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Small diesel generator engine dismantling and repair

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  • OVERALL DIFFICULTY INDEX: 5/10
  • IF YOU HAVE NO TOOLS, YOU PAY $35 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 2 HOURS TO CARRY OUT THIS JOB
  • SAFETY: USED OIL ALLERGY RISK.​
BEFORE YOU START
  • Be comfortably seated on any plastic stool or low support while carrying this work as most bolts require no force.
  • This mono-cylinder diesel engine is one the easiest for beginners to rebuild or repair their first engine.
  • Parts are better purchased after dismantling and while matching them to the old ones because of the lack of documentation for such engines.
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.
Note: the below works are widely compatible with any of the KAMA and KIPOR KDE5000, KDE5500, KDE6000 and KDE6500 generators.

Generator engine repair: step-by-step dismantling pictorial

1- Disconnect the starter motor wires.
2- Disconnect the fuel solenoid valve. 
3- Unscrew the high pressure fuel tube on injection pump side.
4- Disconnect it on the injector side and remove it.
5- Unscrew all bolts.
6- Using a piece of wood, hit the engine side cover with a 1-2 Kg hammer.
7- You just opened the engine.
   
8- Meet the family, from left to right: balancing shaft, crankshaft, camshaft.
9- Remove the metallic gasket.
10- Take out the camshaft.
11- Take out the injection pump cylinder and valves push rods.
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12- Unscrew the two bolts of the piston link, push the piston up and take out crankshaft and balancing shaft.

Check out available Kama / Kipor spares at our partners' stores:

See also other tips for generator repair: