Service manual

68
Reassembly
KohlerEngines.com 62 690 01 Rev. C
Install Flywheel
CAUTION
Damaging Crankshaft and Flywheel Can
cause personal injury.
Using improper procedures can lead to broken
fragments. Broken fragments could be thrown from
engine. Always observe and use precautions and
procedures when installing fl ywheel.
NOTE: Before installing fl ywheel make sure crankshaft
taper and fl ywheel hub are clean, dry, and
completely free of any lubricants. Presence of
lubricants can cause fl ywheel to be over
stressed and damaged when screw is torqued to
specifi cations.
NOTE: Make sure fl ywheel key is installed properly in
keyway. Flywheel can become cracked or
damaged if key is not properly installed.
1. Install woodruff key into crankshaft keyway. Make
sure key is properly seated and parallel with shaft
taper.
2. Install fl ywheel onto crankshaft, being careful not to
shift woodruff key.
3. Install screw and washer.
4. Use a fl ywheel strap wrench or holding tool to hold
fl ywheel. Torque screw to 67.8 N·m (50 ft. lb.).
Install Ignition Modules
1. Rotate fl ywheel to position magnet away from
ignition module bosses.
2. Connect ground lead to single kill tab and install
modules onto crankcase bosses so tab is away from
you (IN) and spark plug lead should be towards you
(OUT). Mount wiring harness clamp with loop UP, on
starter side inner module screw and route harness
through it. Attach rectifi er-regulator ground lead to
outer screw.
3. Slide modules up as far away from fl ywheel as
possible and snug screws to hold them in position.
4. Rotate fl ywheel to position magnet directly under 1
ignition module.
5. Insert a 0.30 mm (0.012 in.) fl at feeler gauge
between magnet and ignition module. Loosen
screws enough to allow magnet to pull module down
against feeler gauge.
6. Torque screws to 6.2 N·m (55 in. lb.) into new holes,
or 4.0 N·m (35 in. lb.) into used holes.
7. Repeat steps 4 through 6 for other ignition module.
8. Rotate fl ywheel back and forth, checking for
clearance between magnet and ignition modules.
Make sure magnet does not strike modules. Check
gap with a feeler gauge and readjust if necessary.
Final Air Gap 0.280/0.330 mm (0.011/0.013 in.).
9. Make sure leads are under molded clip on starter
side.
Install Cooling Fan and Debris Screen
CAUTION
Failure to utilize or reassemble debris screen
as designed could result in debris screen
failure and serious personal injury.
Cooling Fan and Debris Screen Components
1. Position cooling fan onto fl ywheel aligning mounting
locations. Apply a small amount of Loctite
®
243™
Threadlocker to threads and install long mounting
screws. Torque screws to 9.9 N·m (88 in. lb.).
2. Apply a small amount of Loctite
®
243™ Threadlocker
to external threaded section, (unless new parts with
preapplied locking compound are being used).
Thread debris screen hex studs into mounting holes
in fl ywheel. Torque each stud to 9.9 N·m (88 in. lb.).
3. Install stiffener followed by metal debris screen onto
studs. Secure with special washers and mounting
screws using Loctite
®
243™ Threadlocker on
threads. Torque screws to 9.9 N·m (88 in. lb.).