Kohler K91 Service Manual page 33

File off any bu rrs which may have been left o n
3 .
the choke shaft when t h e screws were re­
moved . Place carburetor on workbench with
choke side down . Remove choke shaft ; the
detent ball and spring will fall out.
4 . Note the position of the choke lever with re­
spect to the cut out portion of the choke
shaft .
5 . Carefully g rind or file away the riveted portion
of the shaft . Remove and save the choke
leve r ; discard the old choke shaft .
Attach the choke lever t o the new choke shaft
6 .
from the kit . Make sure the lever is installed
correctly as noted in step
choke shaft as follows :
Models K9 1 - K1 8 1 ,'
Apply Loctite to threads of
x brass screw . Secure lever to shaft .
#2-56 7/32 "
Models K24 1 - K34 1 , .
Apply Loctite to threads of 1
x brass screw. Secure lever to shaft .
#3-48 7/32 "
Remove Throttle Plate and Throttle Shaft;
Transfer Throttle Lever
1 . To ensure correct reassembly, mark throttle
plate and carburetor body with a marking pen .
Also take note of the throttle plate position in
the bore and the throttle lever position.
Carefully and slowly remove the screws secur­
2 .
ing the t hrottle plate to throttle shaft . Remove
and save the throttle plate for reuse .
3 . File off any burrs that may have been left on
the throttle shaft when screws were removed.
NOTE: Failu re to remove burrs from the throttle
shaft may cause permanent damage to carburetor
body when shaft is removed.
4. Remove throttle shaft from carbu retor body.
Remove and discard the foam rubber dust seal
from the throttle shaft .
Remove and transfer the throttle lever as fol­
S .
lows :
Models K9 1 - K1 8 1 ( 1 12 " Carb. ) ,.
Carefully grind or file away t h e riveted portion of
the throttle shaft . Save the throttle shaft as it will
be used to install the new throttle shaft bushing .
Discard the t h rottle lever .
Mode/s K24 1 - K34 1 ( 1 " Carb . ) ;
a . Note the position of the throttle lever with re­
spect to the cutout portion of the throttle
shaft.
b . Carefully grind o r file away the riveted portion
of the shaft . Remove t he throttle lever.
4. Secure lever to
1
c . Compare the old shaft with the new shafts in
the kit . Select the appropriate new shaft and
discard the old shaft.
d . Attach throttle lever t o throttle shaft . Make
sure lever is installed correctly as noted in
step a .
e . Apply Loctite t o threads of
brass screw (use #3-48
is long . Secure lever to shaft .
2-49/64 "
Drill Choke S haft Bores Using A Drill
Press
Mount the carburetor body in a d rill press vise .
1 .
Keep the vise jaws slightly loose .
Install a drill bit o f t h e following size in t h e drill
2 .
press chuck. Lower the bit (not rotating)
through both choke shaft bores ; then tighten
vise . This ensures accurate alignment of the
carburetor body with the d rill press chuck .
Models K9 1 - K 1 8 1 ( 1 12 " Carb . ) ;
ameter drill bit.
Models K24 1 - K34 1 ( 1 " Carb . ) ;
ameter drill bit .
Refer to Figure 6-9 .
Figure 6-9 . Aligning/Drilling Carburetor Body.
Install a 1 9/64" drill bit i n the chuck. Set drill
3 .
press to a low speed suitable for aluminu m .
Drill slowly to ensure a good finish .
Ream the choke shaft bores to a final size of
4 .
For best results use a piloted
5 / 1 6 " .
reamer.
S . Blow out all metal chips using compressed air.
Thoroughly clean the carburetor body in carbu­
retor cleaner.
1 #2-S6 x 7/32 "
x 7/3 2 " screw if shaft
Use a 7/32 " di­
Use a 1 /4 " di­
5 / 1 6 "
6 . 7