Install Breather Cover and Inner Baffl es
Breather Cover Torque Sequence
1
2
3
4
RTV sealant was used on early models between
breather cover and crankcase. A gasket with imprinted
sealant beads is now used and recommended. Install as
follows:
1. Be sure sealing surfaces of crankcase and breather
cover are clean of old gasket material or RTV
sealant. Do not scrape surfaces as this could result
in leakage.
2. Check to make sure there are no nicks or burrs on
sealing surfaces.
3. Install breather reed and breather reed retainer onto
crankcase and secure with screw. Hold assembly in
line when tightening. Torque screw to 3.9 N·m
(35 in. lb.).
4. Insert breather fi lter into position in crankcase. Make
sure no fi lter strands are on sealing surface.
5. Install new breather gasket.
6. Carefully position breather cover on crankcase.
Install fi rst two screws at positions shown and fi nger
tighten at this time.
7. Install inner baffl es using two remaining screws and
fi nger tighten. Do not torque screws at this time; they
will be tightened after blower housing and outer
baffl es are installed.
Install Blower Housing and Outer Baffl es
NOTE: Do not completely tighten screws until all items
are installed to allow shifting for hole alignment.
1. Connect plug to key switch in blower housing (if
equipped).
2. Slide blower housing into position over front edge of
inner baffl es. Start a few screws to hold it in place.
On two-barrel carburetor models, lift debris shield up
above mounting surface, as blower housing is
installed. Make sure ground lead, fuel solenoid lead,
and oil pressure switch leads are accessible and in
proper position.
3. Position outer baffl es and loosely start mounting
screws. M6 screws go into back of cylinders. Short
M5 screws go into lower holes closest to blower
housing. Short screw on oil fi lter side is also used to
mount wire harness clip. Be sure any wire harnesses
or leads are routed out through proper off sets or
notches, so they will not be pinched between blower
housing and baffl es.
4. If rectifi er-regulator was not removed, attach ground
wire or metal grounding bracket for rectifi er-
regulator, using silver colored screw and washer, to
lower blower housing hole.
5. Tighten all shrouding fasteners. Torque blower
housing screws to 6.2 N·m (55 in. lb.) in a new hole,
or to 4.0 N·m (35 in. lb.) in a used hole. Torque
shorter M5 side baffl e screws to 4.0 N·m (35 in. lb.).
Torque upper M5 side baffl e screws (into cylinder
head) to 6.2 N·m (55 in. lb.) in a new hole, or to 4.0
N·m (35 in. lb.) in a used hole. Torque two rear M6
baffl e mounting screws to 10.7 N·m (95 in. lb.) in a
new hole, or to 7.3 N·m (65 in. lb.) in a used hole.
6. If an overlapping style fl ywheel screen is used,
attach it to supports or fl ywheel. For a metal fl ywheel
screen, apply Loctite
®
242
®
to screw threads (M6)
and torque to 9.9 N·m (88 in. lb.). Torque plastic
screen mounting screws (M4) to 2.2 N·m (20 in. lb.).
7. Torque breather cover screws to 11.3 N·m (100 in.
lb.) into new holes or 7.3 N·m (65 in. lb.) into used
holes in sequence shown. Note fi rst screw is torqued
a second time.
Reconnect Rectifi er-Regulator
1. Install rectifi er-regulator in blower housing, if
removed previously, then connect rectifi er-regulator
ground lead with washer and silver screw through
eyelet as shown. If a grounding bracket is used,
secure with lower mounting screw and washer,
against outer side of rectifi er-regulator.
2. Install B+ terminal/lead into center position of
rectifi er-regulator plug and connect plug to rectifi er-
regulator.
SMART-SPARK
™
Module
On engines with SMART-SPARK
™
, reinstall SAM module
to blower housing or cylinder baffl e. Do not overtighten
retaining screws.
Install Electric Starter Motor
NOTE: If engine uses a side mount muffl er on starter
side, be sure to tie wires close to starter to avoid
contact with hot exhaust parts.
1. Install starter motor using two screws. Some inertia-
drive starters have a pinion cover and spacers on
starter bolts.
2. Torque screws to 15.3 N·m (135 in. lb.).
3. On models with a solenoid shift starter, connect
leads to solenoid.
Reassembly
116 24 690 06 Rev. PKohlerEngines.com
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