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Kohler Repair Guides

263 step-by-step procedures compiled from Kohler service manuals.

Service Precleaner (CH6)

General procedure

Service Paper Element (CH6)

General procedure

Disassembly - CH5 Air Cleaner

General procedure

Reassembly - CH5 Air Cleaner

General procedure

Carburetor Adjustment

General procedure

Complete Engine Disassembly Sequence

General procedure

Remove Ignition Modules

General procedure

Remove Oil Pump

General procedure

Decompression Lever Operation Check

KD 441

Flywheel Disassembly

KD 441

Rotor Loosening

4CFKM/4CFKMR, 5CKM/SCKMR, ACKM/4CKMR

TYPICAL DISASSEMBLY SEQUENCE

General procedure

DRAIN OIL AND REMOVE OIL FILTER

General procedure

REMOVE AIR CLEANER

General procedure

DISASSEMBLY

General procedure

DISASSEMBLY

General procedure

REMOVE BREATHER AND VALVE COVER

General procedure

DISASSEMBLY

General procedure

REMOVE FUEL PUMP

General procedure

DISASSEMBLY

General procedure

REMOVE ELECTRIC STARTER

General procedure

REMOVE STATOR

General procedure

REMOVE CYLINDER BARRELS

General procedure

DISASSEMBLY

General procedure

REMOVE VALVES

General procedure

REMOVE PISTON RINGS

General procedure

REMOVE OIL FILTER ADAPTER

General procedure

REMOVE CAMSHAFT AND TAPPETS

General procedure

REMOVE CONNECTING RODS

General procedure

REMOVE OIL PICKUP AND OIL PUMP

General procedure

DISASSEMBLY

General procedure

INSPECTION AND RECONDITIONING

General procedure

TYPICAL DISASSEMBLY SEQUENCE

General procedure

REMOVE AIR CLEANER

General procedure

REMOVE MUFFLER

General procedure

REMOVE FUEL TANK

General procedure

REMOVE RETRACTABLE STARTER

General procedure

REMOVE FUEL PUMP

General procedure

REMOVE ELECTRIC STARTER

General procedure

REMOVE CARBURETOR

General procedure

REMOVE VALVE COVER

General procedure

REMOVE CYLINDER HEAD BAFFLE

General procedure

REMOVE IGNITION MODULE

General procedure

REMOVE FUEL LINE

General procedure

REMOVE CYLINDER HEAD

General procedure

DISASSEMBLY

General procedure

REMOVE CLOSURE PLATE

General procedure

DISASSEMBLY

General procedure

REMOVE BALANCE SHAFT

General procedure

DISASSEMBLY

General procedure

REMOVE PISTON RINGS

General procedure

Procedure 1

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GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Procedure 5

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Procedure 6

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Procedure 7

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Procedure 9

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Procedure 10

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TYPICAL DISASSEMBLY SEQUENCE

General procedure

Procedure 1

General procedure

REMOVE PISTON RINGS

General procedure

remove the key from the switch.

Workman HDX Auto

connect negative (−) battery cable first and positive (+)

Workman HDX Auto

remove any attachments that may interfere with the safe

Workman HDX Auto

remove key from ignition switch. Any load mate-

Workman HDX Auto

Check the carburetor throat for dirt. Dirt in the

CV11-16, CV460-465, CV490-495

Check the oil level. Note if the oil level is within

CV11-16, CV460-465, CV490-495

reassemble, and recheck pressure.

CV11-16, CV460-465, CV490-495

Check the air cleaner daily or before starting the

CV11-16, CV460-465, CV490-495

Inspect Air Cleaner Components

CV11-16, CV460-465, CV490-495

Clean Air Intake/Cooling Areas

CV11-16, CV460-465, CV490-495

clean, approved containers. A container with a

CV11-16, CV460-465, CV490-495

check for faulty fuel pump (Test 4).

