SERVICE MANUAL COMMAND PRO CV940-CV1000 VERTICAL CRANKSHAFT
Contents Section 1. Safety and General Information ............................................................................. Section 2. Tools & Aids ............................................................................................................. 1 2 Section 3. Troubleshooting ...................................................................................................... 3 Section 4. Air Cleaner and Air Intake System ...............................................................
1 Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.
Section 1 Safety and General Information WARNING WARNING WARNING ¡ȱ ȱȱȱęȱȱ Carbon Monoxide can cause severe ¡ȱ ȱȱȱęȱȱ severe burns. nausea, fainting or death. severe acid burns. ȱȱęȱȱȱȱ ȱȱ engine is hot or running. Avoid inhaling exhaust fumes, and never run the engine in a closed ȱȱęȱǯ Explosive Fuel! ȱȱ¡¢ȱĚȱȱ its vapors can explode if ignited.
Section 1 Safety and General Information (QJLQH ,GHQWL¿FDWLRQ 1XPEHUV When ordering parts, or in any communication involving an engine, always give the Model, ęǰȱȱ ȱ ǰȱȱĴȱ Ĝ¡ȱȱȱȱ¢ǯ 1 ,GHQWL¿FDWLRQ Decal ȱȱęȱȱȱȱȱǰȱ ȱǰȱĜ¡ȱȱȱȱǯȱ ȱ Figure 1-1. An explanation of these numbers is shown in Figure 1-2. )LJXUH (QJLQH ,GHQWL¿FDWLRQ 'HFDO /RFDWLRQ A. Model No.
Section 1 Safety and General Information Oil Recommendations Using the proper type, weight, and a consistent brand of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil Type Use high-quality detergent oil of API (American Petroleum Institute) Service Class SJ or higher.
Section 1 Safety and General Information Periodic Maintenance Instructions WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, ȱȱȱȱ DZȱŗǼȱ ȱȱȱȱǻǼǯȱŘǼȱ ȱȱǻȬǼȱĴ¢ȱȱȱĴ¢ǯ Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table.
Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in [ ]. 484.33 [19.068] 365.50 [14.390] 135.00 [5.315] 577.09 [22.720] 90.22 [3.552] 130.00 [5.118] 152.36 [5.999] 232.22 [9.143] 344.54 [13.565] 5.9 [.23] 325.30 [12.807] 14.7 [.58] 26.80 [1.055] 30.00 [1.181] 50.00 [1.969] 89.80 [3.536] 62.70 [2.468] (Optional Guard) 45.00 [1.772] 470.64 [18.529] 411.64 [16.206] 376.56 [14.825] 124.10 [4.886] 427.80 [16.843] 115.12 [4.532] 168.95 [6.652] 17.
Section 1 Safety and General Information *HQHUDO 6SHFL¿FDWLRQVï Power (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.) CV940......................................................................................................... 25.3 kW (34 HP) CV960......................................................................................................... 26.9 kW (36 HP) CV980....................................................................................................
Section 1 Safety and General Information Carburetor, Intake Manifold, and Air Cleaner ȱ ȱ ȱ ȱ Torque Using Sequence in Two Stages ................................................. ęȱȱŗŜǯşȱ ȉȱǻŗśŖȱǯȱǯǼ ȱ ȱ ę¢ȱȱŘŘǯŜȱ ȉȱǻŘŖŖȱǯȱǯǼ Carburetor/Air Cleaner Mounting Nut Torque.......................................... 7.9 N·m (70 in. lb.) ȱ ȱ ȱ ȱ ȱǻ ȱ ȱ Ǽ................... 9.9 N·m (88 in. lb.
Section 1 Safety and General Information Ğȱȱ ȱ ȱǻ ȱ ȱ Ǽ Running Clearance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 in.) 1 Flywheel End Main Bearing Journal O.D. - New ................................................................................................ 44.978/45.00 mm (1.770/1.771 in.) O.D. - Max. Wear Limit ........................................................................... 44.90 mm (1.767 in.
Section 1 Safety and General Information Grass Screen Hex Stud Torque ............................................................................................ 9.9 N·m (88 in. lb.) Mounting Screw Torque................................................................................. 9.9 N·m (88 in. lb.) Governor ȱ ȱ ĞȬȬ ȱ ȱ .......................... 0.025/0.087 mm (0.0009/0.0034 in.) Governor Cross Shaft O.D. New......................................................
Section 1 Safety and General Information Top Compression Ring-to-Groove Side Clearance .................................... 0.04/0.08 mm (0.0015/0.0031 in.) Middle Compression Ring-to-Groove Side Clearance .............................. 0.04/0.08 mm (0.0015/0.0031 in.) 1 Oil Control Ring-to-Groove Side Clearance................................................ 0.03/0.19 mm (0.0011/0.0074 in.) Top and Center Compression Ring End Gap New Bore ..................................................................
Section 1 Safety and General Information Valve Guide Reamer Size Standard .................................................................................................... 7.048 mm (0.2775 in.) 0.25 mm O.S. ............................................................................................. 7.298 mm (0.2873 in.) Nominal Valve Face Angle ............................................................................
Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% 1 Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Size 8-32 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 Grade 2 or 5 Fasteners Into Aluminum Grade 2 Grade 5 Grade 8 2.3 (20) 3.6 (32) 3.6 (32) 7.9 (70) 9.6 (85) 17.0 (150) 18.7 (165) 29.4 (260) 33.9 (300) 2.8 (25) 4.5 (40) 4.5 (40) 13.0 (115) 15.8 (140) 28.3 (250) 30.
1.
Section 2 Tools & Aids Section 2 Tools & Aids 2 ȱ¢ȱȱȱȱȱȱ¢ȱȱęȱ¢ǰȱǰȱȱ¢ȱǯȱ ¢ȱȱȱȱȱȱǰȱ¢ȱȱ¢ȱȱȱǰȱǰȱȱǷȱ ȱǰȱ¢Ȃȱ ȱ¢ȱȱȱȱȱȱ¢ȱȱȱ ǯ ȱȱȱȱȱȱȱȱǯȱȱ Separate Tool Suppliers: ȱ ȱ¢ȱ ȱ¢ǯȱ ȱ Śŗśȱ ȱ ǯ
Section 2 Tools & Aids Tools (Continued) Description Source/Part No.
Section 2 Tools & Aids Aids Description Source/Part No.
Section 2 Tools & Aids Special Tools You Can Make Flywheel Holding Tool ȱĚ¢ ȱȱȱȱȱȱȱȱȱȱ ȱĚ¢ ȱȱȱȱ ȱȱ ȱŘȬŗǰȱȱ ȱȱȱȱȱȱ ǯ ȱ ŗǯȱ ȱȱȱȬěȱ ǰȱȱȱȱ¡ȱ ȱȱȱȱȱȱȱ ǯȱ ȱ Řǯȱ ȱěȱ¢ȱȱȱȱǯȱ ȱ Řǯȱ ȱȱȱȱȱ Ȭ ȱȱȱȱěȱ ȱȱȱȱȱ ȱǰȱȱȱȱ ȱȱĚǯȱ ȱ řǯȱ ȱȱŗȱǯȱȱ ȱ ȱȱ
Section 3 Troubleshooting Troubleshooting Guide When troubles occur, be sure to check the simple ȱ ǰȱȱęǰȱ¢ȱȱȱȱȱȱ considered.
Section 3 Troubleshooting Engine Overheats ȱ ŗǯȱ ȱȦȱǰȱȱęǰȱȱȱ shrouds clogged. ȱ Řǯȱ ¡ȱȱǯ ȱ řǯȱ ȱȱȱǯ ȱ Śǯȱ ȱȱȱǯ ȱ śǯȱ ¢ȱǯ ȱ Ŝǯȱ ȱȱ¡ǯ Engine Knocks ȱ ŗǯȱ ¡ȱȱǯ ȱ Řǯȱ ȱȱȱǯ ȱ řǯȱ ȱȱȱǯ 4. Internal wear or damage.
Section 3 Troubleshooting ȱȱȱȱȱȱȱȱȱȱ the engine is reassembled and placed into operation. ȱȱȱȱȱȱȱ¢ȱ ȱ ȱȱȱȱȱȱǯ ȱ ȱ Basic Engine Tests ȱ Śǯȱ ȱȱȬěȱȱbefore stopping the engine. Crankcase Vacuum Test ȱȱȱȱȱȱȱȱ crankcase when the engine is operating.
Section 3 Troubleshooting Compression Test ȱȱȱȱȱȱȱȱ ȱ ǯȱ ȱ¢ȱȱȱȱ ¢ȱȱȱȱ ȱȱȱȱȱȱǯȱ ȱȱ ȱȱȱěǰȱȱȱĴȱȱ ȱȱȱ the test.
Section 4 Air Cleaner and Air Intake System Air Cleaners General These engines utilize a Heavy-Duty style air cleaner as shown in Figure 4-1, consisting of a cylindrical ǰȱĴȱȱȱȱȱȱ manifold. The air cleaner housing contains a paper element and inner element, designed for longer ȱǯȱ ȱ¢ȱȱ Ȧ ȱęȱ ȱȱȱȱȱȱȱȱęȱ in any way.
Section 4 Air Cleaner and Air Intake System 4. Do not wash the paper element and inner element or use compressed air, this will damage ȱǯȱ ȱ¢ǰȱȱȱȱ elements with new genuine Kohler elements as required. Handle the new elements carefully; ȱȱȱȱȱȱȱȱȱȱ damaged. ȱ śǯȱ ȱȱȱȱ ǰȱǰȱȱǰȱȱ that ejector area is clean. See Figure 4-4. Replace any damaged components.
Section 5 Fuel System and Governor Description This section covers the carbureted fuel system used on these engines. The governor system is covered at the end of this section.
Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. ȱęȱȱȱȱȱ¢ȱȱȱȱǰȱȱȱ ȱǯ Troubleshooting – Fuel System Related Causes Test Conclusion 1. Check the following: a. Make sure the fuel tank contains clean, fresh, proper fuel. b. Make sure the vent in fuel tank cap is open. c. Make sure the fuel valve is open. d.
Section 5 Fuel System and Governor 1. Disconnect the fuel lines from the inlet, outlet ȱȱęĴȱȱȱǯ Fuel Pump General These engines use either a pulse style fuel pump, or optional remote-mounted electric fuel pump ¢ǯȱ ȱ ȱśȬŗȱȱśȬŘǯȱ ȱȱȱ of pulse style pumps is created by the oscillation of positive and negative pressures within the crankcase. ȱȱȱĴȱȱȱȱȱ through the rubber hose connected between the pump and crankcase.
Section 5 Fuel System and Governor Troubleshooting Checklist When the engine starts hard, runs roughly or stalls at low idle speed, check the following areas before adjusting or disassembling the carburetor. • Make sure the air cleaner base and carburetor are securely fastened to the engine using gaskets in good condition. • Make sure the air cleaner element (including precleaner if equipped) is clean and all air cleaner components are fastened securely.
Section 5 Fuel System and Governor High Altitude Operation ȱȱȱȱȱȱȱŗśŖŖȱȱ ǻśŖŖŖȱĞǯǼȱȱǰȱȱȱ¡ȱȱȱȱ over-rich. This can cause conditions such as black, ¢ȱ¡ȱǰȱęǰȱȱȱȱȱ power, poor fuel economy, and poor or slow governor response. ȱȱȱȱěȱȱȱǰȱȱ high altitude jet kits are available.
Section 5 Fuel System and Governor Carburetor Adjustments Adjustment DZȱ ȱȱȱȱȱ¢ȱ Ğȱȱȱȱ ȱǯ The carburetor is designed to deliver the correct fuel-to-air mixture to the engine under all operating conditions. The main fuel jet is calibrated at the factory and is not adjustable*. The idle fuel adjusting needle is also set at the factory and normally does not need adjustment.
Section 5 Fuel System and Governor Governed Idle System ȱȱȱȱ¢ȱȱȱȱȱȱ desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. ȱȱ¢ȱȱȱ ȱȱ governor lever and the governed idle adjuster on the main bracket establishes the governed idle speed. See ȱśȬŝǯȱ 3.
Section 5 Fuel System and Governor Move and Hold Lever in "Full Throttle" Position separate the fuel bowl from the carburetor. Do ȱȱȱȱȱ ȱ Ȭ ǯȱ ȱ any remaining fuel into an approved container. Save all parts. Fuel can also be drained prior to ȱȱ¢ȱȦȱȱȱ ȱ ȱ ǯȱ ȱ ȱśȬŗŘǯȱ High Speed (RPM) Adjustment Screw Fuel Bowl Figure 5-11. Setting High Speed RPM (Air Cleaner Removed for Clarity).
Section 5 Fuel System and Governor Clip Float DZȱ ȱȱȱȱȱȱȱ surface, not the rubber gasket, if still Ĵǯ Inlet Needle Figure 5-14. Float and Inlet Needle Details. ȱ Ŝǯȱ ȱȱĚȱȱȱȱ ȱȱȱ seat and carburetor body. Install the new pivot ȱȱȱĚȱȱȱȱ ȱȱ ȱȱ ǯȱ ȱ ȱśȬŗśǯ Retaining Screw 5 Figure 5-16. Checking Float Height.
Section 5 Fuel System and Governor Fuel Bowl Main Nozzles Bowl Drain Screw Figure 5-18. Fuel Bowl Removed From Carburetor. DZȱ ȱ¢ȱȱȱȱ ȱ is not necessary unless the Fuel Solenoid Kit, or Fuel Bowl Kit (obtained separately), will also be installed. ȱȱŘǯȱ ȱȱĚȱȱ ȱȱĞȱȱȱȱ Ěǰȱǰȱȱȱǯȱ ȱ ȱśȬŗşǯȱ Discard all the old parts. The seat for the inlet needle is not serviceable, and should not be removed. Main Jets Figure 5-20.
Section 5 Fuel System and Governor śǯȱ ȱȱȱȱǻ Ǽȱȱ ȱ and spring from the carburetor. Discard the parts. DZȱ ȱȱȱ ȱȱȱ appropriate cleaning and installation of the parts in the overhaul kit. Further disassembly is not necessary. The ĴȱĞȱ¢ǰȱȱȱǰȱ idle fuel adjustment screws with limiter, and carburetor body, are non-serviceable items and should not be removed.
Section 5 Fuel System and Governor Retaining Screw ŗŜǯȱ ȱȱȱĚȱȱȱǰȱ carefully reinstall the fuel bowl, using new Ȭ ȱȱȱǯȱ ȱ ȱȱȱ original screws. Torque the screws to 2.5 ± 0.3 N·m (23 ± 2.6 in. lb.)ǯȱ ȱ ȱśȬŘŞǯ Pivot Pin Figure 5-26. Installing Float Assembly. ŗŚǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱ hangs vertically and rests lightly against the fuel inlet needle.
Section 5 Fuel System and Governor śǯȱ ȱȱ ȱ¡ȱǻ¢ȬǼȱȱȱȱ ȱȱĞȱȱ ȱȱȱȱ lever from the carburetor housing. Save the bushing to use as a driver for installing the new bushing. Discard the old lever. ȱ Ŝǯȱ ȱȱ ǯ ǯȱȱȱȱĞȱȱȱ required. 7.
Section 5 Fuel System and Governor ŗŘǯȱ ȱȱȱȱȱȱȱȱ the parts. Install the new cap. ¢ȱȱ ȱȱ ȱȱȱ reinstalling carburetors. Repair kits are available which include new gaskets and other components.
Section 5 Fuel System and Governor • Governor General The governor is designed to hold the engine speed constant under changing load conditions.
Section 5 Fuel System and Governor 3. Stop when the desired RPM speed is obtained. Hold Lever in "Full Throttle" Position High Speed (RPM) Adjustment Screw Figure 5-37. Adjusting High Speed RPM (Air Cleaner Removed for Clarity). 5.
Section 6 Lubrication System General This engine uses a full pressure lubrication system. This system delivers oil under pressure to the ĞǰȱĞǰȱȱȱȱȱ surfaces. In addition to lubricating the bearing ǰȱȱȱ¢ȱȱȱȱȱ ¢ȱȱĞǯ ȱȬĜ¢ȱȱȱȱȱȱȱȱ ǯȱ ȱȱȱȱȱȱĚ ȱȱȱ ǰȱȱȱ ȱȱȱȱȱ temperatures.
Section 6 Lubrication System Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil BEFORE EACH USE as DZ ȱ ŗǯȱ ȱȱȱȱȱǰȱȱȱȱȱ so the oil has had time to drain into the sump.
Section 6 Lubrication System ȱ řǯȱ ȱȱȱȱȱȱȱ21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ. ȱ Śǯȱ ȱȱǰȱ ȱ ȱȱȱȱȱ ¢ǰȱȱȱȃ Ȅȱȱȱȱǯȱ ȱȱ ȃ ȱ ¢ȄȱȱȱŜǯŗǯȱ ¢ȱȱȱȱ ȱȱȱȱȱȱǯ ȱ śǯȱ ȱȱȱęȱȦȱȱȱ securely. Figure 6-8. Optional Remote Mounted Oil Filter.
Section 6 Lubrication System Service Oil Cooler ȱȱȱȱ ȱȱȱȱ ȱȱȱ ǯȱŘȱȱ¢ȱǰȱ ȱȱȱȱęǯȱ ȱ ȱŜȬşǯ Oil Cooler Oil Cooler Figure 6-11. Cleaning Underside of Oil Cooler. Oil Sentry™ Figure 6-9. Oil Cooler. Inspect and clean the oil cooler every 150 hours of operationȱǻȱ¢ȱȱȱǼǯȱ ȱȱȱȱěǰȱȱȱȱȱȱȱȱ of debris.
Section 6 Lubrication System Installation ȱ ȱ ¢Ȝȱȱ ȱȱȱȱȱ ȱȱȱǯȱ ȱ ȱŜȬŗŘǯȱ ȱȱȱ ȱ ȱ ȱ ¢Ȝȱȱȱȱȱ ȱ ȱȱ1/8-27 N.P.T.F. pipe plug. ȱȱȱ ǰȱ ȱȱDZ ȱ ŗǯȱ ¢ȱȱȱ ȱ Ě®ȱǻ ® No.
6.
Section 7 Electrical System and Components This section covers the operation, service, and repair of the electrical system components. Systems and components covered in this section are: • ȱ Ȋȱ • ȱ Ȋȱ Spark Plugs Ĵ¢ȱȱ ȱ ¢ Electric Starter ȱ ȱ ¢ȱǻ ȱȱ Ǽȱ řǯȱ ȱȱȱȱȱ ȱȱǯȱ ȱ the gap to 0.76 mm (0.030 in.
Section 7 Electrical System and Components DZȱ ȱȱȱȱȱȱȱȱ normal conditions will have light tan or gray colored deposits. If the center electrode is not worn, a plug ȱȱȱȱȱȱȱȱȱȱȱ reused. ȱ DZȱ Ğǰȱ¢ǰȱȱȱȱ ȱȱȱ¢ȱȱȱȱ ǰȱȱȱǰȱ ȱǰȱȱȱ compression.
Section 7 Electrical System and Components ȱ Řǯȱ Battery General ȱŗŘȬȱĴ¢ȱ ȱŚŖŖȱȱȱȱǻǼȱȱ generally recommended for starting in all conditions. ȱȱ¢ȱĴ¢ȱȱĞȱĜȱȱȱ application is started only in warmer temperatures. ȱȱȱ ȱȱȱȱȱ ȱȱȱȱǯȱ ȱ actual cold cranking requirement depends on engine size, application, and starting temperatures.
Section 7 Electrical System and Components Electronic Ignition Systems ȱȱ ȱěȱ¢ȱȱȱ¢ȱȱȱǯȱ ȱ¢ȱȱȱȱȱ ȱ£ȱȱȱǯȱ ȱěȱȱȱ¢ȱȱȱȱ ¢ȱȱȱȱȱǯ The ¡ȱ ȱ ¢ȱ£ȱȱ ȱ ȱǻ Ǽȱȱǻ ȱ ȱŝȬřǼǯȱ ȱȱȱȱȱ ¢ȱȱȱȱę¡ȱȱȱ ȱȱȱȱȱȱȱȱȱȱȱ eng
Section 7 Electrical System and Components Kill Switch or ‘‘Off’’ Position of Key Switch Ignition Modules Spark Plug Magnet (0.28/0.33 mm) 0.011/0.013 in. Air Gap Flywheel Figure 7-4. Capacitive Discharge Fixed Timing Ignition System. ȱȱȱȱȱȱȱ¢ȱȱȱȱȱĚ¢ ȱȱȱȱȱȱȱȱ dead center. D1 C1 T1 SCS L1 Spark Plug L2 P S Figure 7-5. Capacitive Discharge (CD) Ignition Module Schematic.
Section 7 Electrical System and Components ǯȱ ȱȱȱȱǰȱȱȱ¢ȱ ȱȱȱȱǯȱ ȱȱ¢ȱ ǰȱ wires, connections, safety interlocks, etc. ǯȱ ȱȱȱȱȱȱȱ associated with the ignition or electrical ¢ȱȱȱǯȱ ȱȱȱȱ isolated until all testing is completed. ȱ ȱ ȱȱȱȱȱȱȱȱ gap. Repeat the procedure on the other cylinder.
Section 7 Electrical System and Components Troubleshooting DSAI Ignition Systems ȱ ȱȱ¢ȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱ ȱȱ¢ȱ Ȧȱȱȱǰȱȱǰȱ ǰȱȱȱȱȱ¢ȱȱ ǯȱ ȱ¢ȱȱ¢ȱ ȱȱȱ ȱ ǰȱȱȱ ȱ ȱȱȱȱȱȱ¢ȱ ȱȱȱȱȱȱǯ ȱȱȱȱȱĞȱȱ
Section 7 Electrical System and Components ȱ Řǯȱ ȱȱȱǰȱȱȱȱ ȱśśŖȬŜŖŖȱ ǰȱȱȱǻǼȱȱǯ ȱ řǯȱ ȱȱȱȱȱȱȱ¢ȱȱ ¢ȱȱȱȱ¢ǯ ǯȱ ȱȱ¢ȱȱȱȱȱȱ engine runs poorly, or existing plug condition ȱȱȱǰȱȱ ȱ spark plugs gapped at 0.76 mm (0.030 in.
Section 7 Electrical System and Components Battery Charging System General Most engines are equipped with a 15, 20, or 25 amp ȱȱ¢ǯȱ ȱ ȱŝȬşȱȱŝȬŗřǯȱ DZȱ ȱȱ ȱȱȱ avoid damage to the electrical system and components: ȱ Ȋȱ ȱȱȱĴ¢ȱ¢ȱȱǯȱ ȱȱ ǻȬǼȱȱ¢ȱȱǯ ȱ Ȋȱ ȱȱęȬȱȱȦȱ ȱ ȱȱȱȱȱ¢ȱȱ ȱȱȱȱ ȱ¢ȱȱ
Section 7 Electrical System and Components 15/20/25 Amp Regulated Charging System Figure 7-11. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with CD Ignition and Four Pin Connector. 7.
Section 7 Electrical System and Components 7 Figure 7-12. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector. 7.
Section 7 Electrical System and Components Figure 7-13. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector. 7.
Section 7 Electrical System and Components Stator ȱȱȱȱȱȱȱȱ ȱĚ¢ ǯȱ ȱȱȱȱ ȱŞȱȬȱ ȃ ¢Ȅȱȱ ȱŗŖȱȬȱȃ ¢Ȅȱȱȱ replacement is necessary. 5HFWL¿HU 5HJXODWRU ȱęȬȱȱȱȱȱȱ ȱ¢ǯȱ ȱ ȱŝȬŗŚǯȱ ȱȱǰȱ remove the two mounting screws, then disconnect the plug and ground lead.
Section 7 Electrical System and Components śǯȱ ȱȱȱȱȱȱ ȱȦ ȱ ȱȱȱǯȱ ȱȱȱ ȱ ǯȱ ȱȁȁ ȂȂȱȱȱȱȱȱ ȱȱȱȱȱȱ¢ȱȱȱȱ ǯȱ ȱ ȱŝȬŗŝǯȱ ȱdoes not represent the condition of the part. Ș DZȱ ȱĚȱȁȁ ȂȂȱȱȱȱȱ as a result of an inadequate ground lead connection. Make certain the connection location is clean and the clamp is secure.
Section 7 Electrical System and Components Troubleshooting Guide 15/20/25 Amp Battery Charging Systems ȱȱȱȱȱȱĴ¢ȱȱȱȱĴ¢ȱȱȱȱȱȱǰȱȱȱȱ ¢ȱȱȱ ȱȱȱȱ¢ȱȱ ȱȱĴ¢ǯ NOTE: ¢ȱ£ȱȱȱȱȱȱȱto ensure accurate readings.
Section 7 Electrical System and Components 5HFWL¿HU 5HJXODWRU DC Voltmeter (+) (-) Flywheel Stator Ammeter Battery Figure 7-20. Connections for Testing Charging System. Electric Starting Motors ȱȱȱȱĞȱȱȱȱ ǯȱ ȱ Ȭ ¢ȱȱĞȱȱȱ typically used.
Section 7 Electrical System and Components 7URXEOHVKRRWLQJ *XLGH ± 6WDUWLQJ 'LI¿FXOWLHV Problem Possible Fault Correction Battery ȱ ŗǯȱ ȱȱęȱ¢ȱȱȱĴ¢ǯȱ ȱ ǰȱȱȱ ȱĴ¢ȱȱ¢ǯ Wiring ȱ ŗǯȱ ȱȱȱȱȱȱǯ ȱ Řǯȱ ȱ ȱȱȱȱȱ ȱ¢ȱȱȱ insulation.
Section 7 Electrical System and Components Figure 7-23. Solenoid Removed from Starter. Figure 7-26. Removing Commutator End Plate Assembly. ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱ ȱǯȱ ȱ ȱŝȬŘŝǯ Figure 7-24. Removing Plunger. ȱ Śǯȱ ȱȱ ȱȱǻǼȱǯȱ ȱ ȱ ŝȬŘśǯ Figure 7-27. Starter Frame Removed. ȱ ŝǯȱ ȱȱȱȱȱȱȱ ȱȱȱȱȱǯȱ ȱ ȱŝȬŘŞǯ Figure 7-25. Removing Thru Bolts.
Section 7 Electrical System and Components ȱ Şǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯȱ ȱ ȱŝȬŘşǯ ȱ şǯȱ ȱȱȱ ȱȱȱȱ Ğǯȱ ȱ ȱŝȬŘşǯ ȱŗŗǯȱ ȱȱȱȱȱȱĞǯȱ Save the stop collar. DZȱ ȱ ȱȱȱȱȱǯ Figure 7-31. Removing Retaining Ring. Figure 7-29. Armature and Lever Removed.
Section 7 Electrical System and Components Inspection Commutator O.D. Drive Pinion ȱȱȱȱ ȱDZ ǯȱ ȱȱȱȱȱ ȱȱ damage. ǯȱ ȱȱ ȱȱȱȱȱȱ mechanism for nicks, or irregularities which could cause seal damage. ǯȱ ȱȱȱȱ¢ȱȱȱȱ housing and rotating the pinion. The pinion should rotate in one direction only.
Section 7 Electrical System and Components Brush Replacement Starter Service ȱȱȱȱȱȱȱȱȱǻŚǼǯȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ǰȱȱȱȱ necessary. ȱȱȱȱȱȱĞǯȱ ¢ȱ ȱȱȱȱȱǻȱ ȱŘǼȱ ǻ ȱ řŘŘ ȱȱ ȱ ȱ ȱřŘǼȱȱȱȱ ȱĞǯȱ ȱȱȱȱȱȱȱȱ wear or damage as required.
Section 7 Electrical System and Components řǯȱ ȱȱěȱȱǻǼȱ ȱȱȱ ȱȃěȄȱȱȱ ȱȱȱȦ ǯȱ ȱ ȱŝȬřşǯ ȱ ŝǯȱ ȱȱȱ ǰȱ ȱ¢ȱȱȱ grommet, into the matching recess of the drive end cap. The molded recesses in the grommet ȱȱȃȄǰȱȱȱȱ ȱ ȱȱȱȱǯȱ ȱ ȱŝȬŚŗǯ Thrust Washer Figure 7-39. Installing Thrust Washer.
Section 7 Electrical System and Components Thrust Washer Figure 7-43. Installing Thrust Washer.
Section 7 Electrical System and Components Extension. ǯȱ ȱȱȱ¢ȱ¢ȱȱȱ end housing, and carefully place the tool ǻ ȱ¡Ǽȱȱȱȱ ȱȱ¢ȱȱȱȱȱ ȱȱĞǯȱ ȱȱȱȱ ¢ȱ ȱȱȱȱȱ ǰȱȱȱȱǻƸǼȱȱ lead grommet in the cutout of the frame. See ȱŝȬŚŝǯ Figure 7-49. Torquing Brush Holder Screws. ŗřǯȱ Figure 7-47.
Section 7 Electrical System and Components Solenoid Test Procedure Solenoid Shift Style Starters ȱȱȱȱȱȱȱ ȱȱȱȱĴȱȱȱ ȱȱ terminal. Remove the mounting hardware and separate the solenoid from the starter for testing. Test 1. Solenoid Pull-In Coil/Plunger Actuation Test. ȱȱŗŘȱȱ ȱ¢ȱȱ ȱȱǯȱ ȱȱȱȱȱĚȱȱȃ ȦȄȱȱ on the solenoid.
Section 7 Electrical System and Components Test 4. Solenoid Hold-In Coil/Contact Continuity Test. ȱȱȱȱȱȱȱȱ ¡Ř ȱǰȱȱ connect the two ohmmeter leads to the two large post ǯȱ ȱȱȱȱǻřǼȱȱȱ ȱ¢ǯȱ ȱ ȱŝȬśŚǯȱ ȱȱȱ indicate continuity, if no continuity is indicated the ȱȱȱǯȱ ȱȱȱȱ ȱęȱǯ Plunger Pushed "In" VOM Meter Leads 12 volt Test Leads Figure 7-54.
Section 8 Disassembly WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, ȱȱȱȱ DZȱŗǼȱ ȱȱȱȱǻǼǯȱŘǼȱ ȱȱǻȬǼȱĴ¢ȱȱȱĴ¢ǯ Clean all parts thoroughly as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage.
Section 8 Disassembly Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter ȱ ŗǯȱ ȱȱȱęȱȱȱǯȱ ȱȱ ȱȱȱęǯȱ ȱ ȱŞȬŘǯ 3. Allow ample time for the oil to drain from the crankcase. 5HPRYH 0XIÀHU ȱ ŗǯȱ ȱȱ¡ȱ¢ȱȱĴȱ hardware from the engine. Remove Cylinder Shrouds and Blower Housing 1.
Section 8 Disassembly 3. Remove the lower mounting screw and pull the ȱęȱȱȱȱȱǯ Mounting Nuts Vent Hose Ground Lead Oil Fill Tube Breather Hose Lower Mounting Screw Location Figure 8-7. Removing Oil Fill Tube. Figure 8-9. Air Cleaner Mounting Details. 3. Remove the two screws securing the air cleaner and main control bracket to the intake manifold ǯȱ ȱ ȱŞȬŗŖǯ Remove Electric Starter Motor 1. Disconnect the leads from the starter.
Section 8 Disassembly Remove Fuel Pump WARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱ ȱȱ¢ȱȱȱǰȱȱ ȱǰȱȱǰȱ ¢ȱȱȱȱ Ěǯȱ ȱȱęȱȱȱȱ ȱȱȱȱȱȱ running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent.
Section 8 Disassembly Control Bracket Lower Mount Figure 8-15. Removing Control Bracket. ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱ ȱȱȱȱĞǯȱ ȱ ȱŞȬŗŜǯ Figure 8-17. Removing Carburetor. 4. Remove the carburetor gasket. 5. The carburetor and linkages can be separated as necessary. Governor Lever Remove Oil Sentry™ (If Equipped) 1. Disconnect the lead from the Oil Sentry™ switch. 2. Remove the Oil Sentry™ switch from the oil pan. ȱ ȱŞȬŗŞǯ 8 Figure 8-16.
Section 8 Disassembly Remove Oil Cooler Valley %DIÀH 1. Remove the two oil cooler mounting screws. Do ȱȱ¢ȱ ȱǻȱǼǯȱ ȱ ȱŞȬŘŘǯ )LJXUH 5HPRYLQJ 9DOOH\ %DIÀHV 2. Remove the four screws securing each of the ȱ¢ȱĝȱȱǯȱ ȱ ȱŞȬŘŖǯ Figure 8-22. Removing Oil Cooler Mounting Screws. 2.
Section 8 Disassembly c. Remove the rubber valve and spring from the ǯȱ ȱ ȱŞȬŘŝǯ Oil Filter Housing Cup Mounting Screw Rubber Valve Spring Figure 8-24. Removing Oil Filter Housing. ȱȱ ȱ¢ȱȱȱȱęȱȱ assembly requires individual servicing. ȱ ǯȱ ȱȱȱȱȱȱȱȱęȱ ȱȱȱśȦŗŜȈȱ ȱ Ȧǯȱ ȱ ȱŞȬŘśǯ Figure 8-27. Rubber Valve and Spring Removed from Cup.
Section 8 Disassembly Remove Grass Screen and Cooling Fan ȱ ŗǯȱ ȱȱ ǰȱĴȱ ǰȱȱ¡ȱ ȱȱȱȱǰȱěǰȱȱ ȱȱȱȱĚ¢ ǯȱ ȱ ȱŞȬŘşȱȱ ŞȬřŖǯ Fasteners Figure 8-31. Removing Flywheel Fastener Using Holding Tool. ȱ Řǯȱ ȱȱ¡ȱĚȱ ȱȱ ǯ Figure 8-29. Removing Grass Screen Fasteners.
Section 8 Disassembly 2. Remove the mounting screws securing the ęȬȱȱȱȱȱ assembly. Note the location of the ground lead. ȱȱęȬȱȱȱȱǰȱ it may remain mounted to the backing shroud ¢ǯȱ ȱ ȱŞȬřřǯ Wiring Harness Molded Clips Ground Lead 5HFWL¿HU Regulator Plug Figure 8-35. Removng Wiring Harness. Remove Backing Shroud Assembly 1. Remove the four screws securing the backing shroud assembly to the crankcase.
Section 8 Disassembly Remove Valve Covers 1. Remove the screw and grommet securing each valve cover. 2. Remove the valve cover and gasket from each cylinder head. Note the locations of individual ȱȱȱ¢ȱȱěǯȱ ȱ ȱŞȬřŞǯ Spacer Washers Figure 8-40. Removing Cylinder Head Fasteners. 3. Mark the position of the push rods as either ȱȱ¡ȱȱ¢ȱŗȱȱŘǯȱȱ ȱ rods should always be reinstalled in the same positions. Figure 8-38. Removing Valve Covers.
Section 8 Disassembly Figure 8-42. Removing Hydraulic Lifters. Figure 8-45. Removing Valves with Valve Spring Compressor. 3. Once the valve spring is compressed, remove the ȱǯȱ ȱ ȱŞȬŚŜȱȱŞȬŚŝǯ Match Numbers • • • • • • Valve spring keepers Valve spring retainers Valve springs Valve spring caps Intake and exhaust valves (mark position) Valve stem seals Figure 8-43. Match Numbers on Cylinder Barrel and Heads. 8 Disassemble Cylinder Heads 1.
Section 8 Disassembly Filter Valve Stem Seals Figure 8-49. Removing Breather Filter. Figure 8-47. Valve Stem Seals. NOTE: These engines use valve stem seals on the intake and exhaust valves. Use a new seal whenever valves are removed, or if the seal is deteriorated in any way. Never reuse an old seal. Remove Oil Pan Assembly ȱ ŗǯȱ ȱȱȱ¡ǯȱĚȱ ȱȱ ȱȱȱȱȱǯȱ ȱ ȱŞȬśŖǯ 4. Repeat the above procedure for the other cylinder head.
