Kohler command pro CH940 Service Manual page 80

Reassembly
Install Backing Shroud Assembly
NOTE: New hose clamps are recommended for
reassembly, or if clamps have been loosened
(expanded) several times to avoid leakage.
1. To aid assembly, install lower oil cooler hose onto oil
filter housing prior to installing backing shroud
assembly, and secure with a clamp.
2. Install backing shroud assembly and secure to
crankcase with M6 screws. Torque screws in a
crisscross pattern to 10.7 N·m (95 in. lb.) into new
holes, or 7.3 N·m (65 in. lb.) into used holes.
Install Stator, Wiring Harness, and Rectifier-
Regulator
1. Apply pipe sealant with Teflon
Thread Sealant or equivalent) to stator mounting
holes.
2. Position stator, aligning mounting holes so leads are
at bottom and toward rectifier-regulator mount on
cylinder 1 side.
3. Install and torque screws to 9.3 N·m (82 in. lb.).
4. Route stator wires under molded clips in backing
shroud assembly.
5. Check terminal on end of B+ charging lead to be
sure locking tang is angled upward. Insert terminal
into center location of connector until it locks into
place.
6. Install wiring harness under molded clips in backing
shroud assembly.
7. Position rectifier-regulator onto mounting posts with
cooling fins up. Attach ground lead to outer screw
and washer, then torque mounting screws to
2.5 N·m (22 in. lb.). Connect plug to rectifier-
regulator.
Install Flywheel
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 flywheel.
NOTE: Before installing flywheel make sure crankshaft
taper and flywheel hub are clean, dry, and
completely free of any lubricants. Presence of
lubricants can cause flywheel to be over
stressed and damaged when screw is torqued to
specifications.
NOTE: Make sure flywheel 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.
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® ® ®
CAUTION
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2. Install flywheel onto crankshaft, being careful not to
shift woodruff key.
3. Install screw and washer.
4. Use a flywheel strap wrench or holding tool to hold
flywheel. Torque screw to 69.8 N·m (51 ft. lb.).
Install Fan (Style B)
NOTE: Position locating tabs on back of fan into locating
holes of flywheel.
1. Install fan onto flywheel using screws (engines with
plastic grass screen). Engines with a metal grass
screen will leave fan loosely assembled.
2. Torque screws to 9.9 N·m (88 in. lb.).
Install Ignition Modules
CDI/MDI Ignition System
1. Rotate flywheel 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 flat side out/towards
you.
3. Slide modules up as far away from flywheel as
possible and snug screws to hold them in position.
4. Rotate flywheel to position magnet directly under 1
ignition module.
5. Insert a 0.30 mm (0.012 in.) flat feeler gauge
between magnet and ignition module. Loosen
screws enough to allow magnet to pull module down
against feeler gauge.
6. Torque screws to 9.7 N·m (86 in. lb.) into new holes,
or 4.1 N·m (37 in. lb.) into used holes.
7. Repeat steps 4 through 6 for other ignition module.
8. Rotate flywheel 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.
DSAI Ignition System
NOTE: DSAI modules do not require or have an air gap
adjustment.
1. Install each DSAI ignition module to crankcase
bosses with flat section towards flywheel and
individual spade terminals out. Torque screws to 9.7
N·m (86 in. lb.) into new holes, or 4.1 N·m (37 in. lb.)
into used holes.
2. Apply GE/Novaguard G661 or equivalent dielectric
compound to module surface between base of
terminals to create a moisture proof barrier. Do not
put any compound inside harness connectors.
62 690 01 Rev. J