CV11-16, CV460-465, CV490-495

Remove the injectors using a commercial extractor tool as shown in

25LD330-2, 25LD425-2

CHECKS AND OVERHAUL

25LD330-2, 25LD425-2

Clean heads of carbon deposits and check the cylinder mating

25LD330-2, 25LD425-2

CHECKS AND OVERHAUL

25LD330-2, 25LD425-2

CHECKS AND OVERHAUL

25LD330-2, 25LD425-2

CHECKS AND OVERHAUL

25LD330-2, 25LD425-2

CHECKS AND OVERHAUL

25LD330-2, 25LD425-2

connecting rod must be straightened.

25LD330-2, 25LD425-2

Checking crankshaft dimensions

25LD330-2, 25LD425-2

CHECKS AND OVERHAUL

25LD330-2, 25LD425-2

CHECKS AND OVERHAUL

25LD330-2, 25LD425-2

Check that the shoes (S, fig.37) are level and that the springs have

25LD330-2, 25LD425-2

Checking injection pumps

25LD330-2, 25LD425-2

Checking and setting the injectors

25LD330-2, 25LD425-2

Reassemble the injector following the assembly order shown in

25LD330-2, 25LD425-2

Checking electrical equipment

25LD330-2, 25LD425-2

connect a dc ammeter (fig.50 and 51).

25LD330-2, 25LD425-2

connecting an ohmmeter and ensuring that resistance is zero,

25LD330-2, 25LD425-2

disconnected.

25LD330-2, 25LD425-2

connection or other circuit connections are not made properly.

25LD330-2, 25LD425-2

Clean the mating surfaces of sealing compound residues or other

25LD330-2, 25LD425-2

Half-pulley - Reassembly

KD626-3

Starter Rope Replacement

General procedure

Service Procedure 1

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Static Models (RY) — Disassembly

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GENERATOR DISASSEMBLY — REASSEMBLY

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Disassembly (Continued)

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GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Service Procedure 6

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GENERATOR DISASSEMBLY — REASSEMBLY

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Service Procedure 8

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Remove intake manifold and carburetor.

General procedure

Remove retractable starter.

General procedure

REMOVE PISTON RINGS

General procedure

Service Procedure

Workman HDX Auto

Service Procedure

Workman HDX Auto

Service Procedure

Workman HDX Auto

Service Procedure

Workman HDX Auto

Service Procedure

Workman HDX Auto

Service Procedure

Workman HDX Auto

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

25LD330-2, 25LD425-2

Welch Plug Removal

General procedure

Throttle Shaft Removal

General procedure

High Speed Adjustment

General procedure

Oil Sentry Switch Installation to Crankcase Boss

General procedure

Service Procedure

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Static Models (RY) — Disassembly

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Disassembly (Continued)

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GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Service Procedure

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Service Procedure

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Remove intake manifold and carburetor.

General procedure

Remove retractable starter.

General procedure

REMOVE PISTON RINGS

General procedure

Service Procedure

Workman HDX Auto

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

CV11-16, CV460-465, CV490-495

Service Procedure

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Service Procedure

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

| 3. Remove black plastic speed sensor from end bracket

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Service Procedure

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Disassembly (Continued)

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GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

4. Remove brushes from brush holder, and remove

General procedure

ELECTRICAL SYSTEM AND COMPONENTS

General procedure

Remove intake manifold and carburetor.

General procedure

13, Remove stator.

General procedure

18, Remove pistons from connecting rods.

General procedure

21, Remove oil fitter adapter.

General procedure

24, Remove crankshaft, front oil seal, and bearings.

General procedure

1. Remove the self-tapping screws and top baffle.

General procedure

Service Procedure

General procedure

4. Remove the hex. nuts and plain washers using the

General procedure

2. Remove the hex. cap screws, plain washers, cyl-

General procedure

REMOVE VALVES

General procedure

SPLIT THE CRANKCASE

General procedure

tidges. Check size frequently.

General procedure

Service Procedure

General procedure

Remove retractable starter.

