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Download Kohler CV1000 User's Manual
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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 ......................................................................... 4 Section 5. Fuel System and Governor..................................................................................... 5 Section 6. Lubrication System ................................................................................................. 6 Section 7. Electrical System and Components ...................................................................... 7 Section 8. Disassembly............................................................................................................. 8 Section 9. Inspection and Reconditioning .............................................................................. 9 Section 10. Reassembly............................................................................................................ 10 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. CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related. For Your Safety! These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others. WARNING WARNING Accidental Starts can cause Rotating Parts can cause severe severe injury or death. injury. Disconnect and ground spark plug leads before servicing. Stay away while engine is in operation. Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) Ĵ¢ȱȱȱĴ¢ǯ Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. WARNING Hot Parts can cause severe burns. Do not touch engine while operating ȱȱĞȱǯ Hot Parts! Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running - or immediately Ğȱȱȱȱěǯȱȱȱ the engine with heat shields or guards removed. 1.1 Section 1 Safety and General Information WARNING WARNING WARNING ¡ȱȱȱȱęȱȱ Carbon Monoxide can cause severe ¡ȱȱȱȱęȱȱ 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. Store gasoline only in approved containers, in well ventilated, unoccupied ǰȱ ¢ȱȱȱȱĚǯȱ ȱȱęȱȱȱȱ ȱȱ engine is hot or 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. Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the ȱȱȱȱȱȱęȱ area. CAUTION WARNING Electrical Shock can cause injury. Do not touch wires while engine is running. Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. Flammable Solvents! Carburetor cleaners and solvents are ¡¢ȱĚǯȱȱǰȱ Ěǰȱȱȱȱȱȱ away from the area. Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. 1.2 Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. ȱĴ¢ȱ¢ȱȱȱ ȱ ventilated area. Keep sources of ignition away. Explosive Gas! Ĵȱȱ¡ȱ¢ȱ gas while being charged. To prevent a ęȱȱ¡ǰȱȱĴȱ¢ȱ in well ventilated areas. Keep sparks, ȱĚǰȱȱȱȱȱ ȱ ¢ȱȱȱĴ¢ȱȱȱ ǯȱȱĴȱȱȱȱȱ of children. Remove all jewelry when ȱĴǯ Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. Section 1 Safety and General Information (QJLQH,GHQWL¿FDWLRQ1XPEHUV When ordering parts, or in any communication involving an engine, always give the Model, ęǰȱȱȱǰȱȱĴȱ Ĝ¡ȱȱȱȱ¢ǯ 1 ,GHQWL¿FDWLRQ Decal ȱȱęȱȱȱȱȱǰȱ ȱǰȱĜ¡ȱȱȱȱǯȱȱ Figure 1-1. An explanation of these numbers is shown in Figure 1-2. )LJXUH(QJLQH,GHQWL¿FDWLRQ'HFDO/RFDWLRQ A. Model No. C V 980 S Command Engine Version Code Vertical Crankshaft S = Electric Start Numerical Designation B. Spec. No. CV940-0001 CV960-0001 CV980-0001 CV1000-0001 Complete Spec Number (Incorporating Model No. with Variation No. of Basic Spec.) C. Serial No. Year Manufactured Code Code Year 37 2007 38 2008 39 2009 3705810334 Factory Code )LJXUH([SODQDWLRQRI(QJLQH,GHQWL¿FDWLRQ1XPEHUV 1.3 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. Select the viscosity based on the air temperature at the time of operation as shown in the following table. Refer to Section 6 - “Lubrication System” for detailed procedures on checking the oil, changing the oil and ȱȱȱęǯ Fuel Recommendations WARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ if ignited. Before servicing the fuel system, make sure there ȱȱǰȱȱĚȱȱȱȱȱȱ nearby as these can ignite gasoline vapors. Disconnect and ground the spark plug leads to prevent the possibility of sparks from the ignition system. RECOMMENDED SAE VISCOSITY GRADES 10W-30 ** 5W-20, 5W-30 * Kohler 10W-30 °F -20 °C -30 20 0 -20 -10 32 0 40 60 10 80 20 30 100 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F) * Synthetic oils will provide better starting in extreme cold below 23°C (-10°F) NOTE: Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage. DZȱ ¢ȱȱȱȱȱęȱ may be used with oil changes performed at the recommended intervals. However, to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil. SE RVIC E SAE 10W30 SJ API ȱȱȱ¢ȱȱȱȱęȱȱȱ service class and SAE viscosity grade. See Figure 1-3. Figure 1-3. Oil Container Logo. 1.4 General Recommendations Purchase gasoline in small quantities that can be used within 30 days, and store in only clean, approved ǯȱȱȱȱȱĞȱȱȱȱ previous season, unless treated with a fuel stabilizer (see Storage), to minimize gum deposits and ensure easy starting. Do not use gasoline containing Methanol, or add oil to the gasoline. ȱȱęȱȱȱǯȱȱȱȱȱȱ to expand. Fuel Type For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or ǯȱȱȱȱȱȱǰȱȱ should be 90 octane minimum. Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions. Leaded gasoline is not recommended and must notȱȱȱȱȱǰȱ or on other models where exhaust emissions are regulated. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved. 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 DZȱŗǼȱȱȱȱȱǻǼǯȱŘǼȱȱȱǻȬǼȱĴ¢ȱȱȱĴ¢ǯ Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up. Frequency Maintenance Refer to: • Fill fuel tank. Daily or Before Starting Engine Section 5 • Check oil level. Section 6 1 • Check air cleaner for dirty , loose, or damaged parts. Section 4 • Check air intake and cooling areas, clean as necessary. Section 4 Ȋȱȱęȱȱȱȱȱǯ Section 4 • Check air cleaner element. Section 4 Ȋȱȱȱę Section 5 Ȋȱȱǯȱȱęȱȱǯȱ (More frequently under severe operating conditions) Section 6 • Remove cooling shrouds and clean cooling areas1. Section 4 Ȋȱȱȱȱęǰȱȱȱ¢ǯ Section 6 Every 200 Hours • Check spark plug condition and gap. Section 7 Seasonally or Every 300 Hours Ȋȱȱȱę Section 6 • Replace air cleaner element. Section 4 Yearly or Every 500 Hours Ȋȱ ȱȱĞȱȱȱȱǯ Weekly Seasonally or Every 150 Hours Every 600 Hours Section 7 2 Ȋȱ ȱĞȱȱ . • Replace inner air cleaner element. Section 4 • Replace spark plugs. Section 7 ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. 2 Have a Kohler Engine Service Dealer perform this service. Storage ȱȱȱ ȱȱȱȱȱȱřŖȱ¢ȱȱǰȱ use the following storage procedure. 1. Clean the exterior surfaces of the engine. Avoid spraying water at the wiring harness or any of the electrical components. ȱ Řǯȱ ȱȱȱȱȱęȱ ȱȱȱȱ still warm from operation. See “Change Oil and Oil Filter” in Section 6. 3. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer ȱȱǯȱȱ¢ȱȱȱ use a stabilizer, follow the manufacturer’s recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline. Run the engine for 2 to 3 minutes to get stabilized fuel into the rest of the system. Close the fuel Ȭěȱȱ ȱȱȱȱȱȱȱ transported. To empty the system, run the engine until the tank and the system are empty. 4. Remove the spark plugs and add one tablespoon ȱȱȱȱȱȱȱǯȱȱȱ spark plugs, but do not connect the plug leads. Crank the engine two or three revolutions. ȱ śǯȱ ȱȱĴ¢ȱȱȱȱĴ¢ȱȱȱ ȱȱĴ¢ȱȱȱǯ 6. Store the engine in a clean, dry place. 1.5 1 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] 17.00 [.669] 111.30 [4.382] 35.00 [1.378] 50.00 275.08 [2.362] [10.829] 84.20 [3.315] 60.00 [2.362] 115.12 [4.532] 254.00 [10.00] M8x1.25-6H 25.0 [0.98] DEEP 7 HOLES 89.80 [(3.536)] (89.80) [(3.536)] 17.00 [.669] 70.45 [2.774] 93.45 [3.679] 18.00 [.709] 49.80 [1.961] Figure 1-4. Typical CV PRO Series Engine Dimensions with Heavy Duty Air Cleaner. 1.6 Section 1 Safety and General Information *HQHUDO6SHFL¿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......................................................................................................... 28.3 kW (38 HP) CV1000....................................................................................................... 29.8 kW (40 HP) 1 Bore .................................................................................................................. 90 mm (3.54 in.) Stroke ................................................................................................................ 78.5 mm (3.09 in.) Displacement ................................................................................................... 999 cc (60.96 cu. in.) Compression Ratio ......................................................................................... 8.8:1 Dry Weight ....................................................................................................... 57.6 kg (127 lb.) ȱ¢ȱǻ ȦęǼȱȬȱ¡ǰ ȱ¢ȱȱęȱȱ ........................................................................ 2.9 L (3.1 U.S. qt.) Angle of Operation - Maximum (At Full Oil Level) All Directions......... 25° Blower Housing and Sheet Metal M6 Shoulder Screw Torque DZ New, Untapped Hole (casting) .............................................................. 10.7 N·m (95 in. lb.) Used , Tapped Hole (casting) ................................................................. 7.3 N·m (65 in. lb.) New, Extruded Hole (sheet metal) ........................................................ 4.0 N·m (35 in. lb.) Used, Extruded Hole (sheet metal) ....................................................... 2.0 N·m (17.7 in. lb.) ȱ ȱȱǻ¢ȱĝǼ................................................................. 2.5 N·m (22.1 in. lb.) M6 Screw Torque New, Untapped Hole (casting) .............................................................. 10.7 N·m (95 in. lb) Used, Tapped Hole (casting) .................................................................. 7.3 N·m (65 in. lb) ęȬȱȱ............................................................. 2.0 N·m (18 in. lb.) Oil Cooler Fastener Torque............................................................................ 2.2 N·m (20 in. lb.) Camshaft End Play............................................................................................................ 0.3/1.3 mm (0.011/0.051 in.) Running Clearance.......................................................................................... 0.025/0.063 mm (0.0010/0.0025 in.) ȱǯǯ New............................................................................................................ 20.000/20.025 mm (0.7874/0.7884 in.) Max. Wear Limit....................................................................................... 20.038 mm (0.7889 in.) Ğȱȱȱǯǯ New............................................................................................................ 19.962/19.975 mm (0.7859/0.7864 in.) Max. Wear Limit....................................................................................... 19.959 mm (0.7858 in.) ȱȱęȱǻȱǰȱȱȱȱȱȱȱȱǯǼ Exhaust ............................................................................................................. 35 mm (1.3779 in.) ȱ ............................................................................................................... 35 mm (1.3779 in.) ¹Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly. 1.7 Section 1 Safety and General Information Carburetor, Intake Manifold, and Air Cleaner ȱȱȱȱ Torque Using Sequence in Two Stages ................................................. ęȱȱŗŜǯşȱȉȱǻŗśŖȱǯȱǯǼ ȱ ȱ ę¢ȱȱŘŘǯŜȱȉȱǻŘŖŖȱǯȱǯǼ Carburetor/Air Cleaner Mounting Nut Torque.......................................... 7.9 N·m (70 in. lb.) ȱȱȱ ȱȱǻȱȱǼ................... 9.9 N·m (88 in. lb.) Control Bracket ȱ ȱǻȱȱȱȱȱǼȱ ......... 9.9 N·m (88 in. lb.) Connecting Rod Cap Fastener Torque (torque in increments)............................................... 11.3 N·m (100 in. lb.) ȱȱǯǯȱȓȱŝŖǚ New............................................................................................................ 44.030/44.037 mm (1.7334/1.7337 in.) Max. Wear Limit....................................................................................... 0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Running Clearance New............................................................................................................ 0.030/0.055 mm (0.0012/0.0022 in.) Max. Wear Limit....................................................................................... 0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Side Clearance............................................. 0.30/0.59 mm (0.0118/0.0232 in.) Connecting Rod-to-Piston Pin Running Clearance.................................... 0.015/0.028 mm (0.0006/0.0011 in.) ȱȱȱǯǯȱȓȱŝŖǚ New............................................................................................................ 19.015/19.023 mm (0.7486/0.7489 in.) Max. Wear Limit....................................................................................... 19.036 mm (0.7494 in.) Crankcase ȱȱĞȱȱǯǯ New............................................................................................................ 8.025/8.050 mm (0.3159/0.3169 in.) Max. Wear Limit....................................................................................... 8.088 mm (0.3184 in.) Breather Cover Fastener Torque ................................................................... 5.7 N·m (51 in. lb.) Oil Drain Plug Torque .................................................................................... ŘŗǯŚȱȉȱǻŗśǯŝȱĞǯȱǯǼ Oil Pan Oil Pan Fastener Torque ................................................................................. 24.4 N·m (216 in. lb.) Crankshaft End Play (Free) ................................................................................................ 0.30/1.50 mm (0.011/0.059 in.) ĞȱȱǻȱǼ New, Without Main Bearing................................................................... 50.00/50.025 mm (1.9685/1.969 in.) ȱ ȱȱȱ .................................................................. 45.040/45.145 mm (1.7732/1.7773 in.) Max. Wear Limit....................................................................................... 45.158 mm (1.7778 in.) ĞȱȱȱȱǻǼ Running Clearance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 in.) ĞȱȱǻȱȱǼȱȬȱ ǰȱ ȱ ............................... 50.025/50.00 mm (1.9694/1.9685 in.) 1.8 Section 1 Safety and General Information ĞȱȱȱȱǻȱȱǼ 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.) Max. Taper ................................................................................................ 0.022 mm (0.0009 in.) Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 in.) Closure Plate 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.) Max. Taper ................................................................................................ 0.022 mm (0.0009 in.) Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 in.) Connecting Rod Journal O.D. - New ................................................................................................ 43.982/44.000 mm (1.731/1.732 in.) O.D. - Max. Wear Limit ........................................................................... 43.97 mm (1.731 in.) Max. Taper ................................................................................................ 0.018 mm (0.0007 in.) Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 in.) Width ......................................................................................................... 53.00/53.09 mm (2.0866/2.0901 in.) Crankshaft T.I.R. PTO End, Crank in Engine ..................................................................... 0.279 mm (0.0110 in.) Entire Crank, in V-Blocks........................................................................ 0.10 mm (0.0039 in.) Cylinder Bore ¢ȱȱǯǯ New............................................................................................................ 90.000/90.025 mm (3.543/3.544 in.) Max. Wear Limit ...................................................................................... 90.075 mm (3.546 in.) Max. Out-of-Round ................................................................................. 0.013 mm (0.00051 in.) Max. Taper ................................................................................................ 0.013 mm (0.00051 in.) Main Bearing I.D. (Crankcase/Oil Pan) ȱ ȱǻǼ......................................................................................... 45.040/45.145 mm (1.773.1.777 in.) Max. Wear Limit....................................................................................... 45.158 mm Cylinder Head Cylinder Head Fastener Torque Head Bolt - Torque in Two Stages ......................................................... ęȱȱŘŘǯŜȱȉȱǻŘŖŖȱǯȱǯǼ ȱ ȱ ę¢ȱȱŚśǯŘȱȉȱǻŚŖŖȱǯȱǯǼ Max. Out-of-Flatness ...................................................................................... 0.076 mm (0.003 in.) Pipe Plug, 3/4" Torque .................................................................................... 28.25 N·m (250 in. lb.) Rocker Arm Stud (AVT) Torque.................................................................... 11.3 N·m (100 in. lb.) Setscrew, AVT pivot locking .......................................................................... 7.3 N·m (65 in. lb.) Fan/Flywheel Fan Fastener Torque........................................................................................ 9.9 N·m (88 in. lb.) Flywheel Retaining Screw Torque ................................................................ ŜŝǯŞȱȉȱǻśŖȱĞǯȱǯǼ 1.9 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 ȱȱĞȬȬȱȱ .......................... 0.025/0.087 mm (0.0009/0.0034 in.) Governor Cross Shaft O.D. New............................................................................................................ 7.963/8.000 mm (0.3135/.3149 in.) Max. Wear Limit....................................................................................... 7.936 mm (0.3124 in.) ȱȱĞȬȬȱȱȱ ................... 0.070/0.160 mm (0.0027/0.0063 in.) ȱȱĞȱǯǯ New............................................................................................................ 5.990/6.000 mm (0.2358/0.2362 in.) Max. Wear Limit....................................................................................... 5.977 mm (0.2353 in.) Governor Lever Nut Torque.......................................................................... 7.3 N·m (65 in. lb.) Ignition Spark Plug Type (Champion® or Equivalent) ............................................. XC10YC Spark Plug Gap................................................................................................ 0.76 mm (0.030 in.) Spark Plug Torque........................................................................................... ŘŚǯŚȬŘşǯŞȱȉȱǻŗŞȬŘŘȱĞǯȱǯǼ ȱȱȱ ............................................................................... 0.28/0.33 mm (0.011/0.013 in.) ȱȱȱ ................................................................. 6.2 N·m (55 in. lb.) into new holes, or 4.0 N·m (35 in. lb.) into used holes Lifter Feed Chamber Ȧĝȱ ȱ ............................................................................ 6.2 N·m (55 in. lb.) 0XIÀHU ĝȱȱȱ....................................................................... 24.4 N·m (216 in. lb.) ǰȱĴȱȱǻȱ ȱǼ................................................. 13.5 N·m (120 in. lb.) Oil Cooler Mounting Screws Torque............................................................................... 3.9 N·m (35 in. lb.) Oil Filter Oil Filter Torque .............................................................................................. řȦŚȬŗȱȱĞȱȱ Oil Filter Adapter/Housing Mounting Screw Torque................................................................................. 24.4 N·m (216 in. lb.) Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance ..................................................... 0.006/0.018 mm (0.0002/0.0007 in.) ȱȱȱǯǯ New............................................................................................................ 19.006/17.013 mm (0.7482/0.7485 in.) Max. Wear Limit....................................................................................... 19.025 mm (0.7490 in.) Piston Pin O.D. New............................................................................................................ 18.995/19.000 mm (0.7478/0.7480 in.) Max. Wear Limit....................................................................................... 18.994 mm (0.7478 in.) 1.10 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 .................................................................................................. 0.30/0.55 mm (0.011/0.021 in.) Used Bore (Max.)...................................................................................... 0.94 mm (0.037 in.) Piston Thrust Face O.D.² New ........................................................................................................... 89.953/89.967 mm (3.5414/3.5420 in.) Max. Wear Limit ..................................................................................... 89.925 mm (3.540 in.) Piston Thrust Face-to-Cylinder Bore² Running Clearance New............................................................................................................ 0.033/0.72 mm (0.0013/0.0028 in.) Starter Assembly Thru Bolt Torque ȱ Ȭ¢ȱǻȱĞǼ .................................................................. 5.6-9.0 N·m (49-79 in. lb.) Mounting Screw Torque................................................................................. 15.3 N·m (135 in. lb.) Brush Holder Mounting Screw Torque Delco-Remy Starter.................................................................................. 2.5-3.3 N·m (22-29 in. lb.) Solenoid (Starter) Mounting Hardware Torque Delco-Remy Starter.................................................................................. 4.0-6.0 N·m (35-53 in. lb.) Nut, Positive (+) Brush Lead Torque Delco-Remy Starter.................................................................................. 8.0-11.0 N·m (71-97 in. lb.) Stator Mounting Screw Torque................................................................................. 6.2 N·m (55 in. lb.) Throttle/Choke Control Bracket Fastener Torque ............................................................................................... 9.9 N·m (88 in. lb.) Valve Cover Valve Cover Fastener Torque......................................................................... 7.9 N·m (70 in. lb.) Valves and Valve Lifters ¢ȱȱĞȱȱȱȱ ......................... 0.012/0.050 mm (0.0004/0.0019 in.) ȱȱȬȬȱȱȱ ............................. 0.038/0.076 mm (0.0015/0.0030 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance .......................... 0.050/0.088 mm (0.0020/0.0035 in.) ȱȱȱǯǯ New............................................................................................................ 7.038/7.058 mm (0.2771/0.2779 in.) Max. Wear Limit....................................................................................... 7.135 mm (0.2809 in.) ¡ȱȱȱǯǯ New............................................................................................................ 7.038/7.058 mm (0.2771/0.2779 in.) Max. Wear Limit....................................................................................... 7.159 mm (0.2819 in.) ŶȱȱŗŗȱȱǻŖǯŚřřȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯ 1.11 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 ............................................................................ 45° General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 10% Property Class 4.8 Size M4 M5 M6 M8 1.2 (11) 2.5 (22) 4.3 (38) 10.5 (93) 5.8 1.7 (15) 3.2 (28) 5.7 (50) 13.6 (120) 8.8 2.9 (26) 5.8 (51) 9.9 (88) 24.4 (216) 10.9 4.1 (36) 8.1 (72) 14.0 (124) 33.9 (300) 12.9 5.0 (44) 9.7 (86) 16.5 (146) 40.7 (360) Noncritical Fasteners Into Aluminum 2.0 (18) 4.0 (35) 6.8 (60) 17.0 (150) Tightening Torque: N·m (ft. lb.) + or - 10% Property Class M10 M12 M14 1.12 4.8 5.8 21.7 (16) 36.6 (27) 58.3 (43) 27.1 (20) 47.5 (35) 76.4 (55) 8.8 47.5 (35) 82.7 (61) 131.5 (97) Noncritical Fasteners Into Aluminum 10.9 12.9 66.4 (49) 116.6 (86) 184.4 (136) 81.4 (60) 139.7 (103) 219.7 (162) 33.9 (25) 61.0 (45) 94.9 (70) 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) 30.5 (270) ----------------- ------------------------18.7 (165) 22.6 (200) 39.6 (350) ------------------------- 2.3 (20) 3.6 (32) --------7.9 (70) --------17.0 (150) ------------------------- 40.7 (30) 67.8 (50) 81.4 (60) 108.5 (80) 142.4 (105) 155.9 (115) 223.7 (165) 237.3 (175) 311.9 (230) 352.6 (260) 447.5 (330) 474.6 (350) 637.3 (470) --------------------------------------------------------------------------------------------------------- Tightening Torque: N·m (ft. lb.) + or - 20% Size 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 ------------------------47.5 (35) 61.0 (45) 67.8 (50) 94.9 (70) 101.7 (75) 135.6 (100) 149.2 (110) 189.8 (140) 199.3 (150) 271.2 (200) ---------47.5 (35) 54.2 (40) 74.6 (55) 101.7 (75) 108.5 (80) 142.4 (105) 169.5 (125) 223.7 (165) 244.1 (180) 311.9 (230) 332.2 (245) 440.7 (325) Torque Conversions N·m = in. lb. x 0.113 ȉȱƽȱĞǯȱǯȱ¡ȱŗǯřśŜ in. lb. = N·m x 8.85 Ğǯȱǯȱƽȱȉȱ¡ȱŖǯŝřŝ 1.13 1.14 Section 2 Tools & Aids Section 2 Tools & Aids 2 ȱ¢ȱȱȱȱȱȱ¢ȱȱęȱ¢ǰȱǰȱȱ¢ȱǯȱ ¢ȱȱȱȱȱȱǰȱ¢ȱȱ¢ȱȱȱǰȱǰȱȱǷȱȱǰȱ¢Ȃȱ ȱ¢ȱȱȱȱȱȱ¢ȱȱȱ ǯ ȱȱȱȱȱȱȱȱǯȱȱ Separate Tool Suppliers: ȱ ȱ¢ȱ ȱ¢ǯȱ ȱ Śŗśȱ ȱǯ ǰȱȱȱŚŞŚŚŜ ȱŞŗŖȬŜŜŚȬŘşŞŗȱȱ ȱȱŞŖŖȬŜŜŚȬŘşŞŗȱ ¡ȱŞŗŖȬŜŜŚȬŞŗŞŗ ȱ¢ȱǯ ŝŜŞȱȱȱ ǰȱȱȱŜŖśśş ȱŜřŖȬşŘŖȬŗřŖŖ Tools Description Source/Part No. Ğȱ¢ȱ ȱȱĞȱ¢ǯ ȱȱȬŞŘŚŖś ĞȱȱȱǻǼ ȱȱȱȱĞȱǯ ȱȱȬŞŘŚŗŝ ¢ȱ ȱ ȱȱȱȱȱȱ¢ǰȱǰȱǰȱȱȱȱ ǯ ȱŘśȱŝŜŗȱŖśȬ ȱȱȱǻǼȱȱĞ ȱ ȱȱȱȱǯ ȱȱŘśȱŝŜŗȱŘřȬ ȱȱ ȱȱȱĴȱȱȱȱǯ ȱŘŚȱŝŜŗȱŖŗȬ ȱȱȱȱ ȱȱȱȱȱ ȱȱȱȱȱ ȱȱȱȱşŖǚȱ ȱȱȱȱȱȱ ȱȱȱȱȱǰȱȱ ȱȱȱȱȱǰȱȱȱ ȱ¢ȱǯ ȬŖŗş ȬŖŘŗ ȬŖŘř ȬŖŘś ȬŖŘŝ ȬŖŘş ¢ ȱ ȱȱǻȱǼ ȱȱȬŞŘŚŖŝ ¢ ȱȱ ȱȱĚ¢ ȱȱǯ ȱȱȬŞŘŚŖŞ ¢ ȱȱ ȱȱĚ¢ ȱȱǯ ȱȱȬŞŘŚŖş 2.1 Section 2 Tools & Aids Tools (Continued) Description Source/Part No. ¢ȱȱĞȱ ȱȱȱȱ¢ȱĞǯ ȱŘśȱŝŜŗȱřŞȬ ȱ¢ȱ ȱȱȱȱȱ¢ǰȱ¡ȱǯ ȱȱȱȱȱȱǻǼȱȱ¢ǯ ȱŘśȱŚśśȱŖŗȬ ȱŘŚȱŚśśȱŖŘȬ ěȱȱǻȱǭȱȱǼȱ ȱȱȱȱ¢ȱȱȱǯ ȱȱȬŞŘŚŗŖ ȱȱȱ ȱȱȱ¢ȱȱǯȱ ȱŘśȱŝŜŗȱŖŜȬȱ ęȬȱȱǻŗŘŖȱȱǼ ęȬȱȱǻŘŚŖȱȱǼ ȱȱȱęȬǯȱ ȱŘśȱŝŜŗȱŘŖȬ ȱŘśȱŝŜŗȱŚŗȬ ȱȱȱ ȱȱȱȬȱȱȱ ȱȱȱȱȱȱ ȱ ȱ ȱ¢ȱǯ ȬŖřŗ ȬŖřř ȱȱȱǻǼȱ ȱȱȱȱǻȱȱǼȱȱȱ ȱȬȜǯ ȱŘśȱŝŜŗȱŚŖȬ ȱȱȱȱǻȱǼ ȱȱȱȱȱȱȱǻ¡ȱȱǼǯ ȱŘśȱŝŜŗȱŗŞȬ ȱȱȱǻȱǼ To remove and reinstall drive retaining rings and brushes. SE Tools KLR-82411 Individual Component Available Starter Brush Holding Tool (Solenoid Shift) Tachometer (Digital Inductive) For checking operating speed (RPM) of an engine. Vacuum/Pressure Tester Alternative to a water manometer. 2.2 SE Tools KLR-82416 Design Technology Inc. DTI-110 Kohler 25 761 22-S Section 2 Tools & Aids Aids Description Source/Part No. ĞȱȱǻȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬ ȱȱǻȦȱŜŜŗǼ ȱŘśȱřśŝȱŗŗȬ ȱȱǻȬǼ Ȭ ȱȱȱȱǻȱǼ ȱȱśŘȱřśŝȱŖŗȬ ȱȱȱȱǻȱĞǼȱ ȱśŘȱřśŝȱŖŘȬȱ ȱȱ ®ȱśşŖŖȱ ¢ȱ¢ȱȱŚȱ£ȱȱǯ ¢ȱ¡Ȭǰȱȱȱȱǰȱȱȱȱǰȱȱȱȱ ǯȱțȱǯȱśşŖŖȱȱśşŗŖȱȱȱȱȱȱǯ ȱȱ®ȱśşŗŖȱ ȱȱ®ȱȱȱśşŞȱ ȱȱ®ȱȱȱśŞŝ ȱȱ®ȱȱȱȱ ȱŘśȱśşŝȱŖŝȬ ȱȱ ȱŘśȱřśŝȱŗŘȬ 2 2.3 Section 2 Tools & Aids Special Tools You Can Make Flywheel Holding Tool ȱĚ¢ ȱȱȱȱȱȱȱȱȱȱ ȱĚ¢ ȱȱȱȱ ȱȱȱŘȬŗǰȱȱ ȱȱȱȱȱȱ ǯ ȱ ŗǯȱ ȱȱȱȬěȱ ǰȱȱȱȱ¡ȱ ȱȱȱȱȱȱȱ ǯȱ ȱ Řǯȱ ȱěȱ¢ȱȱȱȱǯȱ ȱ Řǯȱ ȱȱȱȱȱȬȱȱȱȱěȱ ȱȱȱȱȱȱǰȱȱȱȱ ȱȱĚǯȱ ȱ řǯȱ ȱȱŗȱǯȱȱ ȱ ȱȱȱȱ £ȱȱȱȱȱȱȱȱǯȱ ȱ Śǯȱ ȱȱĚȱ ȱ ȱȱȱǯǯȱȱȱȱ ȱ ȱȱ¡¢ȱŗȄȱǯǯȱǻȱ ȱǯȱŗŘȱŚŜŞȱŖśȬǼǯȱȱȱȱ ȱ ȱ ȱȱȱȱȱȱȱǰȱȱ ȱȱȱŘȬŘǯ ȱ řǯȱ ȱȱȱȱȱȱ ȱȱ ȱȱȱȱȱȱȱȱȱ ȱ ȱȱȱȱȱĚ¢ ȱȱȱ ȱǰȱȱȱȱ ȱȱ ǯ Figure 2-2. Rocker Arm/Crankshaft Tool. Figure 2-1. Flywheel Holding Tool. Rocker Arm/Crankshaft Tool ȱȱ ȱȱĞȱȱȱȱȱȱȱ Ğȱ¢ȱȱȱȱȱȱȱȱȱ ǯȱ ȱ ŗǯȱ ȱȱȱȱȱȱȱŗŖȱ ȱȱ ȱǯȱȱȱȱȱȱǯȱ 2.4 Section 3 Troubleshooting Troubleshooting Guide When troubles occur, be sure to check the simple ȱ ǰȱȱęǰȱ¢ȱȱȱȱȱȱ considered. For example, a starting problem could be ȱ¢ȱȱ¢ȱȱǯ ȱȱȱȱȱȱȱȱ ȱ ǯȱȱȱȱȱȱȱǯȱ ȱȱȱęȱǻǼȱ ȱȱȱ ȱȱȱȱǯ Engine Cranks But Will Not Start ȱ ŗǯȱ ¢ȱȱǯ ȱ Řǯȱ ȱȬěȱȱǯ ȱ řǯȱ ȱǰȱȱȱ ȱȱȱȱ¢ǯ ȱ Śǯȱ ȱȱǯ ȱ śǯȱ ȱȱǻǼȱǯ ȱ Ŝǯȱ ȱ ȱȱȃěȄȱǯ ȱ ŝǯȱ ¢ȱȱǯ ȱ Şǯȱ ¢ȱȱǻǼǯ ȱ şǯȱ ȱȱǯ ŗŖǯȱ ȱȱȱǰȱȱȱȱȱ hose. ŗŗǯȱ ȱȱȱȱȱȦǯ ŗŘǯȱ Ĵ¢ȱȱ ǯ ŗřǯȱ ¢ȱȱ¢ȱǯ Engine Starts But Does Not Keep Running ȱ ŗǯȱ ȱȱȱȱǯ ȱ Řǯȱ ȱǰȱȱȱ ȱȱȱȱ¢ǯ ȱ řǯȱ ¢ȱȱȱȱȱĴȱǯ 4. Loose wires or connections that short the kill ȱȱȱȱȱǯ ȱ śǯȱ ¢ȱ¢ȱȱǯ ȱ Ŝǯȱ ¢ȱǯ ȱ ŝǯȱ ȱȱȱǰȱȱȱȱȱ hose. ȱ Şǯȱ Ȧȱȱȱȱȱǯ ȱ şǯȱ ȱ¢ȱǯ 3 7. 8. ȱ şǯȱ ŗŖǯȱ Low compression. Weak spark. ȱȱȱȱȱȱǯ ȱȬȦȱȱ restricted. ŗŗǯȱ ¢ȱȱǯ ŗŘǯȱ ¢ ȱ¢ȱǯ ŗřǯȱ ȱ¢ȱǯ Engine Will Not Crank ȱ ŗǯȱ ȱȱȱǯ ȱ Řǯȱ Ĵ¢ȱȱǯ ȱ řǯȱ ¢ȱȱ ȱȱǯ ȱ Śǯȱ ȱȱ¢ȱ ȱȱǯ ȱ śǯȱ ¢ȱ¢ȱ ȱȱȱ ǯ ȱ Ŝǯȱ ¢ȱȱȱȱǯ 7. Seized internal engine components. Engine Runs But Misses ȱ ŗǯȱ ȱȱ ȱȱȱȱ¢ǯ 2. Spark plug lead disconnected. ȱ řǯȱ ȱ¢ȱȱǯ ȱ Śǯȱ ¢ȱȱǻǼǯ ȱ śǯȱ ȱ ȱȱȱȱĴ¢ȱ ground the ignition kill circuit. ȱ Ŝǯȱ ȱǯ ȱ ŝǯȱ ¢ȱȱȱȱȱȱǯ ȱ Şǯȱ ȱȱ¢ǯ Engine Will Not Idle ȱ ŗǯȱ ȱȱ ȱȱȱȱ¢ǯ ȱ Řǯȱ ȱȱȦȱȱȱǯ ȱ řǯȱ ¢ȱȱǯ ȱ Śǯȱ ȱ¢ȱǯ ȱ śǯȱ ȱȱȱȱ¢ȱǯ ȱ Ŝǯȱ ȱȱȱ ȱ¢ȱǯ 7. Low compression. ȱ Şǯȱ ȱȱȱȱǯ ȱ şǯȱ ȱȬȱ¢Ȧȱȱ problem. Engine Starts Hard ȱ ŗǯȱ ȱȱȱǯ ȱ Řǯȱ ȱȱ ȱȱȱȱ¢ǯ ȱ řǯȱ ȱȱǯ ȱ Śǯȱ ȱȱ¢ȱ ȱȱǯ ȱ śǯȱ ¢ȱȱȱȱȱĴȱǯ ȱ Ŝǯȱ ¢ȱȱǯ 3.1 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. ȱ śǯȱ ¢ȱĞȱǯ ȱ Ŝǯȱ ¢ȱȱǯ ȱ ŝǯȱ ȱȱȱǯ Engine Loses Power ȱ ŗǯȱ ȱȱȱǯ ȱ Řǯȱ ȱȱȱǯ ȱ řǯȱ ¢ȱȱȱǯ ȱ Śǯȱ ȱȱ ȱȱȱȱ¢ǯ ȱ śǯȱ ¡ȱȱǯ ȱ Ŝǯȱ ȱǯ ȱ ŝǯȱ ¢ȱȱǯ 8. Low compression. 9. Exhaust restriction. ȱŗŖǯȱ ȱĴ¢ǯ ŗŗǯȱ ȱȱĴǯ Engine Uses Excessive Amount of Oil ȱ ŗǯȱ ȱȱ¢Ȧ¢ǯ ȱ Řǯȱ ǰȱȱȱȱȱ breather. 3. Worn or broken piston rings. ȱ Śǯȱ ȱ¢ȱǯ ȱ śǯȱ ȱȱȦȱǯ ȱ Ŝǯȱ ȱęǯ ȱ ŝǯȱ ȱȱȦǯ Oil Leaks from Oil Seals, Gaskets ȱ ŗǯȱ ǰȱȱȱȱȱ breather. ȱ Řǯȱ ȱȱ¢ȱȱǯ ȱ řǯȱ ȱ ¢ǰȱȱ¢ȱǯ 4. Restricted exhaust. External Engine Inspection ȱȱȱȱȱǰȱȱȱ ȱȱȱȱ¡ȱȱȱ ǯȱȱȱȱȱȱȱ ȱ ȱȱȱȱȱȱǻȱȱǼȱ when it is disassembled. 3.2 ȱ Ȋȱ ȱȱȱȱȱȱȱȱȱ ǰȱȱęǰȱȱǰȱȱȱ ¡ȱǯȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱ ǯ ȱ Ȋȱ ȱȱȱȱȱȱǰȱȱ ȱǯȱ¡ȱȱȱ ȱȱȱȱȱ¢Ȭȱ ǰȱ Ȧȱȱȱǰȱȱ ȱȱ¢Ȭȱǯ ȱ Ȋȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱȱęȱȱǯ ȱ Ȋȱ ȱȱȱȱǯȱȱȱǰȱ ǰȱȱȱȱȱǰȱȱ ȱȱȱȱ ȱęȱȱȱ ȱǯȱȱȱȱȱȱȱ¢ȱȱ clogged. These could indicate that the engine has ȱȱǯ ȱ Ȋȱ ȱȱȱȱȱǯȱȱȱȱ ȱȱȱȱȱȱȱȱȱ ȱȱ¢ǯ ȱ Ȋȱ ȱȱȱǯȱȱȱȱȱȱȱ ȱ ȱȱȱȱȱǰȱȱȱȱȱ ȱ ȱęǯ ȱ Ȋȱ ȱȱȱȱȱǯȱȱȱȱȱ ȱȱȬȱȱȱȱĚ ȱ¢ǯȱȱȱ ȱȱȱȱȱǯ ȱ ȱ ȱȱȱȱ¢ȬȱȱDzȱȱ ȱȱȱǯȱ¡ȱȱ ȱȱȱȱǰȱ ȱǰȱ¡ȱȱȱȱ ȱ ȱ ȱȱ¢ȱȱȱ ȱǰȱȱȱ ȱ ǯ DZȱ ȱȱȱȱȱȱȱȱȱ ȱ ¢ȱȱȱ ǯȱȱ ȱȱ ȱȱȱȱȱ drainage. Cleaning the Engine Ğȱȱȱ¡ȱȱȱȱǰȱ ȱȱȱ¢ȱȱȱ ǯȱȱȱȱȱȱȱȱ ȱǯȱ¢ȱȱȱȱȱ¢ȱ ȱȱȱȱ ȱȱǯȱȱ ȱ¢ȱ¢ȱȱȱȱ ȱ¢ȱȱǰȱǰȱȱȱȱ engine parts. When such a cleaner is used, follow the manufacturer’s instructions and safety precautions carefully. Section 3 Troubleshooting ȱȱȱȱȱȱȱȱȱȱ the engine is reassembled and placed into operation. ȱȱȱȱȱȱȱ¢ȱ ȱ ȱȱȱȱȱȱǯ ȱ ȱ ȱȱȱȱȱȱȱȱȱȱęȱ ǻ ȦȱǼǰȱȱȱȱȱȱȱȱ ȱ ȱȱȱȱȱȱȱȱǻǼǰȱ ȱȱȱȱȱȱȱ ǯ Basic Engine Tests ȱ Śǯȱ ȱȱȬěȱȱbefore stopping the engine. Crankcase Vacuum Test ȱȱȱȱȱȱȱȱ crankcase when the engine is operating. Pressure ȱȱȱǻ¢ȱȱ¢ȱȱȱȱ ¢ȱȱǼȱȱȱȱȱȱ ȱȱȱȱǰȱǰȱȱȱȱǯ ȱȱȱȱȱ ȱȱȱ ȱȱȱȱȱȱǻȱȱŘǼǯȱ ȱȱȱȱȱȱǯ ȱȱȱȱȱ ȱȱDZ ȱ ŗǯȱ ȱȱȦȱȱȱȱęȱǯȱȱ ȱȱȱȱȱȱȱǯȱ ȱȱȱȱěȱȱȱǯ 2. Start the engine and run at no-load high speed ǻřŘŖŖȱȱřŝśŖȱǼǯ ȱ řǯȱ ȱȱȱȱȱȱ ȱȱȱȱ tube. ȱ ȱ ȱȱȱȱȱȱȱȱȱȱ ȱ10.2 cm (4 in.) ȱȱȱȱȱȱǯ ȱȱȱȱȱ ȱȱȦ ȱȱȱǻȱȱŘǼDZ 3 ȱ ŗǯȱ ȱȱȱȱȱęȱȦǯ ȱ Řǯȱ ȱȱȱȱȱȱęȦȱȱ opening. ȱ řǯȱ ȱȱȱęĴȱȱȱȱ¢ȱȱ the hole in the adapter. 4. Start the engine and bring it up to operating ȱǻřŘŖŖȬřŜŖŖȱǼǯ ȱ śǯȱ ȱȱȱȱȱǯȱȱȱȱ is to the ĞȱȱȃŖȄȱȱȱǰȱȱȱ ȱȱȱǯȱȱȱȱȱȱ the rightȱȱȃŖȄȱȱȱǰȱȱȱȱ present. ȱ ȱ ȱȱȱȱȱȱȱȱ Śȱȱȱ ǯȱȱȱȱȱ ȱȱ ęǰȱȱȱȱȱǰȱȱȱ ȱ ȱȱȱȱȱǯ No Crankcase Vacuum/Pressure in Crankcase Possible Cause Solution ȱȱȱȱǯ ȱǰȱȱȱ¢ǰȱǰȱ and recheck pressure ȱȦȱȱǯȱȱȱ ¢ȱȱǯ Replace all worn or damaged seals and gaskets. Make sure ȱȱȱȱ¢ǯȱȱȱȱ ȱȱȱ ȱ¢ ȱ ȱ¢ȱȱ¢ȱȱǻęȱ¢ȱ ȱǼ ȱǰȱǰȱ¢ȱǰȱǰȱȱȱ guides. Restricted exhaust. ȦȱȱĝȦ¡ȱ¢ 3.3 Section 3 Troubleshooting Compression Test ȱȱȱȱȱȱȱȱ ȱ ǯȱȱ¢ȱȱȱȱ ¢ȱȱȱȱ ȱȱȱȱȱȱǯȱȱȱ ȱȱȱěǰȱȱȱĴȱȱ ȱȱȱ the test. Compression should be at least 160 psi and ȱȱ¢ȱȱȱŗśƖȱ ȱ¢ǯ Cylinder Leakdown Test ȱ¢ȱ ȱȱȱȱȱȱȱ ȱȱȱǯȱ¢ȱ£ȱȱȱ ȱȱȱ¡ȱȱǰȱ¢ȱȱ ȱȱȱȱȱȱȱȱȱ ȱ ¢ǯ ȱ¢ȱ ȱȱȱȱ¢ȱǰȱ ¡ȱ ȱȱȱȱǯȱȱ ȱȱȱȱȱȱĴȱȱ adapter hose, and a holding tool. Leakdown Test Instructions ȱ ŗǯȱ ȱȱȱȱřȬśȱȱȱ ȱȱǯ ȱ Řǯȱ ȱȱȱǻǼȱȱȱȱęȱȱ engine. ȱ ȱ ȱȱĚ¢ ȱȱȱȱǰȱȱȱ ȱȱȱȱȱȱĚ¢ ȱȦ ȱ ȱȱȱȱǯȱȱȱ¢ȱȱȱ ȱȱȱȱȱȱǯȱȱȱ ȱȱȱȱȱȱȱǰȱȱ¢ȱ ȱȱȱȱȱ¢ȱȱȱ ȱȱ ȱǯȱȱȱȱȱȱȱ ȱȱěȱȱȱȱȱǯ 4. Install the adapter into the spark plug hole, but ȱȱĴȱȱȱȱȱȱȱǯ ȱ śǯȱ ȱȱȱȱȱȱȱśŖȱȱȱȱ tester. 6. Turn the regulator knob in the increase direction ǻ Ǽȱȱȱȱȱȱȱȱ¢ ȱ ȃȄȱȱȱȱ ȱȱȱȱǯ 7. Connect the tester quick-disconnect to the adapter ȱ ȱę¢ȱȱȱȱȱǯȱ ȱȱȱȱȱȱȱȱ air at the carburetor intake, exhaust outlet, and crankcase breather. ȱ Şǯȱ ȱȱȱȱȱȱ ȱDZ ȱ řǯȱ ȱȱĞȱȱȱȱǻȱ ¢ȱȱǼȱȱȱȱȱȱȱ the compression stroke. Hold the engine in this position while testing. The holding tool supplied ȱȱȱȱȱȱȱȱȱȱȱ ȱĞȱȱǯȱȱȱȱ ȱȱȱĞǯȱȱȱřȦŞȈȱȱ ȱȱȱȦȱȱȱȱǰȱȱȱ is perpendicular to both the holding tool and Ğȱǯȱ Leakdown Test Results ȱȱȱȱ ....................................................... ȱȱ¢ȱ ǯ ȱȱȱ¡ȱ¢ ............................................................. ȱ¡ȱȦȱǯ ȱȱȱ ...................................................................... ȱȱȦȱǯ ȱȱȱȃ ȄȱǻǼȱ£ ........................................................ ȱȱȱ¢ȱȱ condition. ȱȱȱȃȄȱǻ¢ Ǽȱ£............................................Engine is still usable, but there is some wear present. Customer should start ȱȱȱȱǯ ȱȱȱȃȄȱǻǼȱ£........................................................... ȱȦȱ¢ȱȱ wear. Engine should be reconditioned or replaced. 3.4 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 ȱǯȱȱ¢ȱȱȦȱęȱ ȱȱȱȱȱȱȱȱęȱ in any way. ȱ Řǯȱ ȱȱȱȱȱȱȱȱȱǯȱ Pull the air cleaner element out of the housing on opposite side. See Figures 4-2 and 4-3. Heavy-Duty Style Air Cleaner Inlet Screen Figure 4-2. Accessing Inlet Screen. Paper Element Figure 4-1. Heavy-Duty Style Air Cleaner. Service Weekly and every 150 hours: ȱęȱȱǻȱ Ǽǰȱȱȱ ȱȱȱȱȱȱ and remove the end caps. Perform inspection of the paper element and inlet screen area. Seasonally or every 300 hours ȱȱǻȱ Ğȱȱ¡¢ȱ¢ȱȱ¢ȱǼǰȱ ȱȱȱȱȱȱȱȱ element. Follow these steps. ȱ ŗǯȱȱ ȱȱ ȱȱȱȱȱȱ and remove the end caps from the air cleaner housing. Inner Element Figure 4-3. Removing Elements. ȱ řǯȱ Ğȱȱȱȱȱǰȱȱȱ ȱȱȱȱǯȱȱȱȱ replaced whenever it appears dirty, typically every other time the paper element is replaced or every 600 hoursǯȱȱȱȱȱȱȱ ȱȱȱȱȱȱǰȱȱȱ does not get into the engine. 4.1 4 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 ȱǯȱȱ¢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. Air Intake/Cooling System ȱȱȱǰȱȱȱȱȱǰȱ ȱȱęǰȱȱ¡ȱȱȱȱȱ ȱȱȱȱȱǯ Seasonally or every 150 hoursȱȱȱȱǻȱ Ğȱȱ¡¢ȱ¢ȱȱ¢ȱǼǰȱ ȱȱ¢ȱȱȱ ȱǯȱ ȱȱȱęȱȱ¡ȱȱȱ ¢ǯȱȱȱȱȱȱǯ Cylinder Shroud Ejector Area Figure 4-5. Removing Shrouds for Cleaning. Figure 4-4. Ejector Area. ȱ Ŝǯȱ ȱȱ ȱȱǰȱ ȱ¢ȱȱ paper element. Slide each fully into place in the air cleaner housing. 7. Reinstall the end caps and secure with the retaining clips. See Figure 4-1. Air Cleaner Components Whenever the air cleaner cover is removed, or the ȱȱȱȱȱȱǰȱȱȱ following: Air Cleaner Housing Ȭȱȱȱȱȱȱȱ ȱȱȱȱ¢ȱ. Air Cleaner Inlet - ȱȱȱȱȱȱȱ ȱ¢ȱȱȱȱȱȱȱȱ damaged. Breather Tube - ȱȱȱȱȱĴȱȱȱ ȱȱȱȱȱȱǯ NOTE: Damaged, worn or loose air cleaner ȱȱ ȱęȱȱȱȱ engine causing premature wear and failure. Tighten or replace all loose or damaged components. 4.2 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. WARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱȱȱ¢ȱȱȱǰȱȱ ȱǰȱȱǰȱ ¢ȱȱȱȱ Ěǯȱȱȱęȱȱȱȱ ȱȱȱȱȱȱ ǰȱȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱȱȱȱ ȱȱȱǯȱȱȱȱȱȱȱ ǯ and ensure easy starting. Do not use gasoline containing Methanol, or add oil to the gasoline. ȱȱęȱȱȱǯȱȱȱȱȱȱ to expand. Fuel Type For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research fuel rating method, it should be 90 octane minimum. 5 Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions. Leaded gasoline is not recommended. Fuel System Components The typical carbureted fuel system and related components include the following: • • • • • Fuel Tank and Valve Fuel Lines In-line Fuel Filter Fuel Pump Carburetor Operation The fuel from the tank is moved through the in-line ęȱȱȱȱ¢ȱȱȱǯȱȱȱȱ equipped with a fuel pump, the fuel tank outlet is located above the carburetor inlet allowing gravity to feed fuel to the carburetor. ȱȱȱȱȱĚȱ ȱȱȱ drawn into the carburetor body. There, the fuel is mixed with air. This fuel-air mixture is then burned in the engine combustion chamber. Fuel Recommendations General Recommendations Purchase gasoline in small quantities that can be used within 30 days and store only in clean, approved ǯȱȱȱȱȱĞȱȱȱȱ previous season, unless treated with a fuel stabilizer (see Storage in Section 1), to minimize gum deposits Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler ǯȱȱȦȱȱȱŘŖȱ ȱŞśȱȱȱȱȱȱȱȱǯȱ¢ȱ failures resulting from use of these fuels will not be warranted. Gasoline/Ether blends ¢ȱ¢ȱ¢ȱȱǻǼȱȱȱ ȱȱǻȱȱȱ¡ȱȱŗśƖȱȱ¢ȱ volume) are approved as a fuel for Kohler engines. ȱȦȱȱȱȱǯ Fuel Filter Most engines are equipped with an in-line fuel ęǯȱ¢ȱȱȱęȱȱȱ ȱ ȱȱȱęȱseasonally or every 150 operating hours. Fuel Line ȱȱȱ ȱȱȱřŖȱŝȱȱ ȱDzȱęȱȱȱȱǯȱ ȱȱȱ¢ȱȱȱǯȱȱ replacement hose by part number through a Kohler ȱȱǯ 5.1 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. Make sure the fuel lines to fuel pump are secured and in good condition. ȱ Řǯȱ ȱȱȱȱȱȱǯ a. Disconnect and ground spark plug leads. b. Close the choke on the carburetor. c. Crank the engine several times. d. Remove the spark plug and check for fuel at the tip. ȱ řǯȱ ȱȱȱĚ ȱȱȱȱȱȱȱǯ ȱ ǯȱ ȱȱȱȱȱȱȱęĴȱȱ the fuel pump. ȱ ǯȱ ȱȱȱ ȱȱĴȱȱȱǯȱ ȱȱȬěȱȱǻȱȱǼȱȱ ȱĚ ǯ ȱ 4. Check the operation of the fuel pump. ǯȱ ȱȱȱȱȱȱȱęĴȱȱ the carburetor. b. Crank the engine several times and observe Ě ǯ 5.2 ȱ Řǯȱ ȱȱis fuel at the tip of the spark plug, fuel is reaching the combustion chamber. If there is no fuel at the tip of the spark plug, ȱȱȱĚ ȱȱȱȱȱǻȱřǼǯ 3. If fuel doesȱĚ ȱȱȱǰȱȱȱ¢ȱ fuel pump (Test 4). If fuel does notȱĚ ȱȱȱǰȱȱȱȱ ȱȱǰȱȱȱǰȱȬȱęǰȱ Ȭěȱǰȱȱȱǯȱȱ¢ȱȱ problem and reconnect the line. 4. If fuel doesȱĚ ȱȱȱǰȱȱȱ¢ȱ carburetor. (Refer to the "Carburetor" portions of this section.) If fuel does notȱĚ ȱȱȱǰȱȱȱȱ clogged fuel line. If the fuel line is unobstructed, ȱȱęȱȱȦȱȱȱȱ line. If none of the checks reveal the cause of the problem, replace the pump. 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 ¢ǯȱȱȱśȬŗȱȱśȬŘǯȱȱȱȱ 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. The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the carburetor on its upward stroke. Two check valves prevent fuel from going backward through the pump. ȱ Řǯȱ ȱȱ ȱȱ ȱȱȱěȱ the pump. 3. Connect the pulse line to the new fuel pump and make sure opposite end is properly connected to ȱęȱȱęĴǯ DZȱ ȱȱȱȱȱȱ ȱ pump is consistent with the removed pump. Internal damage may occur if installed incorrectly. Śǯȱ Ĵȱȱ ȱȱȱȱȱ¡ȱĚȱ screws.Torque the screws to 2.3 N·m (20 in. lb.). 5. Reconnect the fuel lines to the inlet and outlet ęĴȱȱȱ ȱȱǯ Carburetor Pulse Fuel Pump Figure 5-1. Pulse Style Fuel Pump. General ȱȱȱȱȱȱ ȱȱȱ ȱ ȬǰȱȬĞȱȱ ȱę¡ȱȱ jets on a matching intake manifold. The carburetor features a self-relieving choke, serviceable slow jets, main jets and a fuel shutdown solenoid. See ȱśȬřǯȱ Self-Relieving Choke Low Idle Fuel Adjustments (With Limiters) Slow Jets Bowl Vent Fuel Shut-Off Solenoid Bowl Drain Screw Figure 5-3. Keihin 2-Barrel Carburetor. Figure 5-2. Optional Electric Fuel Pump. Fuel Pump - Replacement Replacing the Pulse Style Fuel Pump Replacement pumps are available through your source of supply. To replace the pulse pump follow these steps. Note orientation of pump before ǯȱȱȱśȬŗǯ WARNING: Explosive Fuel ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱȱȱ¢ȱȱȱǰȱȱ ȱǰȱȱǰȱ ¢ȱȱȱȱ Ěǯȱȱȱęȱȱȱȱ ȱȱȱȱȱȱ ǰȱȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱȱȱȱ ȱȱȱǯȱȱȱȱȱȱȱ ǯ 5.3 5 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. • Make sure the ignition system, governor system, ¡ȱ¢ǰȱȱĴȱȱȱȱ are operating properly. If the engine is hardstarting, runs roughly, or stalls at low idle speed, it may be necessary to adjust or service the carburetor. ȱ Ȋȱ ȱȱȱȱȱȱęȱ ȱǰȱȱ gasoline. • Make sure the fuel tank cap vent is not blocked and that it is operating properly. • Make sure fuel is reaching the carburetor. This ȱȱȱȱȬěȱǰȱȱ ȱęȱǰȱȬȱȱęǰȱȱȱȱ fuel pump for restrictions or faulty components as necessary. Troubleshooting – Carburetor Related Causes Condition ȱ ŗǯȱ ȱȱǰȱȱ¢ȱ or stalls at idle speed. Possible Cause/Probable Remedy ȱ ŗǯȱ ȱȱȱ¡ȱǻȱǼȦȱ¢ȱ ǯȱȱȱ ȱȱȱǰȱȱȱȱ ȱȱ fuel needle. ȱ Řǯȱ ȱȱȱǻȱ¢ȱ ȱŘǯȱ ȱȱǯȱȱȱǯ black, sooty exhaust smoke, ȱ ǯȱ ȱ¢ȱȱȱǯȱȱȱȱȦ ęǰȱȱȱȱȱ ǰȱ linkage to ensure choke is operating properly. governor hunting, or excessive ȱ ǯȱ ȱȱȱ¡ȱȱ¢ȱǯȱȱ ȱȱ ĴȱǼǯ fuel needle (some models). d. Float level is set too high. Separate carburetor air horn from ȱ¢ǰȱȱĚȱȱȱȱȱ procedure. e. Dirt under the fuel inlet needle. Remove needle; clean needle and seat and blow with compressed air. f. Bowl vent or air bleeds plugged. Remove low idle fuel adjusting needle. Clean vent, ports, and air bleeds. Blow out all passages with compressed air. ȱ ǯȱ ¢ǰȱȱȱȱĚǯȱȱĚȱȱȱȱ leaks. ȱřǯȱ ȱȱȱ¡ȱȱ¢ȱǯȱȱ ȱȱ ȱ řǯȱ ȱȱȱǻȱ¢ȱ ęǰȱȱȱȱȱ ǰȱ fuel needle (some models). governor hunting or excessive b. Float level is set too low. Separate carburetor air horn from ĴȱǼǯȱ ȱ¢ǰȱȱĚȱȱȱȱȱ procedure. c. Idle holes plugged; dirt in fuel delivery channels. Remove low idle fuel adjusting needle. Clean main fuel jet and all passages; blow out with compressed air. 4. Fuel leaks from carburetor. 5.4 ȱŚǯȱ ȱ ǯȱ c. d. ȱȱȱȱǯȱȱ¢ȱŘǯ ȱȱȱȱǯȱȱ¢ȱŘǯ Bowl vents plugged. Blow out with compressed air. Carburetor bowl gasket leaks. Replace gasket. 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. The kits include new main jets, slow jets (where applicable), necessary ȱȱȬǯȱȱȱȱȱȱȱȱ correct kit number. Fuel Shut-off Solenoid ȱȱȱȱ ȱȱȱȬěȱ ǯȱȱȱȱĴȱȱȱȱ ǯȱȱ ȱśȬŚǯȱȱȱȱȱȬȱȱȱ ȱ ȱŗŘȱȱȱȱȱȱǰȱ ȱ ȱĚ ȱȱȱȱǯȱȱȱȱȱ ȱȱ¡ȱȱȱȱĚ ǯ Fuel Shut-Off Solenoid Figure 5-4. Fuel Shut-off Solenoid. ȱȱȱȱǰȱȱ ȱȱȱěǰȱȱ can determine if the solenoid is functioning properly: ȱ ŗǯȱ ȱěȱȱȱȱȱȱȱȱ carburetor. When the solenoid is loosened and removed, gas will leak out of the carburetor. Have a container ready to catch the fuel. ȱ Řǯȱ ȱȱȱȱȱȱ ȱȱȱ ȱȱ ȱȱěȱ ȱȱǰȱȱȱ¢ȱ remaining fuel. Take the solenoid to a location with good ventilation and no fuel vapors present. ȱ ȱȱȱȱŗŘȱȱ ȱȱȱȱ ȱ ȱȱȱěǯ ȱ Śǯȱ ȱȱ ȱȱȃȄȱȱȱȱ pin in the center of the solenoid. The pin should ȱ ȱȱ ȱȃȄȱȱȱȱȱ ȱȱ ȱȱ ȱěǯȱȱȱ times to verify operation. Carburetor Details ȱȱȱ ȬȱȱȱȱȬĞȱ design. The circuits within the carburetor function as described following: Float Circuit: ȱȱȱȱȱ ȱȱȱ¢ȱȱĚȱ ȱȱȱǯȱȱ¢ȱȱȱȱĚȱ ȱȱĚ ȱ ȱȱȱȱȱǯȱȱ ȱȱȱǰȱȱĚȱ ȱȱȱȱ pressure will push the inlet needle away from the seat, allowing more fuel to enter the bowl. When ȱǰȱȱ¢ȱȱȱȱĚȱ ȱ again overcome the fuel pressure, rising to the ȱĴȱȱȱȱĚ ǯ Slow & Mid-Range Circuit: ȱ ȱȱȱȱȱ¢ȱȱȱ ȱ ǯȱȱȱȱȱȱȱȱ ȱȱ the slow air bleed jets, fuel is drawn through the two main jets and further metered through the slow jets. ȱȱȱȱ¡ȱȱȱ¢ȱȱȱ ȱȱȱ exit to the transfer port. From the transfer port the air fuel mixture is delivered to the idle progression chamber. From the idle progression chamber the air fuel mixture is metered through the idle port ǯȱȱ ȱȱ ȱȱȱȱȱ ǰȱȱȦȱ¡ȱȱȱ¢ȱȱĴȱ of the idle fuel adjusting screws. This mixture is then mixed with the main body of air and delivered to ȱǯȱȱȱĴȱȱȱǰȱ ȱȱȱȦȱ¡ȱȱ ȱȱ ȱȱę¡ȱȱȱȱȱǯȱ ȱȱĴȱȱȱȱȱȱȱ becomes great enough so the main circuit begins to work. Main (High-Speed) Circuit: ȱȱȦȱȱȱȱȱȱȱ ǯȱȱȱȱȱȱȱȱ ȱȱ the four air jets, fuel is drawn through the main jets. The air and fuel are mixed in the main nozzles and ȱȱȱȱ¢ȱȱĚ ǰȱ ȱȱ mixing of the fuel and air occurs. This mixture is then delivered to the combustion chamber. The carburetor ȱȱę¡ȱȱDzȱȱȱȱǯ ȱ řǯȱ ȱȱȱ ȱȱȱ ȱȃěȄǯȱ Connect the positive power source lead to the red lead of the solenoid. Connect the negative power source lead to the solenoid body. 5.5 5 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. ȘDZȱ ȱȱȱȱȱ ¡¢ȱŗśŖŖȱȱǻśŖŖŖȱĞǯǼȱ¢ȱ require a special ‘‘high altitude’’ main ǯȱȱȱȁȁ ȱȱȂȂȱ later in this section. If, however, the engine is hard-starting or does not operate properly, it may be necessary to adjust or service the carburetor. Low Idle Speed (RPM) Adjustment 1. ȱȱȱǻǼȱĴDZȱȱȱĴȱ control in the “idleȄȱȱȃslowȄȱǯȱȱȱ low idle speed approximately 300 RPM less than ȱȱȱęȱȱȱǰȱ by turning the low idle speed adjusting screw in or out. Check the speed using a tachometer. IMPORTANT: The Governed Idle Speed ȱȱ ȱ¢ȱĴȱȱȱ Low Idle Speed. ȘDZȱ ȱȱ ȱȱȱȱȱ the application. Refer to the equipment manufacturer’s recommendations. The low idle speed for basic engines is 1200 RPM. To ensure best results when Ĵȱȱ ȱȱȱǰȱȱ ȱ idle speed should be 1200 RPM (± 75 RPM). Low Idle Fuel Adjustments (With Limiters) Low Idle Speed (RPM) Adjustment Screw Bowl Vent Figure 5-5. Carburetor Adjustment Locations. 5.6 Low Idle Fuel Adjustment DZȱ ȱ ȱȱę¡ȱ ȱȱȱȱ caps on the two idle fuel adjusting needles. Step 3 can only be performed within the ȱ ȱ¢ȱȱǯȱȱȱĴȱȱ remove the limiter caps. ȱ ŗǯȱ ȱȱȱȱȱȱȱĴȱȱśȱȱŗŖȱ minutes to warm up. The engine must be warm ȱȱȱŘǰȱřǰȱȱŚǯ ȱŘǯȱ ȱȱĴȱȱȱȱȃȄȱȱȃ Ȅȱ ǯȱȱȱ ȱȱȱȱŗŘŖŖȱ ǯȱ ȱȱȃȱȱ ȱȱȱ ǻǼȄȱǯ 3.ȱ ȱȱȱǻǼȱĴDZ Place the ĴȱȱȱȃȄȱȱȃ Ȅȱǯ a. Turn one of the low idle fuel adjusting needles out (counterclockwise) from the ¢ȱĴȱȱȱȱȱ decreases (rich). Note the position of the needle. Now turn the adjusting needle in (clockwise). The engine speed may increase, then it will decrease as the needle is turned in (lean). Note the position of the needle. Set the adjusting needle midway between the ȱȱȱĴǯȱȱȱśȬŜǯ b. Repeat the procedure on the other low idle adjustment needle. ȱ Śǯȱ Ȧȱȱ ȱȱȱǻǼǰȱȱȱ ęȱĴǯ Adjust to Midpoint Rich Lean Adjust to Midpoint Lean Rich Right Side Left Side Figure 5-6. Optimum Low Idle Fuel Settings. 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. Hold the governor lever away from the ȱȱȱĴȱȱȱȱȱȱ speed (RPM) adjustment screw of the carburetor. Start the engine and allow it to warm up, then adjust the screw to set approximately 1200 RPM. Check using a tachometer. Turn the adjustment screw (inner) clockwise (in) to increase or counterclockwise (out) to decrease speed. 4. Release the governor lever and check that the ĴȱȱȱȱȱȱǻǼȱǯȱ ȱȱśȬşǯȱȱȱȱȱǻǼȱ adjuster screw to obtain the equipment manufacturer’s recommended idle speed (15001800 RPM). The governed idle speed (RPM) is typically 300 RPM (approximate) higher than the ȱȱǯȱȱȱśȬŗŖǯ Governor Spring Governed Idle Spring Figure 5-7. Governor Springs Installed. Governed Idle Speed Adjustment 1. Make sure the governed idle spring is in the outer hole in the governor lever and the hole in the ȱȱǻǼȱǯȱȱȱśȬŝǯ ȱ Řǯȱ ȱȱȱȱȱȱȱȱȱȱ of the governor lever and the hole in the high ȱǻǼȱǯȱȱȱśȬŝǯȱȱȱ governor lever away from carburetor to the limit of its travel and check that the governor spring is ȱȱȱȱ¢ȱǯȱȱȱśȬŝǯȱ Turn the high speed (RPM) adjustment screw counter-clockwise (if required) until spring is ǯȱȱȱśȬŞǯ Figure 5-9. Throttle Lever in Idle Position (Air Cleaner Removed for Clarity). Governed Idle Speed Adjustment Screw Governor Spring Must Be Loose In Slot Figure 5-10. Setting Governed Idle Speed (RPM). Pivot/Hold Lever Away From Carburetor Figure 5-8. Holding Governor Lever and Checking Spring Looseness. śǯȱ ȱȱĴȱȱȱȱ ȬȦȱ Ĵȱȱȱȱȱȱǯȱȱ the RPM using a tachometer. Turn the high speed screw to obtain the intended high speed no-load RPM. The governed idle speed must be set before making this adjustment.ȱȱȱȱśȬŗŗǯ 5.7 5 Section 5 Fuel System and Governor Move and Hold Lever in "Full Throttle" Position separate the fuel bowl from the carburetor. Do ȱȱȱȱȱ ȱȬǯȱȱ any remaining fuel into an approved container. Save all parts. Fuel can also be drained prior to ȱȱ¢ȱȦȱȱȱ ȱ ȱ ǯȱȱȱśȬŗŘǯȱ High Speed (RPM) Adjustment Screw Fuel Bowl Figure 5-11. Setting High Speed RPM (Air Cleaner Removed for Clarity). Carburetor Servicing The following section covers the disassembly, various servicing procedures and reassembly of the carburetor. For each procedure carefully inspect all components and replace those that are worn or damaged. The following should also be noted as Ĝȱȱȱǯ • Inspect the carburetor body for cracks, holes, and other wear or damage. ȱ Ȋȱ ȱȱĚȱȱǰȱǰȱȱȱ ȱȱĚȱǯȱȱȱĚȱȱȱ Ğȱȱ ȱȱǯ Bowl Drain Screw Figure 5-12. Fuel Bowl Removed From Carburetor. ȱ řǯȱ ȱȱĚȱȱ ȱȱĞȱȱȱ ȱĚǰȱȱȱȱǯȱȱȱśȬŗřǯȱ Discard all of the parts. The seat for the inlet needle is not serviceable, and should not be removed. Float • Inspect the fuel inlet needle and seat for wear or damage. • The choke plate is spring loaded. Check to make ȱȱȱ¢ȱȱȱĞǯ DZȱ ȱȱȱ ȱȱȱę¡ȱȱȱ ęȱȱȱȱȱȱǯȱ Fixed jets for high altitudes are available. Float Replacement If symptoms described in the carburetor ȱȱȱĚȱȱǰȱ ȱȱȱȱȱȱȱȱȦ ȱȱȱĚǯȱȱȱĚȱȱȱȱȱĚǰȱ ǰȱĚȱǰȱǰȱȱ ǯ 1. Perform the removal procedures for the appropriate air cleaner and the carburetor ȱȱȱŞȱȃ¢ǯȄȱ ȱ Řǯȱ ȱȱ¡ȱȱȱȱȱȱ material before disassembling the carburetor. Remove the four mounting screws and carefully 5.8 Inlet Needle Figure 5-13. Removing Float and Inlet Needle. 4. Clean the carburetor bowl and inlet seat areas as required, before installing the new parts. ȱ śǯȱ Ĵȱȱȱȱȱȱȱȱȱ ȱĚȱ ȱȱ ȱǯȱȱȱşŖǚȱȱ should point up, with the needle valve hanging ǯȱȱȱśȬŗŚǯ 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 ǯȱȱȱśȬŗśǯ Retaining Screw 5 Figure 5-16. Checking Float Height. ȱ şǯȱ ȱȱȱĚȱȱȱǰȱ carefully reinstall the fuel bowl, using new Ȭȱȱȱǯȱȱ ȱȱȱ original screws. Torque the screws to 2.5 ± 0.3 N·m (23 ± 2.6 in. lb.)ǯȱȱȱśȬŗŝǯ Pivot Pin Figure 5-15. Installing Float Assembly. ȱ ŝǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱ hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the needle (on retainer clip end) should not be depressed. Check ȱĚȱȱǯ DZȱ ȱȱȱȱȱȱȱ ǯȱȱȱȱĚȱȱȱ the fuel inlet needle without depressing the center pin. ȱ Şǯȱ ȱȱĚȱȱĴȱȱ17 mm (0.669 in.) ± 1.5 mm (0.059 in.)ǰȱȱȱȱĚȱ Ĵȱȱȱ¢ȱȱȱǯȱȱȱ śȬŗŜǯȱȱȱĚȱȱȱȱȱěȱ ȱęǯȱDO NOTȱĴȱȱȱ¢ȱ ȱĚȱǯ Figure 5-17. Installing Fuel Bowl. 10. Install the carburetor and reassemble the engine ȱȱȱȱŗŖȱȃ¢ǯȄ Disassembly/Overhaul 1. Clean the exterior surfaces of dirt or foreign material before disassembling the carburetor. Remove the four mounting screws and separate the fuel bowl from the carburetor. Transfer any remaining fuel into an approved container. ȱȱȱȱȱȬǯȱȱ can also be drained prior to bowl removal by Ȧȱȱȱ ȱȱ ǯȱȱ ȱśȬŗŞǯ 5.9 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 ĚǰȱǰȱȱȱǯȱȱȱśȬŗşǯȱ Discard all the old parts. The seat for the inlet needle is not serviceable, and should not be removed. Main Jets Figure 5-20. Main Jets and Nozzles Removed. ȱ Śǯȱ ȱȱ ȱȱȱĚȱ ȱȱ ground lead (if equipped), from the top of the Dzȱȱ¢ȱȱǻĞǼȱȱȱ ȱ ȱǯȱȱ ȱȱ¢ȱȱ£Ȧȱęǰȱ mark or tag for proper reassembly. Note the small ȬȱȱȱĴȱȱȱǯȱȱȱśȬŘŗȱ ȱśȬŘŘǯȱȱȱȱȱȱȱȱ a Jet Kit is also being installed. Clean the slow jets using compressed air. Do not use wire or carburetor cleaner. Float Inlet Needle Figure 5-19. Removing Float and Inlet Needle. ȱ řǯȱ ȱȱȱ£ȱĚȱ ǰȱȱ carefully remove the two main jets from the carburetor. Note and mark the jets by location for ȱǯȱȱȱȱ¢ȱȱ£Ȧȱ ęǯȱĞȱȱȱȱȱǰȱȱȱ ££ȱȱȱȱȱȱȱĴȱ ȱȱȱ ǯȱȱȱȦȱ of the nozzles. The end with the two raised ȱȱȱȦ ȱȱȱȱ main jets. Save the parts for cleaning and reuse. ȱȱśȬŘŖǯ Figure 5-21. Removing Screw and Washer. Slow (Idle Fuel) Jets O-Ring Figure 5-22. Slow Jets and O-Ring Detail. 5.10 Section 5 Fuel System and Governor śǯȱ ȱȱȱȱǻǼȱȱ 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. The ȱĞȱ¢ȱȱǰȱ however it should not be removed unless a Choke Repair Kit will be installed. ȱ Ŝǯȱ ȱȱȱ¢ǰȱȱǰȱȱǰȱ seats, etc. using a good commercially available carburetor solvent. Keep away from plastic or rubber parts if non-compatible. Use clean, dry compressed air to blow out the internal channels and ports. Do not use metal tools or wire to ȱęȱȱǯȱȱȱ¢ȱ check the carburetor for cracks, wear, or damage. Inspect the fuel inlet seat for wear or damage. Check the spring loaded choke plate to make sure ȱȱ¢ȱȱȱĞǯ 7. Clean the carburetor fuel bowl as required. 8. Install the two main nozzles into the towers of the carburetor body. The end of the main nozzles with the two raised shoulders should ȱȦ ȱǻȱȱȱȱǼǯȱȱ ȱȱ££ȱȱ¢ȱĴǯȱ Carefully install the main jets into the towers of the carburetor body on the appropriate side, ȱęȱ ȱȱ ȱǯȱȱ ȱśȬŘřǯ Nozzle End with Two Shoulders (Out/Down) ȱ şǯȱ ȱȱȱȬȱȱȱĴȱȱȱ ȱȱȱ ǰȱȱȱȱǯȱȱ and insert the two slow jets into the top of the ǯȱȱȱśȬŘŘǯȱ ȱŗŖǯȱ ȱȱǰȱĚȱȱ ȱȱȱ ȱȱȱ ǰȱĴȱȱȱ lead if originally secured by the screw. 11. Install the new idle speed (RPM) adjustment screw and spring onto the carburetor. Thread in until 3 or 4 threads are exposed, as an initial ǯȱȱȱśȬŘŚǯ Idle Speed Screw and Spring 5 Figure 5-24. Installing Idle Speed Adjusting Screw and Spring. ŗŘǯȱ Ĵȱȱȱȱȱȱȱȱȱ ȱĚȱ ȱȱ ȱǯȱȱȱşŖǚȱȱ should point up, with the needle valve hanging ǯȱȱȱśȬŘśǯ Figure 5-25. Float and Inlet Needle Details. Main Jets Figure 5-23. Installing Main Nozzles and Main Jets. ȱŗřǯȱ ȱȱĚȱȱȱȱ ȱȱȱ seat and carburetor body. Install the new pivot ȱȱȱĚȱȱȱȱ ȱȱ ȱȱ ǯȱȱȱśȬŘŜǯ 5.11 Section 5 Fuel System and Governor Retaining Screw ŗŜǯȱ ȱȱȱĚȱȱȱǰȱ carefully reinstall the fuel bowl, using new Ȭȱȱȱǯȱȱ ȱȱȱ original screws. Torque the screws to 2.5 ± 0.3 N·m (23 ± 2.6 in. lb.)ǯȱȱȱśȬŘŞǯ Pivot Pin Figure 5-26. Installing Float Assembly. ŗŚǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱ hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the needle (on retainer clip end) should not be depressed. Check ȱĚȱȱǯ DZȱ ȱȱȱȱȱȱȱ ǯȱȱȱȱĚȱȱȱ the fuel inlet needle without depressing the center pin. ŗśǯȱ ȱȱĚȱȱĴȱȱ17 mm (0.669 in.) ± 1.5 mm (0.059 in.)ǰȱȱȱȱĚȱ Ĵȱȱȱ¢ȱȱȱǯȱȱȱ śȬŘŝǯȱȱȱĚȱȱȱȱȱěȱ ȱęǯȱȱȱĴȱȱȱ¢ȱ ȱȱĚȱǯ DZȱ ȱȱȱȱȱȱȱ surface, not the rubber gasket, if still Ĵǯ Figure 5-27. Checking Float Height. 5.12 Figure 5-28. Installing Fuel Bowl. Choke Repair 1. Remove the carburetor from the engine. Discard the old mounting gaskets for the air cleaner and carburetor. ȱ Řǯȱ ȱȱȱȱȱȱĞȱȱȱ self-relieving choke mechanism thoroughly. 3. Remove and discard the plastic cap from the end ȱȱȱȦĞȱ¢ǯ 4. Note the position of the spring legs and the choke plate for correct reassembly later. See Figure ȱ ȱ śȬŘşǯȱȱȱ ȱ ȱĴȱȱȱ ȱȱȱȱĞǯȱȱȱĞȱȱȱȱ carburetor body, note the preload of spring and discard the removed parts. Figure 5-29. Choke Details. 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 ȱȱǯǯȱȱȱȱĞȱȱȱ required. 7. Insert the new bushing through the new choke lever from the outside, and start the bushing in ȱȱĞȱǯȱȱȱȱȱȱ the protruding boss on the carburetor housing is between the two stops formed in the choke lever. ȱȱśȬřŖǯ 9. Install the new return spring onto the new choke Ğǰȱȱȱȱȱȱȱȱȱȱ ȱȱȃȄȱȱȱȱȱȱȱĞǯȱ ȱȱśȬřŘǯ DZȱ ȱȱȱ¢ȱȱȱȱȱ the following step. Choke Shaft Spring Ends 5 Stops Boss Figure 5-30. Assembling Choke Lever. Figure 5-32. Choke Shaft and Spring Details. ȱȱŗŖǯȱ ȱȱȱĞȱȱȱȱȱ ǯȱȱǻǼȱȱĞȱƝȱȱ counterclockwise with the inner leg of the spring, against the formed stop within the choke lever as ¢ȱǯȱȱȱśȬŘşȱȱśȬřřǯȱ The outer leg of the spring must still be behind ȱȱȃȄȱȱȱȱĞǯ 8. Turn the old bushing upside down and use it as a driver to carefully press or tap the new ȱȱȱȱ¢ȱȱȱĴǯȱ Check that the choke lever pivots freely without ȱȱǯȱȱȱśȬřŗǯ Figure 5-33. Installing Choke Assembly Components. Figure 5-31. Installing Bushing. 11. Place a drop of Loctite® on the threads of each new screw. Position and install the new choke ȱȱȱĚȱȱȱȱȱĞǯȱȱȱ two screws. Close the choke and check the plate alignment within the carburetor throat, then tighten the screws securely. Do not overtighten. ȱȱśȬřŚǯ 5.13 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. Ȧȱȱȱȱȱȱ Ȭȱ ȱȱĜȱȱDZ ȱȱ Float Kit Fuel Solenoid Kit Bowl Kit ȱ ȱȱȱǻŗśŘśȬřŖŚŞȱȦśǰŖŖŖȬŗŖǰŖŖŖȱĞǯǼ ȱ ȱȱȱǻȱřŖŚŞȱȦŗŖǰŖŖŖȱĞǯǼ Figure 5-34. Installing Choke Plate. 1. ȱȱȱŘǯȱ 3. 4. ȱȱȱśǯȱ ȱȱȱŜǯȱ 7. 8. ȱ şǯȱ 10. ȱŗŗǯȱ Carburetor Body Subassembly ȱȱ Idle Speed Spring Screw ȱ ȱ Slow Jet - RH Side Slow Jet - LH Side Ȭȱǻ ȱǼȱǻŘǼ Fuel Bowl Ȭȱǻȱ ȱȬȱǼ ȱŗŘǯȱ 13. 14. ȱŗśǯȱ ȱŗŜǯȱ 17. 18. 19. ȱŘŖǯȱ ȱŘŗǯȱ ȱŘŘǯȱ Ȭȱǻȱ ȱȬȱ Ǽ Drain Screw Bowl Screw (4) ȱ ȱ Float Pin Screw ȱ ȱȦȱ ȱ££ȱȬȱȱ Figure 5-35. Keihin BK Two-Barrel Carburetor - Exploded View. 5.14 ȱŘřǯȱȱȱ££ȱȬȱĞȱ ȱŘŚǯȱ ȱȱȬȱȱ ȱŘśǯȱ ȱȱȬȱĞȱ ȱŘŜǯȱ ȱȱ ȱŘŝǯȱ ȱĞ ȱŘŞǯȱ ȱŘşǯȱ 30. Choke Lever 31. Choke Plate ȱřŘǯȱ ȱȱ ȱǻŘǼ Section 5 Fuel System and Governor • Governor General The governor is designed to hold the engine speed constant under changing load conditions. Most ȱȱȱ ȱȱȱĚ¢ ȱ ȱǯȱȱȱȦĚ¢ ȱ mechanism of the mechanical governor is mounted ȱȱȱȱȱȱěȱȱȱȱȱ Ğǯȱȱȱȱ ȱȱ DZ When load is applied and the engine speed and governor gear speed decreases, the governor spring tension moves the governor arm to open ȱĴȱȱ ǯȱȱ ȱȱȱ into the engine, increasing the engine speed. ȱȱȱȱȱȱĴǰȱȱ governor spring tension and the force applied by ȱȱȱ ȱȱěȱȱȱȱ hold a steady engine speed. Adjustments • Centrifugal force acting on the rotating governor ȱ¢ȱȱȱĚ¢ ȱȱȱ outward as speed increases. Governor spring tension moves them inward as speed decreases. General ȱȱȱĴȱȱȱ¢ȱȱ ȱȱȱĴȱǯȱȱȱȱȱȱ constant, depending on the engine application. Linkage Governor Lever Governor Cross Shaft Governor Spring Governed Idle Spring Figure 5-36. Governor Linkage (Air Cleaner Removed for Clarity). Ȋȱ ȱȱĚ¢ ȱȱ ǰȱ¢ȱȱȱ regulating pin to move outward. • DZȱ ȱȱȱ ȱȱȱĴǯȱ ȱȱ£ȱȱȱȱ personal injury. The regulating pin contacts the tab on the cross ĞȱȱȱĞȱȱǯ ȱ Ȋȱ ȱȱȱȱȱĞȱȱȱȱ ǯȱȱȱȱȱȱȱĞȱȱ ĴȱȱȱĴȱȱȱȱȱ ȱȱ¡ȱĴȱǯȱȱȱ śȬřŜǯ ȱ Ȋȱ ȱȱȱȱȱǰȱȱȱĴȱȱȱ the “fastȄȱǰȱȱȱȱȱȱ ȱȱȱĴȱȱǯȱȱȱ engine is operating, the governor gear assembly is rotating. The force applied by the regulating ȱȱȱȱĞȱȱȱȱȱ Ĵȱǯȱȱȱȱȱȱ the force applied by the regulating pin balance each other during operation, to maintain engine speed. Initial Adjustment Procedure Make this adjustment whenever the governor arm is ȱȱȱȱȱȱĞǯȱȱȱ śȬřŜȱȱȱȱ DZ ȱ ŗǯȱ ȱȱȱĴȱȱȱȱȱ ȱȱȱȱȱĴȱȱȱȱ carburetor. ȱ Řǯȱ ȱȱ¡ȱȱȱȱȱȱȱ ȱȱĞǯ 3. Move the governor lever toward the carburetor ȱȱȱȱ ȱȱǻ ȱȱĴǼȱȱȱ in this position. 4. Insert a long thin rod or tool into the hole on the ȱĞȱȱȱȱĞȱ ȱǻ ȱ from the end) as far as it will turn, then torque the hex nut to 7.3 N·m (65 in. lb.). High Speed (RPM) Adjustment (Refer to Figure 5-37.) ȱ ŗǯȱ ȱȱȱǰȱȱȱĴȱ control to fast. Use a tachometer to check the RPM speed. ȱ Řǯȱ ȱȱȦȱ ȱ ȱȱǰȱ or inward to increase the RPM speed. Check RPM with a tachometer. 5.15 5 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). 5.16 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 ǯȱȱȱȱȱȱȱĚ ȱȱȱ ǰȱȱȱ ȱȱȱȱȱ temperatures. A pressure relief valve limits the maximum pressure of the system. Service ȱȱȱȱȱȱȱȱȱȱǰȱ ȱȱȱǰȱȱȱȱǯȱȱȱ ȱȱȱȱȱŞǰȱşǰȱȱŗŖǯ DZȱ ȱȱȱȱȱǰȱȱȱ ǰȱȱ¡ȱȱȱȱȱ than recommended can cause engine damage. NOTE: Synthetic oils meeting the listed ęȱ¢ȱȱȱ ȱȱȱ performed at the recommended intervals. ǰȱȱ ȱȱȱȱ¢ȱ ǰȱȱ ȱȱȱȱȱȱ ȱȱȱȱśŖȱȱȱȱ ȱȱȱȱ ȱȱ synthetic oil. ȱȱȱ¢ȱȱȱȱęȱȱȱ ȱȱȱȱ¢ȱǯȱȱȱŜȬŗǯ SE RVIC E SAE 10W30 SJ ȱȱȱ¢ǰȱ ǰȱȱȱȱ brand of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. ȱȱȱȱȱǰȱȱȱ¢ȱǰȱȱ ȱȱ ȱȱǯȱ API Oil Recommendations Use high-quality detergent oil of API (American Petroleum Institute) service class SJ, or higher. Select the viscosity based on the air temperature at the time ȱȱȱ ȱȱȱ ȱǯ RECOMMENDED SAE VISCOSITY GRADES 10W-30 ** 5W-20, 5W-30 * Kohler 10W-30 °F -20 °C -30 20 0 -20 -10 32 0 40 60 10 80 20 30 100 40 Figure 6-1. Oil Container Logo. ȱȱȱȱȱ¢ȱ ȱȱȱ such as API SERVICE CLASS SJ. The symbol may ȱȱȱȱȱSH, SG/CC, or CDǯȱȱȱȱ ȱȱ¢ȱȱȱ ȱȱŗŖȬřŖǯȱȱȱĴȱȱ ȱȃ¢ȱ ǰȄȱȱȱȱȱȱȱȱȱ fuel economy in passenger car engines. TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F) * Synthetic oils will provide better starting in extreme cold below 23°C (-10°F) 6.1 6 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. ȱ Řǯȱ ȱȱȱȱȱȱęȱȦȱ ȱȱǯȱȱ ȱȱȱȱǰȱ ȱǰȱǯǰȱȱȱȱǯ ȱ řǯȱ ȱȱȱęȱȦDzȱ ȱȱěǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱęȱȱȱȱǯȱȱȱȱȱȱȱ the tube. See Figure 6-2. DZȱ ȱȱ¡ȱȱ ȱȱǰȱ ¢ȱȱȱȱȱȱȱȱ ǯȱȱȱȱȱ ȱȱ ȱȱ ȱȱȁȁȄȱȱȱȱȱȁȁȄȱ mark on the dipstick. Changing Oil and Oil Filter Changing Oil Change oil seasonally or every 150 hours of ǰȱǻȱ¢ȱȱȱǼǯȱ ęȱ ȱȱȱȱȱȱȱȱęȱȱ ȱȃ¢ȱȄȱȱȱȱŜǯŗǯ ȱȱȱ ȱȱȱȱȱ ǯȱȱȱ ȱĚ ȱȱ¢ȱȱ¢ȱ ¢ȱȱǯȱ ȱȱȱȱȱȱ ȱęȱȱȱ oil. ȱȱȱȱ DZ ȱ ŗǯȱ ȱȱȱȱȱȱȱȱǰȱȱ ęȱȦǯ Oil Fill Cap/Dipstick ȱ Řǯȱ ȱȱȱȱȱȱǰȱȱęȱ Ȧǯȱȱȱȱ ȱȱȱȱ complete drainage. Figure 6-2. Oil Fill Cap/Dipstick. ȱ Śǯȱ ȱȱȱȱȱǯȱȱȱ ȱȱ ȱȱȁȁȂȂȱȱȁȁȂȂȱǯȱȱ ǰȱ ȱȱȱȱȱȱęȱȱȱȱȱ ȱȱȱ¢ȱȱȱȱȃȄȱǯȱȱ ȱęȱȱȱǯȱǻȱȱȃȱ¢Ȅȱ ȱȱŜǯŗǯǼȱ ¢ȱȱȱȱ ȱȱ dipstick before adding more oil. Drain Plug Figure 6-4. Drain Plug (Starter Side). F Operating Range L Figure 6-3. Oil Level Marks on Dipstick. 6.2 Oil Drain Plug Figure 6-5. Drain Plug (No. 2. Side). Section 6 Lubrication System ȱ řǯȱ ȱȱȱȱȱȱȱ21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ. ȱ Śǯȱ ȱȱǰȱ ȱ ȱȱȱȱȱ ¢ǰȱȱȱȃȄȱȱȱȱǯȱȱȱ ȃȱ¢ȄȱȱȱŜǯŗǯȱ ¢ȱȱȱȱ ȱȱȱȱȱȱǯ ȱ śǯȱ ȱȱȱęȱȦȱȱȱ securely. Figure 6-8. Optional Remote Mounted Oil Filter. ȱȱȱęȱȱ DZ ȱ ŗǯȱ ȱȱȱȱęǰȱȱȱȱ ȱȱȱęȱȱȱȱȱȱȱ ȱȱȱȱǯȱȱȱȱęǯȱȱ ȱȱȱęȱǰȱȱȱ ȱȱȱ ȱȱȱȱ ȱȱȱȱȱȱęȱȱǯȱ ȱěȱȱȱ ȱȱȱęȱǯ Figure 6-6. Reinstalling Oil Fill Cap/Dipstick. ȱ Řǯȱ ȱȱȱȱȱȱǯ Changing Oil Filter ȱȱęȱȱȱȱȱȱȱȱȱȱ ȱ ȱȱ¢ǯȱȱȱȱ ȱȱȱȱęǯȱȱȱŜȬŝȱȱŜȬŞǯȱ ȱȱȱęȱseasonally (150 hours)ǰȱȱȱȱ ¢ȱȱȱȱǻevery 300 hours ȱǼǯȱ ¢ȱȱȱȱȱȱęǯ ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱ crankcase. Oil Filter Śǯȱ ȱȱȱȱȱȱȱ21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ. ȱ śǯȱ ¢ȱȱȱęȱȱȱȱȱȱȱȱ ȱȱ ȱęǯȱȱęȱȱȱȱęȱ is recommended. Ŝǯȱ ȱȱȱȱęȱȱȱęȱ ȱȱȱǯȱȱȱȱęȱ ȱ ȱȱȱȱȱȱȱęȱȱ ȱǻȱȱǼǰȱȱȱȱęȱȱ additional 3/4-1 turn. ȱ ŝǯȱ ȱȱȱ ȱ ȱȱȱȱȱ¢ȱ ȱȱȃȄȱȱȱȱǯȱ Oil Filter Housing Figure 6-7. Engine Mounted Oil Filter. 8. Start the engine and check for oil leaks. Correct any leaks before placing the engine into service. Check oil level to be sure it is up to but not over ȱȃȄȱǯ 6.3 6 Section 6 Lubrication System Service Oil Cooler ȱȱȱȱ ȱȱȱȱ ȱȱȱǯȱŘȱȱ¢ȱǰȱ ȱȱȱȱęǯȱȱȱŜȬşǯ 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. ȱȱȱȱǰȱȱȱȱȱęȱ ȱȱǰȱǰȱȱȱǯȱȱǰȱ ȱȱ ȱ ȱȱȱȱȱȱȱ ȱȱ¢ǯȱ¢ȱĞȱȱȱ ȱȱȱȱȱȱǯȱĞȱǰȱ ȱȱȱȱȱȱȱȱ ȱȱ ȱȱ ǯ General ȱȱȱȱ ȱȱȱȱ ¢Ȝȱȱȱȱ ǯȱȱȱŜȬŗŘǯȱȱ ȱȱȱȱȱ ȱȱȱǰȱȱ ȱ¢Ȝȱ ȱȱȱěȱȱȱȱȱ ȱ ȱǰȱȱȱȱǯ ȱȱȱ ȱȱȱȱȱȱȱ ȱȱȱȱȱŝȬŗŗȱǰȱȱȱ ȱȱȱȱȱȱ ȱŝȬŗŗȱǯ ȱȱ¢ȱȱĴȱȱǻǰȱ ǰȱǯǼǰȱȱȱ ȱȱȱȱȱ ground the ignition module to stop the engine. On ȱȱǻ ȱǰȱ ǰȱǯǼȱ ȱȱ ȱȱ¢ȱȱȱȱȱȱ ȃ ȱȄȱ ȱȱȱǯ DZȱ ȱȱȱȱȱȱȱȱ each useȱȱȱȱȱȱȱȃȄȱ mark on the dipstick. This includes engines ȱ ȱȱ¢Ȝǯ Figure 6-10. Cleaning Top of Oil Cooler. Pressure Switch Figure 6-12. Oil Sentry™ Pressure Switch. 6.4 Section 6 Lubrication System Installation ȱȱ¢Ȝȱȱ ȱȱȱȱȱ ȱȱȱǯȱȱȱŜȬŗŘǯȱȱȱȱ ȱ ȱȱ¢Ȝȱȱȱȱȱ ȱ ȱȱ1/8-27 N.P.T.F. pipe plug. ȱȱȱ ǰȱ ȱȱDZ ȱ ŗǯȱ ¢ȱȱȱ ȱĚ®ȱǻ® No. śşŘŚŗȱȱǼȱȱȱȱȱȱ ǯ ȱ Řǯȱ ȱȱ ȱȱȱȱȱȱȱǯȱ ȱȱŜȬŗŘǯ ȱ řǯȱ ȱȱ ȱȱŗŖǯŗȱȉȱǻşŖȱǯȱǯǼ. Testing ȱǰȱȱȱǰȱȱȱ ȱȱ¢ȱȱȱȱȱȱȱ ǯ ȱ ŗǯȱ ȱȱ¢ȱȱȱȱȱ ȱȱȱȱȱȱȱ ǯȱȱ 0 psiȱȱȱȱȱ ǰȱȱȱ should indicate continuity (switch closed). ȱ Řǯȱ ¢ȱȱȱȱȱȱ ǯȱȱ the pressure increases through the range of 7-11 psi the tester should indicate a change to no continuity (switch open)ǯȱȱ ȱȱ remain open as the pressure is increased to 90 psi maximum. ȱ řǯȱ ¢ȱȱȱȱȱȱ range of 7-11 psi. The tester should indicate a change to continuity (switch closed) down to 0 psi. 6 ȱ Śǯȱ ȱȱ ȱȱȱȱȱȱȱ ęǯ 6.5 6.6 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¢ȱȱȱ¢ Electric Starter ȱȱ¢ȱǻȱȱǼȱ řǯȱ ȱȱȱȱȱ ȱȱǯȱȱ the gap to 0.76 mm (0.030 in.)ȱ¢ȱ¢ȱ ȱȱȱǯȱȱȱŝȬŗǯ Wire Gauge Spark Plug Spark Plugs ȱęȱȱȱȱȱĞȱȱ ¢ȱȱȱȱȱȱȱȱȱȱȱȱ condition. The engine is equipped with the following spark plugs: ȱȱȱȱȱȱ ŗŖȱǻȱȱǯȱŜŘȱŗřŘȱŖŚȬǼǯȱ ȱȱȱȱȱȱȱ used. Gap: ŖǯŝŜȱȱǻŖǯŖřŖȱǯǼ Thread Size:ȱ ŗŚȱ Reach: ŗşǯŗȱȱǻřȦŚȱǯǼ Hex Size:ȱ ŗśǯşȱȱǻśȦŞȱǯǼ Type: ® Spark Plug Service Every 200 hours of operation, remove each spark ǯȱȱȱȱȱȱȱȱȱȱ replace with a new plug as necessary. Replace spark plugs every 600 hours. To service the plugs, perform the following steps: ȱ ŗǯȱ ȱȱȱȱǰȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱǯ Ground Electrode 0.76 mm (0.030 in.) Gap Figure 7-1. Servicing Spark Plug. ȱ Śǯȱ ȱȱȱȱȱȱ¢ȱȱ and torque to ŘŚǯŚȬŘşǯŞȱȉȱǻŗŞȬŘŘȱĞǯȱǯǼ. Inspection Inspect each spark plug as it is removed from the cylinder head. The deposits on the tip are an indication of the general condition of the piston rings, ǰȱȱǯ ȱȱȱȱȱ ȱȱȱ ȱ photos: ȱ Řǯȱ ȱȱȱȱȱȱǯȱȱ “Inspection” following this procedure. Replace the plug if necessary. DZȱ ȱȱȱȱȱȱȱȱ ȱȱǯȱȱȱȱ remain in the spark plug and enter the engine causing extensive wear and damage. 7.1 7 Section 7 Electrical System and Components DZȱȱȱȱȱȱȱȱȱ normal conditions will have light tan or gray colored deposits. If the center electrode is not worn, a plug ȱȱȱȱȱȱȱȱȱȱȱ reused. ȱDZȱĞǰȱ¢ǰȱȱȱȱ ȱȱȱ¢ȱȱȱȱ ǰȱȱȱǰȱ ȱǰȱȱȱ compression. Worn:ȱȱȱ ȱǰȱȱȱȱ ȱȱ ȱȱȱȱ ȱȱȱȱȱęȱ gap. Replace a worn spark plug immediately. 7.2 ȱDZȱȱ ȱȱȱȱ¢ȱ¡ȱȱȱ ȱȱȱȱǯȱ¡ȱȱȱ ȱȱ¢ȱȱȱȱǰȱȱȱ ǰȱȱȱȱȱ ȱȱȱ ǯȱȱȱȱȱȱȱ¢ȱ ȱ¢ȱȱȱȱǰȱȱȱǰȱ worn piston rings or valve guides. Overheated:ȱ¢ǰȱ ȱȱȱ¢ȱ ȱȱǯȱȱȱȱ ¢ȱȱ¢ȱ¡ȱȱǯȱȱ ȱĴǰȱȱȱȱǰȱȱȱ ȱȱȱȱȱȱȱȱ temperatures. Section 7 Electrical System and Components Battery General ȱŗŘȬȱĴ¢ȱ ȱŚŖŖȱȱȱȱǻǼȱȱ generally recommended for starting in all conditions. ȱȱ¢ȱĴ¢ȱȱĞȱĜȱȱȱ application is started only in warmer temperatures. ȱȱȱ ȱȱȱȱȱ ȱȱȱȱǯȱȱ actual cold cranking requirement depends on engine size, application, and starting temperatures. The cranking requirements increase as temperatures ȱȱĴ¢ȱ¢ȱǯȱȱȱȱȱ operating instructions of the equipment this engine ȱȱęȱĴ¢ȱǯ Battery Size Recommendations Temperature Battery Required Above 32°F (0°C) 300 cca minimum 0°F to 32°F (-18°C to 0°C) 300 cca minimum -5°F to 0°F (-21°C to -18°C) 300 cca minimum -10°F (-23°C) or below 400 cca minimum ȱȱĴ¢ȱȱȱĜȱȱȱȱȱ ǰȱȱȱĴ¢ǯ ȱ Řǯȱ ȱȱǰȱǰȱȱ¡ȱȱ ȱȱĴ¢ȱǯȱȱȬȱȱȱȱ or grime on the external surfaces can cause the Ĵ¢ȱȱȬǯȱȬȱȱ rapidly when moisture is present. ȱ řǯȱ ȱȱǰȱǰȱȱ¡ȱȱ ȱȱȱȱȱȱ ȱǯȱ Rinse thoroughly with clear water. DZȱ ȱȱ ȱȱȱȱȱ to enter the cells as this will destroy the electrolyte. Battery Test ȱȱȱĴ¢ǰȱ¢ȱ ȱȱȱȱǯȱ ȱȱ ȱȱǻȱȱŝȬŘǼDZ ȱ ŗǯȱ ȱȱȱȱȱĴ¢ȱ terminals. ȱ Řǯȱ ȱȱǯȱȱȱĴ¢ȱȱ ȱşȱ ȱ ȱǰȱȱĴ¢ȱȱȱǰȱ discharged, or faulty. DC Voltmeter 7 Battery Maintenance ȱȱȱ¢ȱȱȱĴ¢ȱ life. WARNING: Explosive Gas! Ĵȱȱ¡ȱ¢ȱȱ ȱȱ ǯȱȱȱȱęȱȱ¡ǰȱȱĴȱ¢ȱ ȱ ȱȱǯȱȱȱȱȱ ¢ȱȱ ȱĴ¢ȱȱȱǯȱȱĴȱȱȱȱȱȱ ǯȱȱȱ ¢ȱ ȱȱĴǯ ȱȱȱȱǻȬǼȱȱǰȱȱ ȱȱ ȱȱǯȱȱǰȱȱȱ ȱȱȱȱ ȱȱȱ ȱȱȱȱ¡ȱȱ ¢ȱȱȱȱȱȱǯ Battery Figure 7-2. Battery Voltage Test. ȱ ŗǯȱ ¢ȱȱȱȱȱ¢ǯȱȱ distilled water as necessary to maintain the recommended level. DZȱ ȱȱęȱȱĴ¢ǯȱȱ performance or early failure due to loss of electrolyte will result. 7.3 Section 7 Electrical System and Components Electronic Ignition Systems ȱȱ ȱěȱ¢ȱȱȱ¢ȱȱȱǯȱȱ¢ȱȱȱȱȱ ȱ£ȱȱȱǯȱȱěȱȱȱ¢ȱȱȱȱ ¢ȱȱȱȱȱǯ The ¡ȱȱ¢ȱ£ȱȱȱȱǻǼȱȱǻȱȱŝȬřǼǯȱȱȱȱȱȱ ¢ȱȱȱȱę¡ȱȱȱ ȱȱȱȱȱȱȱȱȱȱȱ engine speed. The ȱȱȱȱǻǼȱ¢ȱǻȱȱŝȬŜǼǯȱȱ¢ȱȱȱȱȱ which is located in the ignition modules. The ignition timing varies depending upon the engine speed with this system. Molex Plug (Some Models) Figure 7-3. Electronic CD Fixed Ignition Timing System. Operation of CD Ignition Systems Fixed Timing System ȱ¢ȱǻȱŝȬřǼȱȱȱȱ ȱ components: ȱ Ȋȱ ȱȱ¢ȱ ȱȱ¢ȱĜ¡ȱ ȱȱĚ¢ ǯ ȱ Ȋȱ ȱȱȬȱȱ modules which mount on the engine crankcase ǻȱŝȬŚǼǯ ȱ Ȋȱ ȱȱ ȱǻȱ¢ȱ Ǽȱ ȱȱȱ modules to stop the engine. • 7.4 Two spark plugs. Operation:ȱȱȱĚ¢ ȱǰȱȱȱ ȱȱȱȱȱǻŗǼǯȱȱȱ ȱęȱȱ¢ȱȱȱȱȱǻŗǼǯȱ ȱȱȱȱęȱ¢ȱŗȱȱȱ ȱŗǯȱȱȱȱ¢ȱȱȱ ǰȱȱȱȱȱȱǻŘǼǰȱ ȱ ȱȱȱ ȱǻǼȱȱȱǯȱ ȱȱȱ ȱȃǰȄȱȱȱȱ ǻŗǼȱȱ¢ȱȱȱȱ¢ȱǻǼȱȱȱ ȱȱǻŗǼǯȱȱȱȱǰȱ ȱȱȱȱȱȱĚ¡ȱęȱȱȱ ȱǯȱȱȱȱȱȱȱ from this action into the secondary winding of the transformer. This pulse is delivered to the spark plug gap. Ionization of the gap occurs, resulting in an arc ȱȱȱǯȱȱȱȱȱȬȱ ¡ȱȱȱȱǯ 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. Troubleshooting CD Ignition Systems ȱȱȱ¢ȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱȱ¢ȱ Ȧȱȱȱǰȱȱȱ ȱȱȱȱ¢ȱȱǯȱ ȱ¢ȱȱ¢ȱȱȱȱ ȱ ǰȱȱȱ ȱȱ information is provided to help you get to the root of ȱȱǯ CAUTION: High-Energy Electric Spark! ȱȱȱ¢ȱȱȱȬ¢ȱȱ ǰȱȱȱȱȱȱǰȱȱȱȱȱ ¢ȱȱǯȱȱȱȱȱȱȱȱ ȱȱ ȱȱȱǯȱ ¢ȱȱȱȱȱȱ ȱȱȱȱǯ ȱȱȱȱȱĞȱȱȱ ȱǯȱȱȱȱȱǰȱ ȱȱ¡ȱ ǯȱȱȱȱȬȱ wires are connected, including the spark plug leads. ȱȱȱȱȱęȱ¢ǯȱȱ sure the ignition switch is in the run position. DZȱ ȱȱȱ¢ȱȱȱȱ excessive load on the kill lead. If a customer complains of hard starting, low power, ȱęȱȱǰȱȱ¢ȱȱȱȱ excessive draw on the kill circuit. Perform the appropriate test procedure. Test Procedure for Standard (Fixed Timing) CD Ignition System ȱȱ¢ȱȱȱȱ ȱȱȱ ignition system. ȱ ŗǯȱ ȱȱȱȱ ȱȱ ȱ harnesses from the engine and equipment are ǯȱȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱ the connectors and position or insulate the kill lead terminal so it cannot touch ground. Try to start the engine to verify whether the reported ȱȱȱǯ DZȱ ȱȱȱȱȱȱȱ¢ȱȱȱ testing, you may need to ground the kill lead to shut it down. Because you have interrupted the kill circuit, it may not stop using the switch. 7.5 7 Section 7 Electrical System and Components ǯȱ ȱȱȱȱǰȱȱȱ¢ȱ ȱȱȱȱǯȱȱȱ¢ȱ ǰȱ wires, connections, safety interlocks, etc. ȱ ȱ ȱȱȱȱȱȱȱȱ gap. Repeat the procedure on the other cylinder. ȱȱȱȱęȱȱȱǯ ǯȱ ȱȱȱȱȱęǰȱȱȱ ǰȱ connections, and terminals on that side. If wiring is okay, replace ignition module and retest for spark. ǯȱ ȱȱȱȱȱȱȱ associated with the ignition or electrical ¢ȱȱȱǯȱȱȱȱȱ isolated until all testing is completed. ǯȱ ȱȱȱ ȱǰȱȱȱȱ misses or won’t run on that cylinder, try a new spark plug. ȱ Řǯȱ ȱȱȱȱȱ¢ȱ ȱȱ ȱǰȱǻȱȱǯȱŘŚȱŚśśȱŖŘȬǼǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯȱȱȱȱȱ a good ground, not to the spark plug. ǯȱ ȱȱȱȱęǰȱȱȱȱ ignition switch and check for shorted kill lead. Molex Plug (Some Models) Figure 7-6. Digital Spark Advance Ignition (DSAI) System. Operation of DSAI Ignition Systems DSAI Ignition System Explanation ȱȱȱȱȱȱ¢ȱǻǼȱȱ ȱȱȱǯȱȱȱȱ¢ȱȱȱ ǰȱŗŘȬȱȱȱȱę¡ȱȱȱ ¢ȱȱȱȱǯȱ ȱȬ¢ȱ ȱȱȱȱȱȱȱȱ ȱǯȱȱ¢ȱȱȱǻȱŝȬŜǼȱ consists of the following components: ȱ Ȋȱ ȱȱ¢ǰȱ ȱȱ¢ȱĜ¡ȱ ȱȱĚ¢ ǯ ȱ Ȋȱ ȱǰȱŗŘȬȱȱǰȱ ȱ ȱȱȱȱȱǻȱŝȬŜǼǯ ȱ Ȋȱ ȱŗŘȬȱĴ¢ǰȱ ȱȱȱȱȱ ignition modules. ȱ Ȋȱ ȱȱ ȱǻȱ¢ȱ Ǽȱ ȱȱȱ spark advance module to stop the engine. • Two spark plugs. 7.6 Operation The system provides more consistent energy to the ȱȱȱȱȱȱ¢ȱȱȱŗŘȬȱ Ĵ¢ȱȱȱȱȱ ǯȱȱȱȱȱ ȱȱǻǼȱȱȱȱ ȱȱ¢ȱȱĚ¢ ȱȱȱȱȱ passes the ignition module. System triggering and ȱȱȱȱ¢ȱȱ¢Ȭȱ microprocessor. This digital control provides ȱȱȱȱ¢ȱȱ ǯȱȱȱȱȱȱȱ independently for each engine cylinder. Section 7 Electrical System and Components Troubleshooting DSAI Ignition Systems ȱȱȱ¢ȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱȱ¢ȱ Ȧȱȱȱǰȱȱǰȱ ǰȱȱȱȱȱ¢ȱȱ ǯȱȱ¢ȱȱ¢ȱ ȱȱȱ ȱ ǰȱȱȱ ȱ ȱȱȱȱȱȱ¢ȱ ȱȱȱȱȱȱǯ ȱȱȱȱȱĞȱȱȱ ȱǯȱȱȱȱȱǰȱ ȱȱ¡ȱ ǯȱȱȱȱȬȱ wires are connected, including the spark plug leads. ȱȱȱȱȱęȱ¢ǯȱȱ sure the ignition switch is in the RUN position. Test Procedure for DSAI Ignition Systems The following procedures are provided for ȱȱȱȱȱȱ engines. They will allow you to isolate and pinpoint ȱȱǻǼǯ Special Tools Required: • Hand Tachometer ȱ Ȋȱ ȱȘȱǻȱȱǯȱŘśȱŚśśȱŖŗȬǼ ȱ Ȋȱ ȱȱ ȱ Ȋȱ ȬȱǻǼ 6SHFL¿FDWLRQV5HTXLUHG ȱ Ȋȱ ȱȱȱŖǯŝŜȱȱǻŖǯŖřŖȱǯǼ ȘDZȱ ȱȱǻȱȱǯȱ ȱ ŘśȱŚśśȱŖŗȬǼǰȱȱȱȱȱȱȱ on these engines. Use of any other tester can ȱȱȱęǯȱȱĴ¢ȱȱ ȱȱȱȱ¢ȱȱȱ¢ȱ ȱȱȱ¢ȱȱȱȱ ǻȱĴ¢ȱȱȱȱȱȱȱ ȱ ȱȱȱǰȱȱȱ Ȃȱ ȱǼǯȱȱȱȱȱȱȱȱ and all external loads are disconnected. Test 1. Isolate and Verify the Trouble is Within the Engine Ignition System ȱ ŗǯȱ ȱȱȱ ȱȱ ȱȱ ȱȱȱȱȱȱǯȱ Separate the connectors and remove the white ȱȱȱȱȱǯȱȱȱ connectors and position or insulate the kill lead terminal so it cannot touch ground. Try to start ȱȱȱ¢ȱ ȱȱȱȱ is still present. DZȱ ȱȱȱȱȱȱȱ¢ȱȱȱ testing, you may need to ground the kill lead to shut it down. Because you have interrupted the kill circuit, it may not stop using the switch. ȱ ǯȱ ȱȱȱȱ ¢ǰȱȱȱ¢ȱȱ ȱȱȱǯȱȱȱ¢ȱ ǰȱ wires, connections, safety interlocks, etc. ȱ ǯȱ ȱȱȱǰȱȱȱȱȱ with the ignition or electrical system of the ǯȱȱȱȱȱȱȱȱȱ is completed. c. Identify the white kill lead of the engine wiring ȱǯȱȱȱȱȱȱ known good ground location. The engine should kill completely. If not, or only one cylinder is ěǰȱȱȱȱŚǰȱȱȱȱȱ ȱȱȱ ȱȱȱȱěȱȱǯȱ Test 2. Test for Spark ȱ ŗǯȱ ȱȱȱǰȱȱȱȱ ȱǯȱȱȱȱȱȱȱȱ ȱȱȱȱǻȱȱǯȱ ŘśȱŚśśȱŖŗȬǼǰȱȱĴȱȱȱȱȱȱ engine ground. DZȱ ȱ ȱȱȱǰȱȱȱȱ ȱ¢ȱȱȱ¢ǯȱ ǰȱȱ¢ȱȱȱȱǰȱ ȱ ȱȱȱȱǯȱȱȱ ȱȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱȱ the engine or perform tests with one spark plug lead disconnected and not grounded, or permanent system damage may occur. 7.7 7 Section 7 Electrical System and Components ȱ Řǯȱ ȱȱȱǰȱȱȱȱ ȱśśŖȬŜŖŖȱǰȱȱȱǻǼȱȱǯ 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.), ȱȱȱǯȱȱȱ ǰȱȱȱȱřǯ ǯȱ ȱȱ¢ȱȱȱȱȱȱȱ ¢ȱȱȱǰȱȱĴȱǰȱ ȱȱȱŚǯ ǯȱ ȱȱ ȱȱȱȱ¢ȱȱ ȱȱǰȱȱȱȱřǯ Test 3. Check for Timing Advance ȱ ŗǯȱ ȱȱȱȱȱȱȱȱĚ¢ ȱȱ with a marking pen, chalk, or narrow tape. See ȱŝȬŝǯ ȱ Řǯȱ ȱȱȱȱȱȱ¢ȱ that had good spark. Flywheel Screen Mark Figure 7-7. Mark For Timing Advance. ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱǯȱ ȱȱȱ ȱȱ ȱȱ¡ȱȱȱȱȱȱ ǯȱȱȱȱĴȱȱ ȱȱ movement of the line on the screen relative to the ȱȱȱ ȱǯȱȱȱ¢ȱȱ good spark, repeat the test on the other cylinder. ȱȱŝȬŞǯ Figure 7-8. Check For Timing Advance. a. If the line on the screen moved away from ȱȱȱȱ ȱȱȱ ǰȱȱȱȱȱ ȱȱ¢ȱȱȱȱ ȱ ¢ǯȱȱȱȂȱȱ ¢ǰȱȱȱȱŚǯ ǯȱ ȱ¢ȱ ȱȱȱȱȱȱȱ ¢ǰȱȱȱ¢ȱȱȱȱ ȱ ȱȱȱşŖǚȱǯȱȱǰȱȱȱȱ Śǯ Test 4. Test the Ignition Modules and Connections ȱ ŗǯȱ ȱȱ ȱȱȱȱǯȱ ȱȱ ȱȱ¢ȱǰȱǰȱȱ ǰȱȱǰȱȱȱ ǯȱȱ that connections are oriented properly on terminals of modules. ȱ Řǯȱ ȱȱȱȱȱȱǻǼȱ ȱȱȱȱȱȱǻȱȱǼȱ with aerosol electrical contact cleaner to remove any old dielectric compound, dark residue, dirt, ȱǯȱȱȱȱȱ leads from the spark plugs. ȱ řǯȱ ȱȱȬǰȱȱȱȱȱȱ ȱȱ ȱȱȱǻǼȱȱ ȱȱȱȱǻȱȱȱȱǼǰȱ and a known good ground location on the engine. ȱ Śǯȱ ȱȱ¢ȱ ȱȱȱȱȱȱ ȱȱŗŘȱȱȱȱȦ ȱǻǼȱȱ ȱȱȱȱǯȱȱȱȱ ȱȱȱȱȬȱȱȱȱřǯ ǯȱȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱǰȱȱȱěȱ module. ǯȱ ȱ¢ȱȱȱȱȱDzȱȱȱ ȱę¡ȱȱǰȱȱǯ 7.8 Section 7 Electrical System and Components Battery Charging System General Most engines are equipped with a 15, 20, or 25 amp ȱȱ¢ǯȱȱȱŝȬşȱȱŝȬŗřǯȱ DZȱ ȱȱ ȱȱȱ avoid damage to the electrical system and components: ȱ Ȋȱ ȱȱȱĴ¢ȱ¢ȱȱǯȱȱȱ ǻȬǼȱȱ¢ȱȱǯ ȱ Ȋȱ ȱȱęȬȱȱȦȱ ȱ ȱȱȱȱȱ¢ȱȱ ȱȱȱȱ ȱ¢ȱȱǯȱ ǰȱȱȱȱȱȱȱ common ground with the engine. ȱ Ȋȱ ȱȱȱǻǼȱȱȱȱȱ shorting while the engine is running. This could damage the stator. 7 $PS6WDWRUDQG5HFWL¿HU5HJXODWRU )LJXUH$PS6WDWRUDQG5HFWL¿HU5HJXODWRU )LJXUH$PS6WDWRUDQG5HFWL¿HU5HJXODWRU DZȱ ŘŖȱȱȱ¢ȱȱȱŗśȱȱȱ ȱȱŘśȱȱęȬǯ 7.9 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. 7.10 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. 7.11 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. 7.12 Section 7 Electrical System and Components Stator ȱȱȱȱȱȱȱȱ ȱĚ¢ ǯȱ ȱȱȱȱȱŞȱȬȱ ȃ¢ȄȱȱȱŗŖȱȬȱȃ¢Ȅȱȱȱ replacement is necessary. 5HFWL¿HU5HJXODWRU ȱęȬȱȱȱȱȱȱ ȱ¢ǯȱȱȱŝȬŗŚǯȱȱȱǰȱ remove the two mounting screws, then disconnect the plug and ground lead. DZȱ ȱȱȱęȬǰȱȱ note of the terminal positions and install the plug correctly. Ground Lead 5HFWL¿HU Regulator Figure 7-15. Connected Adapter. ȱ Řǯȱ ȱȱȱȱȱǻ ȱȱ Ǽȱȱȱ¢ȱȱȱęȬǯ ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱ to the pair of terminals on the open end of the tandem adapter lead (connections are not ȱęǼǯ ȱ Śǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱęȬ ǯȱȱȱŝȬŗŜǯ 7 Connector Plug )LJXUH5HFWL¿HU5HJXODWRU ȱȱȱęȬȱ¢ȱȱȱ ȱ ǰȱȱȱȱęȬȱ ȱǻȱȱŘǼǯ To Test – DZȱ ȱȱȱȱĴȱ ȱȱęȬǯȱȱ¢ȱȱ ȱ ȱȱęȬȱ ȱȱǯȱȱęȱ ȱȱȱ removed from the engine for clarity. Repeat ȱȱȱ two or three times to determine the condition of the part. Figure 7-16. Connected Tester. $PS5HFWL¿HU5HJXODWRUV ȱ ŗǯȱ ȱȱȱȱȱȱ ȱȱ ƸȱǻǼȱȱȱęȬȱȱ tested and the squared single end of the tandem ȱǯȱȱȱŝȬŗśǯ 7.13 Section 7 Electrical System and Components śǯȱ ȱȱȱȱȱȱȱȦ ȱ ȱȱȱǯȱȱȱȱ ȱ ǯȱ ȱȁȁȂȂȱȱȱȱȱȱ ȱȱȱȱȱȱ¢ȱȱȱȱ ǯȱ ȱȱŝȬŗŝǯȱȱdoes not represent the condition of the part. ȘDZȱ ȱĚȱȁȁȂȂȱȱȱȱȱ as a result of an inadequate ground lead connection. Make certain the connection location is clean and the clamp is secure. $PS5HFWL¿HU5HJXODWRUV ȱ ŗǯȱ ȱȱȱȱȱǻ ȱȱ Ǽȱȱȱ¢ȱȱȱęȬȱȱ tested. ȱ Řǯȱ ȱȱȱȱȱȱȱƸȱȱȱ ȱęȬȱȱȱ ȱȱȱ ȱȱȱ ȱȱǯȱȱȱŝȬŗşǯ Figure 7-17. Powered Tester. ȱ Ŝǯȱ ȱȱȁȁȂȂȱĴȱȱȱȁȁȂȂȱȱȱ ȱȱǯȱȱȱŝȬŗŞǯȱ¢ȱ one of the four lights will illuminate indicating the ȱ of the part. )LJXUH7HVWHU&RQQHFWHGWR$PS5HFWL¿HU Regulator. ȱ řǯȱ ȱȱȱȱȱŗŗŖȱȱȱȱȱȱ ȱ ȱ ǯȱȱȱŝȬŗŝǯȱȱȈȈȱ ȱȱȱȱȱȱȱȱȱ ȱȱ¢ȱȱȱȱ ǯȱȱdoes not represent the condition of the part. ȱ Śǯȱ ȱȱȈȈȱĴȱȱȱȈȈȱȱȱ ȱȱǯȱȱȱŝȬŗŞǯȱ¢ȱȱ of the four status lights will illuminate, indicating the condition of the part. Figure 7-18. Pressing Test Button. ǯȱ ȱȱȁȁȂȂȱǻǼȱȱȱǰȱ ȱȱȱȱȱĴȱȱ ȱȱȱȱȱȱȱȱȱ ȱǯȱȱȱǯȱȱȱȁȁȂȂȱ ǻǼȱȱȱȱǰȱȱȱȱȱ ȱ¢ȱȱǯ ǯȱ ȱ¢ȱȱȱȱ¢Șȱȱȱȱ ȱǰȱȱęȬȱȱ¢ȱȱ ȱȱȱǯ 7.14 ǯȱ ȱȱȃȄȱǻǼȱȱȱȱȱ¢ȱ ¢ǰȱȱȱȱȱȱ¢ȱȱǯ ǯȱ ȱ¢ȱȱȱȱ¢ǰȘȱȱęȬ ȱȱ¢ȱȱȱȱȱǯ ȘDZȱ ȱĚȱȃȄȱȱȱȱȱ as a result of an inadequate ground lead connection. Make certain connection location is clean and 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. Voltage tests should ȱȱ ȱȱȱȱȱřŜŖŖȱȱȬȱȱǯȱȱĴ¢ȱȱȱȱȱ¢ȱǯ Problem Test Conclusion ȱ ŗǯȱ ȱƸȱȱȱęȬȱ ȱ ŗǯȱ ȱȱȱ13.8-14.7 and charge rate increases when load is applied, the charging ȱ¢ȱ ǰȱȱȱȱ ¢ȱȱȱȱĴ¢ȱ ȱ¢ȱǯ ǯȱȱȱȱ ȱȱǯȱȱ an ammeter from loose end of B+ ȱ ȱ ȱȱȱȱȱŗřǯŞȱȱȱȱȱ ȱȱȱȱȱĴ¢ǯȱ not increase when load is applied, test stator ǻȱŘȱȱřǼǯ ȱȱȱȱȱ end of B+ lead to negative terminal ȱĴ¢ǯȱȱȱȱ ȱřŜŖŖȱǰȱȱȱȱ voltmeter. ȱ ȱ ȱȱȱŗřǯŞȱȱȱǰȱȱ ȱȱȱȱśȱȘȱȱ Ĵ¢ȱȱȱǯȱȱ ammeter. No Charge to Battery ȱ Řǯȱ ȱȱȱęȬ ǯȱȱȱȱȱ řŜŖŖȱǰȱȱȱȱ ȱȱȱȱȱȱ voltmeter. ȱ Řǯȱ ȱȱȱŘŞȱȱȱǰȱȱȱǯȱ ęȬȱȱ¢ǯȱȱȱ ęȬǯ ȱřǯȱ ȱȱǰȱȱȱ resistance across stator leads using an ohmmeter. ȱřǯȱ ȱȱȱ0.064/0.2 ohms, the stator is ǯ 7 If voltage is less than ŘŞȱ, stator is ¢ȱ¢ȱȱȱȱǯȱȱ ȱȱȱȱȱǻȱřǼǯ ȱ ȱ ȱȱȱȱę¢ȱǰȱȱȱ open. Replace stator. ȱřǯȱ ȱȱȱǰȱȱ the resistance from each stator lead to ground using an ohmmeter. ȱřǯȱ ȱȱȱȱę¢ȱȱǻȱ ¢Ǽǰȱȱȱȱȱǻȱȱȱ Ǽǯ ȱ ȱ ȱȱǻȱ¢Ǽȱȱǰȱȱ stator leads are shorted to ground. Replace stator. ȱ ŗǯȱ ȱȱȱȱȱŗȱǯ Battery Continuously Charges at High Rate ȱ ŗǯȱ ȱȱȱȱŗŚǯŝȱ or less the charging ¢ȱȱǯȱȱĴ¢ȱȱȱȱ ȱȱǯȱȱĴ¢ȱȱȱȱ necessary. If voltage is more than ŗŚǯŝȱǰȱȱęȬ ȱȱ¢ǯȱȱęȬǯ 7.15 Section 7 Electrical System and Components 5HFWL¿HU5HJXODWRU DC Voltmeter (+) (-) Flywheel Stator Ammeter Battery Figure 7-20. Connections for Testing Charging System. Electric Starting Motors ȱȱȱȱĞȱȱȱȱ ǯȱȱȬ¢ȱȱĞȱȱȱ typically used. Starting Motor Precautions DZȱ ȱȱȱȱȱ¢ȱȱ ȱȱŗŖȱȱȱȱǯȱȱȱȱ ȱȱǰȱ ȱȱŜŖȱȱȬ ȱ ȱ ȱȱĴǯȱȱ ȱ ȱȱȱȱȱȱȱ starter motor. DZȱ ȱȱȱȱĜȱȱȱ ȱȱȱȱȱȱȱ ȱǻȱȱǼǰȱȱȱȱ ȱȱ ȱȱȱȱȱȱȱ ȱĴȱȱȱȱǯȱȱ ȱȱȱȱ ȱȱĚ¢ ȱȱ ǰȱȱȱȱȱĚ¢ ȱȱ gear may clash, resulting in damage to the starter. DZȱ ȱȱȱȱȱȱȱǰȱȱ ěȱȱȱ¢ǯȱȱȱȱ ȱĴȱȱȱȱȱȱȱ condition is corrected. DZȱ ȱȱȱȱȱȱȱȱȱ ǯȱȱȱȱȱȱǯ 7.16 Operation – Solenoid Shift Starter ȱ ȱȱȱȱȱȱȱȱ solenoid moves the drive pinion out onto the drive Ğȱȱȱȱ ȱȱĚ¢ ȱȱǯȱȱ ȱȱȱȱȱȱȱȱĞȱȱȱ ȱĚ¢ ȱȱȱȱǯ ȱȱȱȱȱȱȱ ȱȱȱ the starter solenoid is deactivated, the drive lever ȱǰȱȱȱȱȱȱȱȱȱ with the ring gear into the retracted position. Starter Removal and Installation ȱȱȱȃ¢Ȅȱȱȃ¢Ȅȱ Sections for starter removal and installation procedures. Section 7 Electrical System and Components 7URXEOHVKRRWLQJ*XLGH±6WDUWLQJ'LI¿FXOWLHV Problem Possible Fault Correction Battery ȱ ŗǯȱ ȱȱęȱ¢ȱȱȱĴ¢ǯȱȱ ǰȱȱȱ ȱĴ¢ȱȱ¢ǯ Wiring ȱ ŗǯȱ ȱȱȱȱȱȱǯ ȱ Řǯȱ ȱ ȱȱȱȱȱ ȱ¢ȱȱȱ insulation. Starter Switch or Solenoid ȱ ŗǯȱ ¢Ȭȱȱ ȱȱȱ ȱȱȱ ǯȱȱȱ cranks normally, replace the faulty components. Remove and perform individual solenoid test procedure. See pages ŝǯŘśȱȱŝǯŘŜ. Battery ȱ ŗǯȱ ȱȱęȱ¢ȱȱȱĴ¢ǯȱȱ ǰȱȱȱ ȱĴ¢ȱȱ¢ǯ Starter Does Not Energize Brushes Starter Energizes but Turns Slowly Transmission or Engine ȱ ŗǯȱ ȱȱ¡¢ȱ¢ȱȱ ȱȱȱ ǯȱȱȱȱȱȱǻȱ¢ȱǼǯ ȱ Řǯȱ ȱȱȱ¡¢ȱȱ¢ȱ ǯ ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱ placed in neutral. This is especially important on equipment ȱ¢ȱǯȱȱȱȱȱ¡¢ȱȱ neutral to prevent resistance which could keep the engine from starting. ȱ Řǯȱ ȱȱ£ȱȱȱȱȱȱǰȱ connecting rod, and piston. 7 Delco-Remy Starters Torx Head Screws Figure 7-22. Removing Solenoid Screws. Figure 7-21. Delco-Remy Starter. Starter Disassembly ȱ ŗǯȱ ȱȱ¡ȱȱȱȱȱȱ ǻƸǼȱȱȦȱȱȱȱǯ ȱ Řǯȱ ȱȱȱ¡ȱȱ ȱȱȱ ȱȱȱǯȱȱȱŝȬŘŘǯ ȱ řǯȱ ȱȱȱȱȱȱȱǯȱ Remove the gasket from the recess in the ǯȱȱȱŝȬŘřȱȱŝȬŘŚǯ DZȱ ȱȱȱȱȱ ȱȱȱȱŝǯŘśȱȱŝǯŘŜǯ 7.17 Section 7 Electrical System and Components Figure 7-23. Solenoid Removed from Starter. Figure 7-26. Removing Commutator End Plate Assembly. ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱ ȱǯȱȱȱŝȬŘŝǯ Figure 7-24. Removing Plunger. ȱ Śǯȱ ȱȱ ȱȱǻǼȱǯȱȱȱ ŝȬŘśǯ Figure 7-27. Starter Frame Removed. ȱ ŝǯȱ ȱȱȱȱȱȱȱ ȱȱȱȱȱǯȱȱȱŝȬŘŞǯ Figure 7-25. Removing Thru Bolts. ȱ śǯȱ ȱȱȱȱȱ¢ǰȱ ȱȱȱǰȱǰȱǰȱ and locking caps. Remove the thrust washer from ȱȱȱǯȱȱȱŝȬŘŜǯ 7.18 Figure 7-28. Removing Backing Plate and Pivot Bushing. Section 7 Electrical System and Components ȱ Şǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯȱȱȱŝȬŘşǯ ȱ şǯȱ ȱȱȱ ȱȱȱȱ ĞǯȱȱȱŝȬŘşǯ ȱŗŗǯȱ ȱȱȱȱȱȱĞǯȱ Save the stop collar. DZȱ ȱȱȱȱȱȱǯ Figure 7-31. Removing Retaining Ring. Figure 7-29. Armature and Lever Removed. ŗŖǯȱ ȱȱȱȱ ȱȱ¡ȱȱȱ ǯȱȱȱŝȬřŖǯ ŗŘǯȱ ȱȱȱȱ¢ȱȱȱ armature. ŗřǯȱ ȱȱȱȱǯ DZȱȱ Do not soak the armature or use solvent ȱǯȱȱȱȱȱĞȱ cloth, or use compressed air. Drive End Cap Collar Retaining Ring Stop Drive Figure 7-30. Retaining Ring Detail. Armature Screw Plunger Spring Lever Plate Plug Solenoid Frame & Field Washer Brush Holder Tube Nut Commutator End Plate Screw Bolt Figure 7-32. Delco-Remy Starter. 7.19 7 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. Brushes and Springs ȱȱȱȱȱȱȱ ǰȱǰȱ ȱǯȱȱȱȱȱȱǯȱȱ ȱȱȱȱȱ 7.6 mm (0.300 in.)