Sharp CD-CH1000 Service Manual

CH940-CH1000Service ManualKohlerEngines.comIMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to ope

Specifi cations10 62 690 01 Rev. CKohlerEngines.comCLEARANCE SPECIFICATIONS3CH940 CH960 CH980 CH1000Connecting RodCrankpin End I.D. @ 70°F New Max. We

Specifi cations1162 690 01 Rev. C KohlerEngines.comCLEARANCE SPECIFICATIONS3CH940 CH960 CH980 CH1000Cylinder HeadMax. Out-of-Flatness 0.076 mm (0.003 i

Specifi cations12 62 690 01 Rev. CKohlerEngines.comGENERAL TORQUE VALUESMetric Fastener Torque Recommendations for Standard ApplicationsProperty ClassN

Tools and Aids1362 690 01 Rev. C KohlerEngines.comCertain quality tools are designed to help you perform specifi c disassembly, repair, and reassembly

Tools and Aids14 62 690 01 Rev. CKohlerEngines.comTOOLSDescription Source/Part No.Hydraulic Valve Lifter ToolFor removing and installing hydraulic lif

Tools and Aids1562 690 01 Rev. C KohlerEngines.comFLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOLA fl ywheel holding tool can be made out of an old ju

Troubleshooting16 62 690 01 Rev. CKohlerEngines.comEngine Cranks But Will Not Start● Battery connected backwards.● Blown fuse.● Carburetor solenoid

1762 690 01 Rev. C KohlerEngines.comTroubleshootingEngine Loses Power● Dirty air cleaner element.● Engine overheated.● Excessive engine load.● Restr

Troubleshooting18 62 690 01 Rev. CKohlerEngines.comCondition ConclusionCrankcase breather clogged or inoperative. NOTE: If breather is integral part

1962 690 01 Rev. C KohlerEngines.comTroubleshootingCOMPRESSION TESTFor Command Twins:A compression test is best performed on a warm engine. Clean any

Safety2 62 690 01 Rev. CKohlerEngines.comSAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property dam

62 690 01 Rev. CKohlerEngines.com20Air Cleaner/IntakeAIR CLEANERThese systems are CARB/EPA certifi ed and components should not be altered or modifi ed

Fuel System2162 690 01 Rev. C KohlerEngines.comTypical carbureted fuel system and related components include:● Fuel tank and valve.● Fuel lines.● In-

Fuel System22 62 690 01 Rev. CKohlerEngines.comTwo-Barrel Carburetor ComponentsACarburetor BodySubassemblyBIdle SpeedScrewCIdle SpeedSpringD Screw E G

Fuel System2362 690 01 Rev. C KohlerEngines.comEngines in this series are equipped with a two-barrel, side-draft carburetor with fi xed main jets on a

Fuel System24 62 690 01 Rev. CKohlerEngines.comFuel Shut-off SolenoidMost carburetors are equipped with a fuel shut-off solenoid. Solenoid is attached

Fuel System2562 690 01 Rev. C KohlerEngines.com1. Perform removal procedures for appropriate air cleaner and carburetor outlined in Disassembly.2. C

Fuel System26 62 690 01 Rev. CKohlerEngines.com13. Turn old bushing upside down and use it as a driver to carefully press or tap new bushing into car

Governor System2762 690 01 Rev. C KohlerEngines.comThis governor design works as follows:● Centrifugal force acting on rotating governor gear assembl

Lubrication System28 62 690 01 Rev. CKohlerEngines.comThis engine uses a full pressure lubrication system which delivers oil under pressure to cranksh

Lubrication System2962 690 01 Rev. C KohlerEngines.comOIL COOLERNOTE: Oil cooler is mounted under cylinder shroud. Removal of cylinder shroud is nece

Maintenance362 690 01 Rev. C KohlerEngines.comMAINTENANCE INSTRUCTIONS WARNINGBefore working on engine or equipment, disable engine as follows: 1) Dis

Electrical System30 62 690 01 Rev. CKohlerEngines.comSPARK PLUGS CAUTIONElectrical Shock can cause injury.Do not touch wires while engine is running.S

Electrical System3162 690 01 Rev. C KohlerEngines.comCarbon FouledSoft, sooty, black deposits indicate incomplete combustion caused by a restricted ai

Electrical System32 62 690 01 Rev. CKohlerEngines.comFixed Ignition SystemThis system uses a capacitive discharge (CD) coil. Ignition timing and spark

