Reassembly 8. If securing upper brackets to top radiator mounts were loosened, torque to 9.9 N·m (88 in. lb.). 9. If a pulse style fuel pump is used, install it to tapped holes in cylinder 2 side, upper radiator support bracket and torque two screws to 6.8-7.3 N·m (60-65 in. lb.). Connect outlet line between pump and carburetor and vacuum line to crankcase fi tting. Secure with clamps. Install Oil Filter and Fill Crankcase with Oil NOTE: Make sure both oil drain plugs are installed and torqued to specifi cations to prevent oil leakage. 1. Install oil drain plug(s). Torque plug(s) to 13.6 N·m (10 ft. lb.). If oil drain valve is used, make sure valve body is closed and cap is on. 2.
Place new fi lter in shallow pan with open end up. Fill with new oil until oil reaches bottom of threads. Allow 2 minutes for oil to be absorbed by fi lter material. 3. Apply a thin fi lm of clean oil to rubber gasket on oil fi lter. 4. Refer to instructions on oil fi lter for proper installation. 5. Fill crankcase with new oil. Level should be at top of indicator on dipstick. 6. Reinstall oil fi ll cap/dipstick and tighten securely. Install Starter Adapter 1. Install starter adapter to crankcase, so cutout is offset down and facing away from fl ywheel side. Install mounting screws, and position clamp for stator leads on upper screw. Torque screws to 15.3 N·m (135 in. lb.). 2.
Place stator leads within clamp and close loop. 3. If violet B+ charge lead is separate from main harness, secure it to wiring harness with a tie strap, directly above clamp. Install Starter Assembly NOTE: Stator leads and rectifi er-regulator plug must be above starter. 1. Mount starter to adapter plate using screws. 2. Make sure starter is square to fl ywheel, and torque screws to 15.3 N·m (135 in. lb.). 3. Attach leads to appropriate starter solenoid terminals. 4. To avoid damage or breakage, do not over-tighten nut when attaching positive battery cable. Torque nut to 6-9 N·m (53-79 in. lb.). Install Coolant 1. Use equal parts of ethylene glycol (antifreeze) and water only.
Distilled or deionized water is recommended, especially in areas where water contains a high mineral content. Propylene glycol based antifreeze is not recommended. 2. Fill cooling system, through radiator, with coolant mix. Allow coolant to drain into lower areas. Fill overfl ow reservoir midway between FULL and ADD marks, then install radiator and reservoir caps. Reconnect Battery and Spark Plug Leads Connect leads to spark plugs. Reconnect positive (+) battery lead fi rst, and negative (-) lead last when connecting battery. Install Lower Flywheel Cover, Rectifi er-Regulator and Mounting Plate 1. Install/make sure small metal spacers are positioned in mounting holes of lower fl ywheel cover. 2.
Attach lower fl ywheel cover to cylinder 2 (oil fi lter) side lower radiator support bracket, using M6 screws and fl at washers. Finger tighten only at this time. 3. Align lower fl ywheel cover with cylinder 1 (starter) side lower radiator support bracket holes. Position rectifi er-regulator mounting plate, behind cover and install remaining two screws or nuts and fl at washers. Torque four fasteners to 9.9 N·m (88 in. lb.). If screws and Timmerman nuts/clips are used torque to 2.2-2.8 N·m (20-25 in. lb.). 4. If removed, mount rectifi er-regulator to plate with two screws and attach connector plug.
Testing Engine It is recommended engine be operated on a test stand or bench prior to installation in equipment. 1. Make sure all hardware is tightened, and hose clamps are properly secured. 2. Set up engine on a test stand. Install an oil pressure gauge. Start engine and check to be certain that oil pressure (20 psi or more) is present. Run for 5-10 minutes between idle and mid-range. 3. Check all cooling system components and joint connections for leaks. 4. Make sure maximum engine speed does not exceed 3750 RPM (no load). Adjust throttle, choke controls and high speed stop as necessary. Refer to Fuel System section. 5.
Place throttle control into idle or slow position and check low idle speed (RPM). Refer to Fuel System if adjustment is required. 6. Stop engine. 7. Recheck oil and coolant levels. Oil level should be at F mark on dipstick, and coolant level in reservoir should be midway between ADD and FULL marks. Add additional amounts as required. Install Muffl er 1. Install new exhaust gaskets and attach muffl er and mounting hardware. Torque screws to 9.9 N·m (88 in. lb.). 2. Install nuts to exhaust studs. Torque nuts to 24.4 N·m (216 in. lb.). 72 KohlerEngines.com 66 690 01 Rev. C