ǯȱȱȱŝȬřřǯȱȱȱȱȱ¢ȱ ȱ ȱ£ǰȱȱȱȱȱǯ Mica Insulation Figure 7-34. Commutator Mica Inspection. ȱ Řǯȱ ȱȱȱȱȱȱ¡ŗȱǯȱȱȱ ȱ ȱ ȱěȱȱȱȱ ǰȱȱȱȱ¢ǯȱȱȱ ŝȬřśǯȱȱȱȱǯȱ¢ȱȱ¡ȱ ȱȱȱȱȱȱǯ Insulation Check Wear Limit Length 7.6 mm (0.300 in.) Armature Coil Continuity Check Figure 7-35. Checking Armature. Figure 7-33. Checking Brushes. Armature ȱ ŗǯȱ ȱȱȱȱȱǻȱ Ǽǯȱȱȱȱȱȱ ȱȱ ȱȱȱǻǼȱȱȱȱ ȱȱȱǯȱȱȱŝȬřŚǯ ȱ řǯȱ ȱȱ¢ȱ ȱȱȱȱ segments and the commutator segments. See ȱŝȬřśǯȱȱȱȱȱ¢ǯȱȱ ¢ȱ¡ȱ ȱ¢ȱ ǰȱȱȱ ȱǯ ȱ Śǯȱ ȱȱȱ Ȧȱȱ shorting. Shift Fork ȱȱȱĞȱȱȱǰȱȱȱȱ and contact areas are not excessively worn, cracked, or ǯ 7.20 Section 7 Electrical System and Components Brush Replacement Starter Service ȱȱȱȱȱȱȱȱȱǻŚǼǯȱȱ ȱ ȱȱȱȱȱǰȱȱȱȱ necessary. ȱȱȱȱȱȱĞǯȱ¢ȱ ȱȱȱȱȱǻȱȱŘǼȱ ǻȱřŘŘȱȱȱȱ ȱřŘǼȱȱȱȱ ȱĞǯȱȱȱȱȱȱȱȱȱ wear or damage as required. ȱ ŗǯȱ ȱȱŗȬśȱȱȃȱ¢ǯȄ ȱ Řǯȱ ȱȱ ȱ ȱȱȱȱ ȱ¢ȱȱȱȱȱǻǼǯȱȱȱ ȱȱ¢ȱǯȱȱȱŝȬřŜǯȱ ȱȱȱȱȱ¢ǯ Starter Reassembly ȱ ŗǯȱ ¢ȱȱȱǻȱȱŘǼȱȱȱ ȱĞȱǯȱȱȱȱȱ ȱȱȱĞǯ ȱ Řǯȱ ȱȱȱȱȱȦȱ ¢ǯ a. Install the stop collar down onto the armature Ğȱ ȱȱȱȱǻǼȱǯ ǯȱ ȱȱ ȱȱȱȱȱǻǼȱ ȱȱȱȱĞǯȱ£ȱ ȱȱ pliers to compress it in the groove. c. Figure 7-36. Removing Brush Holder. Slide the stop collar up and lock it into place, so the recess surrounds the retainer in the groove. If necessary, rotate the pinion outward on the armature splines against the retainer to help seat the collar around the retainer. 7 ȱ řǯȱ ȱȱȱȱȱǯ ȱ Śǯȱ ȱ ȱȱȱȱȱȱ ȱȱȱȱ ȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱȱ ŝȬřŝǯ Figure 7-38. Installing Stop Collar and Retainer. DZȱȱ ¢ȱȱȱ ȱǯȱȱȱȱ ȱȱ ȱȱȱǯ Figure 7-37. Service Brush Kit. ȱ śǯȱ ȱȱŗŖȬŗřȱȱȱȃȱ¢Ȅȱ ǯȱȱȱȱȱĞȱȱ armature, drive lever, and frame are installed, if ȱȱȱȱǯ 7.21 Section 7 Electrical System and Components řǯȱ ȱȱěȱȱǻǼȱ ȱȱȱ ȱȃěȄȱȱȱ ȱȱȱȦ ǯȱȱȱŝȬřşǯ ȱ ŝǯȱ ȱȱȱ ǰȱ ȱ¢ȱȱȱ grommet, into the matching recess of the drive end cap. The molded recesses in the grommet ȱȱȃȄǰȱȱȱȱ ȱ ȱȱȱȱǯȱȱȱŝȬŚŗǯ Thrust Washer Figure 7-39. Installing Thrust Washer. ȱ Śǯȱ ¢ȱȱȱȱȱȱȱȱȱȱȱ drive end cap, and install the armature with the drive pinion. Figure 7-41. Installing Backup Washer and Grommet. ȱ śǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱ ȱȱȱǻȱȱŘǼǯȱ ȱȱȱȱȱȱȱ ȱȱ captured washer and the rear of the pinion. ȱ Şǯȱ ȱȱǰȱ ȱȱȱȱ ǰȱ ȱȱȱȱȱȱǯȱȱȱ notch with the corresponding section in the ȱǯȱȱȱȱȱȱȱȱ ǰȱȱȱ ȱȱ¢ǯȱȱȱ ŝȬŚŘǯ ȱ Ŝǯȱ ȱȱȱȱȱȱȱǰȱȱ at the same time seat the drive lever into the housing. DZȱ ¢ȱǰȱȱȱȱ ȱȱȱȱȱ ȱȱĚȱ ȱ ȱȱȱȱȱȱ ȱ ȱȱȱȱ ǯȱȱȱŝȬŚŖǯ Figure 7-42. Installing Frame and Drain Tube. ȱ şǯȱ ȱȱĚȱȱ ȱȱȱȱ ȱȱȱȱĞǯȱȱȱŝȬŚřǯ Figure 7-40. Installing Armature and Pivot Lever. 7.22 Section 7 Electrical System and Components Thrust Washer Figure 7-43. Installing Thrust Washer. ȱŗŖǯȱ ȱ¢ȱ ȱȱȱȦ ȱ ȱ¢DZ ǯȱ ȱȱȱ¢ȱ¢ȱȱȱ end housing, and carefully position the ȱȱȱ¢ǰȱ ȱȱ ȱȱǰȱȱȱȱȱ ȱȦǯȱȱȱ ȱȱȱȱȱȱȱȱ ȃȦǯȄȱȱȱȱȱ¢ȱ down into place around the commutator, and ȱȱȱǻƸǼȱȱȱȱȱ ȱȱȱȱǯȱȱȱŝȬŚŚǯȱȱ ȱȱ¢ȱȱȱȱȱȱ future servicing. Figure 7-45. Removing Retaining Clips. ǯȱ ȱȱȱȱȱȱȱȱ ȱȱ¢ȱȱĚȱ ȱȱǯǯȱȱȱ ȱȱ¢ǯȱȱȱȱ ȱȱǻ ȱ¡Ǽǰȱȱȱȱ ȱȱȱȱȱȱȱ ǰȱȱȱȱȱ ¢ǰȱȱȱȱȱȱȱȱ ȱȱȃȦǯȄ ǯȱ ȱȱȱȱȱȱȱȱȱ ȱǯȱȱȱŝȬŚŜǯ 7 Figure 7-46. Brush Installation Tool with Extension. Figure 7-44. Installing Brush Holder Assembly with Supplied Tube. ȱ¢ȱ ȱȱȱȱȦ ȱ ȱ¢DZ ǯȱ ¢ȱȱȱȱȱȱ ȱȱȱȱȱǯȱȱȱ ȱȱǯȱȱȱŝȬŚśǯ 7.23 Section 7 Electrical System and Components Extension. ǯȱ ȱȱȱ¢ȱ¢ȱȱȱ end housing, and carefully place the tool ǻ ȱ¡Ǽȱȱȱȱ ȱȱ¢ȱȱȱȱȱ ȱȱĞǯȱȱȱȱȱ ¢ȱ ȱȱȱȱȱ ǰȱȱȱȱǻƸǼȱȱ lead grommet in the cutout of the frame. See ȱŝȬŚŝǯ Figure 7-49. Torquing Brush Holder Screws. ŗřǯȱ ȱȱȱȱȱȱȱȱ the drive lever, and install the spring into the solenoid. Insert the three mounting screws through the holes in the drive end cap. Use these to hold the solenoid gasket in position, then mount the solenoid. Torque the screws to ŚǯŖȬŜǯŖȱȉȱǻřśȬśřȱǯȱǯǼ. Figure 7-47. Installing Brush Holder Assembly using Tool with Extension. ŗŗǯȱ ȱȱȱȱȱȱȱȱǰȱ ȱȱȱȱȱȱȱȱȱ ȱ the corresponding slot in the grommet of the ȱǻƸǼȱȱǯ ŗŘǯȱ ȱȱ ȱȱǰȱȱȱ ȱȱ ȱȱ ǯȱȱȱȱȱȱ śǯŜȬşǯŖȱȉȱǻŚşȬŝşȱǯȱǯǼǯȱȱȱȱ holder mounting screws to 2.5-3.3 N·m ǻŘŘȬŘşȱǯȱǯǼǯȱȱȱŝȬŚŞȱȱŝȬŚşǯ ŗŚǯȱ ȱȱȱǻƸǼȱȱȦȱ to the solenoid and secure with the hex nut. Torque the nut to ŞȬŗŗȱȉȱǻŝŗȬşŝȱǯȱǯǼǯȱȱȱ ǯȱȱȱŝȬśŖǯ Positive Brush Lead Figure 7-50. Positive (+) Brush Lead Connection. Figure 7-48. Torquing Thru Bolts. 7.24 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 ȱȱȱȱȱĚȱȱȃȦȄȱȱ on the solenoid. Momentarily* connect the other lead ȱȱ ȱȱȱǯȱȱȱŝȬśŗǯ ȱȱȱȱȱȱȱȱ £ȱǻȱǼǰȱȱȱȱǯȱ Repeat the test several times. If the solenoid fails to ǰȱȱȱȱǯȱ Ș:ȱ ȱȱȱȱŗŘȱȱȱȱ connected to the solenoid for any time over what is necessary for performing each of the individual tests. Internal damage to the solenoid may otherwise occur. 12 volt Test Leads Momentary Connection Only VOM Leads Figure 7-52. Testing Pull-In Coil/Solenoid Contact Continuity. Test 3. Solenoid Hold-In Coil Function Test. ȱȱŗŘȱȱȱȱȱȱĚȱȱȃȦ start” terminal on the solenoid, and the other lead to ȱ¢ȱȱȱȱȱȱǯȱǰȱ manually push the plunger “In” and check if the ȃ ȬȄȱȱȱȱȱǯȱȱȱ ŝȬśřǯȱȱȱ ȱȱȱȱȱȱȱ to the solenoid for a prolonged period of time. If the ȱȱȱ¢ȱǰȱȱȱȱȱ replaced. Manually Push Plunger "In" 12 volt Test Leads Momentary Connection Only Figure 7-51. Testing Pull-In Coil/Plunger Actuation. Test 2. Solenoid Pull-In Coil/Contact Continuity Test. ȱȱȱȱȱȱȱȱ¡Řȱǰȱȱ connect the two ohmmeter leads to the two large post ǯȱȱȱȱȱǻŗǼȱȱȱ ȱ¢ǯȱȱȱŝȬśŘǯȱȱȱȱ indicate continuity, if no continuity is indicated the ȱȱȱǯȱȱȱȱȱ ȱęȱǯ 7 12 volt Test Leads Connect Only Long Enough to Test Figure 7-53. Testing Hold-In Coil/Function Test. 7.25 Section 7 Electrical System and Components Test 4. Solenoid Hold-In Coil/Contact Continuity Test. ȱȱȱȱȱȱȱȱ¡Řȱǰȱȱ connect the two ohmmeter leads to the two large post ǯȱȱȱȱȱǻřǼȱȱȱ ȱ¢ǯȱȱȱŝȬśŚǯȱȱȱȱ indicate continuity, if no continuity is indicated the ȱȱȱǯȱȱȱȱȱ ȱęȱǯ Plunger Pushed "In" VOM Meter Leads 12 volt Test Leads Figure 7-54. Testing Hold-In Coil/Solenoid Contact Continuity. 7.26 Section 8 Disassembly WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, ȱȱȱȱ DZȱŗǼȱȱȱȱȱǻǼǯȱŘǼȱȱȱǻȬǼȱĴ¢ȱȱȱĴ¢ǯ Clean all parts thoroughly as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil and grime from engine parts. When such a cleaner is used, follow the manufacturer’s instructions and safety precautions carefully. Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation. Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil. 21. 22. ȱŘřǯȱ 24. 25. ȱŘŜǯȱ 27. ȱŘŞǯȱ 29. ȱřŖǯȱ ȱřŗǯȱ ȱřŘǯȱ 33. Typical Disassembly Sequence Disconnect Spark Plug Leads The following sequence is suggested for complete engine disassembly. The sequence can be varied to accommodate options or special equipment. 1. ȱ Řǯȱ ȱ řǯȱ ȱ Śǯȱ 5. 6. 7. 8. 9. 10. 11. 12. ŗřǯȱ 14. ȱŗśǯȱ 16. 17. ŗŞǯȱ ȱŗşǯȱ 20. Disconnect spark plug leads. ȱěȱȱ¢ǯ ȱȱȱȱȱȱȱęǯ ȱĝǯ Remove cylinder shrouds and blower housing. Remove electric starter motor. Remove air cleaner assembly. Remove fuel pump. Remove control bracket, governor springs and lever. Remove carburetor. Remove intake manifold. Remove Oil Sentry™ (if equipped). ȱĝȱȱȱǯ Remove oil cooler. ȱȱęȱǯ Remove ignition modules. Remove grass screen and cooling fan. ȱĚ¢ ǯ ȱǰȱęȬȱȱ ȱ harness. Remove backing shroud assembly. Remove spark plugs. Remove valve covers. ȱ¢ȱȱȱ¢ȱĞǯ Remove breather assembly. Remove oil pan assembly. ȱĞǯ Remove connecting rods with pistons and rings. ȱĞǯ Removal of governor gear. ȱȱȱ¢ǰȱȱĞȱȱǯ ȱĞȱȱȱȱȱǯ ȱĚ¢ ȱȱȱȱȱǯ Removal of main bearings. 1. Disconnect the leads from the spark plugs. See ȱŞȬŗǯ 8 DZȱ ȱȱȱ¢ǰȱȱȱȱȱȱ plug lead. Figure 8-1. Disconnect Spark Plug Leads. 8.1 Section 8 Disassembly Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter ȱ ŗǯȱ ȱȱȱęȱȱȱǯȱȱȱ ȱȱȱęǯȱȱȱŞȬŘǯ 3. Allow ample time for the oil to drain from the crankcase. 5HPRYH0XIÀHU ȱ ŗǯȱ ȱȱ¡ȱ¢ȱȱĴȱ hardware from the engine. Remove Cylinder Shrouds and Blower Housing 1. Remove the top mounting screw and loosen the ȱȱ ȱȱȱǯȱĞȱěȱȱ ȱ ¢ȱǯȱȱȱŞȬśǯ Cylinder Shroud Figure 8-2. Removing Oil Filter. 2. Remove the dipstick and one of the oil drain plugs. Figure 8-5. Removing Cylinder Shrouds. 2. Remove the four mounting screws and separate the blower housing from the backing shroud ¢ǯȱȱ ȱȱȱȱȱęȦ ȱǯȱȱȱŞȬŜǯȱȱę¡ȱȱ (equipped models) may be removed with the blower housing. Figure 8-3. Removing Dipstick from Tube. Mounting Screws Figure 8-6. Removing Blower Housing. Drain Plug (Starter Side Shown) Figure 8-4. Oil Drain Plug Location. 8.2 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 ǯȱȱȱŞȬŗŖǯ Remove Electric Starter Motor 1. Disconnect the leads from the starter. ȱ Řǯȱ ȱȱ ȱ¡ȱĚȱ ȱȱǯȱ ȱȱŞȬŞǯ Mounting Screws 8 Mounting Screws Figure 8-10. Mounting Screws. 4. Remove the air cleaner from the engine as an ¢ǯȱȱȱŞȬŗŗǯ Figure 8-8. Removing Electric Starter. Remove Air Cleaner Assembly 1. Disconnect the breather hose from the air cleaner, and the formed vent hose from the vent port on the carburetor. ȱ Řǯȱ ȱȱȱ¡ȱĚȱȱȱȱȱ ȱȱȱǯȱȱȱŞȬşǯȱ Figure 8-11. Removing Air Cleaner Assembly. 8.3 Section 8 Disassembly Remove Fuel Pump WARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱȱȱ¢ȱȱȱǰȱȱ ȱǰȱȱǰȱ ¢ȱȱȱȱ Ěǯȱȱȱęȱȱȱȱ 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. NOTE: Based on the style of fuel pump used, refer to the following. Pulse Style Fuel Pump The pulse style fuel pump is mounted to the side of the control bracket. It may be removed separately or with the bracket. To remove separately: ȱ ŗǯȱ ȱȱ ȱ¡ȱĚȱȱ ȱ securing the fuel pump to the control bracket. 2. Disconnect the inlet, outlet, and pulse (vacuum) ȱȱȱȱȱǯȱȱȱŞȬŗŘǯȱ ¢ȱȱ¢ȱȱǯȱ Outlet Hose ȱ Řǯȱ ȱȱĴȱȱȱȱ spring from the governor lever at the small ǯȱȱȱŞȬŗřǯ Pal Nut Governor Springs Choke Linkage Throttle Linkage Figure 8-13. Disconnect Linkages and Governor Springs. ȱ řǯȱ ¢ȱ¢ȱěȱȱȱǰȱȱȱ ȱ washers (note assembly order), and disconnect the choke linkage from the pivot lever. Do not lose any parts. Secure the remaining pivot parts with tape, to avoid losing them. Always use a new pal nut during reassembly. 4. If the fuel pump is being removed with the bracket disconnect the pulse (vacuum) hose and ȱȱȱȱȱȱǯȱ¢ȱ ȱ¢ȱȱǯȱȱȱŞȬŗŚǯ Pulse Hose Pulse Hose Mounting Screws Figure 8-12. Removing Pulse Pump. Electric Fuel Pump 1. Removal will be determined based on mounted location and application. Disconnect the lead connections, fuel line connections and mounting ȱȱǯȱ¢ȱȱ¢ȱ remaining fuel. Remove Control Bracket, Governor Springs and Lever 1. Unhook the governed idle and governor springs from the controls on the main bracket and the governor lever. Note the color, location, and ȱȱǯȱȱȱŞȬŗřǯ 8.4 Fitting Figure 8-14. Disconnecting Pulse Hose. 5. Remove the lower mounting screw going into the intake manifold and remove the main control ǯȱȱȱŞȬŗś Section 8 Disassembly Control Bracket Lower Mount Figure 8-15. Removing Control Bracket. ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱ ȱȱȱȱĞǯȱȱȱŞȬŗŜǯ 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. ȱȱŞȬŗŞǯ 8 Figure 8-16. Removing Governor Lever. Remove Carburetor WARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱȱȱ¢ȱȱȱǰȱȱ ȱǰȱȱǰȱ ¢ȱȱȱȱ Ěǯȱȱȱęȱȱȱȱ 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. ȱ ŗǯȱ ȱȱȱȬěȱȱǯ Pressure Switch Figure 8-18. Oil Sentry™ Switch Location in Oil Pan. 5HPRYH%DIÀHVDQG,QWDNH0DQLIROG ȱ ŗǯȱ ȱȱ ȱȱȱ¢ȱĝȱȱ the cylinder heads and backing shroud assembly. 2. Remove the fuel inlet hose from the carburetor. ¢ȱȱ¢ȱȱǯ 3. Remove the carburetor, and linkages as an ¢ǯȱȱȱŞȬŗŝǯ 8.5 Section 8 Disassembly Remove Oil Cooler Valley %DIÀH 1. Remove the two oil cooler mounting screws. Do ȱȱ¢ȱ ȱǻȱǼǯȱȱȱŞȬŘŘǯ )LJXUH5HPRYLQJ9DOOH\%DIÀHV 2. Remove the four screws securing each of the ȱ¢ȱĝȱȱǯȱȱȱŞȬŘŖǯ Figure 8-22. Removing Oil Cooler Mounting Screws. 2. Loosen the clamps and disconnect each of the ȱȱȱȱǯȱȱȱŞȬŘřǯ NOTE: New clamps are recommended any time disassembly is performed, or if clamps have been loosened (expanded) several times. Mounting Screw Locations )LJXUH5HPRYLQJ2XWHU&\OLQGHU%DIÀHV ȱ řǯȱ ȱȱȱ¡ȱĚȱ ȱȱȱ intake manifold to the cylinder heads. Cut any wire ties securing wiring. 4. Remove the intake manifold and gaskets. See ȱŞȬŘŗǯ Mounting Locations Mounting Locations Figure 8-23. Disconnecting Hoses From Oil Cooler. Remove Oil Filter Housing ŗǯȱ ȱȱ ȱȱȱȱęȱȱ ȱȱȬȱȱȱǰȱȱ ¢ȱȱȱǯȱȱȱŞȬŘŚǯ DZȱ ȱ¢ȱȱȱȱęȱ housing assembly is not necessary unless being serviced individually. Follow Substeps a, b, and c. Figure 8-21. Removing Intake Manifold. 8.6 Section 8 Disassembly c. Remove the rubber valve and spring from the ǯȱȱȱŞȬŘŝǯ 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 ȱȱȱśȦŗŜȈȱȱ Ȧǯȱȱ ȱŞȬŘśǯ Figure 8-27. Rubber Valve and Spring Removed from Cup. Remove Ignition Modules ȱ ŗǯȱ ȱȱĚ¢ ȱȱȱȱȱ ¢ȱȱ the modules. 2. Remove the mounting screws and disconnect the kill lead from the ignition modules. Note the position of the ignition modules and wiring ȱǯȱȱȱŞȬŘŞǯ 8 Mounting Screws Nipple Figure 8-25. Removing Nipple. Ignition Module ȱ ǯȱ ȱȱȱęȱȱȱȱȱ ǯȱȱȱŞȬŘŜǯ Kill Lead Housing Spring Figure 8-28. Removing and Disconnecting Ignition Modules. Cup Nipple Figure 8-26. Disassembled Cup and Spring. 8.7 Section 8 Disassembly Remove Grass Screen and Cooling Fan ȱ ŗǯȱ ȱȱ ǰȱĴȱ ǰȱȱ¡ȱ ȱȱȱȱǰȱěǰȱȱ ȱȱȱȱĚ¢ ǯȱȱȱŞȬŘşȱȱ ŞȬřŖǯ Fasteners Figure 8-31. Removing Flywheel Fastener Using Holding Tool. ȱ Řǯȱ ȱȱ¡ȱĚȱ ȱȱ ǯ Figure 8-29. Removing Grass Screen Fasteners. Screws (3) Hex Studs (4) Fan ȱ řǯȱ ȱȱȱȱȱȱĚ¢ ȱȱȱ ĞǯȱȱȱŞȬřŘǯ DZȱ ¢ȱȱȱĚ¢ ȱȱȱȱ ȱĚ¢ ȱȱȱĞǯȱDo notȱȱȱĞȱȱĚ¢ ǰȱ as these parts could become cracked or damaged. Figure 8-30. Removing Cooling Fan and Hex Studs. Remove Flywheel ȱ ŗǯȱ ȱȱĚ¢ ȱȱ ȱȱȱȱǻȱ ȱŘǼǰȱȱȱȱĚ¢ ȱȱȱȱ ¡ȱĚȱ ȱȱȱĚ¢ ȱȱȱ ĞǯȱȱȱŞȬřŗǯ DZȱ ¢ȱȱȱĚ¢ ȱȱ ȱȱ ȱȱȱȱȱĚ¢ ȱ ȱ ȱȱȱȱĚ¢ ȱ screw. Do not use any type of bar or ȱȱȱȱĚ¢ ǯȱȱȱȱ ȱȱȱȱĚ¢ ȱȱȱ cracked or damaged. 8.8 Figure 8-32. Removing Flywheel with a Puller. ȱ Śǯȱ ȱȱ ěȱ¢ȱȱȱĞǯ 5HPRYH6WDWRU5HFWL¿HU5HJXODWRUDQG Wiring Harness ȱ ŗǯȱ ȱȱȱȱȱęȬǯȱ If the B+ (center ) lead must be removed from the plug, use the tip of the dipstick or a similar small Ěȱȱȱȱȱȱǯȱȱȱȱ the lead. 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 ¢ǯȱȱȱŞȬřřǯ 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. See Figure ŞȬřŜǯ )LJXUH5HFWL¿HU5HJXODWRU'HWDLOV 3. Remove the two screws securing the stator to the crankcase and carefully separate the stator wires ȱȱȱǯȱȱȱŞȬřŚǯ Backing Shroud Assembly Molded Clips Screws 8 Figure 8-36. Removing Backing Shroud Mounting Screws. Mounting Screws Remove Spark Plugs 1. Remove the spark plug from each cylinder head. Figure 8-34. Removing Stator. 4. Unhook the wiring harness from the molded ȱȱȱȱ¢ǯȱȱȱŞȬřśǯ Figure 8-37. Removing Spark Plugs. 8.9 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¢ȱȱěǯȱȱȱŞȬřŞǯ Spacer Washers Figure 8-40. Removing Cylinder Head Fasteners. 3. Mark the position of the push rods as either ȱȱ¡ȱȱ¢ȱŗȱȱŘǯȱȱȱ rods should always be reinstalled in the same positions. Figure 8-38. Removing Valve Covers. Remove Cylinder Heads and Hydraulic Lifters 4. Carefully remove the push rods, cylinder head, ȱȱǯȱȱȱŞȬŚŗǯ 5. Repeat the procedure for the other cylinder head. ȱ ŗǯȱ ȱȱȱȱ ȱȱȱěȱȱ rocker arm adjusting nuts. 2. Remove the pipe plug from the cylinder head to access the screw in the center location. See Figure ŞȬřşǯ Pipe Plug Figure 8-41. Removing Cylinder Head Assembly. Figure 8-39. Removing Pipe Plug. ȱ řǯȱ ȱȱęȱ¡ȱĚȱ ȱȱȱ cylinder head. Note the locations of washers and ȱǯȱȱȱŞȬŚŖǯ 8.10 ȱ Ŝǯȱ ȱȱĞȱȱȱĞȱǯȱȱȱ ¢ȱĞȱǯȱȱȱȱȱȱȱ ȱĞǯȱȱȱĞȱ¢ȱǰȱȱ either intake or exhaust and cylinder 1 or 2. ¢ȱĞȱȱ ¢ȱȱȱȱ ȱȱǯȱȱȱŞȬŚŘȱȱŞȬŚřǯ DZȱ ȱ¡ȱĞȱȱȱȱȱ ȱĞȱȱȱȱȱ ȱȱ ȱĞȱȱȱȱȱȱȱ of the engine. The cylinder head number is embossed on the outside of each ¢ȱǯȱȱȱŞȬŚřǯ 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 ȱǯȱȱȱŞȬŚŜȱȱŞȬŚŝǯ 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. Remove the two adjusters, rocker arm pivots, and rocker arms from the cylinder head. Remove the pivot studs and guide plate as required. See ȱŞȬŚŚǯ Figure 8-46. Valve Train Components. Figure 8-44. Removing Rocker Arms. 2. Compress the valve springs using a valve spring ǯȱȱȱŞȬŚśǯ 8.11 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 ȱȱȱȱȱǯȱȱȱŞȬśŖǯ 4. Repeat the above procedure for the other cylinder head. Do not interchange parts from one cylinder head to the other. Remove Breather Assembly ȱ ŗǯȱ ȱȱȱ¡ȱĚȱ ȱȱȱȱ breather assembly, and gasket to the crankcase. 2. Carefully break the gasket seal and remove the ȱȱęǯȱȱȱ¢ȱȱȱȱ surfaces as it could cause damage resulting in leaks. Note the assembly and orientation of parts. ȱȱŞȬŚŞȱȱŞȬŚşǯ Breather Gasket Figure 8-50. Removing Oil Pan Screws. 2. Locate the two protruding tabs on the oil pan. Carefully tap to break the gasket seal. Do not pry on the sealing surfaces as this could cause leaks. Separate the oil pan from the crankcase. See ȱŞȬśŗȱȱŞȬśŘǯȱȱȱȱǯ Tabs Figure 8-48. Removing Breather Assembly. Figure 8-51. Location of Protruding Tabs. 8.12 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 ȱȁȁȱȱ¢ȂȂȱȱȱşǯ Figure 8-54. Removing Connecting Rod Screws. NOTE: If a carbon ridge is present at the top of either cylinder bore, use a ridge reamer tool to remove the ridge before Ĵȱȱȱȱǯ Remove Camshaft ȱ ŗǯȱ ȱȱĞȱȱȱǻȱǼǯȱȱ ȱŞȬśřǯ 8 Figure 8-55 Remove Connecting Rod Caps. Figure 8-53. Removing Camshaft. Remove Connecting Rods with Pistons and Rings NOTE: The cylinders are numbered on the crankcase. Use the numbers to mark each end cap, connecting rod and piston for reassembly. Do not mix end caps and connecting rods. ŗǯȱ ȱȱ ȱ¡ȱĚȱ ȱȱȱ closest connecting rod end cap. Remove the end ǯȱȱȱŞȬśŚȱȱŞȬśśǯ 8.13 Section 8 Disassembly 2. Carefully remove the connecting rod and piston ¢ȱȱȱ¢ȱǯȱȱȱŞȬśŜǯ 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 Ğǯȱȱȱȱȱȱȱ ȱ¢ǯȱȱȱŞȬśŞǯ Governor Gear Figure 8-56. Removing Piston/Connecting Rod Assemblies. 3. Repeat the above procedures for the other connecting rod and piston assembly. Figure 8-58. Removing Governor Gear. Remove Crankshaft ŗǯȱ ¢ȱȱȱĞȱȱȱǯȱ ȱȱŞȬśŝǯȱȱȱ ȱȱȱȱ used. ȱ řǯȱ ȱȱȱȱĞȱȱ ȱȱ ǯȱȱȱĞȱ¢ȱȱȱȱ needed. Remove Governor Yoke, Cross Shaft, and Oil Seal 1. Remove the two mounting screws securing the ¢ȱȱȱȱȱĞǯȱȱȱŞȬśşǯ Figure 8-57. Removing Crankshaft. Removal of Governor Gear Assembly ȱȱȱȱȱȱȱĞȱ¢ȱȱ molded tabs in the gear. When the gear is removed ȱȱĞǰȱȱȱȱ¢ȱȱȱȱ must be replaced. Therefore, remove the gear only ȱ¢ȱ¢ǯȱȱȱȱȱȱĞǰȱ yoke, or gear condition does not require removal, ȱȱȱ¢ȱȱĞȱȱǯȱȱȱȱ necessary, perform as follows: 8.14 Figure 8-59. Removing Cross Shaft/Yoke Screws. ȱ Řǯȱ ȱȱȱȱĞȱȱȱȱȱ remove seal. Section 8 Disassembly Remove Lifter Feed Chamber Cover and Gaskets ȱ ŗǯȱ ȱȱȱ ȱȱȱĞȱȱ chamber cover, and gaskets. Carefully separate ȱȱȱȱǯȱȱȱŞȬŜŖǯ Screws Cover Removal of Main Bearings DZȱ ¢ ȱȱȱȱȱȱȱ should only be removed if replacement is required due to wear. If removal is performed, use a press and support the adjacent cast surface around the bearing Ěȱ ȱǯȱDo not press ȱȱȱ¢ȱȱȦȱ ȱǯȱȱȱŞȬŜŘǯ Gasket Figure 8-60. Removing Lifter Feed Chamber Cover Components. Remove Flywheel and PTO End Oil Seals 1. Remove the oil seals from the crankcase and oil ȱȱȱȱǯȱȱȱȱŞȬŜŗǯ Support This Surface Figure 8-62. Support Surface Details. 8 Figure 8-61. Removing Oil Seals. 8.15 8.16 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. There are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts. When such a cleaner is used, follow the manufacturer’s instructions and safety precautions carefully. Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation. Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil. Use an aerosol gasket remover, paint stripper, or lacquer thinner to remove any old gasket material. Apply the solvent, allow time for it to work, and then brush the surface with a brassȱ ȱǯȱĞȱ all old material is removed, clean the surface with isopropyl alcohol, lacquer thinner, or aerosol electrical contact cleaner. Do not scrape the surfaces, as any scratches, nicks, or burrs can result in leaks. See Service Bulletin 252 for further information. Refer to A Guide to Engine Rebuilding (TP-2150-A) for additional information. Measurement Guide (TP-2159-B) and Engine Inspection Data Record (TP-2435) are also available; use these to record inspection results. Camshaft Inspection and Service ȱȱȱȱȱĞȱȱ ȱȱǯȱ ȱȱŗȱȱȱĞȱȦȱȱ ęǯȱȱȱȱȱȱ¢ȱ ǰȱ chipped, or missing teeth. Replacement of the Ğȱ ȱȱ¢ȱȱ¢ȱȱȱȱ exist. Crankshaft Inspection and Service ȱȱȱȱȱȱĞǯȱȱȱȱ are badly worn, chipped, or some are missing, ȱȱȱĞȱ ȱȱ¢ǯ ȱȱĞȱȱȱȱǰȱ grooving, etc. Replaceable bearings are used in the ĞȱȱȱȱȱȱȦȱǯȱȱ not replace the bearings unless they show signs of ȱȱȱȱȱȱȱęǯȱ ȱȱĞȱȱ¢ǰȱ ȱǰȱȱȱ is no evidence of scoring, grooving, etc., on the races or bearing surfaces, the bearings can be reused. ȱȱĞȱ¢ ¢ǯȱȱ¢ȱȱ ȱ ȱǰȱȱȱȱĞȱ ȱȱ necessary. Inspect the crankpin for score marks or metallic pickup. Slight score marks can be cleaned with crocus cloth soaked in oil. If the wear limits, as stated ȱȃęȱȱȄȱȱ¡ǰȱȱ ȱȱ¢ȱȱȱȱȱĞȱȱ regrind the crankpin to 0.25 mm (0.010 in.) undersize. If reground, a 0.25 mm (0.010 in.) undersize connecting rod (big end) must then be used to achieve proper running clearance. Measure the crankpin for size, taper, and out-of-round. 9.1 9 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. The connecting rod journal can be ground one size ǯȱȱȱȱĞǰȱȱȱ deposits can get caught in the oil passages, which could cause severe engine damage. Removing the ȱȱ ȱȱĞȱȱȱȱ easy access for removing any grinding deposits that may collect in the oil passages. Use the following procedure to remove and replace the plug. Procedure to Remove Crankshaft Plug: 1. Drill a 3/16" hole through the plug in the Ğǯ 2. Thread a 3/4" or 1" long self-tapping screw with a Ěȱ ȱȱȱȱǯȱȱĚȱ ȱ must be large enough to seat against the shoulder of the plug bore. See Figure 9-2. 3. Tighten the self-tapping screw until it draws the ȱȱȱȱĞǯ Procedure to Install New Plug: ȱ ŗǯȱ ȱȱȱ¢ȱĞȱǰȱȱȱ No. 47 380 09-S as a driver and tap the plug into ȱȱȱȱȱȱȱȱĴȱȱȱ bore. Make sure the plug is tapped in evenly to prevent leakage. Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments. Gasket surfaces must also be free of deep scratches or nicks. Inspect the main bearing (if so equipped) for wear or ȱǻȱȱȱŗǰȱȃęǰȱǰȱ ȱȱȱȄǼǯȱȱȱȱ or crankcase using a miniblock or short block as required. Check the cylinder bore for scoring. In severe cases, ȱȱȱȱĜȱȱȱȱȱ cylinder wall. It washes the necessary lubricating ȱěȱȱȱȱ¢ȱ ǯȱȱ ȱȱ seeps down the cylinder wall, the piston rings make metal to metal contact with the wall. Scoring of the cylinder wall can also be caused by localized hot ȱȱȱȱȱęȱȱȱ inadequate or contaminated lubrication. If the cylinder bore is badly scored, excessively worn, tapered, or out-of-round, resizing is necessary. Use an inside micrometer to determine the amount of wear ǻȱȱȱȃęǰȱǰȱȱȱ ȱȄǰȱȱȱŗǼǰȱȱȱȱȱ suitable oversize of either 0.25 mm (0.010 in.) or 0.50 mm (0.020 in.). Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies. Initially, resize using a boring bar, then use the following procedures for honing the cylinder. Honing While most commercially available cylinder hones can be used with either portable drills or drill presses, the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in ȱȱȱĞȱǯȱ ȱȱȱ 9.2 Section 9 Inspection and Reconditioning accomplished at a drill speed of about 250 RPM and ŜŖȱȱȱǯȱĞȱȱȱȱȱ hone, proceed as follows: ȱ ŗǯȱ ȱȱȱȱȱĞȱǰȱȱ so the stones are in contact with the cylinder ǯȱȱȱȱȱĴȬȱȱȱ recommended. 2. With the lower edge of each stone positioned even with the lowest edge of the bore, start drill and honing process. Move the hone up and down ȱ£ȱȱȱȱȱȱĴȱ ridges. Check the size frequently. DZȱ ȱȱȱȬȱȱ exacting tolerances. When oversizing a cylinder, it should be machined exactly 0.25 mm (0.010 in.) or 0.50 mm (0.020 in.) over the new diameter (Section 1). The ȱ£ȱȱȱ ȱ ȱȱęȱ¢ǯ 3. When the bore is within 0.064 mm (0.0025 in.) of the desired size, remove the coarse stones and replace them with burnishing stones. Continue with the burnishing stones until the bore is within 0.013 mm (0.0005 in.) of the desired size ȱȱȱęȱȱǻŘŘŖȬŘŞŖȱǼȱȱ ȱȱȱȱȱęȱ£ǯȱȱȱ should be observed if honing is done correctly. The crosshatch should intersect at approximately ŘřǚȬřřǚȱěȱȱ£ǯȱȱĚȱȱȱȱ cause the rings to skip and wear excessively, and too steep an angle will result in high oil consumption. See Figure 9-3. taken at three locations in the cylinder – at the ǰȱǰȱȱĴǯȱ ȱȱ should be taken (perpendicular to each other) at each of the three locations. Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and/or honing is very critical to a successful overhaul. ȱȱĞȱȱȱ¢ȱȱȱ¢ȱ ȱȱȱȱȱȱȱȱȱĞȱȱ rebuild. ȱęȱȱȱȱ ¢ȱȱȱ thorough scrubbing with a brush and hot, soapy water. Use a strong detergent that is capable of breaking down the machining oil while maintaining a good level of suds. If the suds break down during cleaning, discard the dirty water and start again with more hot water and detergent. Following the scrubbing, rinse the cylinder with very hot, clear water, dry it completely, and apply a light coating of engine oil to prevent rusting. Measuring Piston-to-Bore Clearance Before installing the piston into the cylinder bore, it is necessary that the clearance be accurately checked. ȱȱȱĞȱǰȱȱȱȱȱȱ ȱ ȱęǰȱȱȱ ȱ¢ȱ result. NOTE: Do not use a feeler gauge to measure pistonto-bore clearance – it will yield inaccurate measurements. Always use a micrometer. Use the following procedure to accurately measure the piston-to-bore clearance: 9 1. Use a micrometer and measure the diameter of the piston 11 mm (0.433 in.)ȱȱȱĴȱȱ the piston skirt and perpendicular to the piston pin. See Figure 9-4. 11 mm (0.433 in.) Figure 9-3. Cylinder Bore Crosshatch after Honing. ȱ Śǯȱ Ğȱ£ǰȱȱȱȱȱǰȱ taper, and size. Use an inside micrometer, telescoping gauge, or bore gauge to take measurements. The measurements should be Measure 11 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin Figure 9-4. Measuring Piston Diameter. 9.3 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). Cylinder Head and Valves Inspection and Service ĞȱǰȱȱȱĚȱȱȱ¢ȱȱ and the corresponding top surface of the crankcase, using a surface plate or piece of glass and feeler gauge as shown in Figure 9-5. The maximum allowable out ȱĚȱ 0.076 mm (0.003 in.). Flywheel Inspection ȱȱĚ¢ ȱȱȱȱȱĚ¢ ȱ ¢ ¢ȱȱǯȱȱȱĚ¢ ȱȱȱȱ ǯȱȱȱĚ¢ ǰȱȱĞǰȱȱ ȱ¢ȱȱĚ¢ ȱ¢ȱȱȱȱȱ¢ ¢ȱȱ damaged. ȱȱȱȱȱȱȱǯȱȱ does not provide the ring gear as a serviceable part. ȱȱĚ¢ ȱȱȱȱȱȱǯ Feeler Gauge Figure 9-5. Checking Cylinder Head Flatness. Carefully inspect the valve mechanism parts. Inspect the valve springs and related hardware for excessive wear or distortion. Check the valves and valve seat ȱȱȱȱȱȱȱĴǰȱǰȱ or distortion. Check clearance of the valve stems in the guides. See Figure 9-6 for valve details and ęǯ 9.4 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.) 1.0 mm (0.0393 in.) H Valve Stem Diameter ŜǯşŞŘȦŝǯŖŖŖȱȱǻŖǯŘŝŚşȦŖǯŘŝśŜȱǯǼ ŜǯşŝŖȦŜǯşŞŞȱȱǻŖǯŘŝŚŚȦŖǯŘŝśŗȱǯǼ Figure 9-6. Valve Details. ȱȱȱȱȱ ȱȱ¢ȱȱ fuel consumption may be symptoms of faulty valves. ȱȱ¢ȱȱȱȱĴȱȱ ȱǰȱȱȱȱȱȱęǯȱĞȱ removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as a warped head, excessive corrosion, or a worn stem end. Replace valves found to be in bad condition. A normal valve and valves in bad condition are shown in the accompanying illustrations. 9.5 9 Section 9 Inspection and Reconditioning Normal:ȱȱĞȱȱȱȱȱȱȱ 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. Note the warped head; margin damaged ȱȱ ǯȱȱȱȱȱĴȱ to excessive hours or a combination of poor operating conditions. Coking: Coking is normal on intake valves and is not harmful. If the seat is good, the valve could be reused Ğȱǯ 9.6 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. 9 Gum: Gum deposits usually result from using stale gasoline. Gum is a prevalent cause of valve sticking. The cure is to ream the valve guides and clean or replace the valves, depending on their condition. Overheating: An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide. Worn guides and faulty valve springs may cause this condition. Also check for clogged air ǰȱȱȱęȱ ȱȱȱȱǯ 9.7 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. Then, using an outside micrometer, measure the diameter of the valve stem at several points on the stem where it moves in the valve guide. Use the largest stem diameter to calculate the clearance by subtracting the stem diameter from the guide diameter. If the intake clearance exceeds 0.038/0.076 mm (0.0015/0.0030 in.), or the exhaust clearance exceeds 0.050/0.088 mm (0.0020/0.0035 in.), determine whether the valve stem or guide is responsible for the excessive clearance. The maximum (I.D.) wear on the intake valve guide is 7.134 mm (0.2809 in.) while 7.159 mm (0.2819 in.) is the maximum allowed on the exhaust guide. The guides are not removable but can be reamed 0.25 mm 0.010 in.) oversize. Valves with 0.25 mm oversize stems must then be used. If the guides are within limits but the valve stems are worn beyond limits, install new valves. Valve Seat Inserts ȱȱ¢ȱȱȱ¡ȱȱȱ ȱȱȱęĴȱȱȱ¢ȱǯȱȱ inserts are not replaceable but can be reconditioned if ȱȱ¢ȱĴȱȱǯȱȱȱȱ¢ȱ warped, the cylinder head should be replaced. Recondition the valve seat inserts following the ȱȱ ȱȱȱȱĴȱȱ ǯȱȱ¢ȱĴȱȱ ȱȱȱşȬŝǯȱȱęȱ ȱȱȱȱ ȱȱŞşǚȱĴȱȱęȱ ȱȱȱȱȱȱȱşȬŜǯȱĴȱȱ ȱŚśǚȱȱȱȱȱęȱȱȱ 9-6, and the proper valve seat angle (44.5°, half of the ȱŞşǚȱǼǰȱ ȱȱȱȱŖǯśǚȱǻŗǯŖǚȱȱ cut) interference angle where the maximum pressure occurs on the outside diameters of the valve face and seat. 9.8 Valve Seat Cutter Pilot Figure 9-7. Typical Valve Seat Cutter. Lapping Valves Reground or new valves must be lapped in, to provide ȱęǯȱȱȱȱȱȱ ȱȱȱ ȱȱęȱǯȱ¢ȱȱȱȱȱ ȱ ȱȃęȄȱȱȱȱǰȱȱȱȱ valve on its seat with the grinder. Continue grinding until a smooth surface is obtained on the seat and on the valve face. Thoroughly clean the cylinder head in soap and hot water to remove all traces of grinding ǯȱĞȱ¢ȱȱ¢ȱǰȱ¢ȱȱ light coating of SAE 10 oil to prevent rusting. Valve Stem Seals These engines use valve stem seals on the intake and exhaust valves. Always use new seals when the valves are removed from the cylinder head. The seals should also be replaced if deteriorated or damaged in any way. Never reuse an old seal. Pistons and Rings Inspection Ĝȱȱȱȱȱȱ¢ȱ ȱ occurs when internal engine temperatures approach the welding point of the piston. Temperatures high enough to do this are created by friction, which is ¢ȱĴȱȱȱȱȦȱ overheating of the engine. ¢ǰȱ¢ȱĴȱ ȱȱȱȱȱȱ boss-piston pin area. If the original piston and ȱȱȱȱȱĞȱ ȱȱȱ installed, the original pin can also be reused but new piston pin retainers are required. The piston pin is included as part of the piston assembly – if the pin boss in the piston or the pin are worn or damaged, a new piston assembly is required. 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. Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure ¢ȱĞȱǯȱȱȱ ȱĚȱȱ which meet and explode to create extreme hammering ȱȱȱęȱȱȱȱǯȱȱ generally occurs from using low octane fuels. When cylinder temperatures get too high, lacquer and varnish collect on pistons causing rings to stick, which results in rapid wear. A worn ring usually takes on a shiny or bright appearance. Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation. ȱȱȱĞȱȱȱȱ detonation damage. Preignition is caused by a hot spot in the combustion chamber from sources such ȱ ȱȱǰȱȱȱęǰȱȱ improperly seated valve, or wrong spark plug(s). Scratches on rings and pistons are caused by abrasive material such as carbon, dirt, or pieces of hard metal. ȱȱşȬŞȱȱȱȱ¢ȱȱȱȱ ring damage. Stuck, Broken Rings Abrasive Scratched Rings Overheated or Deteriorated Oil Scored Piston and Rings 9 Figure 9-8. Common Types of Piston Damage. 9.9 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. The cylinder bore must be deglazed before service ring sets are used. 2. If the cylinder bore does not need reboring and if the old piston is within wear limits and free ȱȱȱěȱǰȱȱȱȱ¢ȱȱ reused. 3. Remove the old rings and clean up the grooves. Never reuse old rings. 4. Before installing the new rings on the piston, place the top two rings, each in turn, in its running area in the cylinder bore and check the end gap. (See Figure 9-9.) Compare the ring gap ȱȱęȱȱȱȱŗǯ Figure 9-10. Measuring Piston Ring Side Clearance. Install New Piston Rings To install new piston rings, proceed as follows: NOTE: Rings must be installed correctly. Ring installation instructions are usually included with new ring sets. Follow instructions carefully. Use a piston ring expander to install rings (see Figure 9-11). Install the ĴȱǻȱǼȱȱęȱȱȱȱ compression ring last. Refer to Figure 9-12. Piston Ring Piston Ring Expander Figure 9-11. Installing Piston Rings. Figure 9-9. Measuring Piston Ring End Gap. ȱ śǯȱ Ğȱȱȱ ȱȱǻȱȱ middle) rings on the piston, check the pistonto-ring side clearance. Compare the clearance ȱęȱȱȱȱŗǯȱȱȱȱ ȱȱȱȱęǰȱȱ ȱȱ must be used. Refer to Figure 9-10. 