Governor Cross Shaft O.D.11
Main Bearing I.D. (Crankcase/Closure Plate)11
Piston, Piston Rings, and Piston Pin11
Valves and Valve Lifters11
General Torque Values12
English Fastener Torque Recommendations for Standard Applications12
Metric Fastener Torque Recommendations for Standard Application12
Torque Conversions12
Tools and Aids13
Separate Tool Suppliers13
Aids14
Flywheel Holding Tool15
Rocker Arm/Crankshaft Tool15
Troubleshooting16
Engine Cranks but will Not Start16
Engine will Not Crank16
Engine Starts but Does Not Keep Running16
Engine Loses Power17
Engine Uses Excessive Amount of Oil17
Oil Leaks from Oil Seals, Gaskets17
External Engine Inspection17
Basic Engine Tests18
No Crankcase Vacuum/Pressure in Crankcase18
To Test Crankcase Vacuum with Manometer18
Compression Test19
Cylinder Leakdown Test19
Leakdown Test Instructions19
Leakdown Test Results19
Air Cleaner/Intake20
Low-Profile Air Cleaner20
Breather Tube20
Fuel System and Governor21
Keihin BK Two-Barrel Carburetor - Exploded View21
Fuel Line22
Fuel Pump22
Fuel Pump Replacement22
Fuel System Tests22
Carburetor23
Troubleshooting -- Carburetor Related Causes23
Troubleshooting Checklist23
Fuel Shut-Off Solenoid24
Carburetor Adjustments24
Carburetor Circuits24
Low Idle Fuel Adjustment24
Carburetor Servicing25
Float Replacement/Overhaul/Choke Repair25
High Altitude Operation26
Governor26
Governor Adjustments27
Initial Adjustment Procedure27
Governed Idle Speed Adjustment27
High Speed (RPM) Adjustment27
Lubrication System28
Check Oil Level28
Change Oil and Oil Filter29
Service Oil Cooler29
Oil Sentry29
Spark Plugs30
Spark Plug Service30
Electrical System30
Inspection31
Normal31
Worn31
Carbon Fouled31
Electrical System32
Battery32
Electronic Ignition Systems32
Battery Size Recommendations32
Troubleshooting CD Ignition Systems33
Troubleshooting -- CD Ignition Systems33
Test Procedure for DSAI Ignition Systems33
Troubleshooting -- Electric Ignition System34
Check Ignition System34
Isolate and Verify Trouble Is Within Engine34
Test for Spark34
Electron CD Fixed Ignition Timing System35
Digital Spark Advance Ignition (DSAI) System35
Rev. C35
Battery Charging System41
15/20/25 Amp Regulated Charging System41
Rectifier-Regulator41
20/25 Amp Rectifier-Regulators41
Troubleshooting Guide42
Electric Starting Motors43
Starter Removal and Installation43
Starting Motor Precautions43
Troubleshooting Guide – Starting Difficulties43
Delco-Remy Starters44
Starter Disassembly44
Drive Pinion45
Brush Replacement45
Starter Service45
Shift Fork45
Solenoid Test Procedure46
Disassembly47
Heavy-Duty Air Cleaner47
Disconnect Spark Plug Leads48
Drain Oil from Crankcase and Remove Oil Filter48
Remove Muffler48
Remove Carburetor48
Remove Oil Filter Housing and Oil Filter Adapter49
Remove Ignition Modules49
Remove Grass Screen and Cooling Fan49
Remove Spark Plugs49
Remove Cylinder Heads and Hydraulic Lifters50
Disassemble Cylinder Heads50
Bleeding Lifters50
Valve Guides50
Remove Breather Assembly51
Remove Oil Reservoir and Pickup Screen51
Oil Pump Assembly51
Remove Closure Plate Assembly51
Remove Camshaft52
Remove Connecting Rods with Pistons and Rings52
Connecting Rods52
Piston and Rings52
Remove Crankshaft53
Install New Piston Rings53
Remove Governor Gear Assembly54
Remove Governor Yoke, Cross Shaft, and Seal54
Remove Lifter Feed Chamber Cover and Gaskets54
Remove Main Bearings54
Honing55
Clean Cylinder Bore after Honing55
Measuring Piston-To-Bore Clearance55
General56
Install Flywheel End Oil Seal56
Install Governor Shafts, Seal, and Governor Gear56
Install Flywheel End Main Bearing56
Install Connecting Rods with Pistons and Rings57
Install Camshaft57
Determining Camshaft End Play57
Install Closure Plate Main Bearing and Oil Seal57
Oil Seal58
Install Oil Pickup Screen58
Install Oil Reservoir58
Check Crankshaft End Play58
Reassembly59
Install Breather Assembly59
Install Hydraulic Lifters59
Valve Stem Seals60
Assemble Cylinder Heads60
Install Cylinder Heads60
Install Valve Covers60
Install Oil Filter Adapter61
Install Oil Filter Housing Assembly61
Install Backing Shroud Assembly61
Install Intake Manifold61
Install Flywheel62
Install Outer Cylinder Baffles62
Install Oil Cooler62
Install Cooling Fan and Grass Screen62
Install Valley Baffles63
Install Carburetor63
Install Governor Lever63
Install Throttle and Choke Linkages63
Governor Spring/Rpm Chart64
Install Oil Sentry64
Install Blower Housing and Cylinder Shrouds64
Install Control Panel64

Kohler CH940-CH1000

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