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How to reassemble a small diesel engine and generator

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  • OVERALL DIFFICULTY INDEX: 6/10
  • IF YOU HAVE NO TOOLS, YOU PAY $50 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 8 HOURS TO CARRY OUT THIS JOB
  • SAFETY: USED OIL ALLERGY, HAND INJURIES RISK.​
BEFORE YOU START
  • Rushing on the assembly erases all the good efforts made to repair. Take your time, be meticulous and clean whatever in your hand prior to refitting it.
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.

Reassembly of the single cylinder diesel engine

You may also refer to the exploded view of the engine further below on this page.
1- Clean well your engine, refit the crankshaft, tighten well the piston link.



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2- Refit the valves push rods and the injection pump cylinder than the balancing shaft and camshaft. Do not forget to align them both to the crankshaft by making sure the single punch marking is centered in between the double punch marking.
3- Clean the cover and the oil pump and replace the crankshaft seal.



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4- Use again the RTV silicone gasket maker on both cover and engine.   
5- Place the metallic gasket in between and push the cover gently after putting some oil on the crankshaft to avoid damaging the seal.
6- Tighten all bolts to the same torque of 2.5 mKg.
7- Rotate the engine by hand to bring the valves to compression.
8- Adjust the valves clearance to the following values: 0.10-0.15, both IN & EX
9- Use an RTV silicone gasket maker and close the cylinder head.

Reassembling the engine and alternator, refitting in canopy

Clean the base frame of your diesel genset. 
Reverse all dismantling steps. See related pages for engine/alternator, exhaust, sound proof canopy,etc.
Final checks of the diesel genset reassembly: all parts should be clean, all bolts should have been re-used, all electrical connectors should be reconnected.
If you have an external soundproof canopy, clean it before reintroducing the generating set. Cleanliness is a important component of diesel engines and generators maintenance.

Exploded view of the single cylinder diesel engine body:

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

See also other tips for generator repair: