Kohler Aegis TP-2509 - Manual (Page 94)

10.2
Section 10
Inspection and Reconditioning
Inspect the crankpin for score marks or metallic pick
up. Slight score marks can be cleaned with crocus
cloth soaked in oil. If wear limits, as stated in
“Specifications and Tolerances,” are exceeded, it will
be necessary to either replace the crankshaft or
regrind the crankpin to 0.25 mm (0.010 in.) undersize.
If reground, 0.25 mm (0.010 in.) undersize connecting
rods (big end) must then be used to achieve proper
running clearance. Measure the crankpin for size,
taper, and out-of-round.
NOTE: If the crankpin is reground, visually check to
ensure that the fillet blends smoothly with the
crankpin surface. See Figure 10-1.
Figure 10-1. Crankpin Fillets.
When grinding a crankshaft, grinding stone deposits
can get caught in oil passages which could cause
severe engine damage. Removing the crankpin plug
each time the crankshaft is ground provides easy
access for cleaning any grinding deposits that may
collect in the oil passages.
High Point From
Fillet Intersections
The Fillet Must
Blend Smoothly
With The Bearing
Journal Surface
Minimum
This Fillet
Area Must Be
Completely Smooth
Flat Washer
Self-Tapping Screw
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Plug
Crankshaft
Figure 10-2. Removing Crankpin Plug.
3. Tighten the self-tapping screw until it draws the
plug out of the crankshaft.
Procedure to Install New Plug:
1. Use a single cylinder camshaft pin Kohler Part
No. 47 380 09-S as a driver and tap the plug into
the plug bore until it seats at the bottom of the
bore. Make sure the plug is tapped in evenly to
prevent leakage.
45°
Use the following procedure to remove and replace the
plug.
Procedure to Remove Crankshaft Plug:
1. Drill a 3/16" hole through the plug in the
crankshaft.
2. Thread a 3/4" or 1" long self-tapping screw with a
flat washer into the drilled hole. The flat washer
must be large enough to seat against the
shoulder of the plug bore. See Figure 10-2.