Dismantling the exhaust assembly of a small diesel generator

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  • OVERALL DIFFICULTY INDEX: 3/10
  • IF YOU HAVE NO TOOLS, YOU PAY $15 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 1 HOUR TO CARRY OUT THIS JOB
  • RISK OF HAND INJURY, SEE BELOW​
BEFORE YOU START
  • Your engine should be cold for this intervention. Do not attempt to work on a hot engine.
  • Watch out when unscrewing the exhaust bolts, they could loosen suddenly sending your hand onto a hard or sharp surface resulting in an injury.
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 exhaust removal - Dismantling mufflers

1- Two bolts do hold the exhaust mufflers to to the flexible exhaust tube connected to the cylinder head.
2- Remove them, take away the mufflers and remove the two bolts that hold the sound-proof box to the alternator.   
3- The sound-proof box is still fixed to the engine by many 6 mm bolts that need a size 10 socket.
4- Remove all bolts.
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5- Take out the box.
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6- Unscrew and take out the flexible tube and the box wall plates on engine side.
7- Your generating set is now ready for the next step, separating alternator from engine.

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

See also other tips for generator repair: