​Small diesel engine camshaft repair | 
KIPOR generator problems

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  • OVERALL DIFFICULTY INDEX: 7/10
  • IF YOU HAVE NO TOOLS, YOU PAY $75 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 8 HOURS TO CARRY OUT THIS JOB
  • RISK OF SKIN ALLERGY TO USED OIL.​
BEFORE YOU START
  • The below pictorial covers the repair itself only. For engine dismantling and assembly, see related pages.
  • Wear gloves all along this intervention.
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.

Small generator camshaft repair pictorial

This engine stopped suddenly and does not restart. It cranks easily and at a high speed denoting a lack of compression. It seems one at least of the valves is stuck open. You may follow the below steps if you're facing similar trouble.
1- Remove the valves cover.
2- The inlet valve adjusting screw  is found broken and half of it missing. 
3- Take out the driving rod with a magnet tool and check if it is straight.
4- Find the valve rod cap and put it aside.
5- Open the oil refill plug and insert a magnet tool.
6- The collected debris indicate something is broken inside the engine.
7- See related pages for extracting the generator from its canopy, separating and dismantling the engine. Pick the second half of the valve screw with a magnet.   
8- The presence of debris is for sure linked to the broken screw reason why the camshaft is carefully inspected.
9- The crankshaft bearing is found broken. Some of it has melted into many small parts. The problem is found.
10- It also appeared that the crankshaft end is worn when purchasing a new bearing. A new crankshaft was purchased.
11- Now the pinion needs to be moved to the new shaft. Spray a lot of WD40 and extract it.
12- it will come out after applying some strong force on the extractor.
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13- Transfer the small pinion blocker from shaft to shaft.
14- Place the pinion by hand first, find a socket of the appropriate diameter.
15- Give it a first push with a C-clamp to make sure it goes straight.
16- Continue with your extractor used from the other side.
17- The pinion has been successfully transferred to the new shaft.
18- Replace the $5 faulty bearing that led to hours of work...
19- Complete your repair by fitting a new valve driving screw. See the related page for reassembling your engine and generator.

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

See also other tips for generator repair: