Kohler KD 500 Workshop Manual - Page 22

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Checks and overhaul

- 22 -

The operation is carried out by applying a calibrated pressure to

the convex side in the middle of the connecting rod stem set on

surface plates (fig. 20).

Crankshaft

It is advisable to check the condition of the crankshaft whenever

the engine is demounted and particularly when cylinders and

pistons must be replaced following wear due to dust having

been intaken.

Thoroughly clean inside the oil ducts using a shaped metal point.

If there are heavily caked incrustations, immerse the crankshaft

into a bath of petroleum or gasoline before proceeding with the

scraping operation (fig. 21).

When the crankshaft is perfectly clean, check with a micrometer

to ascertain wear and main journal ovality in the two

perpendicular positions (fig. 22).

Grind the shaft if the wear exceeds the values in the table by

0.08 mm or more.

Dimensions

A C

NOTE: crankshaft grinding operations of more than 0.25

mm should not be carried out.

Undersized bearings can be mounted without any reaming work

required.

WARNING: do not remove material from the main journal

shims during the grinding operation as this would

alter crankshaft float. Also make sure that the grinder

radii correspond to those indicated in fig. 21 to prevent

fracture sections from initiating on the shaft.

Oil retention rings

Make sure that the rings have not hardened in the retention lip

and that there is no sign of breakage or wear.

Lubrication circuit

Lubrication of the main bearings and connecting rod big end is

the forced type with a rotor oil pump.

Excessive pressure in the oil circuit is prevented by the by-pass

valve (3, fig. 23).

All the other parts are splash lubricated.

Oil vapours are eliminated from inside the casing by a

diaphragm mounted in the rocker arm cover.

Illustration in fig. 23:

1. Internal intake oil filter in casing - 2. Oil pump - 3. By-pass

valve - 4. Engine oil filter - 5. Pressure switch - 6. Main bearing -

7. Big end bearing.

Workshop Manual KD500 _ cod. ED0053029390 - 1° ed_rev. 00

STD mm

-0,25 mm

41,97 ÷ 41,99

41,72 ÷ 41,74

39,98 ÷ 40

39,73 ÷ 39,75