General procedure

41. Remove the oi! drain plug and oil fill cap/dipstick.

General procedure

2. Remove the muffler and gasket from exhaust out-

General procedure

REMOVE VALVE COVER

General procedure

the kill lead to the crankcase. Remove the four

General procedure

Figure 9-41. Removing Connecting Rod. 1. Remove the woodruff key from the flywheel taper

General procedure

Service Procedure

General procedure

Service Procedure

General procedure

Service Procedure

CH5, CH6

ment cover w/grommet off. Remove paper

CH5, CH6

OD. Remove the spark plug and check for fuel at

CH5, CH6

A. Remove the fuel line from the inlet fitting of the

CH5, CH6

Figure 5-1C. CH6 Adjustable Main Adjust To I

CH5, CH6

3. Remove the low idle fuel adjusting needle and only if these parts are to be cleaned or replaced.

CH5, CH6

Welch Plug Installation

CH5, CH6

Procedure 1

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Procedure 2

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

| 3. Remove black plastic speed sensor from end bracket

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Procedure 7

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Disassembly (Continued)

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GENERATOR DISASSEMBLY — REASSEMBLY

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

4. Remove brushes from brush holder, and remove

General procedure

ELECTRICAL SYSTEM AND COMPONENTS

General procedure

Remove intake manifold and carburetor.

General procedure

13, Remove stator.

General procedure

18, Remove pistons from connecting rods.

General procedure

21, Remove oil fitter adapter.

General procedure

24, Remove crankshaft, front oil seal, and bearings.

General procedure

1. Remove the self-tapping screws and top baffle.

General procedure

1. Remove the hex. nut, copper washer, breather

General procedure

4. Remove the hex. nuts and plain washers using the

General procedure

2. Remove the hex. cap screws, plain washers, cyl-

General procedure

REMOVE VALVES

General procedure

SPLIT THE CRANKCASE

General procedure

tidges. Check size frequently.

General procedure

Procedure 1

General procedure

Remove retractable starter.

General procedure

41. Remove the oi! drain plug and oil fill cap/dipstick.

General procedure

2. Remove the muffler and gasket from exhaust out-

General procedure

REMOVE VALVE COVER

General procedure

the kill lead to the crankcase. Remove the four

General procedure

Figure 9-41. Removing Connecting Rod. 1. Remove the woodruff key from the flywheel taper

General procedure

2. Remove the cross shaft and plain washer from the

General procedure

Procedure 9

General procedure

Procedure 1

CH5, CH6

ment cover w/grommet off. Remove paper

CH5, CH6

OD. Remove the spark plug and check for fuel at

CH5, CH6

A. Remove the fuel line from the inlet fitting of the

CH5, CH6

Figure 5-1C. CH6 Adjustable Main Adjust To I

CH5, CH6

3. Remove the low idle fuel adjusting needle and only if these parts are to be cleaned or replaced.

CH5, CH6

Welch Plug Installation

CH5, CH6

SPECIAL TOOLS

General procedure

BASIC ENGINE TESTS

General procedure

LOW COMPRESSION

General procedure

AIR INTAKE SYSTEM

General procedure

AIR INTAKE SYSTEM

General procedure

AIR INTAKE SYSTEM

General procedure

Reassembly - Side Draft Carburetor

General procedure

Disassembly - Fixed Main Jet Type Side Draft Carburetor

General procedure

Dry Type Air Filter Disassembly and Cleaning

KD 702, KD 702_1003_1404, KDW 1003, KDW 1404

Service - Piston and Ring Replacement

K361

Reboring Cylinder - Honing

K361

Retractable Starter Removal

General procedure

Blower Housing Removal

General procedure

Oil Sentry Module Removal

General procedure

Valve Cover and Rocker Arm Removal

General procedure

Intake Valve Stem Seal Replacement

General procedure

Ignition Module Removal

General procedure

Flywheel Removal

General procedure

Motor and Pump Service

General procedure

Adjustable Jets (Plastic) Service

General procedure

Suction Inlet (Plastic) Service

General procedure

Starter Reassembly

General procedure

Starter Reassembly

General procedure