Kohler Courage SV810 [73/84] Reassembly
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Kohler Courage SV810 [73/84] Reassembly

Kohler Courage SV810 [73/84] Reassembly
73
Reassembly
32 690 01 Rev. H KohlerEngines.com
Install Ignition Modules
Fixed or DSAM Ignition System
1. Rotate fl ywheel to position magnet away from
ignition module bosses.
2. DSAM ignition system ignition modules are installed
in similar ways with tabs out.
Fixed ignition system ignition modules are installed
with spark plug lead from module always away from
cylinder. On cylinder 1, single kill tab should be up/
towards you. On cylinder 2, single kill tab should be
down/away from you.
3. Install each ignition module to crankcase bosses
with screws. Slide modules up as far away from
fl ywheel as possible and snug screws to hold them
in position.
4. Rotate fl ywheel to position magnet directly under 1
ignition module.
5. Insert a 0.30 mm (0.012 in.) fl at feeler gauge
between magnet and ignition module. Loosen
screws enough to allow magnet to pull module
against feeler gauge.
6. Torque screws to 4.0-6.2 N·m (35-55 in. lb.).
7. Repeat Steps 4 through 6 for other ignition module.
8. Rotate fl 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.).
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 fl at section towards fl ywheel and
individual spade terminals out. Torque screws to
4.0-6.2 N·m (35-55 in. lb.).
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.
Install Flywheel and Fan
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 fl ywheel.
NOTE: Before installing fl ywheel, make sure crankshaft
taper and fl ywheel hub are clean, dry, and
completely free of lubricants. Presence of
lubricants can cause fl ywheel to be overstressed
and damaged when screw is torqued to
specifi cations.
NOTE: Make sure fl ywheel key is installed properly in
keyway. Flywheel can become cracked or
damaged if key is not installed properly.
1. Install fl ywheel key into keyway of crankshaft. Make
sure key is properly seated and parallel with shaft
taper.
2. Install fl ywheel onto crankshaft being careful not to
shift fl ywheel key.
3. Install fan onto fl ywheel, so locating pins fi t into
corresponding recesses.
4. Install fan mounting plate onto fan, aligning 4
cutouts, followed by heavy fl at washer and screw.
5. Use a fl ywheel strap wrench or holding tool to hold
fl ywheel. Torque screw securing fl ywheel to
crankshaft to 74.5 N·m (55 ft. lb.).

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