Electrical System3362 690 01 Rev. C KohlerEngines.comBGOBPSDHKIJDBFBGALMNXBQCWRZRSAJAJVCAAAEABFUGFDAEBTYADAFAHAIACA Blue B Red CGreen (Oil Sentry™ Pul

Electrical System34 62 690 01 Rev. CKohlerEngines.comACAFAIAEADAADBOQSZXCADGYEBAHWWWVBUTGGBFFPFBDAHJJXRGGABBFBIHNLKJMABA Blue B Red CGreen (Oil Sentry

Electrical System3562 690 01 Rev. C KohlerEngines.comWire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Conne

Electrical System36 62 690 01 Rev. CKohlerEngines.comWire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Conne

Electrical System3762 690 01 Rev. C KohlerEngines.comElectronic Ignition Systems TestsSpecial Tools Required:NOTE: Ignition tester must be used to te

Electrical System38 62 690 01 Rev. CKohlerEngines.comTest Timing Advance (DSAI only)1. Make a line near edge of fl ywheel screen with a marking pen, c

Electrical System3962 690 01 Rev. C KohlerEngines.comTo test 20/25 amp rectifi er-regulators:1. Connect single lead adapter in between B+ (center) ter

Maintenance4 62 690 01 Rev. CKohlerEngines.comOIL RECOMMENDATIONSWe recommend use of Kohler oils for best performance. Other high-quality detergent oi

Electrical System40 62 690 01 Rev. CKohlerEngines.comTo test charging system for no charge to battery:1. Insert an ammeter in B+ lead from rectifi er-

Electrical System4162 690 01 Rev. C KohlerEngines.comELECTRIC STARTING MOTORNOTE: Do not crank engine continuously for more than 10 seconds. Allow a

Electrical System42 62 690 01 Rev. CKohlerEngines.comSolenoid Shift Starter ComponentsA Tube B WasherC Armature D DriveE Stop F Retaining RingG Collar

Electrical System4362 690 01 Rev. C KohlerEngines.com b. Install a new retainer in larger (rear) groove of armature shaft. Squeeze with a pliers to

Electrical System44 62 690 01 Rev. CKohlerEngines.comTo test solenoid pull-in coil/plunger:Actuation1. Use a 12 volt power supply and 2 test leads.2.

Disassembly/Inspection and Service4562 690 01 Rev. C KohlerEngines.com WARNINGBefore working on engine or equipment, disable engine as follows: 1) Dis

Disassembly/Inspection and Service46 62 690 01 Rev. CKohlerEngines.comClean all parts thoroughly as engine is disassembled. Only clean parts can be ac

Disassembly/Inspection and Service4762 690 01 Rev. C KohlerEngines.comRemove Oil CoolerNOTE: New clamps are recommended any time disassembly is perfo

Disassembly/Inspection and Service48 62 690 01 Rev. CKohlerEngines.comRemove FlywheelNOTE: Always use a fl ywheel strap wrench or holding tool to hold

Disassembly/Inspection and Service4962 690 01 Rev. C KohlerEngines.comRemove Valve Covers and Fuel Pump WARNINGExplosive Fuel can cause fi res and seve

Specifi cations562 690 01 Rev. C KohlerEngines.comDimensions in millimeters. Inch equivalents shown in [ ].Engine Dimensions with Heavy-Duty Air Cleane

Disassembly/Inspection and Service50 62 690 01 Rev. CKohlerEngines.com3. Mark position of push rods as either intake or exhaust and cylinder 1 or 2.

Disassembly/Inspection and Service5162 690 01 Rev. C KohlerEngines.comAfter cleaning, check fl atness of cylinder head and corresponding top surface of

Disassembly/Inspection and Service52 62 690 01 Rev. CKohlerEngines.comRemove Breather Assembly1. Remove fasteners securing breather assembly, breathe

Disassembly/Inspection and Service5362 690 01 Rev. C KohlerEngines.com1. Make sure recess in closure plate for oil pump gerotor gears is clean.2. Lu

Disassembly/Inspection and Service54 62 690 01 Rev. CKohlerEngines.comRemove CamshaftRemove camshaft and shim (if used).InspectionCheck lobes of camsh

Disassembly/Inspection and Service5562 690 01 Rev. C KohlerEngines.comPiston and RingsInspectionPiston and Rings Components and DetailsA Piston Ring B

