ONAN E125 V, E140V ENGINE SERVICE MANUAL

Table of Contents – Page 1 of 3

SAFETY PRECAUTIONS
GENERAL
BATTERIES
PROTECT AGAINST MOVING PARTS
FUEL SYSTEM
EXHAUST SYSTEM
EXHAUST GAS IS DEADLY
KEEP THE UNIT AND SURROUNDING AREA CLEAN

SUPPLEMENT 965-1053
PURPOSE
SERVICE MANUAL 965-0764 REVISIONS
CARBURETOR (BEGINNING SPEC E)

SECTION 1. GENERAL INFORMATION

SECTION 2. SPECIFICATIONS

SECTION 3. DIMENSIONS AND CLEARANCES

SECTION 4. ASSEMBLY TORQUES

SECTION 5. ENGINE TROUBLESHOOTING

SECTION 6. MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
ENGINE INSPECTION
AIR CLEANER AND ELEMENT WRAPPER
OIL CHANGE
OIL FILTER CHANGE
COOLING
VALVE CLEARANCE
SPARK PLUG

SECTION 7. LUBRICATION
OIL CHANGE
OIL FILTER CHANGE
OIL LEVEL CHECK
OIL PRESSURE
OIL PRESSURE RELIEF VALVE
OIL PUMP
DISASSEMBLY
ROTOR LOBE CLEARANCE
OUTER ROTOR AND PUMP BODY CLEARANCE
ROTOR AND COVER CLEARANCE
ASSEMBLY

SECTION 8. ELECTRICAL
IGNITION SYSTEM
SPARK PLUG
IGNITION COIL
IGNITION TIMING
FLYWHEEL ALTERNATORS
ALTERNATOR OUTPUT TESTS
ONAN E125 V, E140V ENGINE SERVICE MANUAL
Table of Contents – Page 2 of 3
SECTION 9. FUEL
GASOLINE CARBURETOR
DISASSEMBLY
INSPECTION/SERVICE
ASSEMBLY
CO ADJUSTMENT
IMPULSE FUEL PUMP
INSPECTION/SERVICE
FUEL PUMP REMOVAL
FUEL PUMP INSTALLATION
LPG FUEL SYSTEM
GOVERNOR ADJUSTMENTS
1. GOVERNOR LEVER ADJUSTMENT
2. IDLE SPEED ADJUSTMENTS
3. CHOKE ADJUSTMENT
4. SPEED CONTROL CABLE ADJUSTMENT
AIR CLEANER
FOAM WRAPPER ELEMENT
PAPER ELEMENT

SECTION 10. STARTING

RECOIL STARTER
110 VAC STARTER
SOLENOID SHIFT STARTER
SOLENOID
ARMATURE
COMMUTATOR AND MICA
STARTER BODY
BRUSHES
OVERRUNNING CLUTCH

SECTION 11. ENGINE BLOCK ASSEMBLY

INTRODUCTION
ENGINE DISASSEMBLY/ASSEMBLY
SUGGESTED DISASSEMBLY ORDER
SUGGESTED ASSEMBLY PROCEDURE
OPERATION
COMPRESSION TEST
FLYWHEEL
DISASSEMBLY
SERVICE/INSPECTION
ASSEMBLY
VALVE COVER
ROCKER ARM
DISASSEMBLY
INSPECTION/SERVICE
ASSEMBLY
CYLINDER HEAD
DISASSEMBLY
ASSEMBLY
ONAN E125 V, E140V ENGINE SERVICE MANUAL
Table of Contents – Page 3 of 3
SECTION 11. ENGINE BLOCK ASSEMBLY –CON’T
VALVE SYSTEM
TAPPETS
DISASSEMBLY
INSPECTION/SERVICE
VALVE STEM AND VALVE GUIDE CLEARANCE:
VALVE GUIDE REPLACEMENT:
ASSEMBLY
VALVE SPRING:
VALVE FACE AND SEAT GRINDING
INSPECTION/SERVICE
VALVE SEAT WIDTH:
VALVE SEAT CUTTING:
VALVE CLEARANCE:
OIL BASE
DISASSEMBLY
ASSEMBLY
GOVERNOR
BALANCING SHAFTS
DISASSEMBLY
OIL BASE BEARING TO SHAFT CLEARANCE:
ASSEMBLY
CRANKSHAFT AND CAMSHAFT
DISASSEMBLY
INSPECTION/SERVICE
CRANKSHAFT JOURNAL:
CAMSHAFT LOBE HEIGHT:
OIL BASE BEARING TO CAMSHAFT CLEARANCE:
ASSEMBLY
COMPRESSION RELEASE SYSTEM
PISTON, PISTON PIN, RINGS, CONNECTING ROD
DISASSEMBLY
PISTON INSPECTION
PISTON INSPECTION:
PISTON PIN HOLE INSIDE DIAMETER:
PISTON PIN OUTSIDE DIAMETER:
PISTON RING AND RING GROOVE CLEARANCE:
CONNECTING ROD SMALL END INSIDE DIAMETER:
CONNECTING ROD TO CRANKSHAFT JOURNAL OIL CLEARANCE:
CONNECTING ROD SIDE CLEARANCE:
ASSEMBLY
CYLINDER BLOCK
CLEANING
INSPECTION
REBORING THE CYLINDER
HONING CYLINDER (USING PRECISION HONES)
DEGLAZING CYLINDER BORE
BALL BEARINGS
OIL SEAL
 El25V, El40V
Elite Series

Printed in U.S.A. 965-0764

Spec A-C
6-94
 Safety Precautions
Beforeoperatingthe engine, read the Operator's Manual and PROTECT AGAINST MOVING PARTS
equipment. Safe andefficient
become familiarwith it and the
operatloncanbeachievedonly If the equipment Is
Do not wear loose clothing in the vicinity of moving parts,
such asPTO shafts,flywheels, blowers, couplings, fans,
properly operated and maintained.
belts, etc.
The following symbols, found throughout this manual, alert you Keep your hands away from moving parts.
to potentiallydangerous conditions to theoperator, service per-
sonnel, or the equipment. FUEL SYSTEM
Thls symbol warns of immediate hazards DO NOT fill fuel tanks while engine is running.
whlch will result in severe personal Injury or death. DO NOT smoke or use an open flame in the vicinity of the
engine or fuel tank. Internal combustion engine fuels are
WARNING This symbol refers to a hazard or unsafe highly flammable.
practice whlch can result in severe personal Injury or Fuel line must be of steel piping, adequately secured, and
death. free from leaks. Piping at the engineshould be approved
flexible line. Do not use copperpiping for flexible lines as
CAUTION) This symbol refers to a hazard or unsafe copper will work harden and become brittle enough to
practlce whlch can result
In personal Injury or product
or break.
property damage.
Be sure all fuel supplies have a positive shutoff valve.
Fuels, electrical equipment, batteries, exhaust gases and
moving parts present potential hazardsthat can result in severe Benzene and lead, found in some gasoline, have been
personal injury. Take care in following these recommended identifiedby some state and federal agencies as causing
procedures. All local, state and federal codes should be cancer or reproductive toxicity. When checking, draining
consulted and complied with. or adding gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.
W A R N I N G Thls engine is not designed or Intended for
use In any type of aircraft. Use of this engine aircraft
In can EXHAUST SYSTEM
result In engine failureand cause severe personal injury or Exhaust products of any internal combustion engine are
death. toxic and can cause injury, or death if inhaled. When
operating the engine in a confined area, make sure the
GENERAL ventilation system is operating properly.
Provide appropriate fire extinguishers and installthem in DO NOT use exhaustgases to heat a compartment.
convenient locations. Use an extinguisher rated ABC by Make sure that your exhaust system is free of leaks. Make
NFPA. sure thatexhaust manifolds are secure and are not
Make sure that all fasteners on the engine are secure and warped by bolts unevenly torqued.
accurately torqued. Keep guards in position over fans, EXHAUST GAS IS DEADLY!
driving belts, etc.
Exhaust gases contain carbon monoxide, a poisonousgas that
If itis necessary to make adjustments while the engine is can cause unconsciousness and death. It is anodorless and
running, use extremecaution when close to hotexhausts, colorless gas formedduring combustion of hydrocarbonfuels.
moving parts, etc. Symptoms of carbon monoxide poisoning are:
Dizziness Vomiting
Used engine oils have been identifiedby somestate and
Headache 0 Muscular Twitching
federal agencies ascausing cancer or reproductive
toxicity. Whenchecking or changing engine oil, takecare Weakness and Sleepiness Throbbing in Temples
not to ingest, breathe the fumes, or contact used oil. If you experience any of these symptoms, get out into fresh air
immediately, shut down the unit and do not use it until it has
Do not work on this equipment when mentally or been inspected.
physically fatigued, or after consuming any alcohol or
The best protection against carbon monoxide inhalation is
drug that makes the operation of equipment unsafe.
proper installation andregular, frequent inspections of the
complete exhaust system. Ifyou notice a change in the sound
BATTERIES
or appearance of exhaust system, shut the unit down immedi-
Before starting work on the engine, disconnect batteries ately and have it inspectedand repairedat once by a competent
to prevent inadvertent starting of the engine. Disconnect mechanic.
negative cable first.
AREA CLEAN
KEEP THE UNIT AND SURROUNDING
DO NOT SMOKE while servicing batteries. Lead acid bat- Make sure that oily rags are notleft on or nearthe engine.
teries give off a highly explosive hydrogen gas which can
be ignited by flame, electrical arcingor by smoking. Remove all unnecessary grease and oil from the unit.
Accumulated grease and oilcan cause overheating and
Verify battery polarity before connecting battery cables. subsequent engine damage and present a potential fire
Connect negative cable last. hazard.
E-8
 Supplement 965-1053
Date:1-95
lnsert with-
Title: E l 25V/E140V Service Manual
Number (Date):965-0764(6-94)

PURPOSE
Spec €engines. Note
This Supplement transmits the revisions to the Service Manual necessary for covering
that the nameplate on a Spec E engine will have the statement: “This engine meets 1995-1998 California
emissions regulations forULGEengines.”
To satisfy California emissions regulations Spec E engines have internal engine modifications and precision-
manufactured carburetors with tamper-resistant fuel mixtureIt jets.
should therefore be noted that, other than
installing the optional high-altitude jet (Figure 9-3a), fuel mixture adjustments should
be not
attempted. Nor
should the carburetor be overhauled. Instead, a malfunctioning carburetor (see Engine Troubleshooting)
should be replaced.
California users should note that unauthorized modifications or replacement of fuel, exhaust, air intake, or
speed control system components that affectengineemissions are prohibited by California regulations and
the optional high-altitude main jet
is not intended for use in California. Modification, removal or replacement of
the generator set labelIs also prohibited.

SERVICE MANUAL 965-0764 REVISIONS

1 . Insert this cover sheet behind the front cover of the manual.
2.On Page 1-1 of the manual add the following note at the bottom
of the page: “See the Operator’s Manual
for fuel and engine oil recommendations and the Periodic Maintenance Schedule.”
3. On Page 9-1 of the manual add “(Does Apply
not to Spec E and Later)”to the subheadings “Disassembly”
and “Inspection/Service”.

4. On Page 4 2 of the manual add “(Does Not Apply

to Spec E and Later)” to the subheading “Assembly” and
to the heading“CO Adjustment”.

5. insert the attached page(9-2-1) between Page 9-2 and Page9-3of the manual.

Attachment: Page 9-2-1.

Page 1 of 1
SECTION TITLE PAGE
Safety Precautions inside cover
1 General Information 1-1
2 Specifications 2-1
3 Dimensions and Clearances 3-1
4 Assembly Torques 4-1
5 Engine Troubleshooting 5-1
6 Maintenance
7 Lubrication
8 Electrical
9 Fuel
10 Starting10-1
Engine Block Assembly 11 -1

WARNING
INCORRECTSERVICEORREPLACEMENTOFPARTSCAN
RESULT IN SEVERE PERSONAL INJURY AND/OR EQUIPMENT
DAMAGE.SERVICEPERSONNELMUSTBEQUALIFIED TO
PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.
 Section 1 GeneralInformation
INTRODUCTION disassembly, inspection, repair, and assembly of
the engine components.
Thismanualprovidesspecificmechanicaland
electrical information needed by engine mechanics Use only Genuine Onan replacement parts to pro-
for troubleshooting, servicing, or overhauling the videqualityandthebestrepairandoverhaul
engine. results.Whenorderingparts,alwaysusethe
Use the separate parts manual for parts identifica- complete model and spec number as well as the
serial
tion and for establishing their proper location on as- number shownon thenameplate.
semblies. The parts manual contains detailed ex-
ploded views of each assembly and the individual
piece part numbers and their proper names for TABLE 1-1. ENGINE MODEL IDENTIFICATION
ordering replacement parts.
The illustrations and procedures presentedin each
section apply to the engines listedthe cover.
on The
air cleaner side of the engine
is the front end. Right
and left sides are determined by viewing the engine
from the front.
or an overhaulis necessary, have a
If a major repair
trained and experienced mechanic perform the re-
pair and see that all dimensions, clearances and
1. Model letter designation.
torque values are within the specified tolerances.
2. BHP rating. Add a decimal one digit in from the
Use the table of contents for a quick reference
the to right end. (Example 140 = 14.0)
separate engine system sections.
3. Designation (V = vertical shaft, H = horizontal
The troubleshooting guide is provided as a quick shaft).
reference
for
locating
and
correcting
engine 4. Engine fuel. (Example N = gasoline, L = LP,
problems. D = Dual fuel)
The wiring diagram shows how the electrical com- 5. Factory code for designated optional equip-
ponents are interconnected. ment, if any.
The Engine BIock Assemblysection contains major 6. Specification (spec letter) which advances with
overhaulproceduresforstepbystepremoval, factory production modifications.

INCORRECT SERVICEOR REPLACEMENT OF PARTS CAN RESULT IN SEVERE PERSONAL IN-

JURY AND OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED
TO PERFORM
ELECTRICAL
AND/OR
MECHANICAL
SERVICE. \
 Section 2. Specifications
These specifications are in customaryU.S. units of measure with approximate metric equivalents following in
parentheses.
TABLE 2-1. SPECIFICATIONS

UNIT OF SERIES
MEASURE
SPECIFICATION El 25V El4OV

Number of Cylinders 1

Bore mm 84.2
(3.31) (in) (3.31)

Stroke mm 70.0
) (2.76) (in)
Displacement 389 Cm3 389
(in3) (23-7) (23-7)

Compression Ratio to8.5

8.5
1 to 1

Power at 10.4 kW 9.3

Rated Speed (3600 rpm) (BW 2.5) (1 (14.0)

Oil 1-7
rts) With Fitter

Compression Cylinder 483 or more

(Psi) (70 or more)

2-1
 Section 3. Dimensions and Clearances
All measurements given at room temperature70°F
of (21 "C).Al measurements are given in millimeters with
approximate inch measurementsin parentheses. Measurements are for standard size parts. Refer to the
headings for notesabout which specs are covered,if the spec is not listed the dimensions cover all specs.
TABLE 3-1. DIMENSIONS AND CLEARANCES

CYLINDERBLOCK

Cylinder Bore Taper

 ALLOWABLE
DESCRIPTION
____- I
LIMIT
CAMSHAFT SPEC A AND B
Lobe- Height, Diameter Over Nose
El25 Intake 34.46 34.31 33.81
(1.357) (1.351) (1.331)
El25 Exhaust 34.77 34.62 34.12
(1.369) (1.363) (1.343)
E140 Intake 35.33 35.18 34.68
(1.391)
(1.385) (1.365)
El40 Exhaust 35.33 35.18 34.68
(1.391) (1.385) (1-365)
End Clearance 0.10 0.20 0.25
(0.004) (0.008) (0.010)
Oil Base Bearing Clearance .0.01 0.05 .0.08
(-0020) (0004) (.0031)
CAMSHAFT BEGIN SPEC C
Lobe Height, Diameter Over Nose
El25 Intake 34.23 34.55 33.73
(1-348) (130) (1-328)
El25 Exhaust 34.53 34.85 34.03
(1-359) (1.372) (1-340)
El40 Intake 35.09 35.41 34.59
(1-381) (1.394) (1.362)
El40 Exhaust 35.09 35.41 34.59
(1.381) (1.394) (1.362)
End Clearance 0.10 0.20 0.25
(0.004) (0.008) (0.01 0)
Journal Bearing O.D. 17.975 17.990 17.93
(.7077) (.7083) (.7059)
Oil Base Bearing Clearance 0.01 0.05 0.08
(.OOO4) (.0020) (.0031)
-_---

3-2
 TABLE 3-3. DIMENSIONS AND CLEARANCES

FACTORY SPECIFICATION ALLOWABLE

DESCRlPTlON MAX MIN LIMIT
PISTON SPEC A AND B
Piston SkirtO.D.
90 deg to Pin, 26.5 from Top of Piston 84.09 84.1 2
(3.311) 2()3.31
.25Oversize 84.37
84.34
(3.322) (3.320)
50 Oversize 84.62
84.59
(3.331) (3.330)
Pin Bore I.D. 20.000 20.010 20.020
(0.7874) (0.7878) (0.7882)
PISTON BEGIN SPEC C
Piston Skirt O.D.
deg to Pin, 26.5
from Top of Piston84.1 84.09
90 2
(3.311 ) (32
.)
31
.25Oversize 848.
43
.7
34
(3.322) (3.320)
50 Oversize 84.62
84.59
(3.331) (3.330)
Bore
Pin I.D. 20.02004.01 2 20.022
(0.7879) (0.7876) (0.7883)
PISTON PIN SPEC A AND B
Pin
Piston O.D. 20.000 20.005 19.990
(0.7876) (0.7874) (0.7870)
Clearance in Piston .005 .010 0.30
(0.0004) (.0002) (0.001 2)
Clearance in Connecting Rod .010
.025 .035
(0.004) (0.001 0) (0.0014)
PISTON PIN BEGIN SPEC C
Piston Pin O.D. 20.000 20.005 19.990
(0.7874) (0.7876) (0.7870)
Clearance in Piston ......................
-0
.1
02
01 0.03
(.OooO) (0.0005) (0.001 2)
Clearance in Connecting Rod .010 .025 .035

3-3
 TABLE 3-4. DIMENSIONS AND CLEARANCES
FACTORY SPECIFICATION ALLOWABLE
DESCRIPTION LIMIT
PISTON RINGS
Top Compression Ring Thickness 1.47 1.49 1.42
(.058) (.059) t.056)
Second Compression Ring Thickness 1.47 1.49 1.42
(.058) (.059) (-056)
Top Compression Ringto Ring Groove
Clearance 0.03 0.08 0.13
(0.001) (0.003) (0.005)
Second Compression Ring to Ring Groove
Clearance 0.03 0.08 0.13
(0.001) (0.003) (0.005)
Top Compression Ring End Gap 0.25 0.51 1.oo
(0.(
00
2.
00
)10) (0.039)
Second Compression Ring End Gap 0.25 0.51 1.oo
(0.010) (0.020) (0.039)
Oil Ring Side Rail Gap 1.40 0.38 1.80
(0.015) (0.055) (0.071)
INTAKE VALVE
Valve Stem O.D. 6.960 6.975
(0.2740) (0.2746)
Valve Guide I.D. 7.000 7.015
(0.2756) (0.2762)
Valve Stem to Guide Clearance 0.03 0.06
(0.002) (0.001) (0.004)
E l 25V Valve Lash 0.075 0.25
(-003) (0.010)
El40V Valve Lash 0.15 0.25
(-006) (0.010)
Face Angle 45"
INTAKE VALVE SEAT
Seat Width 1.7
(.067)
Seat Angle
EXHAUST VALVE
Valve Stem O.D. 7.940 7.960
(0.31 26) (0.31 34)
Valve Guide I.D. 8.000 8.015
(0.3150) (0.31 56)
Valve Stem to Guide Clearance 0.04 0.08
(.003)
 TABLE 3-5. DIMENSIONS AND CLEARANCES

DESCRIPTION
EXHAUST VALVE (cont)
E125V Valve Lash 0.075 0.25
(-003) (0.010)
E140V Valve Lash 0.1 5 0.25
(-006) (0.01 0)
FaceAngle 45"
EXHAUST VALVE SEAT
Seat Width 1.7
(0.067)
SeatAngle
VALVE SPRINGS INTAKE AND EXHAUST
SPEC A AND B
Valve Spring Free Length (Approx.) 43.5
(1.71)
Valve Spring Length
Valve Closed 32.6
(1.28)
ValveOpen 23.2
(0.91 )
Spring Load (Valve Closed Length) 5.67 kg 6.62 kg
(1 2.5Ib) (1 4.6 Ib)
Spring Load (Valve Open Length) 11-52 kg 13.43 kg 10.21 kg
(25.4 Ib) (29.6 Ib) (22.5 Ib)
VALVE SPRINGS INTAKE AND EXHAUST
BEGIN SPECC
Valve Spring Free LengthApprox 43.5
(1.71)
Valve Spring Length
Valve Closed 32.6
(1.28)
ValveOpen 23.2
(0.91)
Spring Load (Valve Closed Length) 12.6 kg 14.6 kg
(27.7 Ib) (32.1 Ib)
Spring Load (Valve Open Length) 26.4 kg 28.4 kg 24.9 kg
(58.2 Ib) (62.7 Ib) (55 Ib)

3-5
 -"--
AND CLEARANCES
FACTORY SPECIFICATION ALLOWABLE
DESCRIPTION MAX MIN
-__.__I- -_I___-__

ROCKER ARM
Rocker Arm Inside Diameter 12.000 12.018
(0.4724) (0.471 8)
Rocker Arm Shaft O.D. 11.973 11.984
(0.4714 (0.471 8)
Rocker Arm to Shaft Clearance 0.016 0.045 0.15
(0.0006) 8) (0.001 (0.0059)
*----_I-

LUBRICATING SYSTEM
Engine Oil Pressure
At Idling 3.0 psi or more
At 3300 rpm 14.0 psi or more 4.0 psi
Rotor Lobe Clearance 0.15 or less 0.20
( 0.006 or less) (0.008)
Outer Rotor to PumpBody Clearance 0.19 0.12 0.25
(0.005) (0.007) (0.010)
Rotor and Cover Clearance 0.02 0.09
(0.004) (0.001)
IGNITION SYSTEM
S p a r k Plug Gap 1.02 0.89 0.89
(0.035) (0.035) (0.040)
Ignition Timing (BTDC) Not Adjustable 23"
Ignition Unit Core to Rotor Magnet
Clearance (Air Gap) 0.50
(0.020)
_--
ELECTRICAL SYSTEM
Commutator O.D. 28.0) 27.00
(1.102) (1.063)
Difference of Commutator O.D.'s Less than' 0.05 0.016
(Less than 0.002) (0.41)
Armature's Shaft to0.07
Bushing Clearance 0.02 0.20
(0.003) (0.001) (.008)
Mica Undercut 0.45 0.75 0.20
(0.018) (0.030) (0.008)
BALANCE SHAFT
End Clearance (Both Shafts). 0.10 0.20 0.25
(0.008) (0.004) (0.010)

3-6
 Section 4. Assembly Torques
Thetorquevalueslisted in Table 4-1 havebeenTighten all studs, nuts andcapscrewsasspecified
determined for specific applications. The engine to keep them from working loose. Refer to the Parts
assemblytorquesgivenhere will provide proper Manual for the location of washers and capscrews.
tightness without danger of stripping threads. All
threadsmustbe
clean, rust free andlightly
lubricated.

TABLE 4-1. ASSEMBLY TORQUES

DESCRIPTION

Conn
TORQUERod Bolts BASE M8x44 OIL24-27 18-20
Oil Base Bolts M8x 50 16-22 12-16- Toque bolts in clockwise SEQUENCE
Oil Pump Cover Screws M6x 14 7-11 58 direction startingwith "A"
Oil Pump Screen Cover M6x 14 7-11 Torque
5-8 'A" twice.
Oil Drain Plugs 3/8” NPT 7-11 5-8
Oil Base Pressure 7-11
NPT
114" 58
Line Plugs
LOPCO or Pipe Plug 1/8”NPT 7-11 58
Adapter Filter Head 3/416" 24-30 18-22
Oil Filter 3/41
gskt
after
Turn
Oil Indicator Cap 1.5-2 1.1-1.5(13-18LB*IN)
contacts base
Cy1 HeadBolts Toque in sequence shown.
NO. 1-5 Bolts42-50 M10 31-37
Two bolts outside valve cover
No. 6 Flange Bolt M8x50 16-22 12-16 (#2& #4) To be retorqued
after others are done.
Valve Lash Adj
Nut 7-11 M7 5-8 Tighten every other boltuntil
Valve Cover Bolts 7-11
25xM6 58 all bolts are tightened. C-1138
Retorquethe first bolttwice.
Spark Plug 10-24 7-18
Air Deflector Bolts
M8x 16
M8x 11-20 8-15
M6x
7-11
10 58
2.3-2.8
Pulse Pumpto Deflector #10 1.7-2.1 (20-25LB-IN
Nuts
Pulse Pump Spud 118" NPT 7-11 5-8
Int Elbow to Cy1Hd Screws M8x 50 11-16 8-12 Tighten twi
c e (1-2-1)
Air Cleaner Pan to
Air Deflector 114" x .50" 6.7-8.1 5-6 (60-72L
Carb.to Int Elbow M6x 85 10-15 7-11
Knob-Inner Air CLnr 1-1/2-2turns aftercover
Knob-Outer Air Clnr Not Specified Not Specified contacts element
Cy1 Air HsgBolt M6x 10 7-11 58 CYLINDER HEAD
M8 11-20 8-15 TORQUE SEQUENCE
Exhaust Elbow Bolts M8x 45 11-20 8-15
Muffler Bolts M8X95 16-22 12-16
Starter Bolts M8x 40 16-22 12-16
Alternator Stator Screws M6x 25 10-15 7-11
Stator Wire Clamp Screw M6x 14 10-15 7-11
Flywheel Nut M18 122-138 90-102
Ignition CoilBolt M6 x 27 10-15 7-11
Blower Hsg Bolts M6x20 7-11 5-8
Voltage R e g Screws 114" x .50” 6.7-8.1 5-6 (60-72LB_IN
Chaff Screen Bolt M6x 10 7-11 58
Stationary Guard Bolt M6x 20 1.4-2 1-1.5 (12-18 LB*IN)
Recoil Starter Cup Screw M8x 16 24-30 18-22
Recoil Starter Bolts M6x 12 7-11 5-8
Control Plate Stud M8 11-16 a12
Control Plate Pivot Bolt M8 11-16 8-12
Nut-Control Plate Stud M6 7-11 5-8
Governor Arm Nut M6 8.1-10.9 68
Throttle Cable Clamp Screw 1032" 1.4-2 1-1.5 (12-18LB-IN

4-1
5-1
 Section 6. Maintenance
PERIODICMAINTENANCESCHEDULE Neglectingroutinemaintenance wil result in poor
performance and reduced engine life.
Keep an accurate logbook of maintenance, service,
and operating time: Follow a regular schedule of
inspection and service, based on operating hours. WARNING Incorrect service or replacement of
parts can result in severe personal Injury and/or
UsethefactoryrecommendedPeriodicMainte- equipment damage. Servicepersonnelmust be
nance Schedule(basedon favorable operating qualified to perform electricaland/ormechani-
conditions) to serve as a guide to get long and effi- cal service.
cient engine life.
Regular service periods are recommended for nor- WARNING Accidental starting of the engine
mal service and operating conditions. If the engine can result in severe personal Injury or death.
is in an application with extreme temperatures, se- DIsconnect the negative battery cable and
veredutycycles,etc.,serviceatmorefrequent spark plug wire before servicing the engine,
intervals. controls, or associatedequipment.

TABLE 6-1. PERIODIC MAINTENANCE SCHEDULE

Air Cleaner Element and

X
X2
X

1 Check for fuel leaks. With engine running, visually and audibly check exhaust system for leaks.
2- Perform more often when running under severe operating conditions.
3- Required for initial break-in
only.
4- Required for initial100 hours, 200 hour interval thereafter.
 ENGINE
INSPECTION CLEANER
AIR AND
ELEMENT
WRAPPER
Refer to Air Cleaner,in section9, for disassembly,
Checkthe
fuel
lines
and
fittings
for
leaks. Do not
the
and assembly procedures.
start engine until leaks are repaired.
OIL CHANGE
WARNING Breathing exhaust gases can result
in severepersonal injury or death. Inspect the Refer toOil Change, in section 7, for inspection and
exhaust system audibly and visualiy for leaks service procedures.
daiiy and repair leaks immediateiy.
OIL FILTER CHANGE
Inspect the exhaust system for cracks and run the Refer to Oil FilterChange, in 7, for inspection and
engine to check for leaks. Repair problems before service procedures.
allowing the engine to be used.
COOLING
Examine the air cleaner components for damage, Refer to Flywheel, in section 11, for inspection and
properfit,etc.Repairorreplacecomponentsasserviceprocedures.
necessary.
VALVE CLEARANCE
Check-the oil level with the engine off and the equip- Referto valve system, in section for inspection
ment on a level surface.If the oil level is at or below and service procedures.
the full mark on the dipstick, add oil of the proper
viscosity ( s e e Oil Change section) until the level SPARK PLUG
reaches the full mark. Do not operate the engine
with the oil level below the add or above the full Refer to Spark Plug, in section 8, for inspection and
mark. service procedures.
 Section 7. Lubrication
A pump driven by one of the balancer shafts pro- the drain plug and remove the plug (open the drain
videspressurelubricationoftheconnectingrod cock). Replace the drain plug (close the cock) when
journal through drilled passages in the crankcase the oil has stopped draining. Refill with oil meeting
and crankshaft. An oil hole in the crank arm pro- the API classification SG, SG/CD, or SG/CE and
vides spray lubrication of the piston, cylinder walls, having the proper viscosity for the ambient temper-
and other crankcase components. The lubrication ature. See Table 7-1. Straight weight oil is recom-
system includes an oil pressure relief valve and full- mended for severe duty use and minimum oil con-
flow oil filter (Specs
B and C). Theoil pump is acces- sumption at temperatures above32" F (0"C).
sible by removing a coverin the oil base.
TABLE 7-1. OIL VISCOSITY RECOMMENDATIONS
WARNING Improper serviceor replacement of
parts can result in severe personalinjury and/or
equipment damage. Servicepersonnel must be
qualified to perform electrical and/or mechani-
cal service.
WARNING Accidental starting of the engine
can result in severe personal injury or death.
Disconnectthenegativebatterycableand
spark plug wires while servicing engine,
controls, or associated equipment.

OIL CHANGE
WARNING Crankcase pressure can blow out OIL FILTER CHANGE
hot oil, which can cause severe personal
injury.
Do not checkoil while the engineIs running. WARNING Hot crankcaseoil can causeburns
if it comes In contact with skin. Wearprotective
WARNING Hot crankcaseoil can causeburns clothing and keep fingers and hands clear when
if it comes in contact with skin. Wearprotective draining oil.
clothing and keepfingers and hands clear when
draining oil. CAUTION Excess oil can cause high oil con-
sumption, high operating temperatures, and oil
WARNING Some States or federal agencies foaming. Do not overfill crankcase.
have determinedthat used engine oil is carcino-
genic and causes reproductive toxicity. Take Spin the oil filter elementoff and discard it. Clean
care not to breathe, ingest or come Into contact the filter mounting surface and make sure a gasket
with used engineoil. is inserted in the new element. Apply a thin filmof
CAUTION Excess oil can causehigh oil con- new oil to the gasket. Spin the element down by
hand until the gasket just touches the mounting s
sumption, high operating temperatures, and oil
face. Then add another 1/2-3/4 turn. Do not over-
foaming. Do not overfill crankcase.
tighten. Fill with oil to theFULL mark and start and
Run the engine until it is thoroughly warm before run the engine until it is warm. Check for oil leaks.
a pan under
draining the oil. Stop the engine, place Check oil level.

7-1
 OIL LEVEL CHECK
WARNING Crankcase pressure can blow out
hot oil, which can cause severe personal injury
Do not check oil while the engine is running.
Correct oil level in the crankcaseis required to in-
sure proper lubrication and prevent saturating the
air cleaner paper element with oil.
Always check the oil with the engine stopped and on
a level surface. When checking oil the
level, always
screw the oil fill cap into the dipstick tube until it
lightly seats on the oilfill tube.
The oil fill cap has a rubber seal that seats oil on the
fill tube. Inspect this rubber seal and replaceif dam-
aged, stretched or missing.
OIL PRESSURE
Refer to Figure 7-1. Install an engine oil pressure
tester in the oil base as shown. The engine wil have
an oil pressure switch or a 1/8” pipe plug the
tapped hole. Start the engine. After warming up,
measure the idle and maximum speed oil pressure.
If oil pressureis not as specified in Dimensions and
Clearances, the following may be the cause: FIGURE 7-1. CHECKING OIL PRESSURE
engine oil level low
clogged oil strainer
defective oil pump
clogged oil gallery
excessive clearance between crankshaft jour-
nal and connecting rod
defective relief valve or spring
Determine cause of low oil pressure andcorrect as
necessary.

7-2
 OIL PRESSURE RELIEF VALVE
SPECS B AND C
Refer to Figure 7-2. On Specs B and C the oil relief
valve is accessible only after the oil base has been
removed. The check ball and spring are retained by I
a retainer ring. On Spec A the oil pressure relief ?
valve is removable form the outside by removing
the retaining bolt.
Wash all components in solvent and allow themto
dry. Inspect the components for damage and wear.
Replace partsas necessary.
WARNING Most parts cleaning solvents are
flammable and can cause severe personal In-
jury or death If used Improperly. Follow the
manufacturer's recommendations when clean-
ing parts.
Lubricate the oil relief valve with oil before assem-
bling. On Specs B and C use a new retaining ring
and driveit right down to the shoulder of the counter
SPEC A

FIGURE 7-2. OIL RELIEF VALVE COMPONENTS

7-3
 OIL PUMP
Disassembly
Refer to Figure
7-3. Remove the capscrews holding
oil base. Separate the in-
the oil pump cover to the
ner and outer rotor.

FIGURE 7-3. OIL PUMP DISASSEMBLY

-I

Rotor Lobe Clearance

Refer to Figure 7-4. Measure the clearance be-
tween the inner rotor
lobes and the outer rotor lobes
Ifclearance is not as specified
with a feeler gauge.
in Dimensions and Clearances, replace o i l pump.

*-----

FIGURE 74. MEASURING ROTOR LOBE

CLEARANCE
Outer Rotor and Pump Body Clearance

Refer to Figure 7-5.Measure the clearance be-

tween the outer rotor and the pump body with a
feeler gauge. If the clearanceis not as specified in
Dimensions and Clearances,replace the oil pump.

FIGURE 7-5. MEASURING OUTER ROTOR TO

PUMP BODY CLEARANCE

Rotor and Cover Clearance

Refer to Figure7-6.Place a strip of plastigauge on

the rotor face. Install the pump cover and tighten the
in ASSEMBLY TORQUES.
screws to that specified
Remove the cover carefully and measure the width
of the plastigauge with the table provided.
If clear-
ance is notasspecified in DlMENSlONSAND
CLEARANCE, replace oil pump.

Assembly

Prime each part with oil before reassembling.Fol-

low torques given in ASSEMBLYTORQUES when
tightening hardware. Check oil pressure after serv- -__;--.--
icing or replacing any lubrication system compo- FIGURE 7-6. MEASURING ROTOR TO COVER
nent. CLEARANCE

7-5
 Section 8. Electrical
~ W A R N I N Gincorrect
~ service or replacement of Spark Plug
parts can result in severepersonalinjury and/or
equipment damage. Service personnel must be REMOVAL:Cleanthe area around the sparkbe-plug
qualified toperform electrical and/or mechani- fore removingit. Remove the spark plug lead from
cal service. spark plug. Remove the spark plug from the cylin-
der head.
IGNITION SYSTEM
Refer to Figure 8-1. The ignition coil produces a Inspection/Service Check or replace spark plugs
high voltage pulse that fires the spark plug each as rev-recommended in the PeriodicMaintenance
olution of the engine when the magnet in the rimof Schedule (located in Operator's Manual). Replace
the flywheel passes across the pole faces of the or electrode
spark plugs that show signs of fouling
ignitioncoil.Theignitioncircuitmayincludea erosion.
throttle plate switch and/ora low oil pressure cutout
switch.
Installation Refer to Figure 8-2. Set spark plug
gaptothatspecified in DimensionsandClear-
ances.

Never assemble a cold spark plug a

into
hot cylinder
head.

Tighten spark plug to the torque specified in AS-

SEMBLY TORQUES.

FIGURE 8-1TYPICAL IGNITION SYSTEM FIGURE 8-1. SPARK.PLUG GAP

8-1
Ignition Coil Measuring Coll/Flywheel Clearance: Referto
Figure 8-2. Measure the clearance between each
Spark Test: If the engine will not start conduct a pole face of the coil and the magnet on the flywheel.
spark test as follows: If the clearance is not as specified in Dimensions
WARNING Gasoline and LPG vapors are ex- andClearances, loosenthe two coilmounting
tremely flammable and can cause severe Injuryscrews and adjustto specifications.
or death if ignited. Make certain there are no
gasoline or LPGfumes present before conduct-
ing the spark test.
WARNING ignition voltage can cause severe
personal injury. Do not touch Ignition compo-
nents while conducting the spark test.
1. Obtain a test plug or new plug of the same type
asspecifiedfortheengine.Disconnectthe
spark plug cable from the engine spark plug,
connect it to the test plug and ground the side of
the test plug to bare metal on the engine block.
2. Crank the engine while looking at the spark
plug.
If the spark is strong, the ignition system is
good.
If the spark is weak, check for and readjust the
clearance between thecoil and flywheel.Also
check the condition of the spark plug cable. If
the
cable
appears
damaged, replace
the
igni- IgnitionTiming
tion coil.
If there is no spark, bypass the kill switch Ignition timingis set at the factory and
is not adjust-
(throttle plate switch) and oil pressure switch (if able. The solid state ignition components are not
provided) with a jumper to bare metal on the adjustable and require no routine maintenance. If
engine block.If there is now spark, replace the .the engine’s timingis not close to that specified in
faulty switch. If there is no spark, replace the Dimensionsand Clearances check the key be-
ignition coil. tween the flywheel and crankshaft.
 FLYWHEEL ALTERNATORS When the engine is equipped with 110 a VAC starter
motor and/or recoil starter a permanent magnet fly-
When the engineis equipped with a12 VDC starter wheel alternator and fullbridge rectifier may bepro-
motor a permanent magnet flywheel alternator and vided for the customer DC interface (clutch, hour
electronic voltage regulator may be provided for meter, etc.). Refer to Figure 8-4. The 110 VAC start-
battery charging. Refer to Figure8-3.The flywheel er is provided with a power cord connected to a
will have three to six permanent magnets depend- switch /power receptacle block for mounting on the
ing on the output capacity. equipment.
See Section 10. Starting regarding starter motor See Section 10. Starting regarding starter motor
service. service.

FIGURE 8-3. TYPICAL FLYWHEEL ALTERNATOR FIGURE 8-4. TYPICAL FLYWHEEL ALTERNATOR
SYSTEM FOR BATTERY CHARGING AND 12 VDC SYSTEM FOR CUSTOMER DC INTERFACE AND
STARTER 110 VAC STARTER

a-3
Alternator Output Tests gine is running between1800and 3600 RPM. Refer
to Table 8-1 for test specifications.Use a multi-me-
Keep the following points in mind when testing or ter (Simpson270) when testing the alternator.
servicing the flywheel alternator.
1. Check battery voltage when the engineis not
CAUTION Operatlon withreversedpositive (+) running. (Not applicable on recoil or110 VAC
and negative(-) battery connections or without starterengines.) If notwithinspecifications
connection toa battery wlll damage the voltage (Table 8-l),charge the battery before going to
regulator and/orthe alternator stator. Step 2.
1. Never reverse the battery leads. 2. With the engine running, check voltage regula-
2. Charging system tests require a fully charged tor output (DC voltage) at the battery terminals
battery in good condition. Make sure the en- or bridge rectifier output (DC voltage), as appli-
gine is being run long enough and fast enough cable. Replace thevoltage regulator if output
in service to recharge the battery after each is greater than specified. If voltage regulatoror
start (engines with12 VDC starters). Alternator bridge' rectifier output
is less than specified, go
output is proportional to engine speed and ac- to Step 3.
cessories consume power otherwise available 3. Disconnect the alternator stator leads from the
for battery recharging. voltage regulatoror bridge rectifier and test for
3. The voltage regulator has built in protection alternator stator output (AC voltage) with the
against open circuit and short circuit faults )B+ engine running. If stator output is less than
terminal). It will not "turn on" under either condi- specified, go to Step 4. If stator output is as
tion or when battery discharge is extreme. specified but voltage regulator or bridge rectifi-
4. Check to see that the connections at the termi- er outputis low, replace the voltage regulator or
nals of the voltage regulator (three) or of the bridge rectifier.
rectifier bridge (four) are clean and tight. 4. Shut down the engine and check for electrical
5. Check to see that the wiring connectedto the resistancebetweeneitheralternatorstator
B+ terminal (middle) of the voltage regulator or lead and ground (bare engine metal) with an
to the+ and terminals of the bridge rectifier ohmmeter. The meter should indicate infinite
are not damaged, shorted or grounded. resistance onits highest scale. If resistance is
high, go to Step5. If not, replace the stator.
6. To ensure a, good ground path to battery nega-
tive (-), check to see that the voltage regulator 5. Check alternator stator resistance by'connect-
mounting surfaceis clean and that the screws ing an ohmmeter across the stator leads. Re-
are tight. place the alternator stator assembly If stator re-
sistance onthe lowest scale of the meter is ei-
6. Check to see that the positive and negative bat- ther higher or lowerthan specified. Replace the
tery cables have good connections at the bat- flywheelassembly if alternatorstatorresis-
tery and engine and that they are not damaged. tance is as specified but alternator stator output
After checkingall of the above perform the following is less than specified. The probable cause is
tests if there still is no alternator output when the en- loss of magnetism.
 TABLE 8-1. ALTERNATOR OUTPUT TEST SPECIFICATIONS
VOLTAGE BRIDGE ALTERNATOR ALTERNATOR
ALTERNATOR BATTERY REGULATOR RECTIFIER STATOR STATOR
VOLTAGE
OUTPUT OUTPUT OUTPUT RESISTANCE
Approx. 30 VDC Approx. 29 VAC
Non-Battery at 1800RPM at 1800 RPM
Charging 0.27-0.33 Ohms
Alternator Approx. 60 VDC Approx. 57 VAC
at 3600 RPM at 3600 RPM
5 Amp Approx. 29 VAC
13.6 to 14.7 VDC at 1800 RPM
Battery 12 to 13 at Any Speedin 0.27-0.33 Ohms
Charging VDC Operating Range Approx. 57 VAC
Alternators at 3600 RPM
15Amp Approx. 29 VAG
13.6 to 14.7 VDC at 1800RPM
Battery 12 to 13 at Any Speed in 0.54-0.66 Ohms
Charging VDC Operating Range Approx. 57 VAC
Alternators at 3600RPM
20 Amp Approx. 29 VAC
13.6 to 14.7 VDC at 1800 RPM
Battery 12 to 13 at Any Speed in Ohms
0.54-0.66
Charging VDC Operating Range Approx. 57 VAC
Alternators at 3600 RPM
Spec A
2.5 Amp
Battery 12 to 13 0.30-0.36 Ohms
Charging VDC
Alternator
 .

Section 9. Fuel
~AWARNING] Incorrect service or replacement of
parts can result in severe personal injury and/or
equipment damage. Service personnel must be
qualified to perform electrical and/or mechanl-
cal service. IDLE MIXTURE LOW IDLE

/AWARNING1 Accidental starting of the engine

can result in severe personal injury or death.
Disconnect the negative battery cable and
spark plug wires while servicing engine, con-
trols, or associated equipment.
[AWARNING] Ignition of fuel can result In severe
personal injury or death. Do not smoke or allow
any spark, pilot light, or arcing switch or eguip-
ment near the fuel system or in areas with
shared ventilation.

GASOLINE CARBURETOR
Disassembly -- not applicable, Sp& E MAIN
JET
Carburetor parts are delicate and must be handled
k-l with care. Never force parts when disassembling or
assembling. FLOAT

Remove the air cleaner assembly and disconnect

the fuel line and throttle and choke links. Remove
the carburetor assembly from the intake manifold.
Refer to Figure 9-1 for Spec C and to Figure 9-2 for
Specs A and B. Remove the float bowl, slide the
float pin out and remove the float and float valve.
Remove the main jet and idle adjusting screw and
spring. For Specs A and B also remove the main
nozzle, passage cover and slow jet.
FLOAT
Inspection/Service - not applicableSPecE BOWL

Soak metal components in carburetor cleaner. Do

not soak non-metal parts and gaskets. Follow the
cleaner manufacturer’s recommendations and
safety precautions.
Clean carbon from the carburetor bore, especially
around the throttle and choke plates. Dry out all
passages with low (35 psi) air pressure. Do not use
wire or other objects for cleaning passages as doing
so may damage the critical passages.
Replace the float if it is cracked, damaged, or
loaded with fuel. FIGURE 9-1. GASOLINE CARBURETOR (SPEC C)

9-I
 CARBURETOR (BEGINNING SPEC E) TAMPER-RESISTANT THROTTLE CHOKE
PLUG OVER IDLE LEVER LEVER
Carburetor Replacement MIXTURE NEEDLE

Other than replacing the carburetor main fuel jet

(fixed-type) with the optional high-altitude jet(Fig-.
ure9-3a),fuelmixture adjustments should not be
attempted.Norshouldthecarburetorbeover-
hauled. Instead, a malfunctioning carburetor should
be replaced. Before replacing a carburetor, howev-
er, make certain 1) that all other necessary engine
and generator adjustments and repairs have been
performed and 2) that the carburetor is actually
malfunctioning {see Engine Troubleshooting).
To remove the carburetor, remove the air cleaner
and air cleaner base, disconnect the fuel line and
choke and throttle linkages and unbolt the carbure-
tor from the intake manifold. When mounting the
carburetor always use new gaskets. Readjust the
chokeandthrottlecablesandenginespeedas
instructed in the engine or equipment Operator’s
Manual.
STOP SCREW
Carburetor High-Altitude Jet (Optional)
If the engineis operated at an altitude above 5,000
feet (1,524 metres), it is recommended that the car-
buretor main fueljet be replaced with the optional
high-altitude jet (which has a slightly smaller ori-
fice).
CAUTION To avoid slipping and gouging the
maln fueljet use a screwdriverwlth ,a 5/16 inch
(8mm) wide blade.

FIGURE 9-3a. CARBURETOR

Replace the carburetorif there is excessive playin
the choke and throttle shafts.
if it is bent, worn
Replace the idle adjustment needle
or damaged in any way.
Assembly
CAUTION The mixture adjustment screw is
easiiy damaged. Turn the mixture adjustment
can be feit.
screw in only until light tension
LOW IDLE
When installing the idle adjusting screw, turn the
screw in until LIGHT tensionis felt. For SpecC turn
the screw out 3-1/8 turns. ForSpecs A and B turn
the screw out 2-1/2 turn.
Turn the carburetor body upside down to assemble
the main jet, main nozzle (Specs A and B), float
valve, float and float bowl as illustrated
in Figure 9-1
or 9-2.
bolts to the torque
Torque the carburetor mounting
specified in ASSEMBLY TORQUES,reconnect the
fuel line and throttle and choke links and secure the
air cleaner assembly.
See the instructions that follow in this section for
governor, choke andspeed adjustments.
Co Adjustment
If a CO (Carbon Monoxide) meteris available, ad-
just the idle mixture screwto provide 6% to 7% CO
at 3300 rpm with no load on the engine. If a meteris
not available, set the idle mixture screw at 3-1/8
turns out (Spec C) or 21/2 turns out (Specs A and
B) as noted above.

FLOAT
CHAMBER

FIGURE 9-2. GASOLINE CARBURETOR

(SPECS A AND B )

9-2
 IMPULSE FUEL .PUMP performance. Also check the sealon the oilfill
tube.
The engine may be equipped with an impulse type
7. I f the gasoline has been stored for an extende
fuel pump that uses crankcase pressure (vacuum)
time, drain and properly dispose ofold the
gas-
pulses to operate a spring loaded diaphragm inside
oline. Refill the fuel tank with fresh unleaded
thepump to pumpthefuelthrough two check regular gasoline.
valves.Enginecrankcasevacuum is connected
through a hose to the back of the pump. The fuel If fuel delivery problems still occur, perform the fol-
flow directionis marked on the cover of the pump. lowing performance checks based on the symptom.
U s e adequate ventilation when working on the fuel Engine WillNot Start: Crank the engine, then im-
system. Prevent ignition sources
in the areas shar- mediately remove and inspect the spark plug.
ing ventilation. If the plug is wet and it has a strong gasoline odor,
If the fuel pump leaks, replace it. This fuel pump
is check for:
a fuel leak problem.
not intended to be rebuilt for An ungrounded ignition ground wire
A defective throttle plate or low oil pressure
WARNING ignition of fuel can result in severe
switch or other equipment switch for ignition
personal injury or death.Do not smokeor allow
grounding
or equip-
any spark, pilot light, or arcing switch
mentnear the fuelsystemorinareaswith A fouled spark plug
shared ventilation. An improperly adjusted carburetor choke
If the plug Isdry, ground the spark plug lead
so that'
Inspection/Service ignition sparks can not ignite the gasoline.
If a problem with fuel delivery to the engine is sus- Remove the fuel line from the carburetor and splice
pected, check the following items before inspecting in a fuel line of approximately eight inches in length.
the fuel pump. Place the end of the fuelin aline container to collect
1. Make sure the fuel shutoff valve is open. the gasoline Crank the engine with the electric
starter or the recoil starter for 20 seconds. There
2. Check the fuel filter and replaceit if required.
should be fuel flow into the container. If there is no
3. Make sure the fuel hoses are not kinked or fuel flow from the pump, replacethe fuel pumpas
pinched, causing a fuel restriction. Dips and ex-instructed in this section.
cessively long runs of fuel inline a hot area can
cause vapor locking. Engine Runs But Will Not Operate At High Load:
If the engine starves for fuel at high load, connect
4. Check the fuel tank cap for a restricted vent.
gravity feed fuel supply directly to the carburetor.
5. Check theoil level to make sure it is at the full Plug the fuel line from the fuel pump during this
mark. If the gravity feed fuel supply eliminates fuel starv
6. Inspect the crankcase, especially at the gas- tion, replacethe fuel pump as instructed in this sec-
kets, for visible oil leaks, indicating crankcase tion. If the fuel starvation continues, the fuel ispump
air leakage that can cause reduced fuel pump not the cause.

9-3
 Fuel Pump 'Removal 7. Disconnect the
from
hose
-fuel
inlet the fuel
Refer to Figure9-3. The pumpis not intended to be pump.
rebuilt and should be replaced as a complete as- 8. Disconnect the outlet fuel hose from the fuel
pump
sembly. (it may be necessary to loosen the air
cleaner pan mounting screws to gain access to
1. Turn off the fuel shutoff valve at the tank.
the fuel pump).
2. Place a drip pan under the fuel pump and car-
9. Remove the fuel pump.
buretor to collect fuel.
3. Disconnect the starting battery (if equipped). Fuel Pump lnstallation
Disconnect the negative (-) cable first to re-
duce the risk of arcing. Install the new fuel pump in reverse orderof remov-
4. Remove the air cleaner cover and air filter al. Replace any damaged or deteriorated fuel lines.
assembly. After installation, check governor and engine speed
adjustments for proper engine response.
5. Loosen the screws that secure the fuel pump to
the air cleaner pan assembly. Tighten all mounting hardware to that specified in
6.Disconnect the pulse hose from the fuelpump. Assembly Torques.

IMPULSE FUEL

9-4
 LPG FUEL SYSTEM Referring to the block diagram,. operation of the
LPG fuel systemis as follows:
Refer to Figure 9-4. The carburetor, gas pressure
regulator, air pump and vacuum sustain valve com-
1. Crankcase vacuumpulses cause theair pump
prise theLPG fuel system components that are part
to pump clean air from the air cleaner to the
of the engine assembly. A vacuum cutout deviceis
provided by the equipment manufacturer. vent side of the gas pressure regulator, which
has a factory adjusted and sealed bleed valve.
The carburetor should not require service and there This provides for a precisely adjustable flow of
are no replaceable partsor adjustments except for gas for proper idle mixture.
the low idle speed screw.
2. The vacuum sustain valve consists of a check
WARNING Carbon Monoxide (CO) Is deadly! valve and bleed-offorifice. It bleeds off crank-
The Idle mixture screwson the carburetor and case vacuum when the engine stops to cause
gaspressureregulator are factoryset and the vacuum lock-out device to shut off the gas
sealed. DO NOT READJUST. supply. The check valve removes the vacuum
pulses permitting the lock-out device to open
Note: It is the responsibilityof the user to makecer-
tain that indoor carbon dioxide regulations are met. during cranking.

The air pumpis identical to the gasoline fuel pump See the instructions that follow in this section for
illustrated in Figure 9-3. governor, choke and speed adjustments.

SCREW PEED I I
LPG SUPPLY TANK I
I I
I I
L----,,
I
I
I
I
I
CARBURETOR LPG I

CRANKCASE VACUUM I
VACUUM
PULSES Device

AIRPUMP
PRESSURIZED
AIRREGULATOR
I
PRESSURE
I
I

t
AIR CLEANER I
FIGURE 9-4.LPG CARBURETOR AND FUELSYSTEM BLOCK DIAGRAM

9-5
 GOVERNOR ADJUSTMENTS Spec B gasoline enginesthelever is clamped
around the straight shanked governor shaft with a
In order to obtain the best performance from the draw bolt and nut. Before removing the lever, stop
equipment it is essential that the governor lever, lowthe engine and disconnect the throttle link and gov-
andhigh idle speeds,chokeandspeedcontrol ernor spring. For Spec C gasoline engines use a
cable be adjusted properly. standard battery cable clamp lifter available at any
Symptoms of improper adjustment are: excessive automotive parts store to break the tapper fit be-
loss of engine speed under load, engine stalling, tween shaft and lever hub.
no-load speed surging, poor starting and spark plugGovernorLeverAdjustment: The engine mustbe
fouling. stopped to assemble and adjust the lever.
The equipment Owner's Manual will specify the low 1. Loosely assemble the governor lever and shaft
and high idle speed settings for optimum perform- so that the lever is free to rotate about the shaft.
ance. Always set engine speed with an accurate ta- 2. Attach the throttle link between the governor le-
chometer.Neverexceedthehighspeedsetting ver and carburetor. Replace the nylon clips if
specified by the equipment manufacturer. they areworn or broken.
The order of adjustmentsin this section MUST be 3. Attach the governor spring, move the throttle
followed in order to obtain proper adjustments. The control lever to align the lock pin holes in the
order is as follows: control plate and throttle control lever and in-
1. Governor Lever Adjustment sert a pin to lock the lever in place. See Figure
9-6.
2. Idle Speed Adjustments
4. Check to see that the governor spring is hold-
3. Choke Adjustment ing the carburetor throttle plate in the wide
4. Speed Control Cable Adjustment open position.
1. Governor Lever Adjustment 5. For Spec C gasoline engines tighten the lock
nut on the end of the governor shaft making
Refer to Figure 9-5. The proper angular relationship surethe 'governor shaftrotatesclockwise
between the governor lever and the governor shaft against the internal governor parts, and torque
is essential for obtaining the full range of engine to specifications.ForLPGandSpec A and
speed/loadperformance. The position the of gover- Spec B gasolineengines use aflat-bladed
nor lever should be readjusted whenever the intake screwdriver to rotate the governor shaft clock-
manifold is reinstalled after removal for service. wise against the internal governor parts while
Governor Lever Removal: The governor lever on tightening the lever draw bolt.
Spec C gasoline engines is secured to the tapered 6. Removethe lock pin torelease the throttle con-
governor shaft with a nut. On LPG and Spec A and trol lever and proceed to the next adjustment.
 I -
CONTROL
LEVER

GOVERNOR SHAFT GOVERNOR SPRING

SPEC C GASOLINE LPG ENGINES SPEC AGASOLINE

ENGINES SPEC B GASOLINE ENGINES ENGINES

FIGURE 9-5. ENGINE GOVERNOR LEVER

9-7
2. Idle speed Adjustments
SPEED 9/64 IN. (3.5 mm
CONTROL LOCK PIN HOLE
WARNING Too high a speed settlng can cause CABLE CLAMP
severe personal injury or death-Follow the
low and high
manufacturer’s speclfications for
idle speedsas found in the equlpment Owner’s
Manual. Usean accurate tachometer

High Idle Speed Adjustment; Refer to Figure

9-6.

1. Set up the tachometer according

to the instruc-
tions with the tachometer.
2. Start the engine according to the equipment
manufacturer’srecommendations,observing
all safety precautions, and allow the engine to
warm up for at least10 minutes.
3. While the engine is running move the throttle
controi lever to align the lock pin holes in the CONTROL
control plate and throttle control lever and in- CONTROL PLATE PIVOT
sert a pin to lock the leverin place. Loosenthe PLATE BOLT
speed control cable clamp if necessary.
4. Loosen the choke rod clamp screw and push FIGURE 9-6. HIGH IDLE SPEEDADJUSTMENT
the choke rod towards the carburetor so that
the choke will be fully open.
5. High idle speed is adjusted by rotating the con-
trol plate around the pivot bolt-away from the
carburetor to increase speed and toward the
carburetor to decrease speed. Therefore, loos-
en the control plate pivot bolt 1/8 turn and the
the control plate setbolt 1/4 turn. Adjust high
idle speed to that specified by the equipment
manufacturer, tighten the control plate bolts,
recheck speed and readjustif necessary.
6. Remove the lock pin to release the throttle con-
trol lever.

bow Idle Speed Adjustment; Refer to Figure

9-7.
1. Continue running the engine withthe tachome-
ter connected and move the throttle control le- -LOW IDLE SPEED
.POSITIONOF
ver to thelow idle speed position. M E THROTTLE
2. Adjust engine speed to the specified low idle CONTROLLEVER
speed by’turning the low idle speed screwon
the carburetor. See Figure9-1,9-2 or 9-4, .as
appropriate. Shutoff the engine and proceedto
the choke adjustment.
3. Choke Adjustment
Refer to Figure 9-8. Proper choke adjustment is es-
sential for obtaining consistent starting at low tem- SPECS BAND C
peratures and wide open operation under normal
running conditions. 9/64 IN. (3.5 mm)

1. Shut off the engine and loosen the choke rod

clamp screw so that the rodis free to movein
the choke swivel.
2. Move the throttle control lever to align the lock
pin holesin the control plate and throttle control
lever and insert a pin, making sure the pin ex-
tends past the choke lever to function as a stop
for the choke lever.
3. Push the choke rod towards the carburetor to
make sure the chokeis fully open.
4. Rotate the choke lever towards the carburetor
until the lever bears against the pin stop.
5. Tighten the choke rod clamp screw. For A Spec
gasoline engines there mustbe a0.01 to 0.03
inch (0.25 to 0.76 mm) gap,as shown, between MAKE SURE THE
the choke and throttle control levers. LOCK PIN EXTENDS
PASTTHE CHOKE
6. Remove theair filter paper element and check LEVER TO FUNCTION
that the choke is fully open. Remove the lock AS A STOP FOR THE
of
pin in the control plate and check operation LEVER
the choke linkage.Ifthe linkage binds, replace
the components that are damaged.
7. Proceed to the following speed control cable
adjustment. SPEC A

0.01 to 0.03 in.

(0.26 to 0.76 mm)
GAP

FIGURE 9-8.CHOKE ADJUSTMENT

9-9
4. Speed Control Cable Adjustment
Refer to Figure9-9. The speed control cable must
be installed properly to obtain full-load, full-speed PULL CABLESHEATH
operation. Adjust the speed control cable as fol- THIS WAY TO REMOVE
CABLE SLACK
lows:
1. Stop the engine and loosen the speed control
cable clamp located on the engine throttle con- SPEED CONTROL 9/64 IN (3.5 mm)
PIN
LOCK
CLAMP
CABLE HOLES
trol plate.
2. Push the speed control lever on the equipment
to the high speed position. On equipment with-
out a separate choke control be sure the speed
control leveris not in the start or choke position.'
3. Move the throttle control lever to align the lock
pin holes in the control plate and throttle control
lever and insert a pin to lock the in lever
place.
4. Remove the slack from the speed control cable
and tighten the speed control cable clamp. Re-
move the lock pinin the control plate.
5. Start the engine according to the equipment
manufacturer'srecommendations,observing
all safety precautions.

ALTERNATE SPEED \
CONTROL CABLE THROTTLE
CLAMP LOCATION CONTROL LEVER

TYPICAL EQUIPMENTSPEED CONTROL

FIGURE 9-9. SPEED CONTROL CABLE

ADJUSTMENT
 AIR CLEANER Install the foam wrapper over the paperair cleaner
element by stretching over the inner cover. Com-
Foam Wrapper Element pletely cover all exposed paper pleats on the air
cleaner paper element. If the foam wrapper has
Refer to Figure 9-9. See Periodic Service Schedulestretched or become tom, replace the foam wrap-
for foamwrapperserviceinterval.Removethe per. Assemble the outerair cleaner cover and nut.
outer air cleaner nut and plastic outer cover. When
servicing the foam wrapper onlyDo NOT remove Paper Element
the inner air cleaner nut and inner cover. RefertoPeriodicMaintenanceScheduleforair
cleaner service and replacement interval. Service
Wipe away loose dirt and chaff from the air cleaner or replace more often when operating under severe
assembly and then remove the foam wrapper by operating conditions.
pulling the foam wrapper over the inner cover. Wash
thefoamwrapper in wateranddetergentand Remove the outer air cleaner nut and plastic outer
squeeze dry like a sponge. Rinse withDry water.
the cover. Wipe away loose dirt and chaff fromthe air
foamwrapperbycompressingbetweenseveral cleaner assembly and then remove the inner air
sheets of paper toweling. Apply 2 tablespoons of cleaner nut and inner air cleaner cover. Remove
new engine oil and knead into the foam wrapper air un-filter paper element and foam wrapper from the
til it is evenly distributed. Remove excess oil by engine. Wipe off excess dirt from air cleaner base
compressing the foam between several sheets of and install the new paper element, inner cover an
paper toweling. Failure to remove excess oil will inner nut.lighten the inner nut one and aturns
half
cause the paper air cleaner to become oil soaked. after seating on the inner cover. Service the foam
This will cause a loss in engine performance and a wrapper per the instructions givenabove. Assem-
shortened paper air cleaner element life. ble the outer air cleaner cover and nut.

LPG ENGINES
GASOLINE ENGINESSPECSAAND B) GASOLINE ENGINES (SPEC C)
 Section 10. Starting
WARNING Incorrect service or replacementof 110 VAC STARTER
parts can result in severe personal injury and/or
equlpment damage. Service personal mustbe Disassembly: Refer to Figure 10-2. Remove the
qualified to perform electrical and/or mechanl- two drive cap mounting screws and remove the as-
cal service sembly from the engine.

WARNING Accidental starting of the englne Inspection/Servlce: Replace the

entire
plug/
can result In severe personal Injury or death. switch/motor assembly if the motor does not oper-
Disconnect the negative (-) battery cable and ate or is not strong enough to turn the engine. Re-
spark plug wife before serviclng the englne, place the pinion gear and associatedif the parts pin-
controls, or associated equlpment. ion is worn and/or binds on the shaft. The parts are
available in kit form. Follow the kit instructions.
If the
RECOIL STARTER drive cap bearing appears worn, replace the drive
cap.
Disassembly: Refer to Figure 10-1. Remove the
four capscrews holding the recoil assembly on
the
engine.Removetherecoilassemblyfrom the
blower housing.
Inspection/Service Inspect the assembly as a
unit. Therope should pull out freely with spring ten-
sion, pulling the rope back in without binding or
slack.Whenpullingtherope out, the dog ears
should come out of their cup and they should benot
bent, broken, or missing.
Assembly; Place the recoil assembly on the blower
a
housing. Install and torque the four capscrews to
the torque specifiedin Assembly Torques.

CAP
SCREW

RECOIL
ASSEMBLY
PLUG/SWITCH/MOTOR DRIVE
ASSEMBLY CAP

M-1811

FIGURE 10-1. RECOIL STARTER REMOVAL FIGURE 10-2.110 VAC STARTER

10-1
 SOLENOID SHIFT STARTER Assembly: Refer to Figure 10-3. Assembly is the
reverse of disassembly. Apply grease to the shift
WARNING Accidental starting of the engine fork hinge and prongs and the splines on the arma-
can result In severe personal Injury or death. ture shaft.
Disconnect the negative (-) battery cable and
spark plug wire before servicing the engine, Solenoid
controls, or associated equipment.
Inspection/Service: With the starter assembled, Attraction Text: Connect a jumper lead from the
disconnect the connecting lead from the starter so- ST terminal to the positive terminal of a 6 volt bat-
lenoid C terminal. Connect a jumper lead from the tery. Connect a jumper lead betweenC the terminal
connecting lead to the battery positive terminal. and negative terminal of a 6 volt battery. If the
Connect a jumper lead momentarily between the plunger pulls in and holds strongly, the solenoidis
starter motor housing and the battery negative ter- good; if it doesn't, replace solenoid.
minal. If the motor doesn't run, check the motor for
problems. Retention Test:Connect a jumper lead fromST the
terminal to the positive terminal of a 6 volt battery.
Disassembly: Refer to Figure 10-3. Remove the Connect a jumper lead between the solenoid body
starterfromtheengine.Unscrewthesolenoid and negative terminal of a6 volt battery. Push the
mounting nuts and disconnect the connecting lead.plunger in and release it. If the plunger stays in, the
Remove the solenoid by sliding it up to disconnect solenoid is good; if it doesn't, replace solenoid.
the shift fork. Unscrew thetwo motor through bolts
and remove the motor end bell. Carefully remove Plunger Return Stroke: Apply 12 volts between
the brush insulator, brushes (four), brush springs terminal C and the solenoid body. Pushthe plunger
and brush holder. Separate the motor frame from in and then release Ifit.the plunger returns immedi-
the drive housing and then draw the armature out ately, the solenoid
is good; if it doesn't, replace sole-
with the shift fork. noid.

V..

BRUSH SPRING
Armature Armature Coil Core and Commutator Continu-
ity: Refer to Figure be-
10-6. Check for no continuity
Continuity Between Segments: Refer to Figure shaft. If con-
tween the commutator and armature’s
10-4. Check for continuity between the segments oftinuity exists, replace the armature.
the commutator.If there is no continuity, replace the
armature.

COMMUTATOR
commutator

FIGURE 106. MEASURING ARMATURE SHAFT

ES1872 AND COMMUTATOR CONTINUITY
flGURE 10-4. MEASURING SEGMENT
CONTINUITY Armature Shaft and Bushing Clearance: Refer to
Figure 10-3, 10-7, and 10-8. Measure the bushing
Armature Coil Core and Commutator Continu- inside diameterin the starter drive housing and end
ity: Refer to Figure10-5. Check for no continuity be- frame. Measure the armature shaft outside diame-
tween the commutator and the armature coilIf core. ter on the pinion side and commutator side.If the
continuity exists, replace the armature. clearance is not as specified in Dimensions and
Clearances, replace the bushing.

BUSHING

COMMUTATOR STARTER DRIVE

ES1873 HOUSING ES-1876

FIGURE 10-5. MEASURING ARMATURE COIL FIGURE 10-7. MEASURING STARTER DRIVE
CORE AND COMMUTATOR CONTINUITY HOUSING INSIDEDIAMETER

10-3
 MICA SEGMENT
UNDERCUT EDGES
DEPTH

SAW BLADE
PINION SIDEOF
ARMATURE SHAFT
ES-1877

FIGURE 10-8. MEASURING ARMATURE ES-1879

SHAFT OUTSIDE DIAMETER
FIGURE 10-10. MICA UNDERCUT DEPTH
Commutator And Mica
Commutator:Refer to Figure 10-9. Clean commu- Starter Body
tator surface with sandpaper. Measure the commu-
Inspection: Refer to Figure 10-11. Check for conti-
tator outside diameter at several points. If the differ-
nuity across the starter body and brushes. There
ence of the outside diameteris not as specified in
are four brushes in the starter body. The
two that are
Dimensionsand Clearances,correct the commuta-
tor on a lathe to factory specifications. If the mini- not grounded are 180" apart starting at the terminal
mum outside diameter is less than the allowable which connects to the solenoid. The two that are
limit, replace the armature. grounded are located 90" from the non-grounded
terminals. If continuity exists at the non-grounded
terminals,replacethestarter body. If continuity
does not exist at the grounded terminals, replace
the starter body.

NON-GROUNDED
TERMINAL

ES-1878

FIGURE 10-9. MEASURING COMMUTATOR

OUTSIDEDIAMETER

Mica: Refer to Figure10-10. Measure themica un-

dercut depth.If the undercutis less than that speci-
fied in Dimensions and Clearances, use a saw
' ES-1880

blade to increase the depth and then chamfer the FIGURE 10-11. CHECKINGFOR STARTER
segment edges. BODY CONTINUITY
Brushes age. Do not clean overrunning clutch in liquid
cleaning solutions.
Inspection/Service RefertoFigure 10-12.
Clean the brush base with sandpaper. Measure the Inspection/ServiceRefer to Figure10-13. Inspect
brush length. If the length is not as specifiedin Di- the pinion and spline teeth for wear and damage. If
mensions and Clearances, replace the starter body wear or damage exists, replace pinion. Rotate the
and brush holder. pinion clockwise and seeif it turns freely. Replace
the pinionif it doesn't. Rotate the pinion clockwise
to
see if it locks. Replace the pinionif it doesn't.

PINION

Es-1881

FIGURE 10-12. MEASURING BRUSH LENGTH

Overrunning Clutch
WARNING Cleaning overrunningclutch InIiq- FIGURE 10-13. CHECKING PINION FOR
uid cleaning solutionwlll result in starter dam- PROPER OPERATION

10-5
 Section 11. Engine Block Assembly
INTRODUCTiON Suggested Assembly Procedure
This section covers service procedures for the en-
gine block assembly. A compression test can be Engine assemblyis normally the reverseof the dis-
performed to determine the condition of the engine. assembly procedure, observing proper clearances
and torques. Use a torque wrench to assure proper
WARNING Accidental starting of the engine tightness. Coat the internal engine parts with oil as
can result in severe personal injury or death. they are assembled. After the internal engine parts
Disconnect the negatlve (-) battery cable and are assembled, the engine should turn over by ha
spark plug wire before servicing the engine, freely. Use only genuine Onan parts and special
controls, or associated equipment. tools when reassembling your engine.
ENGINE DlSASSEMBLY/ASSEMBLY 1. Install tappets, crankshaft and camshaft as-
When complete engine disassemblyis necessary, semblies.
firstremove all completeassemblies.Individual 2. Install the connecting rod and piston.
assemblies such as the carburetor can be disas-
sembled and repaired at another time. 3. Install the balance shaft assemblies.
4. Install the oil base, reuse the original end play
Suggested Disassembly Order
shims on their respective shafts.
1. Drain crankcase oil.
5. Install the cylinder head assembly and lash
2. Disconnect all fuel, exhaust and electric lines. valves.
3. Remove the engine from its mountings and
place it on a suitable bench or work stand. 6. Install the accessories such as valve cover, oil
filter,starter,intakemanifold,exhaustmani-
4. Remove the muffler,chaffscreen,blower
fold, spark plug, etc.
housing, cylinder air housing, etc.
5. Remove the air cleaner assembly, carburetor, 7. Install the flywheel and ignition
module.
and air deflector. 8. Install the air deflector, carburetor, and cleaner
6. Remove the ignition module. assembly.
7. Remove the flywheel using a puller. 9. Install the cylinder air housing, muffler, blower
8. Remove all accessoriessuchas oil filter, housing, chaff screen, etc.
starter,intakemanifold,exhaustmanifold, I

spark plug, etc. 10. Install the engine on

its mounting.
9. Removethevalvecoverandcylinderhead 11. Connect all fuel, exhaust and electric lines.
assembly.
12. Fill crankcase with oil.
IO. Remove theoil base carefully, keepingall end
play shims on their respective shafts.
Operation
1.1. Remove the balance shaft assemblies.
12. Remove the connecting rod and piston.
Start the engine and check oil pressure. Run for
13. Remove crankshaft and camshaft assemblies. proximately 15 minutesto bring engineto operating
Keep all partsin their respective orders. Keep valve temperatures. Check for oil leaks, fuel leaks, and
assemblies together. Analyze the reasons for parts exhaust leaks. Adjust carburetor and governor for
failure. sensitivity. and speed, I
 Compression
The compression tester is used to determine the so no oil or dirt
Clean tapered section of the flywheel
condition of valves, piston, piston rings and the are present. Install
woodruff key on the crankshaft.
engine cylinder. Install flywheel on crankshaft and tighten to torque
specified in Assembly Torques. Install sheet metal.
specified
torque
Tocompression:
check
to Tighten
bolts in Assembly
1. Run
the
engine
until
thoroughly
warm. Torques.
2. Stop
engine
theand
remove
spark
the
plug. VALVE COVER
3. Remove the air cleaner and place the throttle
andchoke in thewideopenposition.Removethevalvecovertogainaccesstothecylin-
der head, breather assembly and valve system.
4. Insert the compression gauge in the spark plug
hole. and bolts mounting
cover valve the
1. Remove
5. Crankthe
engineand
note
the
reading.
pull
off
the
valve cover.
2. Clean the valve cover. Be careful not to dam-
Refer to Specifications for compression pressure.
age the surface of the cover where the gasket
There may be variations due to equipment, tem-
mounts.
perature,atmospheric conditions
andaltitude.
These pressures are for a warm engine at cranking 3. Clean the cylinder head and cover thoroughly
speed
(about 300 rpm). in
cover
gasket
the
mating
area.
Make
the
sure
breatherassembly is correctlyseated in the
FLYWHEEL cavity. head cylinder
4. Install a new valve cover gasket.
Disassembly cover
valve
5.the
Place the
install
in position
and
mounting bolts. Torqueall of the boltsin a star
WARNING Accidental starting of the englne pattern until they are tightened to the specified
can result In severe personal Injury or death. torque.
Disconnect the negatlve (-) battery cable and
spark plug wire before the servlcing engine, ROCKER ARM
controls, or associated equipment.
Disassembly
WARNING Incorrectflywheelremoval can
Do not remove
result In severe personal Injury. Refer toFigure11-1. Remove snap ring and
pull out
theflywheelnutcompletelywhenusing the rocker arm.
flywheel puller.
Inspection/Service
Remove screen or recoil starter assembly and fly-
wheel cup if equipped with recoil starter. Remove Rocker A m and RockerA m Shaft Clearance:
sheet metal surrounding flywheel. Loosen the fly- Measure the rocker arm shaft outside diameter.
wheel mounting nut. Use a flywheel puller to re- Measure the rocker arm inside diameter and calcu-
move flywheel. Remove the woodruff key on the late the clearance.Ifclearance is not as specified in
crankshaft. Dimensions .and Clearances, replace the rocker
arms. If clearance still exceeds that specifiedin Di-
Service/Inspection\ mensionsandClearances, replacerockerarm
Removedirt,chaff,orothercontaminantsfrom shaft assembly.
screen and flywheel. Inspect screen and flywheel Assembly
for damage. Replace screen ifdamaged in any way.
Replace flywheel if ring gearor flywheel is damaged Apply engine oil to the rocker arm shaft. Assemble
in any way. components on rockerarm shaft.
 ROCKER

SNAP RING

VT-1050

FIGURE 11-1. ROCKERARM ASSEMBLY

CYLINDER HEAD
Disassembly
Torquing or removlng the cylinder
head when hot (above100F[37C] wlll result
Allow the head to cool to below
in head damage.
100F(37C)before torquing or removlng.
Refer to Figure11-2. The engine mustbe at room
temperaturebeforestartingthisprocedure.Re-
move the valve cover capscrews and valve cover.
Remove the spark plug. Remove the rocker arm as-
sembly by unscrewing bolt holding the assembly
on. Pull out the push rods. Removethe remaining
cylinderheadscrewsandremovethecylinder
head. Removethe cylinder head gasket.
ROCKER ARM ASSEMBLY
RETAlNlNG BOLT
NUMBERS INDICATE CYLINDER
HEAD BOLT TORQUE SEQUENCE
c-1120

FIGURE 11-2. CYLINDERHEAD BOLTS

Assembly essential for good engine performance. Use the fol-
lowing procedures to inspect and service the valve
CAUTION Over torquing bolts can cause en- system.
gine damage. Do not over torque nuts.
Refer to Figure 11-2. Install a new cylinder head Tappets
gasket. Position cylinder head on engine and posi-
tionrockerarm,bolts,andwashers inpositions Very little wear takes place on tappet diameters
or in
shown. Make sure push rods are properly installed tappet bores. If the clearance between tappet and
in tappets and rocker arm. tighten cylinder head bore in the cylinder block exceeds specifications,
bolts to the torque specified in Assembly Torquesin replace the tappet.
the order: bolt1, bolt 2, bolt 3, bolt 4, bolt 5, bolt 6.
Inspect the tappet faces which contact camshaft
Bolts 2 and 4 must be retorqued after all bolts are
lobes for roughness, scuffing,or concave wear. Re-
torqued. Adjust
valve
clearance.
Remove the
place any worn tappets. If tappets are worn, inspect
gasket from valve cover. Install the breather in the
the camshaft for wear.
cylinder head. Install a new valve cover gasket and
tighten valve cover capscrewsin a two-step cross
patternto
the
torquespecified in Assembly Valves, Springs, Guides
Torques.
Disassembly
VALVE SYSTEM
Refer to Figure11-3. Compress valve springs and
This engine uses an overhead valve design, shownpull out the valve locks. Remove the valve spring
in figure11-3. A properly functioning valve system is retainer, valve spring, washer and valve.

VALVE LOCKS VALVE

SPRING
INTAKE
SEAL
STOPPER CYLINDER HEAD
INTAKE
VALVE

EXHAUST
SPRING
RETAINER
VALVE
SEAT
VALVE
VALVE
WASHER
GUIDE
VALVE

11-4
 VALVE GUIDE
Valve Stem and Valve Guide Clearance:

Refer to Figures 11-4 and 11-5. Remove carbon

from valve guide and valve stem. Measure the valve
stem outside diameter six at positions. Measurethe
valve guide inside diameter at three positions. Cal-
culatetheclearance. If the clearance is not as
specified in Dimensions and Clearances, replace
the valve. If clearance still exceeds the allowable
limit, replace the valve guide.

FIGURE 11-5. MEASURING VALVE GUIDE

Valve Guide Replacement:

CAUTION Driving out old valve guides can
cause guide and guide bore damage. Do not
strike guide or guide bores wlth driver during
removal.
Refer to Figure11-6. Press out the used valve guide
using a special valve guide replacing tool. Apply
engine oil tonew a valve guide. Installastopper ring
to the valve guide. Press the new valve inguideuntil
the stopper ring contacts the cylinder head. Ream
FIGURE 114. MEASURING VALVE STEM the new guide to achieve the specified stem to
guide clearance.

STOPPER RING

11-5
Assembly wheel. A very light grindis usually enough to square
the stem and remove anypits or burrs. The valve
Clean off any carbon onthe valve stem and valve guide should be thoroughly cleaned. If the valve
guide hole. Apply engineoil to the valve and valve guide is worn, o r the valveis warped, the necessary
guide. Assemble in reverse of disassembly proce- parts must be replaced.
dures.
Refinish valve faces ato 45" angle on a valve refac-
Valve Spring: ing machine. The first cut from valve face be must
a
Check valve springs for cracks, worn ends, distor- light grinding. Check if there is an unevenness of
tion, and tension. If spring ends are worn, check metal being removed. If only partof valve's face has
valve spring retainer for wear. Check for spring dis- been touched, check to see ifthe valve is properly
seated
tortion by placing the spring on a flat surface next to in the machine or if the valve is warped,
a square. Measure height of spring (A) and rotate it worn, or distorted. When cut is even around the
against square edge to measure distortion (B), see whole valve face, keep grinding until the complete
Figure 11-7. If distortionexceeds 0.06 inch face is ground clean. Be sure the correct valve face
(1.5 mm) replace the spring. Check spring tension angle is maintained. When the valvehead is
at the valve open position using an accurate valve warped, a knife edge be willground (Figure11-8) on
spring tester. Replace any valve springis weak,
that part or all of the head due to the large amount of
cracked, worn, or distorted. metal that must be removed to completely reface
thevalve.'Heavyvalveheadsarerequiredfor
strength and good heat dissipation. Knife edges
lead to breakage, burning, and pre-ignition dueto
heat localizing on the edge.
Replace any valve that cannot be entirely refaced
11-8) or
while keeping a good valve margin (Figure
is warped,worn, or damaged in anyway.The
amount of grinding necessary to true a valve indi-
cates whether the valve headis worn or warped.

WARPED VALVE
WITH K N I F E EDGE K N I F E EDGE

FIGURE 11-7. MEASURING VALVE SPRING

Valve Face and Seat Grinding

Before installing new or used valves, inspect the GOOD MARGIN
valve seats for proper valve seating. If used valves
are reinstalled, the valve stems should be cleaned
and valve faces ground to their specified angles of
45F Refinish valve seats to a 45" angle.When
refacing valves and seats, removeall evidence of
pitting and grooving.If the endof the valve stemis
pitted orworn, true it and cleanit up on the refacer FIGURE 11-8. VALVE HEAD MARGIN

11-6
Inspection/Service valve and seat. Repeat the lasttwo steps untilthe
correct, contact is achieved. Lap valve until the
Valve Seat Width: seated rate becomes more than 70% of the total
Clean the valve seat surface. Measure the valve contact area.
seat width. Apply red lead to the valve surface to
check for scratches and unevenness.If the meas-
urement is within that specifiedin Dimensions and
Clearances, check the seating ratio. If the ratio is
less than70%, refit it. If the measurement is not as
specified in Dimensions and Clearances, replace I
the cylinder head and valve and refit the valve seat.
Valve Seat Cuffing:
Refer to Figures 11-9 and 11-10. Clean the valve
seat up by using 45Oa valve seat cutter. Replace the 15"
valve and visually check the contact position be-
tween the valve face and seat with red lead. Cut the
upper surfaceof the valve seat with 15"avalve seat
cutter until the valve seat touchesto the center of
the valve face (A should equalBas shown in Figure
11-10). Cut the valve seat again with the 45" valve
seatcutterandrecheckthecontactbetweenthe FIGURE 11-9. VALVE SEAT CUTTER

45"

VT-1049

FIGURE 11-10. VALVE SEAT CONTACT

11-7
Valve Clearance: Shim as necessary to obtain the clearances speci-
fied in Dimensions and Clearances.
The engine must be at room temperature when per-
forming this test. Remove the valve cover. Remove Apply grease to the oil seal lip and make sure it's not
the spark plug. Turn the engine over
until the piston damaged when installing the oil base. Be sure the
is at COMPRESSION TOP DEAD CENTER. Check oil pump shaft lines up with the slot on the balancer
the intake and exhaust valveclearance with a feelershaft. Tighten the oil base mountinginboltsaclock-
gauge. If the clearanceis not as specifiedDimen-
in wise pattern to the torque specified in Assembly Y
sions and Clearances, loosen the lash adjusting nut Torques. Torque the bolt first torqued once more.
and turn the lash adjusting screw until the correct di-
mension is obtained. Tighten lash adjusting nut and
recheck clearance measurement.

VT-1058

GOVERNOR
FIGURE 11-11. MEASURINGVALVE LASH
With the oil base removed, the governor be can
in-
OIL BASE spected or disassembled for service. The governor
assembly must spin freely the on center pin without
:Disassembly excessive loosenessor wobble. Sleeve tip wearis
the most common cause of governor failure. Check
Remove theoil pressure switch located next to the forflatspotsonthesleevetip. If thegovernor
.oilfilter. Unscrew the oil base mounting screws. Tap are worn or damaged, re-
sleeve, gear, or flyweights
.the oil base with a plastic hammer.Remove oil place them.
base. Do not pry cover off with a screwdriver chisel,
etc. Note whereail shims comeoff from.
To disassemble, pull the governor gear assembly
Assembly off the mounting shaft (Figure
11-13). To assemble,
install the
washer, gear assembly, and retainer onto
Install a newoil base gasket. Install shims in their the shaft. Thread the sleeve between the flyweights
original locations (Figure11-12). If the crankshaft, and push the assembly onto the shaft. See inset
camshaft or balancer shafts have been replaced, drawing (Figure11-13) for positionof flyweight and
usePlasti-gagetochecktheirendclearances. sleeve.

11-8
 BALANCER BALANCER
SHAFT 2 *-I CT-1110

CT-1089-1a
FIGURE 11-14. BALANCINGSHAFT ALIGNMENT
RETAINER
FIGURE 11-13. GOVERNOR CRANKSHAFT AND CAMSHAFT

BALANCING SHAFTS Disassembly

Disassembly Set the engine blockon the flywheel side. Pull the
crankshaftoutwiththecamshaft.Removethe
Carefully pull each shaft out, one at a time. tappets.
Oil Base Bearlngto Shaft Clearance:
Measure thebalancerjournalbearing O.D. onboth Inspection/Service
balancershafts.Measurethecorresponding oil
base bearingI.D.’s. If the measurements are not as Crankshaft Journal:
specified in Dimensions and Clearances, replace Refer to Figure 11-15. Measure the crankshaft jour-
the defective parts. nal. If the crankshaft journal is not as specified in
Assembly DimensionsandClearances, useanundersize
connecting rod and correct the crankshaft journal.
Refer to Figure 11-14. Align the alignment marks on Precisely grind the comer radius of the journal to a
the gears. The crankshaft has two alignment marks 0.07 to 0.09 inch radius (1.8 to 2.2 mm). Chamfer
which must line up with balancer shaft 1. Balancer the oil hole circumference with an oil stone 0.04to a
shaft 1 has one alignment mark which must line up to 0.06 inch (1-0 to 1.5 mm) radius. The journal
with the one alignment mark on balancer shaft2. surface must be fine finished to higher than 6 pin
Install each shaft one at a time. (0.4 µm Ra ).

11-9
 Oil Base Bearing to Camshaft Clearance:
OIL Measure the camshaft journal bearing O.D. Mea-
CRANKSHAFT sure the corresponding oil base bearingI.D. If the
JOURNAL measurements are notas specified in Dimensions
RADIUS and Clearances, replace the defective parts.

Assembly

Install tappets into the block. Refer

to Figure 11-17.
Apply engine oil to the governor lever shaft. Apply
CT-I111 grease to the oil seal lip and
be careful not to roll the
seal when inserting the crankshaft. Line the crank-
FIGURE 11-15. CRANKSHAFT JOURNAL shaft and camshaft timing marks up and insert both
into the block at the same time.
Camshaft Lobe Height:
Refer to Figure 11-16. Measure the height of each
point.If measurements are not
cam at its highest as
specified in Dimensions and Clearances, replace
the camshaft.

CT-1112a1112

FIGURE 11-16. MEASURING CAMSHAFTLOBE FIGURE 11-17. CRANKSHAFT AND CAMSHAFT

HEIGHT TIMING MARKS

11-10
 COMPRESSION RELEASE SYSTEM
ENGINE START POSITION
This engine has a compression release that,system
decreases the amount of effort required
to start the CAM GEAR
TAPPET
engine and reduces engine run-on when stopping I FLYWEIGHT
(Figure 11-18).

The system works as follows:

1. As the engine is started, a spring holdsin the
flyweight, which in turn pushes a decompres-
sion pin upward.
2. Thedecompressionpinpushesuponthe
exhaust tappet and opens the exhaust valve
momentarilyto release compression and make
starting easier.
3.As theengine speeds up, theflyweight is
forced outward by centrifugal force and the
decompression pin moves down so that it no
longer opens the exhaust valve.
4. When the engine is stopped, engine speed
drops and the flyweight pullsin and the decom-
pressionpinmovesup.Thepinopens the
exhaust valve again releasing compression.
The most common problem with this system is a
faulty spring. The spring maybe too longor it may
not be connected.A spring that is too long will re-
duce the decompression cutoffspeed. Make sure CT-1121.
the springis properly attached,if a problem withthe
cutoff speed is suspected, replace the spring. FIGURE 11-18. COMPRESSION RELEASE SYSTEM

11-11
 PISTON, PISTON PIN, RiNGS,
CONNECTING ROD

Disassembly
CAUTIONImproper piston removal can cause
piston damage. Use a rldge reamer to remove
cylinder ridge before removing plston.

Refer to Figure11-19. Unscrew the connecting rod

screws and remove the connecting rod cap. Turn
the crankshaft so the piston is at top dead center.
Pull the piston and connecting rod out of the cylin-
der liner. Make a mark on the pistonon the same PISTON PIN
side as the machined surface on the connecting SNAP RING
rod.

