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CH940-CH1000
Kohler CH940-CH1000
65 pages
Manual
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FORM NO.:
62 690 01 Rev
. C
ISSUED: 9/10
REVISED: 5/1
1
FOR SALES
AND SERVICE INFORMA
TION
IN U.S.
AND CANADA, CALL
1-800-544-2444
KohlerEngines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
© 201
1 by Kohler Co.
All rights reserved.
64
Table of Contents
Main Page
Contents
1
Safety
2
Safety Precautions
2
Maintenance
3
Maintenance Schedule
3
Repairs/Service Parts
3
Weekly
3
Oil Recommendations
4
Storage
4
Fuel Recommendations
4
Specifications
5
Engine Dimensions with Heavy-Duty Air Cleaner
5
Engine Dimensions with Low-Profi Le Air Cleaner
6
Engine Identification Numbers
7
General Specifications
7
Torques
7
Blower Housing and Steel Metal
7
Wear Limits
9
Connecting Rod-To-Piston Pin Running Clearance
10
Connecting Rod Journal
10
Crankshaft T.I.R.
10
Cylinder Bore
10
Governor Cross Shaft O.D.
11
Main Bearing I.D. (Crankcase/Closure Plate)
11
Piston, Piston Rings, and Piston Pin
11
Valves and Valve Lifters
11
General Torque Values
12
English Fastener Torque Recommendations for Standard Applications
12
Metric Fastener Torque Recommendations for Standard Application
12
Torque Conversions
12
Tools and Aids
13
Separate Tool Suppliers
13
Aids
14
Flywheel Holding Tool
15
Rocker Arm/Crankshaft Tool
15
Troubleshooting
16
Engine Cranks but will Not Start
16
Engine will Not Crank
16
Engine Starts but Does Not Keep Running
16
Engine Loses Power
17
Engine Uses Excessive Amount of Oil
17
Oil Leaks from Oil Seals, Gaskets
17
External Engine Inspection
17
Basic Engine Tests
18
No Crankcase Vacuum/Pressure in Crankcase
18
To Test Crankcase Vacuum with Manometer
18
Compression Test
19
Cylinder Leakdown Test
19
Leakdown Test Instructions
19
Leakdown Test Results
19
Air Cleaner/Intake
20
Low-Profile Air Cleaner
20
Breather Tube
20
Fuel System and Governor
21
Keihin BK Two-Barrel Carburetor - Exploded View
21
Fuel Line
22
Fuel Pump
22
Fuel Pump Replacement
22
Fuel System Tests
22
Carburetor
23
Troubleshooting -- Carburetor Related Causes
23
Troubleshooting Checklist
23
Fuel Shut-Off Solenoid
24
Carburetor Adjustments
24
Carburetor Circuits
24
Low Idle Fuel Adjustment
24
Carburetor Servicing
25
Float Replacement/Overhaul/Choke Repair
25
High Altitude Operation
26
Governor
26
Governor Adjustments
27
Initial Adjustment Procedure
27
Governed Idle Speed Adjustment
27
High Speed (RPM) Adjustment
27
Lubrication System
28
Check Oil Level
28
Change Oil and Oil Filter
29
Service Oil Cooler
29
Oil Sentry
29
Spark Plugs
30
Spark Plug Service
30
Electrical System
30
Inspection
31
Normal
31
Worn
31
Carbon Fouled
31
Electrical System
32
Battery
32
Electronic Ignition Systems
32
Battery Size Recommendations
32
Troubleshooting CD Ignition Systems
33
Troubleshooting -- CD Ignition Systems
33
Test Procedure for DSAI Ignition Systems
33
Troubleshooting -- Electric Ignition System
34
Check Ignition System
34
Isolate and Verify Trouble Is Within Engine
34
Test for Spark
34
Electron CD Fixed Ignition Timing System
35
Digital Spark Advance Ignition (DSAI) System
35
Rev. C
35
Battery Charging System
41
15/20/25 Amp Regulated Charging System
41
Rectifier-Regulator
41
20/25 Amp Rectifier-Regulators
41
Troubleshooting Guide
42
Electric Starting Motors
43
Starter Removal and Installation
43
Starting Motor Precautions
43
Troubleshooting Guide – Starting Difficulties
43
Delco-Remy Starters
44
Starter Disassembly
44
Drive Pinion
45
Brush Replacement
45
Starter Service
45
Shift Fork
45
Solenoid Test Procedure
46
Disassembly
47
Heavy-Duty Air Cleaner
47
Disconnect Spark Plug Leads
48
Drain Oil from Crankcase and Remove Oil Filter
48
Remove Muffler
48
Remove Carburetor
48
Remove Oil Filter Housing and Oil Filter Adapter
49
Remove Ignition Modules
49
Remove Grass Screen and Cooling Fan
49
Remove Spark Plugs
49
Remove Cylinder Heads and Hydraulic Lifters
50
Disassemble Cylinder Heads
50
Bleeding Lifters
50
Valve Guides
50
Remove Breather Assembly
51
Remove Oil Reservoir and Pickup Screen
51
Oil Pump Assembly
51
Remove Closure Plate Assembly
51
Remove Camshaft
52
Remove Connecting Rods with Pistons and Rings
52
Connecting Rods
52
Piston and Rings
52
Remove Crankshaft
53
Install New Piston Rings
53
Remove Governor Gear Assembly
54
Remove Governor Yoke, Cross Shaft, and Seal
54
Remove Lifter Feed Chamber Cover and Gaskets
54
Remove Main Bearings
54
Honing
55
Clean Cylinder Bore after Honing
55
Measuring Piston-To-Bore Clearance
55
General
56
Install Flywheel End Oil Seal
56
Install Governor Shafts, Seal, and Governor Gear
56
Install Flywheel End Main Bearing
56
Install Connecting Rods with Pistons and Rings
57
Install Camshaft
57
Determining Camshaft End Play
57
Install Closure Plate Main Bearing and Oil Seal
57
Oil Seal
58
Install Oil Pickup Screen
58
Install Oil Reservoir
58
Check Crankshaft End Play
58
Reassembly
59
Install Breather Assembly
59
Install Hydraulic Lifters
59
Valve Stem Seals
60
Assemble Cylinder Heads
60
Install Cylinder Heads
60
Install Valve Covers
60
Install Oil Filter Adapter
61
Install Oil Filter Housing Assembly
61
Install Backing Shroud Assembly
61
Install Intake Manifold
61
Install Flywheel
62
Install Outer Cylinder Baffles
62
Install Oil Cooler
62
Install Cooling Fan and Grass Screen
62
Install Valley Baffles
63
Install Carburetor
63
Install Governor Lever
63
Install Throttle and Choke Linkages
63
Governor Spring/Rpm Chart
64
Install Oil Sentry
64
Install Blower Housing and Cylinder Shrouds
64
Install Control Panel
64
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