Section 8 Disassembly Figure 8-52. Removing Oil Pan. Oil Pump Assembly The oil pump is mounted to the inside of the oil pan. If service is required, refer to the service procedures ȱȁȁ ȱ ȱ ¢ȂȂȱȱ ȱşǯ Figure 8-54. Removing Connecting Rod Screws.
Section 8 Disassembly 2. Carefully remove the connecting rod and piston ¢ȱȱȱ¢ȱǯȱ ȱ ȱŞȬśŜǯ 1. Remove the locking tab thrust washer and note orientation. 2. Using a screwdriver, carefully pry up to unseat governor gear assembly from the governor gear Ğǯȱ ȱȱȱȱȱȱ ȱ¢ǯȱ ȱ ȱŞȬśŞǯ Governor Gear Figure 8-56. Removing Piston/Connecting Rod Assemblies. 3. Repeat the above procedures for the other connecting rod and piston assembly.
Section 8 Disassembly Remove Lifter Feed Chamber Cover and Gaskets ȱ ŗǯȱ ȱȱȱ ȱȱȱĞȱȱ chamber cover, and gaskets. Carefully separate ȱȱȱȱǯȱ ȱ ȱŞȬŜŖǯ Screws Cover Removal of Main Bearings DZȱ ¢ ȱȱ ȱȱȱȱȱ should only be removed if replacement is required due to wear.
8.
Section 9 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor & External Governor, Section 5 Ignition, Charging & Electric Starter, Section 7 Clean all parts thoroughly. Only clean parts can be accurately inspected and gauged for wear or damage.
Section 9 Inspection and Reconditioning NOTE: If the crankpin is reground, visually check to ȱȱȱęȱȱ¢ȱ ȱ the crankpin surface. See Figure 9-1. Self-Tapping Screw High Point from Fillet Intersections Flat Washer Plug The Fillet Must Blend Smoothly with the Bearing Journal Surface Crankshaft 45° Minimum Figure 9-2. Removing Crankpin Plug. This Fillet Area Must Be Completely Smooth Figure 9-1. Crankpin Fillets.
Section 9 Inspection and Reconditioning accomplished at a drill speed of about 250 RPM and ŜŖȱȱȱǯȱ Ğȱȱȱȱȱ hone, proceed as follows: ȱ ŗǯȱ ȱȱȱȱȱĞȱǰȱȱ so the stones are in contact with the cylinder ǯȱ ȱȱȱȱĴȬȱȱȱ recommended. 2. With the lower edge of each stone positioned even with the lowest edge of the bore, start drill and honing process.
Section 9 Inspection and Reconditioning 2. Use an inside micrometer, telescoping gauge, or bore gauge and measure the cylinder bore. Take the measurement approximately 63.5 mm (2.5 in.) below the top of the bore and perpendicular to the piston pin. ȱ řǯȱ ȬȬȱȱȱȱěȱ ȱ the bore diameter and the piston diameter (step 2 minus step 1).
Section 9 Inspection and Reconditioning EXHAUST VALVE E INTAKE VALVE F E F C G G D INT H B A H EXH D Dimension Intake Exhaust A Seat Angle Şşǚ Şşǚ B Seat Taper 30° 30° C Guide Depth ŞǯśȱȱǻŖǯřřŚȱǯǼ ŞǯśȱȱǻŖǯřřŚȱǯǼ D Guide I.D. ŝǯŖřŞȦŝǯŖśŞȱȱǻŖǯŘŝŝŗȦŖǯŘŝŝşȱǯǼ ŝǯŖřŞȦŝǯŖśŞȱȱǻŖǯŘŝŝŗȦŖǯŘŝŝşȱǯǼ E ȱ ȱ řŞǯŜŘśȦřŞǯŜŞśȱȱǻŗǯśŘŖŜȦŗǯśŘřŖȱǯǼ řŗǯŜŘśȦřŗǯŞŘśȱȱǻŗǯŘŚśŖȦŗǯŘśŚşȱǯǼ F Valve Face Angle 45° 45° G Valve Margin (Min.) 1.0 mm (0.0393 in.) 1.
Section 9 Inspection and Reconditioning Normal:ȱ ȱĞȱȱȱȱȱȱȱ can be reconditioned and reused if the face and margin are in good shape. If a valve is worn to where the margin is less than 1/32" do not reuse it. The valve shown was in operation for almost 1000 hours under controlled test conditions. Leakage: A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only. Bad Condition: The valve depicted here should be replaced.
Section 9 Inspection and Reconditioning Excessive Combustion Temperatures: The white deposits seen here indicate very high combustion temperatures, usually due to a lean fuel mixture. Stem Corrosion: Moisture in fuel or from condensation are the most common causes of valve stem corrosion. Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures. Replace corroded valves.
Section 9 Inspection and Reconditioning Valve Guides ȱȱȱȱȱ ȱ¢ȱęǰȱȱ ȱ not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a splitball gauge, measure the inside diameter of the guide.
Section 9 Inspection and Reconditioning Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter the combustion chamber ȱȱȱȱȱ ȱȱǯȱ ȱȱ consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition. Oil control is also lost when ring gaps are not staggered during installation.
Section 9 Inspection and Reconditioning Replacement pistons are available in STD bore size, and in 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize. Replacement pistons include new piston ring sets and new piston pins. Replacement ring sets are also available separately for STD, 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize pistons. Always use new piston rings when installing pistons. Never use old rings. Some important points to remember when servicing piston rings: 1.
Section 9 Inspection and Reconditioning Piston Ring Dykem Stripe End Gap Service replacement connecting rods are available in STD crankpin size and 0.25 mm (0.010 in.) undersize. Always refer to the appropriate parts information to ensure that correct replacements are used.
Section 9 Inspection and Reconditioning Oil Pan Assembly Inspection Inspect the oil seal in the oil pan and remove it if it is worn or damaged. Refer to ‘‘Install Oil Pan Oil Seal’’ in Section 10 for new oil seal installation. Inspect the main bearing surface for wear or damage ǻȱȱ ȱŗǰȱȃ ęǰȱ ǰȱȱ ȱ ȱ ȄǼǯȱ ȱȱȱȱȱ pan assembly if required.
Section 9 Inspection and Reconditioning 4. Install the O-Ring in the groove of the oil pump housing. Use a small quantity of grease to hold it in place. See Figure 9-16. 7. Check the alignment of parts and torque the ȱȱȱ ȱȱęȱȱȱ ȱ ȱȱ ȱşȬŗŞǯ ȱ ȱ ȱȱ¡ǯȱĚȱ ȱȱ DZ a. Install fastener into location No. 1 and lightly tighten to position the pump. O-Ring b. Install fastener into location No.
9.
Section 10 Reassembly General NOTE: Make sure the engine is assembled using ȱęȱȱǰȱȱ ǰȱȱǯȱ ȱȱȱ ęȱȱȱȱȱ ȱ ȱǯȱ ¢ȱȱ ȱǯȱ ¢ȱȱ ȱȱȱȱȱȱȱȱȱ ȱȱ¢ǰȱȱȱ ȱȱ ®ȱȱęȱȱǯȱ ȱȱȱȱȱ¢ȱȱȱȱȱ ȱȱȱȱȱȱȱǯȱ ȱȱ
Section 10 Reassembly ȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯ ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱ ǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱĴȱ ȱȱǯȱ ȱ ȱŗŖȬŘȱȱŗŖȬřǯ Mounting Screws Lifter Feed Chamber Cover Gasket Figure 10-4. Lifter Feed Chamber Assembly Details.