FIGURE 11-20, PISTON ASSEMBLY

Piston Inspection
CAUTION Improperpiston cleaning can cause
piston damage. Do not use a caustic cleaning
solvent or wire brush for cleaning pistons.
Follow the procedures given below when inspecting
pistons and connecting rods.
Piston Inspection:
1. Inspect the piston forfractures at the ring lands,
skirts and pin bosses. Check for wear at the
ring lands using a new ring and feeler gauge
(Figure 11-23). Replace the piston when the
side clearance of the top compression ring
CT-1097a-1097
reachesthatspecified in Dimensionsand
Clearances.
FIGURE 11-19. PISTON MARKING 2. Replace a piston showing signs of scuffing,
scoring, worn ring lands, fractures or damage
Refer to Figure11-20. Remove rings from piston by from preignition. Excessive piston wear near
using a ring tool. Remove the piston pin snap ring the edgeof the top ring land indicates preigni-
and push out the piston pin. tion.

11-12
Piston Pin Hole inside Dlameter: Piston' Ringand Ring Groove Clearance:

Refer to Figure 11-21. Measure thepiston pin hole Refer to Figure11-23. Remove carbon from the ring
inside diameter at various places. If the measure- grooves.Insert a newpistonringintothering
ment is not as specifiedin Dimensions and Clear- grooveandmeasuretheclearanceatseveral
ances, replace the piston. points. If the measurements are not as specified
in
Dimensions and Clearances,replace the piston.

.1100

FIGURE 11-21. MEASURING PISTONPIN HOLE

FIGURE 11-23. MEASURING RING GROOVE
CLEARANCE
Piston Pin Outside Diameter:
Connecting Rod Small End Inside Diameter:
Refer to Figure 11-22. Measure the pistonpin out-
side diameter. If the measurement is not as speci- Refer to Figure 11-24. Measure the connecting rod
fied in DimensionsandClearances, replace the small end inside diameter with an inside microme-
piston pin. ter. If dimension is not as specified in Dimensions
and Clearances,replace the connecting rod.

CT-1101

FIGURE 11-22. MEASURING PISTON PIN

FIGURE 11-24. MEASURING CONNECTINGROD
SMALL END

11-13
Connecting Rodto Crankshaft JournalOil Assembly
Clearance:
in 212°F
Referto Figure77-26. Immerse the piston
oil for 10 to 15 minutes and then insert the piston pin
Refer to Figure 11-25. Measure the crankshaft jour- into the piston
and connecting rod. Be sure the con-
nal outside diameter with an outside micrometer. If necting rod machined surface is on the same side
the dimensionis not as specifiedin Dimensionsand as the pistonmark.
Clearances, grind the crankshaft journal and re-
place the connecting rod. Tighten the connecting
rodscrewstothetorquespecified in Assembly
Torques. Measure the connecting rod large end in-
side diameter at the points shown. If the dimension
is not as specifiedin Dimensions and Clearances,
replace the connectingrod. Calculate oil clearance.
If the oil clearance in Dimensions
is not as specified
and Clearances, grind the crankshaft journal and
replace the connecting rod.

CT-1097

flGURE 11-26. ASSEMBLING PISTON

Refer to Figure 11-27. Always install new rings

when assemblingthe engine. Existing rings will not
seat properly. Install the rings with the ring manu-
facturer’s mark facing toward the top of the piston.

CT-1106

FIGURE 11-25. MEASURING CONNECTINGROD

LARGE END

Connectlng RodSide Clearance: RING

MANUFACTURER’S
MARK
Assemble the connecting rod to the crankshaft.
Measure the side clearance of the connectingrod
If dimension is not as specified
on the crankshaft. in
Dimensions and Clearances,replace the connect-
ing rod. FIGURE 11-27. RING MARK

11-14
Refer to Figure 11-28. Insert piston pin snap ring. Refer to Figure 11-30. Use a ring compressor to in-
Position rings on piston as shown. Gap on top ring sert the piston and connecting rod in into the cylin-
must face opposite of intake and exhaust valves. der liner. Apply engine oilto the inside diameter of
the connecting rod cap and connecting rod screws.
Align the machined surfaces of the connecting rod
and connecting rod cap. Applyto oil the connecting
SECOND TOP RING rod bolts and tighten themto the torquespecified in
Assembly Torques.

MACHINED
SURFACE
MUST FACE
CAMSHAFT
CT-1107cr-I107
CT-1109
FIGURE 11-28. ASSEMBLING RINGS

Refer to Figure11-29. Apply engineoil to the cylin-

so
der liner. Line up the piston and connecting rod
the machined surface of the connecting rod faces FIGURE 11-30. CONNECTING ROD AND CAP
towards the camshaft. ALIGNMENT

CYLINDER BLOCK
The cylinder blockis the main support for all other
basic engine parts. The crankshaft and camshaft
are supported by the block, assuring alignment of
the crankshaft and cylinder bore.

MACHINED Cleaning
SURFACE
MUST FACE After removing pistons, crankshaft, cylinder heads,
CAMSHAFT etc., inspectthe block for crackswear.and If block is
still sewiceable, prepareit for cleaningas follows:
1. Scrape all old gasketmaterialfromblock.
CT1113 Remove oil by-pass to allow cleaning solution
to contact inside of oil passages.
FIGURE 11-29. PISTON ORIENTATION
2. Remove grease and scale from the cylinder
block by agitating it in a bath of commercial
CAUTION An improperly installed piston wiil cleaning
solution or hotsoapy
washing
solution.
of the
cause engine damage. The machined side
connecting rod must face the camshaft. 3. Rinse the block in clean hot water to remove
the cleaning solution.

11-15
.Inspection

When rebuilding the engine, thoroughly inspectthe

it unfit for
block for any condition that would make TOP OF CYLINDER
further use. This inspection must be made afterall
parts have been removed and the block has been
thoroughly cleaned and dried.
RING
1. Makeathoroughcheckforcracks.Minute WEAR
cracks may be detected by coating the sus- AREA
pected area with a mixture 25of percent kero-
sene and 75 percent light motor oil. Wipe the
part dry and immediately apply a coating of zinc
oxide (white lead) dissolved
in wood alcohol.If
cracks are present, the white coating will be-
come discolored atthe defective area. Always iBOTTOM OF RING TRAVEL
replace a cracked cylinder block.
B-418
2. Inspect all machined surfaces and threaded
holes. Carefully remove any nicks or burrs from FIGURE 11-31. METHODS OF MEASURING THE
machinedsurfaces.Cleanouttappedholes DIAMETER OFA CYLINDER BORE
and clean up any damaged threads.
3. Check the top of the block for flatness with a B. Measure and record as "B" cylinder bore
straight edge and a feeler gauge. diameter (parallel to crankshaft) at the bot-
tom of piston travel.
Cylinder Bore Inspection Inspect cylinder bore
C. Measure and record as "C"cylinder bore
for scuffing, scratches, wear, and scoring.
If cylinder
diameter(perpendicular to crankshaft)
bore is scuffed, scratched, worn,or scored,it must
near the top of cylinder bore.
be rebored and honed for the next oversize piston.
D. Measure and record as "D" cylinder bore
When the appearance of the cylinder boreis good diameter (perpendicular to crankshaft) at
and there are no scuff marks, check cylinder bore the bottom of piston travel.
for wear orout of roundness as follows: E. Reading "A" subtracted from reading "B"
and reading "C" subtracted from reading
1. Check cylinder bore for taper, out of round, and "D" indicates cylinder taper.
wear with a cylinder bore gauge, telescopic
If cylinder taper exceeds that specified in
gauge, or inside micrometer. These measure-
Dimensions and Clearances rebore and
ments shouldbe taken at four places: top and
hone cylinderto the next oversize.
bottom of piston ring travel, parallel and per-
pendicularto axis of crankshaft (Figure 11-31). F. Reading "A" compared to reading "C"and
reading "B"compared to reading"D"indi-
2. Record measurements taken at top and bot- cate whether or not cylinderisout of round.
tom of piston travel as follows: If out of round exceeds that specified
in Di-
A. Measure and record as "A" the cylinder mensions and Clearances the cylinders
.bore diameter (parallel
to crankshaft) near must be rebored and honed to the next
the top of cylinder bore. oversize.
Reboring the Cylinder 1. Position block solidly for either vertical or hori-
zontal honing. Use eitherdrill a pressor heavy-
Rebore and hone the engine whenever cylinder duty drill which operates at approximately 250
bore is worn, damaged, out of round, or if cylinder to 450 rpm.
taper exceeds specifications.A worn cylinder bore
should be resized the to smallest standard oversize 2. Follow hone manufacturer's instructions for the
diameter at which it will clean up. Thefinal finish and use of oil or lubricant on stones.Do not uselu-
bore diameter should thenbe obtained by honing. bricants with a dry hone.
Final bore diameter should equal the standard di- 3. Insert hone in bore and adjust stones to fit
ameter added tothe oversize. snugly to thenarrowestsection.Whenad-
justed correctly, the hone should not shakeor
CAUTIONimproperboring willresult in engine chatter in cylinder bore, butwill drag freely up
damage. Boring must be done by qualified and down when honeis not .running.
mechanics. 4. Connect the drillto the hone and start drill. Feel
After boring to the correct oversize cylinder bore di- out the bore for high spots, which causein-an
mension, piston and ring clearance should be ap- creased drag on stones. Move hone up and
propriate. There is no need to adjust to "fit" piston down in bore with short overlapping strokes
and rings. about 40 times per minute. Usually the bottom
of'cylinder must be worked out first because it
When reboring cylinder, takethe following precau- is smaller.Asthecylindertakesauniform
tions: diameter, move the hone up and downall the
1. Make sure the cutting tool is properly ground way through cylinder bore.
before usingit. 5. Check the diameter of the cylinder regularly
2. Be sure the top of engine block is smooth and during honing.A dial bore gauge is the easiest
deposit free. method but a telescoping gauge be used.
can
3. Clean the base of the boring bar before bar is Check size at six places
in bore: measure twice
set up. Deposits under the boring bar will cause at top, middle and bottom at 90-degree angles.
it to tilt and the cylinderwill be distorted after 6. Crosshatch formed by the stones should form
boring. an included angleof 23 degrees. This canbe
4. Make an initial rough cut, followed by a finish achieved by moving the rotating hone(250 to
cut. Then hone the cylinder boreto the speci- 450 rpm) up and down in cylinder bore about
fied oversize. 40 times per minute.
7. Cleancylinderborethoroughlywithsoap,
Honing Cylinder (Using Precision Hones) water and clean rags. A clean white rag should
Refer to hone manufacturer's recommended grit not become soiled on wall aftercleaning is
size to produce specified surface finish of 20 to complete. Do not use a solvent or gasoline
40 RMS. Too rough of a finish will wear out the rings since they wash oil from the walls but leave
and too smooth of a finish can retard piston ring metal particles.
seating. 8. Dry crankcase and coatit with oil.

11-17
Deglazing Cylinder Bore

Deglaze the cylinder bore if there are no scuff marks

and no wearor out of round beyond specifications,
before installing new rings. Deglazing gives a fine
finish, but does not enlarge cylinder diameter, so
the original pistons with new rings may still be used.

The reason for deglazing a cylinder is to provide

cavities to holdoil during piston ring break-in. PRODUCE CROSS AVOID THIS FINISH
HATCHSCRATCHES FOR
FAST RING SEATING
1. Wipe cylinder bore with a clean cloth that has
been dippedin clean, light engine oil. C-1091s

2. Use a brush type deglazing tool with coated FIGURE 11-32. CROSSHATCHING
bristle tipsto produce a crosshatch patternin
the cylinder bore. BALL BEARINGS
I

3. Use a slow speed drill to drive the deglazing The oil base holds one crankshaft bearing. The en-
tool. Move the deglazing tool up and downin gineblockcontainsonecamshaftbearing,one
crankshaft bearing and two balancer shaft bear-
the cylinder(10 to 12 complete strokes) rapidly
ings. Use a bearing puller to remove these bear-
enough to obtain crosshatch
a pattern ings.Cleanthebearingmountingsurfacesand
(Figure 11-32). press new bearings back in.

Improper cylinder cleaning wlll OIL SEAL

result Inenglne damage. Do not use gaso-
Use an oil seal remover to pry theoil seal out of the
line, solvents, or commercial cleaners to
engine block. Clean the oil seal resting surface and
clean cylinder bore. lubricate the surface before installing a oil new
seal.
Press the new oil seal into the engineuntil block
the
4. Cleancylinderborethoroughlywithsoap, oil seal is flush with the cylinder block boss. Lubri-
water and clean rags. Continue cleaning until a cate the lips of the oil seal with a light coating of
clean white rag shows no discoloring when grease. This providesinitial lubrication until engine
wiped throughthe cylinder bore. oil reaches the seal.

11-18