Engine Service Manual

75
Disassembly/Inspection and Service
32 690 03 Rev. I KohlerEngines.com
Remove Camshaft and Valve Tappets
1. Position crankcase so fl ywheel side is down.
Remove camshaft and shim.
2. Remove valve tappets from crankcase and mark
them by their location, as either intake or exhaust
and cylinder 1 or 2. Tappets should always be
reinstalled in same position.
Camshaft Inspection and Service
Check lobes of camshaft for wear or damage. See
Specifi cations for minimum lift specifi cations. Inspect
cam gear for badly worn, chipped or missing teeth.
Replacement of camshaft will be necessary if any of
these conditions exist.
Valve Tappets Inspection
Check base surface of valve tappet(s) for wear or
damage. Replace tappet(s) if condition is questionable
in any way. Corresponding camshaft lobe(s) should also
be checked for wear or damage. Whenever tappets are
replaced, apply a liberal coating of Kohler lubricant to
base of each new tappet before it is installed.
Remove Governor Cross Shaft
Governor Cross Shaft Oil Seal Details
B
A
A 2.0 mm (0.0787 in.) B
Governor Cross
Shaft Seal
1. Round Cross Shaft End: Remove push-on
retaining ring and nylon washer from governor cross
shaft.
7 mm Hex Cross Shaft End: Remove E-Clip and
nylon washer from governor cross shaft.
2. Remove cross shaft with lower washer through
inside of crankcase.
3. Remove governor shaft seal from crankcase.
If governor cross shaft seal is damaged and/or leaks,
replace it using following procedure.
Remove oil seal from crankcase and replace it with a
new one. Install new seal to depth shown.
Connecting Rods/Piston/Breather Components
G
I
F
A
B
D
B
E
H
C
A Piston Ring Set B Piston Pin Retainer
C Piston D Piston Pin
E Connecting Rod F
Connecting Rod
End Cap
G Breather Filter H
Breather
Cover
I Oil Seal
Remove Breather Assembly
Breather system is designed to control amount of oil
in head area and still maintain necessary vacuum in
crankcase.
When pistons move downward, crankcase gases are
pushed past reed through breather fi lter into intake
system. Upward travel of pistons closes reed and
creates a low vacuum in lower crankcase. Any oil
separated out through fi lter drains back into crankcase.
1. Remove screws securing breather cover to
crankcase.
2. Carefully remove cover and breather fi lter. Make
sure drain back hole is not plugged or restricted.
Remove Connecting Rods with Pistons and Rings
NOTE: If a carbon ridge is present at top of either
cylinder bore, use a ridge reamer tool to remove
it before attempting to remove piston.
NOTE: Cylinders are numbered on crankcase. Use
numbers to mark each end cap, connecting rod
and piston for reassembly. Do not mix end caps
and connecting rods.
1. Remove screws securing closest connecting rod end
cap. Remove end cap.
2. Carefully remove connecting rod and piston
assembly from cylinder bore.
3. Repeat above procedure for other connecting rod
and piston assembly.
Connecting Rods
Offset, stepped-cap connecting rods are used in all
these engines.