Disassembly/Inspection and Service56 62 690 01 Rev. CKohlerEngines.com3. Top compression ring (top groove): Install top ring using a piston ring expa

Disassembly/Inspection and Service5762 690 01 Rev. C KohlerEngines.comRemove Governor Yoke, Cross Shaft, and Seal1. Remove mounting screws securing y

Disassembly/Inspection and Service58 62 690 01 Rev. CKohlerEngines.comClean Cylinder Bore After HoningProper cleaning of cylinder walls following bori

59Reassembly62 690 01 Rev. C KohlerEngines.comCrankcase ComponentsAQOBCPDEHJKLMN CFGIA Camshaft B Locking Tab C Regulating Pin D Governor GearE Cross

Specifi cations6 62 690 01 Rev. CKohlerEngines.comDimensions in millimeters.Inch equivalents shown in [ ].Engine Dimensions with Low-Profi le Air Cleane

60ReassemblyKohlerEngines.com 62 690 01 Rev. CInstall Governor Shafts, Seal, and Governor GearGovernor Components and DetailsA Crankcase Surface BSeal

61Reassembly62 690 01 Rev. C KohlerEngines.comInstall Camshaft1. Liberally apply camshaft lubricant to each cam lobe. Lubricate camshaft bearing surf

62ReassemblyKohlerEngines.com 62 690 01 Rev. CSeveral color coded shims are available:White: 0.69215/0.73025 mm (0.02725/0.02875 in.)Blue: 0.74295/0.7

63Reassembly62 690 01 Rev. C KohlerEngines.com1. Use bolts with heads removed, or a similar item as temporary alignment pins and install into 2 cente

64ReassemblyKohlerEngines.com 62 690 01 Rev. CNOPQRMLKIJHGCEFADBA Gasket B Valve C Cylinder Head D Pipe PlugE Spacer F Washer G Spark Plug H Valve Ste

65Reassembly62 690 01 Rev. C KohlerEngines.comInstall Cylinder HeadsTorque Sequence2244553311NOTE: Match numbers embossed on cylinder heads and crank

66ReassemblyKohlerEngines.com 62 690 01 Rev. COil Cooler/Filter ComponentsABCDEFGMJIIHKJMNLKA Oil Filter B Oil Filter NippleC Cup D Valve SpringE Cup

67Reassembly62 690 01 Rev. C KohlerEngines.comFlywheel/Ignition ComponentsNMKLJIHGEFACDBOA Rectifi er-Regulator B Ignition Module C Washer D Flywheel S

68ReassemblyKohlerEngines.com 62 690 01 Rev. CInstall Flywheel CAUTIONDamaging Crankshaft and Flywheel Can cause personal injury.Using improper proced

69Reassembly62 690 01 Rev. C KohlerEngines.comABTCDEFGIHJKMLKIHNRQUOOPSTUQXVWVVA Oil Filter B Oil Filter Nipple C Oil Filter Cup D Valve SpringE Cup S

Specifi cations762 690 01 Rev. C KohlerEngines.comENGINE IDENTIFICATION NUMBERSKohler engine identifi cation numbers (model, specifi cation and serial) s

70ReassemblyKohlerEngines.com 62 690 01 Rev. CInstall Oil Cooler1. Connect hoses between oil fi lter adapter and oil cooler. Secure with new clamps.2.

71Reassembly62 690 01 Rev. C KohlerEngines.comInstall Governor LeverInstall governor lever onto governor shaft and connect throttle linkage with black

72ReassemblyKohlerEngines.com 62 690 01 Rev. CInstall Oil Sentry™ (if equipped)1. Apply pipe sealant with Tefl on® (Loctite® PST® 592™ Thread Sealant

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76KohlerEngines.com 62 690 01 Rev. C © 2011 by Kohler Co. All rights reserved.

Specifi cations8 62 690 01 Rev. CKohlerEngines.comTORQUE SPECIFICATIONS3,5CH940 CH960 CH980 CH1000Control PanelM6 screw 10.7 N·m (95 in. lb.) into new

Specifi cations962 690 01 Rev. C KohlerEngines.comTORQUE SPECIFICATIONS3,5CH940 CH960 CH980 CH1000Oil Pickup ScreenMounting Screw 10.7 N·m (95 in. lb.)