Engine Service Manual

88
Reassembly
KohlerEngines.com 32 690 03 Rev. I
Install Ignition Modules
Smart-Choke
™
Defl ector Support Tab
A
B
A Position tab towards crankcase.
B Rotate tab against module before tightening.
NOTE: On engines equipped with Smart-Choke
™
, make
sure to install defl ector support tab on #2
cylinder ignition module.
1. Rotate fl ywheel to position magnet away from
ignition module bosses.
2. CDI modules are installed with spark plug lead wire
from module always away from cylinder. On cylinder
1, single kill tab should be towards you. On cylinder
2, single kill tab should be away from you (in).
MDI modules are installed with fl at side out/towards
you.
3. Install each ignition module to crankcase bosses.
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 0.25 mm (0.009 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 4.0-6.2 N·m (35-55 in. lb.).
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 0.203/0.305 mm (0.008/0.012 in.).
Install Intake Manifold
Torque Sequence
1
2
3
4
1. On engines equipped with Smart-Choke
™
, install air
vane defl ector into intake manifold. Torque screw to
1 N·m (9 in. lb.).
2. Install intake manifold using new O-rings, with wiring
harness attached, onto cylinder heads. Slide any
wiring harness clips onto appropriate bolts before
installing. Using sequence shown, torque screws in
2 increments, fi rst to 7.4 N·m (66 in. lb.), then to
9.9 N·m (88 in. lb.).
3. Connect kill lead to tab terminal on standard ignition
modules.
Install Rectifi er-Regulator (if equipped)
1. Install B+ terminal/lead into center position of
rectifi er-regulator plug so it locks in place, and
connect plug to rectifi er-regulator.
2. Attach rectifi er-regulator to opening in backing plate
from underside, and secure with mounting screws.
Torque screws to 4.0 N·m (35 in. lb.).
Install Inner and Outer Cylinder Baffl es
1. Attach outer cylinder baffl es and secure with M6
screw (lower cylinder location), and M5 screw into
backing plate. Tighten screws as listed following step
2.
2. Attach inner baffl es including any lifting straps to
cylinder head fl anges and to 2 crankcase mounting
bosses. Lift strap should be outside outer baffl e.
Secure with M5 screws. Remaining lower inner
baffl e mounting screws will be installed later.
Torque baffl e mounting screws:
M5 screws: 6.2 N·m (55 in. lb.) into a new cored
hole, or 4.0 N·m (35 in. lb.) into a used hole.
M6 screws: 10.7 N·m (95 in. lb.) into a new cored
hole, or 7.3 N·m (65 in. lb.) into a used hole.