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Install Flywheel End Oil Seal and Camshaft Oil Seal
1. Check to make sure that there are no nicks or burrs
in crankshaft and camshaft seal bores of crankcase.
2. Apply a light coat of engine oil to outside diameter of
fl ywheel end oil seal.
3. Install oil seal into crankcase using a seal driver.
Make sure oil seal is installed straight and true in
bore, until tool bottoms against crankcase.
4. Apply a light coat of engine oil to outside diameter of
camshaft oil seal.
5. Install camshaft oil seal to a depth of 1.0-1.5 mm
(0.039-0.059 in.) below top of seal bore. Do not
bottom seal in bore or oil passage may be
obstructed.
Install Governor Cross Shaft
1. Lubricate governor cross shaft bearing surfaces in
crankcase with engine oil. Apply a small amount of
grease to lips of oil seal.
2. Slide small lower washer onto governor cross shaft
and install cross shaft from inside of crankcase.
3. Install nylon washer onto governor cross shaft, then
start push-on retaining ring. Hold governor shaft up
in position, then place a 0.25 mm (0.010 in.) feeler
gauge on top of nylon washer, and push retaining
ring down shaft to secure. Remove feeler gauge,
which will have established proper end play.
4. Pivot governor cross shaft so bottom end faces
cylinder 1 side.
Install Crankshaft
NOTE: Apply cellophane tape over crankshaft keyway
to prevent cutting oil seal during installation.
1. Lightly lubricate lips of crankshaft seal with grease.
2. Carefully slide fl ywheel end of crankshaft into
crankcase through oil seal.
Install Connecting Rods with Pistons and Rings
Piston/Connecting Rod Details
A
Cylinder 1
66 690 14 Rev. A
B
A
B
Cylinder 2
KohlerEngines.com
NOTE: Cylinders are numbered on crankcase. Make
sure to install piston, connecting rod and end
cap into its appropriate cylinder bore, as
previously marked at time of disassembly. Do
not mix end caps and connecting rods.
NOTE: Proper orientation of piston/connecting rod
assemblies inside engine is extremely important.
Improper orientation can cause extensive wear
or damage.
NOTE: Make sure to align chamfer of connecting rod
with chamfer of its mating end cap. When
installed, fl at faces of connecting rods should
face each other. Faces with raised rib should be
toward outside.
1. If piston rings were removed, refer to Disassembly/
Inspection and Service procedure to install new
rings.
2. Lubricate cylinder bore, piston, and piston rings with
engine oil. Compress rings of cylinder 1 piston using
a piston ring compressor.
3. Lubricate crankshaft journals and connecting rod
bearing surfaces with engine oil.
4. Make sure FLY stamping on piston is facing toward
fl ywheel side of engine. Use a hammer with a rubber
grip and gently tap piston into cylinder. Be careful oil
ring rails do not spring free between bottom of ring
compressor and top of cylinder.
5. Guide lower end of connecting rod and rotate
crankshaft to join two. Install rod cap to connecting
rod using screws and torque in increments to
13.6 N·m (120 in. lb.).
6. Repeat above procedure for other connecting rod
and piston assembly.
Install Camshaft
1. Inspect edges of camshaft keyway, make sure they
are not nicked or burred. Use a seal protector
(11/16") to prevent damaging seal lips, or dislodging
inner spring when camshaft is installed. Cellophane
tape over keyway is also recommended.
2. Lubricate camshaft bearing surfaces of crankcase
and camshaft with engine oil. Apply a small amount
of grease to lips of oil seal.
3. Rotate crankshaft and position timing mark of
crankshaft gear at 12 o'clock position.
4. Turn governor cross shaft clockwise until lower end
of shaft contacts crankcase (cylinder 1 side). Make
sure cross shaft remains in this position while
installing camshaft.
5. Slide camshaft into bearing surface of crankcase,
positioning timing mark of camshaft gear at 6 o'clock
position. Make sure that camshaft gear and
crankshaft gear mesh, and timing marks are aligned.
Reassembly
87
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