Kohler cabinetry upgraded hinge kits to ensure durability. The new hinges are made of all metal and no longer have plastic components as shown on the older hinges. Hinge packs and hardware kits have been upgraded to the new metal hinges.
The fingers on the new hinge are a tight fit when replacing the older style with new.
It is best to loosen the door hinge screws to give the new hinge fingers some room to maneuver. While the fit of these new hinges may be difficult on older cabinets, they will go on and are the new replacements that are available.
Hinge screw sizes:
Hinge to Door: #6-32 x 3/8" 100 Deg Philips Head 18/8 Stainless
Hinge to Cabinet: #8-32 x 3/8" Truss Head
Note: New cabinets are now manufactured with slightly larger slots and will not have the same issue.