Section 10 Reassembly Main Bearing Řǯȱ ȱȱȱȱĞȱ ȱǰȱȱȱ ¢ȱȱȱȱĞȱȱȱȱȱ ȱȱ ȱȱ ȱŗŖȬŗŖǯ Notch Governor Gear Shaft Figure 10-6. Installed Main Bearing.
Section 10 Reassembly Śǯȱ Ĵȱȱȱ¢ȱȱȱȱĞȱȱȱ ȱȱȱȃȄȱȱǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱȱȱȱȱȱ ȱȬǰȱ¢ȱȱȱȱȱ ® ǯȱŘŜŜȱȱǰȱȱȱ ȱȱȱ ǯȱ ȱȱ ȱȱ2.2 N·m (20 in. lb.)ǯȱ ȱ ȱŗŖȬŗŘǯ Governor Gear Assembly Figure 10-14. Installing Governor Gear Assembly. Figure 10-12. Installed Governor Shaft Yoke.
Section 10 Reassembly Install Connecting Rods with Pistons and Rings DZȱ ȱ¢ȱȱȱȱȱǯȱ ȱȱȱȱȱǰȱȱ ȱȱȱȱȱȱȱ¢ȱ ȱȱ¢ȱȱȱ¢ǯȱ Do notȱ¡ȱȱȱȱȱȱ ǯ DZȱ ȱȱȱȱȦȱ ȱȱȱȱȱȱ¡¢ȱ ǯȱ ȱȱȱȱ ¡ȱ ȱȱǯȱ ȱȱȱ ȱȱȱ
Section 10 Reassembly Timing Marks Figure 10-20. Torquing Connecting Rod End Cap Screws. Figure 10-22. Aligning Crankshaft and Camshaft Timing Marks.
Section 10 Reassembly ȱ śǯȱ ȱȱȱ¢ȱȱȱȱȱ ȱȱ¢ǯ Install Oil Pan Seal and Main Bearing Oil Seal Main Bearing ȱȱȱȱȱȱ ȱȱȱǰȱ ȱ ȱȱȱȱȱȱȱǯ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱȱ ǰȱ¢ǰȱȱȱȱȱȱǯ Řǯȱ ȱȱ ȱȱ ȱȱȱȱȱ ŗŘȱȂȱǰȱȱȱȱȱǯȱ ȱȱȱȱȱ¢ȱȱȱȱ Ěǯȱ ȱ
Section 10 Reassembly Install Oil Pan Assembly ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱǰȱ¢ǰȱȱȱȱ¢ȱȱȱ ȱǯȱ ȱȱ ȱ Ȭ ȱȱȱȱǯȱ ȱ ȱŗŖȬŘŝǯ O-Ring Figure 10-29. Installing Oil Pan. Ŝǯȱ ȱȱȱ¡ȱĚȱ ȱȱ ȱȱȱȱȱǯȱ ȱȱȱ ȱȱȱ ȱȱ ȱŗŖȬřŗȱȱ 24.4 N·m (216 in. lb)ǯ Figure 10-27. O-Ring Installed.
Section 10 Reassembly Check Crankshaft End play Install Breather ȱ ŗǯȱ ȱȱȱȱ ǰȱȱȱȱȱȱ ȱȱȱĞȱȱ¢ȱȱȱ ęȱȱȱ ȱŗǯȱ ȱ ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱȱǰȱȱȱȱ¢ȱ ȱȱǯȱDo not ȱȱȱȱȱ ȱȱȱǯȱ Řǯȱ ȱȱȱȱȱȱ ǯȱ ȱ ȱŗŖȬřřǯȱ ȱȱȱȱ ¢ȱȱȱ
Section 10 Reassembly ȱ řǯȱ ȱȱȱ¡ȱĚȱ ǰȱȱȱ ȱȱȱ ȱȱ ȱŗŖȬřśȱȱ 5.7 N·m (51 in. lb.)ǯ 1 4 DZȱ ȱȱȱȱ¢ȱȱȱ ȱȱȱȱȱȱȱ ȱǯȱ ȱ ȱŗŖȬřŝǯ 3 2 Figure 10-35. Breather Assembly Fastener Torque Sequence.
Section 10 Reassembly DZȱ ¢ȱĞȱȱ ¢ȱȱ ȱȱȱȱȱȱȱ ¢ǯȱ ȱ¡ȱĞȱȱ ȱȱȱȱĞȱȱȱ ȱȱ ȱȱȱĞȱȱ ȱȱȱȱȱȱȱǯȱ ȱ ¢ȱȱȱȱȱȱ ȱȱȱȱȱȱ¢ȱ ǯȱ ȱ ȱŗŖȬŚŖǯ Valve Stem Seals Figure 10-41. Valve Stem Seals.
Section 10 Reassembly Spacer Washers Figure 10-43. Installing Valves with Valve Spring Compressor. Figure 10-45. Washers and Spacer Locations on Cylinder Head Screws. Install Cylinder Heads ȱ Śǯȱ ȱȱ¡ȱĚȱ ȱȱ ȱDzȱęȱ ȱ22.6 N·m (200 in. lb.)ǰȱę¢ȱȱ45.2 N·m (400 in. lb.
Section 10 Reassembly ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱ ¢ȱȱȱȱȱ¢ǯȱ ȱȱȱ ȱȱ¢ȱȱȱȱ ǯȱŘȱǻ Ǽȱ ȱȱȱȱ29.3 N·m (260 in. lb.
Section 10 Reassembly ȱ ȱDZ ȱ ȱ ǯȱ ȱ ȱȱȱȱȱȱȱ ȱ ȱǯ ȱ ȱ ǯȱ ¢ ¢ȱȱĞȱ ȱȱȱ ȱǛŗȱȱ ȱ ¢ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱȱȦȱȱȱȱȱ ȱ Ğȱȱȱ¢ȱȱȱǯȱȱ ȱ¢ȱȱǰȱȱȱĞȱȱȱ ȱǯȱ ȱ řǯȱ Ȭȱ ĞDZȱ ¢ȱ ȱȱȱ ȱȱȱȱȱȱǰȱȱȱȱ ĞȱȱȈĴȈȱȱȱǯȱ ȱ ȈȈȱȱ¢ȱ
Section 10 Reassembly Check Assembly Important: ȱȱȱȱȱȱȱ ¢ȱȱȱȱǯȱ ȱȱȱ ǻȱȱȱȱǼǰȱȱȱȱȱ ȱ ȱȱȱȱ¡ȱȱęȱȱȱ ¢ȱȱȱȱȱ ȱȱȱ ȱ ȱĞȱȱȱ ǰȱȱȱȱ ȱǯ Turn Adjuster Rotate Push Rod and Feel for Drag Figure 10-53. Establishing the "0" Lash Point.
