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Disassembly/Inspection and Service
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark plug lead(s)
before servicing.
Be sure to memorize location of individual parts when
disassembling generator so that generator can be
reassembled correctly. Tag disassembled part with
necessary information to facilitate easier and smoother
reassembly.
For more convenience, divide parts into several groups
and store them in boxes.
To prevent screws from being misplaced or installed
incorrectly, replace them temporarily to their original
position.
Handle disassembled parts with care; clean them before
reassembly using a neutral cleaning fl uid.
Remove battery before disassembling generator.
Be sure to attach foam rubber linings inside covers on
their original position when reassembling generator.
When deformation or damage of foam rubber lining is
found, replace it with new part. Failure to do so will result
in poor performance and durability of generator.
Tie wires and fuel hoses using cable ties as they were in
original confi guration.
When installing screws, hand tighten at fi rst before using
tools to avoid cross threading and potentially breaking
rivet nuts loose from frame.
Remove Cover
1. With cover open, remove screws securing grounding
cable and remove cable. Close cover.
2. Remove screws securing cover.
3. Remove cover.
Remove Side Panel
1. Remove all screws securing side panel.
2. Remove side panel.
Remove Back Panel
1. Remove all screws securing back panel.
2. Remove back panel.
14
WARNING
KohlerPower.com
Before working on engine or equipment, disable engine as
follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Do not allow children to operate generator.
Remove Door Panel
1. Remove all screws securing door panel.
2. Remove door panel.
Remove Battery Tray
NOTE: Removal of battery tray is not necessary for
servicing engine or alternator.
1. Remove screws securing battery tray to lifting ring
frame and upper alternator baffl e.
2. Remove battery tray.
Remove Intake Air Tube
1. Loosen hose clamp securing intake air tube to
alternator baffl e.
2. Remove intake air tube from air cleaner and upper
alternator baffl e.
Remove Lifting Ring Frame
NOTE: Lifting ring frame and upper alternator baffl e are
secured together with screws. Unless either
need replacing, disassembly is not necessary.
1. Remove screws securing lifting ring frame to
retention container and lower alternator baffl e.
2. Remove return fuel hose from fuel tank and pull
through upper alternator baffl e. Transfer any
remaining fuel into an approved container.
3. Remove lifting ring frame and upper alternator baffl e
as an assembly.
Remove Upper Alternator Baffl e
NOTE: Removal of upper alternator baffl e from lifting
ring frame is not necessary for servicing engine
or alternator.
1. Remove screws securing upper alternator baffl e to
lifting ring frame.
2. Remove upper alternator baffl e from lifting ring
frame.
Remove Lifting Ring
NOTE: Removal of lifting ring is not necessary for
servicing engine or alternator.
1. Remove cotter pin.
2. Remove jam nut, nut and washer.
3. Remove lifting ring.
38 690 01 Rev. --
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