Disassembly/Inspection and Service Remove Crankshaft Carefully pull crankshaft from crankcase. Note thrust washer and shims if used. Inspection and Service Crankshaft Components and Details Specifi cations, are exceeded, it will be necessary to replace crankshaft or regrind crankpin to 0.25 mm (0.010 in.) undersize. If reground, a 0.25 mm (0.010 in.) undersize connecting rod (big end) must then be used to achieve proper running clearance. Measure crankpin for size, taper, and out-of-round. Connecting rod journal can be ground 1 size under. When grinding a crankshaft, grinding stone deposits can get caught in oil passages, which could cause severe engine damage.
Removing crankpin plug when crankshaft is ground provides easy access for removing any grinding deposits that may collect in oil passages. Use following procedure to remove and replace plug. Remove Crankshaft Plug 1. Drill a 3/16 in. hole through plug in crankshaft. 2. Thread a 3/4 in. or 1 in. long self-tapping screw with a fl at washer into drilled hole. Flat washer must be large enough to seat against shoulder of plug bore. 3. Tighten self-tapping screw until it draws plug out of crankshaft. Install New Crankshaft Plug Use 1 single cylinder camshaft pin, as a driver and tap plug into plug bore until it seats at bottom of bore. Make sure plug is tapped in evenly to prevent leakage.
Remove Governor Cross Shaft NOTE: Always use a new retaining ring when reassembling. Do not reuse old retaining ring. 1. Remove retaining ring and nylon washer from governor cross shaft. 2. Remove cross shaft and small washer out through inside of crankcase. Governor Cross Shaft Oil Seal Cross Shaft Oil Seal Details Inspect gear teeth of crankshaft. If teeth are badly worn, chipped, or some are missing, replacement of crankshaft will be necessary. Inspect crankshaft bearing surfaces for scoring, grooving, etc. Replaceable bearing is used in crankshaft bore of closure plate and/or crankcase.
Do not replace bearing unless they show signs of damage or are out of running clearance 0.039/0.074 mm (0.0015/0.0029 in.). If crankshaft turns easily, without noise, and there is no evidence of scoring, grooving, etc., on races or bearing surfaces, bearing can be reused. Inspect crankshaft keyways. If they are worn or chipped, replacement of crankshaft will be necessary. Inspect crankpin for score marks or metallic pickup. Slight score marks can be cleaned with crocus cloth soaked in oil. If wear limits, as stated in Clearance Remove governor cross shaft oil seal from crankcase and replace it with a new one if seal is damaged and/ or leaks.
Install new seal to depth shown using a seal installer. 56 KohlerEngines.com 66 690 01 Rev. C A B C D A Self-Tapping Screw B Flat Washer C Plug D Crankshaft F G E H E Fillet Must Blend Smoothly with Bearing Journal Surface F High Point from Fillet Intersections G 45° Minimum H This Fillet Area Must Be Completely Smooth A B A 2.0 mm (0.0787 in.) B Governor Cross Shaft Seal