Section 10 Reassembly Install Spark Plugs ȱ ŗǯȱ ȱ ȱ ®ȱ ŗŖ ȱǻȱǼȱ ȱǯ Cup ȱ Řǯȱ ȱȱȱȱ0.76 mm (0.030 in.)ǯ ȱ řǯȱ ȱ ȱȱȱȱȱ24.4-29.8 N·m ǻŗŞȬŘŘȱĞǯȱǯǼǯȱ ȱ ȱŗŖȬśŝǯ Valve Spring Figure 10-59. Installing Valve and Spring to Cup. Spring Figure 10-57. Installing Spark Plugs. Install Oil Filter Housing Assembly ȱȱȱęȱȱȱȱ ¢ǯȱ ȱ ȱŗŖȬśŞȱȱŗŖȬŜřǯ Figure 10-60.
Section 10 Reassembly Nipple Cup (with Spring and Valve) Řǯȱ ȱȱęȱȱ¢ȱȱȱ ȱȱ Şȱ¡ȱȱ ǯȱ ȱȱȱȱ ȱȱĚȱȱȱȱ Ȭ ȱȱ ȱǯȱ ȱȱ ȱȱ24.4 N·m (216 in. lb.)ǯȱ ȱ ȱŗŖȬŜśǯ Mounting Screw Housing Figure 10-62. Installing Nipple into Cup and Oil Filter Housing. Oil Filter Housing Figure 10-65. Torquing Oil Filter Housing.
Section 10 Reassembly Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱ ȱȱȱȱȱȱȱȱ ǯȱ ȱȱȱ ȱȱ ȱǰȱ ęȱȱ16.9 N·m (150 in. lb.)ǰȱę¢ȱȱ 22.6 N·m (200 in. lb.)ǰȱȱȱȱ ȱ ȱ ȱŗŖȬŜŞǯ Figure 10-69. Lower Oil Cooler Hose Details. Řǯȱ ȱȱȱȱ¢ȱȱȱ ȱȱȱ ȱȱȱ Ŝȱ ǯȱ ȱ ȱȱ ȱȱȱȱȱȱ 10.7 N·m (99 in. lb.
Section 10 Reassembly Tabs ŝǯȱ ȱȱęȬȱȱȱȱ ȱ ȱȱȱęȱȃǯȄȱ Ĵȱȱ ȱȱȱȱȱ ȱȱ ǰȱȱ ȱȱȱ ȱȱ 2.0 N·m (18 in lb.)ǯȱ ȱȱȱȱȱ ęȬǯȱ ȱ ȱŗŖȬŝŚǯ Ground Lead Mounting Screws 5HFWL¿HU Regulator Figure 10-71. Installing Stator.
Section 10 Reassembly Figure 10-76. Clean and Dry Flywheel Hub. Figure 10-78. Installing and Torquing Flywheel Fastener.
Section 10 Reassembly śǯȱ ȱȱ0.30 mm (0.012 in.)ȱĚȱȱȱ ȱȱȱȱȱȱǯȱ ȱ ȱŗŖȬŞŖǯȱ ȱȱȱȱȱ ȱȱȱȱȱĴǯȱ ȱȱ ȱ ȱȱ ȱȱȱȱȱȱȱ ȱȱȱȱǯ Feeler Gauge Figure 10-80. Setting Ignition Module Air Gap.
Section 10 Reassembly Install Oil Cooler ŗǯȱ ȱȱ ȱȱȱȱ ȱȱȱ ęȱȱȱȱȱǯȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŖȬŞŚǯ ȱ ȱ ȬȱȱȱȱȱǼǯȱ ȱȱȱ¡ȱȱȱȱȱȱ ȱȱȱȱĚ¢ ǯȱ ȱȱȱ ȱ9.9 N·m (88 in. lb.
Section 10 Reassembly ȱ řǯȱ ȱȱȱȱȱǯȱ ȱ ȱ ŗŖȬŞŞǯ ȱ Řǯȱ ĴȱȱĴȱȱȱȱȱȱȱ ȱȱȱ¢ǯȱ ȱ ȱȱ ȱȱȱĴȱȱȱ ¢ǯȱ ȱ ȱŗŖȬşŖǯȱ Gasket (Tab "Up") Carburetor Throttle Linkage Figure 10-88. Connecting Leads to Starting Motor.
Section 10 Reassembly Install Control Bracket and Air Cleaner Assembly ȱ ŗǯȱ ȱȱȱȱ¢ȱȱ ȱȱȱȱǰȱȱȱ ȱǯȱ ȱ ȱŗŖȬşŘǯ Control Bracket Mounting Locations 3 1, 5 2 4 Figure 10-94. Torque Sequence for Air Cleaner Mounting Nuts. Figure 10-92. Installing Control Bracket.
Section 10 Reassembly Control Cable Clamp Locations (B) Push-on Nut (B) Choke Linkage Links Connected Here Figure 10-96. Installing Choke Link and Push-On Nut. Figure 10-98. Throttle/Choke Linkage Details for "Inner Pull" Actuation.
Section 10 Reassembly Adjusting Governor ȱ ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱ¢ȱȱȱȱȱȱ ȱȱĞǯȱ ȱ ȱŗŖȬŗŖŖǯ Governed Idle Spring Governor Spring Governor Lever Figure 10-102. Governor Springs Installed. Brushed/ Knurled Area Governor Spring/RPM Chart Figure 10-100. Brushed/Knurled Area.
Section 10 Reassembly ȱ Řǯȱ ȱȱȱ ȱȱȱȱ ȱ ¢™ ǯ Mounting Screws Install Blower Housing and Cylinder Shrouds ŗǯȱ ȱȱȱǰȱ ȱȱ ȱ ȱ Ȭ ǰȱȱȱǯȱ ȱ ȱȱ ȱ ȱ ǯȱ ȱȱ ȱȱ4.0 N·m (35 in. lb.)ǯȱ ȱ ȱŗŖȬŗŖśǯ ȱ Řǯȱ ĴȱȱĞȱȱǻȱǼȱȱȱ ȱȱ ȱȱ ǯȱ ȱȱ ȱ ȱ9.9 N·m (88 in. lb.)ǯȱ ȱ ȱŗŖȬŗŖśǯ Cylinder Shrouds Figure 10-107.
Section 10 Reassembly Install Oil Filter and Add Oil to Crankcase ȱ ŗǯȱ ȱȱȱȱǯȱ ȱ ȱŗŖȬŗŖşǯȱ ȱȱȱȱŘŗǯŚȱ ȉȱǻŗśǯŝȱĞǯȱǯǼǯ DZȱ ȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱ ęȱȱȱȱǯ Figure 10-111. Reinstall the Dipstick in Tube. Connect Spark Plug Leads ȱ ŗǯȱ ȱȱȱȱȱȱǯȱ ȱ ȱ ŗŖȬŗŗŘǯ Drain Plug (Starter Side Shown) Figure 10-109. Reinstall Oil Drain Plugs.
Section 10 Reassembly Testing the Engine ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱȱ ǯ ȱ ŗǯȱ ȱȱȱȱȱȱȱǯȱ ȱȱȱ ȱǯȱ ȱȱȱȱȱȱ ȱȱȱȱȱǻŘŖȱȱȱǼȱȱ ǯȱ ȱȱȱȱȱȱŘȬřȱǰȱ ȱśȬŜȱȱȱ ȱȱȱ ǯȱ ȱȱȱ¡ȱĴȱ ȱ¢ȱǻȱǼǯ Řǯȱ ȱȱȱ
10.
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