Kohler L600 / L654 — Engine Reassembly
Repair & overhaul
For the Kohler L600 / L654, from the Kohler service manual.
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Before you start
- Do not pound or force pistons into position.
Procedure
- Coat tappets with oil and insert each in tappet bore inside crankcase.
- Secure front support plate to crankcase with new gasket and four capscrews.
- Oil camshaft and carefully guide through bushings into position; install end play spring and thrust plunger before gear cover.
- Reinstall valves with spring compressor and taper locks (do not mix intake/exhaust).
- Position main bearing upper halves, align timing marks on cam and crankgears, guide crankshaft in, install caps and tighten capscrews to 50 ft. lbs.
- Install piston-rod assemblies (L654: locating tabs opposite camshaft), tighten connecting rod castle nuts to 215 in. lbs.
- Lubricate and twist oil pump into aligning holes and mesh with drive gear.
- Install oil pan with new gasket.
- Install gear cover with end play spring, thrust plunger and oil slinger; install pulley.
- Install generator support with new gasket, guiding rear oil seal over crankshaft.
- Install cylinder head with new gasket, tighten in sequence to torque; install thermostat and housing.
- Reinstall engine system equipment, generator and controller; fill crankcase with non-detergent SAE 30 for first five hours.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Main bearing 50 ft. lbs.
- Connecting rod 215 in. lbs.
- Cylinder head 35 ft. lbs.
Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.