Disconnect Spark Plug Leads; Drain Oil From Crankcase And Remove Oil Filter; Remove Muffler; Remove Carburetor - Kohler CH940-CH1000 Service Manual

Disassembly
Clean all parts thoroughly as engine is disassembled.
Only clean parts can be accurately inspected
and gauged for wear or damage. There are many
commercially available cleaners that will quickly remove
grease, oil and grime from engine parts. When such a
cleaner is used, follow manufacturer's instructions and
safety precautions carefully.
Make sure all traces of cleaner are removed before
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down
lubricating properties of engine oil.

Disconnect Spark Plug Leads

NOTE: Pull on boot only, to prevent damage to spark
plug lead.
Disconnect leads from spark plugs.

Drain Oil from Crankcase and Remove Oil Filter

1. Clean oil fi lter and housing area. Remove and
discard oil fi lter.
2. Remove dipstick and one of oil drain plugs.
3. Allow ample time for oil to drain from crankcase.
Remove Muffl er
Remove exhaust system and attaching hardware from
engine.
Remove Cylinder Shrouds and Blower Housing
1. Remove top mounting screw and loosen two
shoulder screws on each side. Lift off two cylinder
shrouds.
2. Remove four mounting screws and separate blower
housing from lower half.
Remove Electric Starter Motor
1. Disconnect leads from starter.
2. Remove two hex fl ange screws and starter.
Remove Air Cleaner Assembly
NOTE: Low-profi le air cleaner is removed same way as
heavy-duty air cleaner.
1. Disconnect breather hose from air cleaner, and
formed vent hose from vent port on carburetor.
2. Remove four hex fl ange nuts, ground lead, and
choke return spring bracket from mounting studs.
3. Remove two screws securing air cleaner and main
control bracket to intake manifold bosses.
4. Remove air cleaner as an assembly from engine.
Removing Control Bracket, Governor Springs, and
Lever
1. Unhook governed idle and governor springs from
controls on main bracket and governor lever. Note
color, location and position of each.
2. Disconnect throttle linkage and dampening spring
from governor lever at small bushing.
48
3. Carefully pry off pal nut, remove two washers
(note assembly order), and disconnect choke linkage
from pivot lever. Do not lose any parts. Secure
remaining pivot parts with tape to avoid losing them.
Always use a new pal nut during reassembly.
4. Remove rear mounting screw on each side and lift
off control bracket.
5. Loosen hex fl ange nut and remove governor lever
from cross shaft.

Remove Carburetor

Explosive Fuel can cause fi res and severe
burns.
Do not fi ll fuel tank while engine is hot or
running.
Gasoline is extremely fl ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or fl ames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
1. Disconnect fuel shut-off solenoid lead.
2. Remove fuel inlet hose from carburetor or fuel pump.
Properly contain any remaining fuel.
3. Remove carburetor and linkages with choke return
components as an assembly.
4. Remove carburetor gasket.
5. Carburetor and linkages can be separated as
necessary.
Remove Oil Sentry
1. Disconnect lead from Oil Sentry
2. Remove Oil Sentry
Remove Baffl es and Intake Manifold
1. Remove screws securing valley baffl es to cylinder
heads and backing shroud assembly.
2. Remove four screws securing each of outer cylinder
baffl es in place. Two of screws are accessed from
backing shroud side.
3. Remove four hex fl ange screws securing intake
manifold to cylinder heads. Cut any wire ties that
secure wiring harness or leads to intake manifold.
4. Remove intake manifold and gaskets.
Remove Oil Cooler
NOTE: New clamps are recommended any time
disassembly is performed, or if clamps have
been loosened (expanded) several times.
1. Remove two oil cooler mounting screws. Do not lose
any washers (if used).
2. Loosen clamps and disconnect each of hoses from
oil cooler.
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WARNING
(if equipped)
™
switch.
™
switch from closure plate.
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62 690 01 Rev. C