Remove Governor Gear Assembly (Mechanical Governor Only); Remove Governor Yoke, Cross Shaft, And Seal (Mechanical Governor Only); Crankcase Inspection And Service; Honing - Kohler ECV940 Service Manual

Disassembly/Inspection and Service
Remove Governor Gear Assembly (Mechanical
Governor Only)
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
(Mechanical Governor Only)
1. Remove mounting screws securing yoke to governor
cross shaft.
2. Pull governor cross shaft out of crankcase and
remove seal.
Remove Lifter Feed Chamber Cover and Gaskets
Remove screws securing lifter feed chamber cover and
gaskets. Carefully separate parts from crankcase.
Remove Flywheel End Oil Seal
Remove oil seal from crankcase using a seal puller.
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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.
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 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.

Honing

Detail
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NOTE: Kohler pistons are custom-machined to exacting
tolerances. When oversizing a cylinder, it should
be machined exactly 0.25 mm (0.010 in.) or
0.50 mm (0.020 in.) over new diameter.
corresponding oversize Kohler replacement
piston will then fi t correctly.
While most commercially available cylinder hones can
be used with either portable drills or drill presses, use
of a low speed drill press is preferred as it facilitates
more accurate alignment of bore in relation to crankshaft
crossbore. Honing is best accomplished at a drill speed
of about 250 RPM and 60 strokes per minute. After
installing coarse stones in hone, proceed as follows:
KohlerEngines.com
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23°-33° Crosshatch
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