Kohler Command PRO CH940 - Page 80

80
Reassembly
KohlerEngines.com 62 690 01 Rev. J
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
lter 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 Rectier-
Regulator
1. Apply pipe sealant with Teon
®
(Loctite
®
PST
®
592™
Thread Sealant or equivalent) to stator mounting
holes.
2. Position stator, aligning mounting holes so leads are
at bottom and toward rectier-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 rectier-regulator onto mounting posts with
cooling ns up. Attach ground lead to outer screw
and washer, then torque mounting screws to
2.5 N·m (22 in. lb.). Connect plug to rectier-
regulator.
Install Flywheel
CAUTION
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 ywheel.
NOTE: Before installing ywheel make sure crankshaft
taper and ywheel hub are clean, dry, and
completely free of any lubricants. Presence of
lubricants can cause ywheel to be over
stressed and damaged when screw is torqued to
specications.
NOTE: Make sure ywheel 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.
2. Install ywheel onto crankshaft, being careful not to
shift woodruff key.
3. Install screw and washer.
4. Use a ywheel strap wrench or holding tool to hold
ywheel. 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 ywheel.
1. Install fan onto ywheel 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 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 at side out/towards
you.
3. Slide modules up as far away from ywheel as
possible and snug screws to hold them in position.
4. Rotate ywheel to position magnet directly under 1
ignition module.
5. Insert a 0.30 mm (0.012 in.) 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 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 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 0.280/0.330 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 at section towards ywheel 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.