Kohler Aegis LH775 Service Manual page 76

Reassembly
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
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. Stagger piston rings in grooves until end gaps are
120° apart. Oil ring rails should also be staggered.
2. Lubricate cylinder bore, piston, and piston rings with
engine oil. Compress rings of cylinder 1 piston using
a piston ring compressor.
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B
A
B Cylinder 2
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3. Lubricate crankshaft journals and connecting rod
bearing surfaces with engine oil.
4. Make sure FLY stamping on pistons is facing
towards fl ywheel side of engine. Use a hammer with
rubber grip and gently tap piston down into cylinder.
Be careful that 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
11.3 N·m (100 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.
Checking/Setting Camshaft End Play
1. Install shim removed during disassembly onto
camshaft.
2. Position end play tool on camshaft.
3. Apply pressure on end play checking tool (pushing
camshaft toward crankshaft). Use a feeler gauge to
measure end play between shim and end play tool.
Camshaft end play should be 0.076/0.127 mm
(0.003/0.005 in.).
4. If camshaft end play is not within specifi ed range,
remove original shim and reinstall end play tool. Use
a feeler gauge to determine clearance between
camshaft and tool. Subtract 0.100 mm (0.004 in)
from measured clearance to obtain required shim
thickness. Refer to table below and install shim that
matches calculated thickness. Repeat steps 1-3 to
verify that correct end play exists.
Camshaft Shims
White: 0.69215/0.73025 mm (0.02725/0.02875 in.)
Blue: 0.74295/0.78105 mm (0.02925/0.03075 in.)
Red: 0.79375/0.83185 mm (0.03125/0.03275 in.)
Yellow: 0.84455/0.88265 mm (0.03325/0.03475 in.)
Green: 0.89535/0.99345 mm (0.03525/0.03675 in.)
Gray: 0.94615/0.98425 mm (0.03725/0.03875 in.)
Black: 0.99695/1.03505 mm (0.03925/0.04075 in.)
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