Kohler K91 Service Manual page 98

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WARNING: Accidental Starts
Before servicing the engine or equi pment, always
remove the spark plug lead to prevent the engine
from starting accidentally. Ground the lead to pre­
vent sparks that could cause fires.
Clean all parts thoroughly as the engine is disas­
sembled . Only clean parts can be accurately in­
spected and gauged for wear or damage . There
are many commercially available cleaners that
quickly remove g rease , oi l , and grime from engine
parts . When such a cleaner is used , follow the
manufacturer's instructions carefully . Make sure all
traces of the cleaner are removed before the en­
gine is reassembled and placed in operation-even
small amounts of these cleaners quickly break
down the lubricating properties of engine oil .
Check all parts for evidence of:
Excessive sludge and varnish
•
Scoring of the cylinder wall
•
Piston damage
•
Evidence of external oil leaks
•
Evidence of overheating .
•
Any of the listed problems could be the result of
im proper engine servicing or maintenance . The
owner should be made aware of the benefits of
proper servicing and maintenance .
The following sequence is suggested for complete
engine disassembly. This procedure may have to
be varied slightly to accommodate options or spe­
cial equipment .
1 . Disconnect spark plug lead .
2 . Drain oil from crankcase .
3 . Remove air cleaner.
4. Remove muffler.
5 . Remove throttle linkage and carburetor.
6 . Rem ove external governor components and
th rottle control .
7 . Remove fuel pum p .
8 . Remove retractable starter.
SECTION 1 0
D ISASSEM B L Y
9 . Remove electric starter.
I
1 0 . Remove fuel tank .
1 1 . Remove d ipstick.
1 2 . Remove cylinder head baffle and side air
baffles.
1 3 . Remove breather assembly .
1 4 . Remove spark plug and cylinder head .
1 5 . Remove blower housing .
1 6 . Remove drive cup or rope start pulley, grass
screen and flywheel .
1 7 . Remove stator.
1 8 . Remove valves .
1 9 . Remove oil pan .
20. Remove connecting rod and piston .
2 1 . Remove piston from connecting rod .
2 2 . Remove piston rings .
23 . Remove crankshaft and bearing plate.
24. Remove camshaft and tappets .
2 5 . Remove balance gears .
2 6 . Remove governor gear and cross shaft .
2 7 . Remove oil seals .
2 8 . Remove bearings.
D I SCONN ECT S PARK PLUG LEAD
DRAIN OIL FROM CRAN KCASE
REMOVE AIR CLEANER
1 .
Disconnect the spark plug lead and position it
away from the spark plug terminal .
2 . Unscrew t he oil drain plug (s) and drain the
crankcase oil into a suitable container for d is­
posa l .
3 . Remove t h e wing n u t , air cleaner cover ,
precleaner (if so equipped) , paper element ,
three base screws , base , and base gasket .
REMOVE M U FFLER
1 . If the engine is equipped with a flat muffler,
remove muffler and gasket by unscrewing cap
screws . If equipped with a round m uffler re­
move by turning the threaded exhaust pipe
between the m uffler and engine with a pipe
wrench .
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