Service Manual

56
Disassembly/Inspection and Service
KohlerEngines.com 66 690 01 Rev. C
Remove Crankshaft
Carefully pull crankshaft from crankcase. Note thrust
washer and shims if used.
Inspection and Service
Crankshaft Components and Details
A
B
C
D
A Self-Tapping Screw B Flat Washer
C Plug D Crankshaft
E
G
F
H
E
Fillet Must Blend Smoothly with Bearing Journal
Surface
F High Point from Fillet Intersections
G 45° Minimum
H This Fillet Area Must Be Completely Smooth
Inspect gear teeth of crankshaft. If teeth are badly worn,
chipped, or some are missing, replacement of crankshaft
will be necessary.
Inspect crankshaft bearing surfaces for scoring,
grooving, etc. Replaceable bearing is used in crankshaft
bore of closure plate and/or crankcase. Do not replace
bearing unless they show signs of damage or are out of
running clearance 0.039/0.074 mm (0.0015/0.0029 in.).
If crankshaft turns easily, without noise, and there is no
evidence of scoring, grooving, etc., on races or bearing
surfaces, bearing can be reused.
Inspect crankshaft keyways. If they are worn or chipped,
replacement of crankshaft will be necessary.
Inspect crankpin for score marks or metallic pickup.
Slight score marks can be cleaned with crocus cloth
soaked in oil. If wear limits, as stated in Clearance
Specifi cations, are exceeded, it will be necessary to
replace crankshaft or regrind crankpin to 0.25 mm
(0.010 in.) undersize. If reground, a 0.25 mm (0.010 in.)
undersize connecting rod (big end) must then be used to
achieve proper running clearance. Measure crankpin for
size, taper, and out-of-round.
Connecting rod journal can be ground 1 size under.
When grinding a crankshaft, grinding stone deposits
can get caught in oil passages, which could cause
severe engine damage. Removing crankpin plug when
crankshaft is ground provides easy access for removing
any grinding deposits that may collect in oil passages.
Use following procedure to remove and replace plug.
Remove Crankshaft Plug
1. Drill a 3/16 in. hole through plug in crankshaft.
2. Thread a 3/4 in. or 1 in. long self-tapping screw with
a fl at washer into drilled hole. Flat washer must be
large enough to seat against shoulder of plug bore.
3. Tighten self-tapping screw until it draws plug out of
crankshaft.
Install New Crankshaft Plug
Use 1 single cylinder camshaft pin, as a driver and tap
plug into plug bore until it seats at bottom of bore. Make
sure plug is tapped in evenly to prevent leakage.
Remove Governor Cross Shaft
NOTE: Always use a new retaining ring when
reassembling. Do not reuse old retaining ring.
1. Remove retaining ring and nylon washer from
governor cross shaft.
2. Remove cross shaft and small washer out through
inside of crankcase.
Governor Cross Shaft Oil Seal
Cross Shaft Oil Seal Details
B
A
A 2.0 mm (0.0787 in.)
B Governor Cross Shaft Seal
Remove governor cross shaft oil seal from crankcase
and replace it with a new one if seal is damaged and/
or leaks. Install new seal to depth shown using a seal
installer.