After spending about 3 hours and 10,000 lick with a 1 pound hammer getting the flywheel off the Kohler I was going to make sure I didn`t have that problem putting it back on. After much cleaning of what looked to be pristine shaft to start with and cleaning the inside of the pulley/flywheel....I could pretty much slide it nearly all the way on by hand. I cleaned the key way in both pieces enough so the 1/4 in square key would slide easily in the groove. Assuming I needed to get it back to the original position on the shaft...the shiny part up to the tarnished exposed part of the shaft next to the engine.
I managed to slide it up to about 3/4 in of the original position by hand and with a little help from hammer got to about 1/4 in short of its original position on the shaft.. And now it just seems to have stopped altogether. After a few careful licks with the 3 lb hammer ... it seems to have stopped.
Part of me says to pull it back off...and dreading another back up and redo....part of me thinks it may be close enough. After scratchin my head and trying to calculate what would change in the final bolt up of the clutch/tranny bell housing to the flywheel housing...all I can come up would be the front most part of the shaft coming out the tranny. It is the shiny slick part about an 1 1/2 in long that rides in the bushing inside the flywheel. You can see on the shaft the part that was inside the oil seal and there is a little extra on the shaft before you step up to the splined full size part. I couldn`t find any dimension on the PK service manual about shaft. I hate to wrestle the engine /tranny together only to find out it is not right !
Any thoughts anybody ????
Oh yeah another thing....anybody know where the half moon key goes ???? Seems like I remember taking it out of something ??