Remove Governor Gear Assembly; Remove Governor Yoke, Cross Shaft, And Seal; Remove Lifter Feed Chamber Cover And Gaskets; Remove Main Bearings - Kohler CH940-CH1000 Service Manual

Disassembly
Inspect crankshaft keyways. If they are worn or chipped,
replacement of crankshaft will be necessary.
Inspect crankpin for score marks or metallic pickup.
Slight score marks can be cleaned with crocus cloth
soaked in oil. If wear limits, as stated in Specifi cations
and Tolerances are exceeded, it will be necessary to
either replace crankshaft or regrind crankpin to 0.25 mm
(0.010 in.) undersize. If reground, a 0.25 mm (0.010 in.)
undersize connecting rod (big end) must then be used to
achieve proper running clearance. Measure crankpin for
size, taper, and out-of-round.
Connecting rod journal can be ground one size under.
When grinding a crankshaft, grinding stone deposits
can get caught in oil passages, which could cause
severe engine damage. Removing crankpin plug when
crankshaft is ground provides easy access for removing
any grinding deposits that may collect in oil passages.
Use following procedure to remove and replace plug.
Procedure to Remove Crankshaft Plug:
1. Drill a 3/16 in. hole through plug in crankshaft.
2. Thread a 3/4 in. or 1 in. long self-tapping screw with
a fl at washer into drilled hole. Flat washer must be
large enough to seat against shoulder of plug bore.
3. Tighten self-tapping screw until it draws plug out of
crankshaft.
Procedure to Install New Plug:
1. Use a single cylinder camshaft pin, as a driver and
tap plug into plug bore until it seats at bottom of
bore. Make sure plug is tapped in evenly to prevent
leakage.

Remove Governor Gear Assembly

Governor gear is held onto shaft by small molded tabs
in gear. When gear is removed from shaft, these tabs
are destroyed and gear must be replaced. Therefore,
remove gear only if absolutely necessary. If governor
cross shaft, yoke, or gear condition does not require
removal, governor gear may be left in place. If removal
is necessary, perform as follows:
1. Remove locking tab thrust washer and note
orientation.
2. Using a screwdriver, carefully pry upward to unseat
governor gear assembly from governor gear shaft.
Remove regulating pin and governor gear assembly.
3. Inspect governor gear shaft for wear or damage.
Remove shaft only if replacement is needed.
Inspection
Governor gear is located within crankcase. Inspect
governor gear teeth. Replace gear if it is worn, chipped,
or if any teeth are missing. Inspect governor weights.
They should move freely in governor gear.

Remove Governor Yoke, Cross Shaft, and Seal

1. Remove two mounting screws securing yoke to
governor cross shaft.
2. Pull governor cross shaft out of crankcase and
remove seal.
54

Remove Lifter Feed Chamber Cover and Gaskets

Remove three screws securing lifter feed chamber
baffl e (some models only), cover, and gaskets. Carefully
separate parts from crankcase.
Remove Flywheel and PTO End Oil Seals
Remove oil seals from crankcase and closure plate
using a seal puller.

Remove Main Bearings

NOTE: Flywheel and PTO side main bearings should
only be removed if replacement is required due
to wear. If removal is performed, use a press
and support casting surface around bearing
fl ange. Do not press against or support by
gasket/outer perimeter surface.
Crankcase
Inspection and Service
Check all gasket surfaces to make sure they are free of
gasket fragments. Gasket surfaces must also be free of
deep scratches or nicks.
Inspect main bearing (if so equipped) for wear or
damage. Replace bearing or crankcase using a
miniblock or short block as required.
Check cylinder bore for scoring. In severe cases,
unburned fuel can cause scuffi ng and scoring of cylinder
wall. It washes necessary lubricating oils off piston and
cylinder wall. As raw fuel seeps down cylinder wall,
piston rings make metal to metal contact with wall.
Scoring of cylinder wall can also be caused by localized
hot spots resulting from blocked cooling fi ns or from
inadequate or contaminated lubrication.
If cylinder bore is badly scored, excessively worn,
tapered, or out-of-round, resizing is necessary. Use
an inside micrometer to determine amount of wear,
then select nearest suitable oversize of either 0.25 mm
(0.010 in.) or 0.50 mm (0.020 in.). Resizing to one of
these oversizes will allow usage of available oversize
piston and ring assemblies. Initially, resize using a boring
bar, then use following procedures for honing cylinder.
KohlerEngines.com 62 690 01 Rev. C