9.10 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. Hydraulic Lifters ,GHQWL¿FDWLRQ Mark Inspection ȱȱȱȱȱȱ¢ȱĞȱȱ ȱ ȱǯȱȱȱĞȱȱȱȱǰȱ¢ȱȱ ȱȱȱȱȱ25 357 14-S to the ȱȱȱ ȱĞȱȱȱȱǯ Piston Top Compression Ring Center Compression Ring Rails Oil Control Ring (Three-piece) Expander Figure 9-12. Piston Ring Installation. ȱ ŗǯȱ ȱȱȱǻĴȱǼDZȱȱȱ expander and then the rails. Make sure the ends of the expander are not overlapped. “Bleeding” the Lifters To prevent a possible bent push rod or broken rocker ǰȱȱȱȱȱȃȄȱ¢ȱ¡ȱȱȱȱȱ Ğȱȱ¢ȱȱǯ 1. Cut a 50-75 mm (2-3 in.) piece from the end of an old push rod and chuck it in a drill press. 2. Lay a rag or shop towel on the table of the drill ȱȱȱȱĞǰȱȱȱǰȱȱȱ towel. 3. Lower the chucked push rod until it contacts the ȱȱȱĞǯȱ ¢ȱȃȄȱȱȱ two or three times to force the oil out of the feed ȱȱȱȱȱȱĞǯ Governor Gear Assembly 2. Middle Compression Ring (Center Groove): Install the center ring using a piston ring ȱǯȱȱȱȱȃęȄȱ mark is up or the dykem stripe (if contained) is to ȱĞȱȱȱȱǯ Inspection The governor gear is located within the crankcase. Inspect the governor gear teeth. Replace the gear if it is worn, chipped, or if any teeth are missing. Inspect the governor weights. They should move freely in the governor gear. 3. Top Compression Ring (Top Groove): Install the top ring using a piston ring expander. Make sure ȱȃęȄȱȱȱȱȱȱ¢ȱ ȱǻȱǼǰȱȱȱȱĞȱȱȱȱǯ Disassembly The governor gear must be replaced once it is removed from the crankcase. Connecting Rods ěǰȱȬȱȱȱȱȱȱȱ engines. DZȱ ȱȱȱȱȱȱȱĞȱ¢ȱ small molded tabs in the gear. When the ȱȱȱȱȱĞȱȱȱȱ destroyed and the gear must be replaced. Therefore, remove the gear only if absolutely necessary. Inspection and Service Check the bearing area (big end) for excessive wear, score marks, running and side clearances (refer to ȱŗǰȱȃęǰȱǰȱȱȱ ȱȄǼǯȱȱȱȱȱȱȱȱȱ excessively worn. 9.11 9 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 ǻȱȱȱŗǰȱȃęǰȱǰȱȱ ȱȱȄǼǯȱȱȱȱȱȱ pan assembly if required. Inspection Inspect the oil pump housing, Gerotor gears, and oil pan recess for nicks, burrs, wear, or any visible damage. Inspect the inlet seal for the pickup in the housing. If any parts are worn or damaged, replace the inlet seal, oil pump or oil pan as required. Reassembly 1. Make sure the recess in the closure plate for the oil pump gerotor gears is clean. 2. Lubricate the oil pump Gerotor gears with grease (Lubriplate®ȱŗŖŖǰȱȬȱŚśȱȱǼǰȱȱ install into the recess. See Figure 9-14. Oil Pump Assembly Disassembly ȱ ŗǯȱ ȱȱȱ¡ȱĚȱ ȱȱ the oil pump housing including the relief valve ĝǰȱȱȱȱ ȱȱȱǯȱȱ Figure 9-13. 2. Remove the oil pump housing and pickup from the oil pan. 3. Remove the oil pump gerotor gears from the oil pan recess. 4. Remove the oil pickup by pulling it free from the oil pump body. 5. The relief valve is a one-piece style, staked to the oil pump housing; removal should not be Ĵǰȱȱȱȱȱǯȱȱȱ problem with the relief valve is encountered, the oil pump should be replaced. See Figure 9-15. Mounting Screws Oil Pump Pickup %DIÀH (Covering Relief Valve) Pickup Mounting Screw Figure 9-14. Installing and Lubricating Oil Pump Gerotor Gears. 3. Lightly lubricate with oil and install the inlet seal into the oil pump housing until it is fully seated. See Figure 9-15. Inlet Seal Relief Valve Figure 9-13. Oil Pump and Pickup. Figure 9-15. Installing Inlet Seal in Oil Pump Housing. 9.12 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 ȱȱȱşȬŗŞǯ 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. 2 and fully torque to the recommended value. c. Install fastener into location No. 3 and fully torque to the recommended value. d. Finish torquing fastener in location No. 1 to the recommended value. Figure 9-16. O-Ring Installed in Oil Pump Housing. First Time Installation: 10.7 N·m (95 in. lb.) All Reinstallations: 6.7 N·m (60 in. lb.) 5. Lightly lubricate the I.D. of the inlet seal with oil and carefully insert the end of the pickup through the seal, into the oil pump housing. 6. Install the oil pump housing with the pickup tube, over the oil pump boss and gears. Position ȱȱȱĝȱȱ ȱŘȱȱřǯȱȱȱ three screw hole locations. Mounting Screws Oil Pump %DIÀH (Covering Relief Valve) 3 1 4 2 Figure 9-18. Oil Pump Screws Torque Sequence. ȱ Şǯȱ ȱȱȱȱȱȱ ȱȱ 10.7 N·m (95 in. lb.) into a new hole, or 7.3 N·m (65 in. lb.) into a used hole. See Figure 9-17. Pickup Pickup Mounting Screw Figure 9-17. Installing Oil Pump and Pickup. 9.13 9 9.14 Section 10 Reassembly General NOTE: Make sure the engine is assembled using ȱęȱȱǰȱȱ ǰȱȱǯȱȱȱȱ ęȱȱȱȱȱ ȱ ȱǯȱ ¢ȱȱ ȱǯȱ¢ȱȱ ȱȱȱȱȱȱȱȱȱ ȱȱ¢ǰȱȱȱȱȱ ®ȱȱęȱȱǯȱ ȱȱȱȱȱ¢ȱȱȱȱȱ ȱȱȱȱȱȱȱǯȱ ȱȱȱȱȱȱȱ¢ȱ ȱ ȱȱȱȱȱȱǯ ȱȱȱǰȱǰȱ¢ȱǰȱȱ ȱȱȱȱȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱǰȱ ȱǰȱȱȱȱȱȱ¢ȱ ȱǯȱȱȱȱ ȱ¢ȱ ǰȱǰȱȱǰȱȱȱȱ ǯ Typical Reassembly Sequence ȱ ȱȱȱȱȱȱ ȱ¢ǯȱȱȱȱȱȱ ȱȱ ȱȱȱȱǰȱȱ ȱȱ¢ȱ ȱȱȱǯȱ ȱȱ¢ȱ¢ȱȱȱȱȱ ȱǯȱȱȱ ǯ ȱ ŗǯȱ ȱ Řǯȱ ȱ řǯȱ ȱ Śǯȱ ȱ śǯȱ ȱ Ŝǯȱ ȱ ŝǯȱ ȱ Şǯȱ ȱ şǯȱ ȱŗŖǯȱ ŗŗǯȱ ŗŘǯȱ ŗřǯȱ ŗŚǯȱȱ ȱŗśǯȱ ȱĚ¢ ȱȱȱǯ ȱĞȱȱȱȱȱǯ ȱĚ¢ ȱȱȱǯ ȱȱĞǰȱȱȱȱǯ ȱĞǯ ȱȱȱ ȱȱȱǯ ȱĞǯ ȱȱȱȱȱȱǯ ȱȱȱ¢ǯ ȱĞȱ¢ǯ ȱȱ¢ǯ ȱ¢ȱĞǯ ȱȱȱ¢ȱǯ ȱȱȱȱȱǯ ȱȱǯ ȱŗŜǯȱ ŗŝǯȱ ŗŞǯȱ ȱŗşǯȱ ȱŘŖǯȱ ȱŘŗǯȱ ŘŘǯȱ Řřǯȱ ŘŚǯȱ Řśǯȱ ȱŘŜǯȱ Řŝǯȱ ŘŞǯȱ ȱŘşǯȱ řŖǯȱ řŗǯȱ řŘǯȱȱ řřǯȱ ȱřŚǯȱ ȱřśǯȱ řŜǯȱ řŝǯȱ ȱȱǯ ȱȱęȱǯ ȱȱǯ ȱȱȱ¢ǯ ȱǰȱ ȱǰȱȱęȬ ǯ ȱĚ¢ ǯ ȱȱǯ ȱȱ¢ȱĝ ȱȱǯ ȱȱȱȱȱǯ ȱȱǯ ȱ¢ȱĝǯ ȱǯ ȱȱǯ ȱȱȱȱȱȱ¢ǯ ȱĴȱȱȱǯ ȱȱǯ ȱȱ¢ ȱǻȱǼǯ ȱ ȱȱȱ¢ȱǯ ȱĝǯ ȱȱęȱȱȱȱȱǯ ȱȱȱǯ ™ Install Flywheel End Oil Seal ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱ¢ȱȱȱǯȱȱȱ ŗŖȬŗǯ 10 Figure 10-1. Seal Bore of Crankcase. 10.1 Section 10 Reassembly ȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯ ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱ ǯȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱĴȱ ȱȱǯȱȱȱŗŖȬŘȱȱŗŖȬřǯ Mounting Screws Lifter Feed Chamber Cover Gasket Figure 10-4. Lifter Feed Chamber Assembly Details. Install Flywheel End Main Bearing ȱȱĚ¢ ȱȱȱȱ ȱȱȱ ǰȱȱȱ ȱȱȱȱȱȱ ȱǯ Figure 10-2. Installing Oil Seal. ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱǰȱ¢ȱȱȱȱȱȱǯ ȱ Řǯȱ ȱȱĚ¢ ȱȱȱȱȱȱ ȱ ȱȱȱȱȱŗŘȱȂȱȱȱ ȱȱȱȱǯȱȱȱŗŖȬśǯȱȱȱ ȱȱȱȱ¢ȱȱȱȱĚȱ ȱȱȱȱȱȱȱȱȱǯȱȱ ȱŗŖȬŜǯ řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱǯ Figure 10-3. Installed Flywheel Side Oil Seal. Install Lifter Feed Chamber Gaskets and Cover ȱ ŗǯȱ ȱȱĞȱȱȱǰȱ ȱ¢ȱ ȱĞȱȱǰȱȱȱĞȱȱǯ ȱ Řǯȱ ȱȱȱ ǯȱȱȱȱȱȱ ȱ¢ȱǯȱȱȱ ȱȱ 6.2 N·m (55 in. lb.)ȱȱ ȱǰȱȱ4.0 N·m (35 in. lb.)ǰȱȱȱǯȱȱȱŗŖȬŚǯ 10.2 Figure 10-5. Installing Main Bearing. Section 10 Reassembly Main Bearing Řǯȱ ȱȱȱȱĞȱ ȱǰȱȱȱ ¢ȱȱȱȱĞȱȱȱȱȱ ȱȱ ȱȱȱŗŖȬŗŖǯ Notch Governor Gear Shaft Figure 10-6. Installed Main Bearing. Install Governor Shafts, Seal, and Governor Gear ȱȱȱĞǰȱǰȱȦȱȱȱ ȱ ȱȱ¢ǰȱȱȱ ǯ ȱ ŗǯȱ ¢ȱȱȱȱȱȱȱȱ ȱ ȱȱȱĞȱȱ ȱǯȱȱ ȱȱȱȱȱȱȱȱ ȱȱ ȱŗŖȬŞǯȱ Figure 10-9. Installed Governor Gear Shaft. 12.66 mm (0.498 in.) Governor Gear Shaft Crankcase Surface Seal Figure 10-10. Governor Gear Shaft Press Depth. Figure 10-7. Installing Governor Cross Shaft Seal. Seal depth 1.5 - 2.0 mm (0.059 - 0.078 in) ȱ řǯȱ ȱȱȱȱĞȱȱ ȱȱȱȱ ȱȱǯȱȱ ȱȱ ȱȱĚȱȱȱȱȱ¢ȱ ȱȱȱęȱȱȱȱȱĚȱȱ ȃȄǯȱȱȱŗŖȬŗŗǯ Governor Cross Shaft Crankcase Surface Oil Seal Figure 10-8. Governor Shaft Seal Depth. Figure 10-11. Installing Governor Cross Shaft. 10.3 10 Section 10 Reassembly Śǯȱ Ĵȱȱȱ¢ȱȱȱȱĞȱȱȱ ȱȱȱȃȄȱȱǯȱȱ ȱ ȱ ȱ ǯȱȱȱȱȱȱȱ ȱȬǰȱ¢ȱȱȱȱȱ® ǯȱŘŜŜȱȱǰȱȱȱ ȱȱȱ ǯȱȱȱ ȱȱ2.2 N·m (20 in. lb.)ǯȱȱȱŗŖȬŗŘǯ Governor Gear Assembly Figure 10-14. Installing Governor Gear Assembly. Figure 10-12. Installed Governor Shaft Yoke. śǯȱ ȱȱęȱȱȱ ȱȱȱ ȱȱȱ ȱȱȱ¢ǯȱȱȱ ȱȱ ȱȱȱȱȱ ȱȱĚ¢ ȱ¢ȱȃȦ Ȅȱȱȱ ȱĞȱȱȱȱȱǯȱ¢ȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȃȄȱȱȱŜȱȂȱǯȱ ȱȱŗŖȬŗřǰȱŗŖȬŗŚǰȱȱŗŖȬŗśǯ Tab Position Figure 10-15. Installed Locking Tab Washer. Install Crankshaft ȱ ŗǯȱ ¢ȱȱȱĚ¢ ȱȱȱȱĞȱ ȱȱȱȱȱȱǯȱȱ ȱŗŖȬŗŜǯ Second Regulating Pin Governor Gear First Regulating Pin Figure 10-13. Regulating Pin Details. Figure 10-16. Installing Crankshaft. 10.4 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 ǯȱȱȱȱȱ ¡ȱ ȱȱǯȱȱȱȱ ȱȱȱȱȱȱ ¡¢ȱȱ ȱȱȱŗŖȬŗŝǯ Figure 10-18. “Fly” Mark on Piston. ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱŗŘŖǚȱǯȱȱȱȱȱȱ ȱȱǯ No. 1 Side No. 2 Side Figure 10-17. Proper Piston and Connecting Rod Orientation. ȱ Řǯȱ ȱȱ¢ȱǰȱǰȱȱȱ ȱ ȱȱǯȱȱȱȱȱȱ Ǜŗȱȱȱȱȱȱǯ ȱ řǯȱ ȱȱĞȱȱȱȱ ȱȱȱ ȱȱǯ Figure 10-19. Installing Piston Assembly Using Ring Compressor Tool. śǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱ ȱ¡ȱĚȱ ǯȱȱȱ ȱȱȱȱ11.3 N·m (100 in. lb.)ǯȱ ȱȱȱȱȱȱ ȱȱǯȱȱȱŗŖȬŘŖǯ DZȱ ȱȱȱȱȱȱȱ ȱ ȱȱȱȱȱȱǯȱȱ ǰȱȱĚȱȱȱȱȱȱ ȱȱȱǯȱȱȱ ȱȱ ȱȱȱȱ ȱȱǯ ȱ Śǯȱ ȱȱȱȃ¢Ȅȱȱȱȱȱȱ ȱ ȱȱĚ¢ ȱȱȱȱǯȱ ȱȱŗŖȬŗŞǯȱȱȱȱ ȱȱȱ ȱȱ¢ȱȱȱȱȱȱ¢ȱȱ ȱȱȱŗŖȬŗşǯȱȱȱȱȱȱȱ ȱȱȱȱȱ ȱȱĴȱȱȱ ȱȱȱȱȱȱ¢ǯ 10.5 10 Section 10 Reassembly Timing Marks Figure 10-20. Torquing Connecting Rod End Cap Screws. Figure 10-22. Aligning Crankshaft and Camshaft Timing Marks. ȱ Ŝǯȱ ȱȱȱȱȱȱȱ ȱȱȱȱ¢ǯ Determining Camshaft End Play ȱ ŗǯȱ ȱȱ ȱȱȱȱȱȱȱȱ ǯȱ Install Camshaft ȱ ŗǯȱ ¢ȱ¢ȱĞȱȱǻȱ ȱǯȱ25 357 14-SǼȱȱȱȱȱȱǯȱ ȱȱĞȱȱȱȱȱ ȱȱȱĞȱ ȱȱǯȱȱ ȱŗŖȬŘŗǯ Lubricant Applied Figure 10-21. Camshaft Lubricant Applied to Cam Lobes. ȱ Řǯȱ ȱȱȱȱȱȱĞȱȱȱ ȱŗŘȱȂȱǯ ȱ řȱ ȱȱĞȱȱȱȱȱȱȱ ǰȱȱȱȱȱȱȱ ĞȱȱȱȱŜȱȂȱǯȱȱ ȱȱȱĞȱȱȱĞȱȱ ǰȱ ȱȱȱȱǯȱȱȱ ŗŖȬŘŘǯ 10.6 ȱ Řǯȱ ȱȱĞȱ¢ȱȱȱȱȱ Ğǯȱȱȱȱȱȱȱȱ¢ȱ ȱȱĞȱȱ¢ȱȱǯȱ Ğȱ¢ȱȱȱ ȱ0.3/1.3 mm (0.011/0.051 in.)ǯȱȱȱŗŖȬŘřǯ Feeler Gauge Figure 10-23. Checking Camshaft End Play. ȱ řǯȱ ȱȱȱ¢¢ȱȱȱȱ¢ǯȱ ǰȱȱȱĞȱȱ¢ȱȱȱ ȱ ȱęȱǰȱȱȱȱȱȱ ȱȱ¢ǯ ȱȱȱȱȱDZ White:ȱ ŖǯŜşŘŗśȦŖǯŝřŖŘśȱȱǻŖǯŖŘŝŘśȦŖǯŖŘŞŝśȱǯǼ Blue:ȱ ŖǯŝŚŘşśȦŖǯŝŞŗŖśȱȱǻŖǯŖغ؜ȦŖǯŖřŖŝśȱǯǼ Red:ȱȱ ŖǯŝşřŝśȦŖǯŞřŗŞśȱȱǻŖǯŖřŗŘśȦŖǯŖřŘŝśȱǯǼ Yellow:ȱ ŖǯŞŚŚśśȦŖǯŞŞŘŜśȱȱǻŖǯŖřřŘśȦŖǯŖřŚŝśȱǯǼ Green:ȱ ŖǯŞşśřśȦŖǯşşřŚśȱȱǻŖǯŖřśŘśȦŖǯŖřŜŝśȱǯǼ Gray:ȱ ŖǯşŚŜŗśȦŖǯşŞŚŘśȱȱǻŖǯŖřŝŘśȦŖǯŖřŞŝśȱǯǼ Black:ȱ ŖǯşşŜşśȦŗǯŖřśŖśȱȱǻŖǯŖřşŘśȦŖǯŖŚŖŝśȱǯǼ 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 ĚǯȱȱȱŗŖȬŘŚǯ Figure 10-25. Installed Oil Seal in Oil Pan. řǯȱ ¢ȱȱȱȱȱȱȱ ȱ ȱǯ Main Bearing Notch Oil Seal 3 mm (0.118 in.) Figure 10-26. Oil Seal Depth in Oil Pan. Figure 10-24. Installed Main Bearing In Oil Pan. Oil Seal ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱĞȱȱȱȱȱȱǯ ȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱǯ Śǯȱ ¢ȱȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱǯ Oil Pump Assembly ȱȱȱȱȱȱȱȱǯȱȱȱ ȱǰȱȱȱȱȱ ȱǰȱȱȱ ȱ¢ȱȱȱȃȱȱ¢Ȅȱ ȱȱşǯ ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱȱ ǯȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱ ȱȱȱ ŗŖȬŘŜǯ 10.7 10 Section 10 Reassembly Install Oil Pan Assembly ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱǰȱ¢ǰȱȱȱȱ¢ȱȱȱ ȱǯȱȱȱ ȱȬȱȱȱȱǯȱȱ ȱŗŖȬŘŝǯ O-Ring Figure 10-29. Installing Oil Pan. Ŝǯȱ ȱȱȱ¡ȱĚȱ ȱȱ ȱȱȱȱȱǯȱȱȱȱ ȱȱȱ ȱȱȱŗŖȬřŗȱȱ 24.4 N·m (216 in. lb)ǯ Figure 10-27. O-Ring Installed. Řǯȱ ȱȱ ȱȱȱȱȱȱǯ řǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱǯ Śǯȱ ȱȱȱȱȱȱȱ ȱȱȱ ȱȱȱȱȃ Ȅȱȱȱ ȱ ȱ ŜȱȂȱȱȱȱǯȱȱȱ ŗŖȬŘŞǯ Figure 10-30. Torquing Oil Pan Fasteners. 1 3 5 Figure 10-28. Locking Tab Washer Details. ȱ śǯȱ ȱȱĚȱȱȱȱȱȱȱȱȱ ȱȱȱĚȱȱȱĞǯȱȱȱ ȱȱȱȱȱǯȱ¢ȱ ȱȱĞȱȱȱĞȱȱȱ ȱǯȱȱȱĞȱ¢ȱȱ ȱȱȱȱȱȱȱǯȱȱ ȱŗŖȬŘşǯ 10.8 14 12 7 10 9 8 11 13 6 4 2 Figure 10-31. Oil Pan Fastener Torque Sequence. Section 10 Reassembly Check Crankshaft End play Install Breather ȱ ŗǯȱ ȱȱȱȱ ǰȱȱȱȱȱȱ ȱȱȱĞȱȱ¢ȱȱȱ ęȱȱȱȱŗǯȱ ȱ ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱȱǰȱȱȱȱ¢ȱ ȱȱǯȱDo not ȱȱȱȱȱ ȱȱȱǯȱ Řǯȱ ȱȱȱȱȱȱ ǯȱ ȱȱŗŖȬřřǯȱȱȱȱȱ ¢ȱȱȱȱȱȱ ŗŖȬřŚǯȱȱȱȱęȱȱȱ¡ȱȱ ȱȱȱȱȱȱȱ¢ȱǯȱ Figure 10-32. Checking Crankshaft End play. Figure 10-33. Breather Chamber and Gasket. Breather Hose Flange Nuts (4) Gasket 10 Adapter Gasket Filter Studs (4) Crankcase Figure 10-34. Breather Assembly Details. 10.9 Section 10 Reassembly ȱ řǯȱ ȱȱȱ¡ȱĚȱ ǰȱȱȱ ȱȱȱ ȱȱȱŗŖȬřśȱȱ 5.7 N·m (51 in. lb.)ǯ 1 4 DZȱ ȱȱȱȱ¢ȱȱȱ ȱȱȱȱȱȱȱ ȱǯȱȱȱŗŖȬřŝǯ 3 2 Figure 10-35. Breather Assembly Fastener Torque Sequence. ȱ Śǯȱ ¢ȱȱȱ ȱȱȱȱȱ ȱ ȱȱȱȱȱȱȱȱȱ ¢ǯȱȱȱȱȱȱ ȱ ȱ ȱȱȱȱȱǯȱ Figure 10-37. Tappet and Ball Bearing Welded Together. Řǯȱ ¢ȱĞȱȱǻȱȱŘǼȱȱȱ ĴȱȱȱȱĞǯȱȱȱŗŖȬřŞǯȱ ȱȱ¢ȱĞȱȱȱĞȱȱ ȱȱȱ ȱȱǯȱDo not prime ȱĞǯȱ Install Hydraulic Lifters ŗǯȱ ȱȱ¢ȱĞȱȱȱȱȱȱȱ ȱȱȱĞȱȱȱȱ¢ȱǯȱ ȱȱȱěȱȱȱȱȱȱȱ ǰȱȱǰȱȱǰȱȱ ¢ȱ¢ȱ pressure two or three timesȱȱȱȱĞǯȱ ȱȱŗŖȬřŜǯȱȱȱȱȱȱȱȱȱ Ğǰȱȱȱȱȱȱȱȱ ȱ ȱȱȱȱȱȱȱȱȱĞǯȱ Figure 10-38. Applying Camshaft Lubricant to Bottom of Lifters. ȱ řǯȱ ȱȱȱȱȱ¢ȱȱ¢ȱ Ğȱȱȱȱȱ¡ȱȱ¢ȱ ŗȱȱ¢ȱŘǯȱȱȱ¢ȱĞȱȱ ȱȱȱȱȱǯȱȱ ȱȱȱǯȱȱȱŗŖȬřşǯ Figure 10-36. Push Rod Tool. 10.10 Section 10 Reassembly DZȱ ¢ȱĞȱȱ ¢ȱȱ ȱȱȱȱȱȱȱ ¢ǯȱȱ¡ȱĞȱȱ ȱȱȱȱĞȱȱȱ ȱȱ ȱȱȱĞȱȱ ȱȱȱȱȱȱȱǯȱȱ ¢ȱȱȱȱȱȱ ȱȱȱȱȱȱ¢ȱ ǯȱȱȱŗŖȬŚŖǯ Valve Stem Seals Figure 10-41. Valve Stem Seals. Assemble Cylinder Heads ȱȱǰȱȱȱȱ ȱ ȱǰȱ¢ȱȱĴȱȱȱȱȱȱ ȱȱǰȱȱȱȱȱǯȱȱ ȱ ȱȱȱȱȱȱ ȱȱȱ ȱȱǯȱȱȱŗŖȬŚŘȱȱŗŖȬŚřǯ Figure 10-39. Installing Hydraulic Lifters. ȱ Ȋȱ ȱ Ȋȱ ȱ Ȋȱ ȱ Ȋȱ ȱ Ȋȱ ȱ Ȋȱ ȱ Ȋȱ ȱȱ¡ȱ ȱȱ ȱ ȱȱ ȱȱ ȱ ȱ Match Numbers Guide Plate Valve Pivot Studs Spring Figure 10-40. Match Numbers on Cylinder Barrel and Head. Valve Stem Seals ȱȱȱȱȱȱȱȱȱ ȱ¡ȱǯȱ ¢ȱȱ ȱȱ ȱȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱ¢ȱ ¢ǯȱȱȱȱȱǯȱȱ ŗŖȬŚŗǯ 10 Retainer Keepers Figure 10-42. Valve Components. 10.11 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.)ǰȱ ȱȱȱȱȱ ȱ ȱ ŗŖȬŚŝǯ ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱ¢ȱȱȱȱ ǯ ȱ Řǯȱ ȱȱȱ ȱȱȱȱȱȱȱ ȱ ȱǰȱȱȱȱ ȱ¢ȱȱ ȱǻ ȱȱǼǯȱȱȱŗŖȬŚŚǯ śǯȱ ȱȱȱȱȱȱ¢ǯ Figure 10-46. Torquing Cylinder Head Fasteners. Figure 10-44. Installing New Head Gaskets. DZȱ ȱȱȱȱȱȱ ¢ȱȱȱǯȱȱȱ ŗŖȬŚŖǯ řǯȱ ȱȱ¢ȱǯȱȱȱȱȱȱ Ěȱȱȱȱȱ ȱǯȱȱȱȱĚȱ ȱȱȱ ȱȱȱlower two locations (1 and 3)ȱȱȱ closest ȱȱ¡ȱ ȱ(location 5)ǯȱȱȱŗŖȬŚśȱȱŗŖȬŚŝǯȱȱ ȱȱęȱ¡ȱĚȱ ǯ 2 2 5 4 1 3 5 4 3 1 No. 1 No. 2 Figure 10-47. Cylinder Head Fastener Torque Sequence. 10.12 Section 10 Reassembly ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱ ¢ȱȱȱȱȱ¢ǯȱȱȱȱ ȱȱ¢ȱȱȱȱǯȱŘȱǻ Ǽȱ ȱȱȱȱ29.3 N·m (260 in. lb.)ǯȱȱ ȱŗŖȬŚŞǯ DZȱ ȱȱȱ ¢ȱȱȱȱ ȱȱȱȱȱ¢ǯ ȱ řǯȱ ¢ȱȱȱȱȱȱȱȱȱ ȱȱȱȱǯȱȱȱȱ ǰȱȱȱǰȱȱȱȱȱǛŗȱ ¢ȱǯ Pipe Plug Adjusters Pivots Figure 10-48. Installing Pipe Plug in Cylinder Heads. Install Guide Plate, Pivot Studs, Push Rods and Rocker Arms ŗǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱȱ¢ȱȱȱȱ ¢ǯȱȱȱȱȱȱ12.4 N·m (110 in. lb.). ȱȱŗŖȬŚşǯ DZȱ ȱȱȱȱȱȱȱȱ Ěȱȱdown ǻ ȱ¢Ǽȱȱȱ No. 1 sideǰȱȱup ǻ ¢ȱȱ¢Ǽȱ ȱȱNo. 2 sideǯȱ Rocker Arms Figure 10-50. Installing Rocker Arms, Pivots and Adjusters. Adjust Valve Clearance ȱȱȬȱĞȱȱ ȱ ŗǯȱ ȱȱȱȱȱȱȱ¢ȱȱ clockwiseȱǻ Ǽǰȱ¢ȱȱȱȱȱ ȱȱȱǯȱȱȱŗŖȬśŗǯ Turn Adjusters (Clockwise) ȱ Řǯȱ ȱȱȱȱȱ¢ȱȱȱȱȱ ȱȱȱ¡ȱȱ¢ȱǛŗȱȱǛŘǯȱȱ ȱȱȱȱȱȱȱȱȱȱǰȱ ȱȱȱȱȱȱȱȱȱȱ ¢ȱĞȱǯȱȱȱŗŖȬśŖǯ 10 Push Rods Guide Plate Figure 10-51. Turning Adjusters In To Retain Push Rods. Řǯȱ ȱȱĞȱȱȱȱȱ ȱǻǼȱȱȱȃȱȄȱȱ ȱǛŗȱ¢ǯ Pivot Studs Figure 10-49. Installing Guide Plate, Pivot Studs and Push Rods. 10.13 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 ȬȱĞDZȱ¢ȱ ȱȱȱ ȱȱȱȱȱȱǰȱȱȱȱ ĞȱȱȈĴȈȱȱȱǯȱȱ ȈȈȱȱ¢ȱȱ¢ǯȱHold in this position for Step 4. ȬȱĞDZȱ ȱȱȱȱ ȱDZȱȬȱĞǰȱȱ ¢ȱ ȱȱĞȱȱȱǯȱ DZȱ ȱȱȱ ȱȱȱȱȱȱ ǯȱȱȱȱȱȱ ȱȱȱȱĞȱȱ ȱȱȱȱ ȱȱȱ ȱ¢ȱǯ ȱ Śǯȱ ȱȱ0.127 mm (0.005 in.)ȱȱȱ ȱ ȱȱȱȱȱȱȱȱǯȱȱ ȱȱȱȱȱȱȱǯȱ ȱȱ ȱȱȱȱȱȱȱȱ ǯȱȱȱ ȱȱ7.3 N·m (65 in. lb.). Ğȱȱȱȱ ǯȱȱȱȱȱ 0.101/0.152 mm (0.004/0.006 in.)ǯȱȱȱŗŖȬśŘǯ ȱ Ŝǯȱ ȱȱȱȱǰȱȱȱĞȱ ŘŝŖǚȱǻřȦŚȱǼȱcounterclockwise and align ȱĞȱ¢ ¢ȱ ȱȱǛŘȱ¢ǰȱ ȱ ȱȱȱ¢ȱȱȱȱȱ ȱǯȱ ȱ ŝǯȱ ȱȱřȬśȱȱĴȱȱȱȱȱ ȱǛŘȱǯ ȱ Şǯȱ ȱȱĞȱȱȱȱȱȱ ȱȱȱǯȱȱȱȱ ȱ ȱȱȱȱȱȱĞǰȱȱȱ ȱȱǻǼȱȱǯȱȱ ȱ clearance is 0.25 mm (0.010 in.)ǯ Check Assembly Important: ȱȱĞȱȱȱȱ ȱ ȱȱȱ¢ȱȱȱȱ ǯ Adjust Valve Clearance ȱȬȱĞǰȱȱ¢ȱ ȱȱĞȱ ȱȱȱȱǯ ȱ ŗǯȱ ȱȱȱȱȱȱȱ ȱ ǻ ȱǼȱ¢ȱȱȱȱȱȱ ȱȱȱǯȱȱȱŗŖȬśŖǯ ȱ Řǯȱ ȱȱĞȱȱȱȱȱ ȱǻǼȱȱȱȃȱȄȱȱ ȱǛŗȱ¢ǯ ȱ ȱDZ ȱ ȱ ǯȱ ȱ ȱȱȱȱȱȱȱ ȱ ȱǯ ȱ ȱ ǯȱ ¢ ¢ȱȱĞȱ ȱȱȱ ȱǛŗȱȱ ȱ ¢ǯ Push Down to "Bottom" Lifter Plunger and Hold ȱȱȦȱȱȱȱȱ ȱ Ğȱȱȱ¢ȱȱȱǯȱȱ ȱȱ¢ȱȱǰȱȱȱĞȱȱȱ ȱǯ řǯȱ ȱȱȱȱǛŗȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱ ȱǯȱȱȱȈŖȈȱǯȱȱȱŗŖȬśřǯ Adjust Feeler Gauge Figure 10-52. Adjusting Valve Clearance. ȱ śǯȱ ȱȱȱȱȱȱȱȱȱ ǯ 10.14 ȱ ȱ ǯȱ ȱ ȱ ȱ Section 10 Reassembly Check Assembly Important: ȱȱȱȱȱȱȱ ¢ȱȱȱȱǯȱȱȱȱ ǻȱȱȱȱǼǰȱȱȱȱȱȱ 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. Śǯȱ ȱȱȱȱĴȱȱȱȱǰȱ ȱȱǻǼȱȱȱȱfour (4) complete revolutions clockwiseǰȱȱȱĚȱȱ nut (1/6 turn), or a total of 4-1/6 turnsǯȱ Install Valve Covers ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱ ȱ¢ȱȱȱǯ ȱ Řǯȱ ȱȱ¢ȱȱȱȱȱȱȱȱ ȱǯȱȱȱŗŖȬśśǯȱ Seal Turn 4-1/6 Revolutions From "0" Lash Figure 10-55. Installing Seal on Valve Cover. ȱ Řǯȱ ȱȱȱȱȱȱȱȱȱ ¢ȱǯȱ Figure 10-54. Setting Valve Lash (Non-Bled Lifters). ȱ śǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱ ǯȱȱȱ ȱȱ 7.3 N·m (65 in. lb.)ǯȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱ ȱǯ ȱ řǯȱ ȱȱ ȱȱȱȱȱȱ ȱ ǯȱȱȱ ǯȱ ȱ Śǯȱ ȱȱȱȱȱȱȱǰȱȱ ȱȱ ȱȱ7.9 N·m (70 in. lb.)ǯȱȱ ȱŗŖȬśŜǯ ȱ ŝǯȱ ȱȱȱȱǰȱȱȱĞȱ ŘŝŖǚȱǻřȦŚȱǼȱcounterclockwise and align the Ğȱ¢ ¢ȱ ȱȱǛŘȱ¢ǰȱ ȱ ȱȱȱ¢ȱȱȱȱȱȱ ǯ ȱ Şǯȱ ȱȱřȬŜȱȱĴȱȱȱȱȱ ȱǛŘȱǯ şǯȱ ȱȱĞȱȱȱȱȱȱ ȱȱȱǯȱȱȱȱ ȱȱ ȱȱȱȱȱĞǯȱȱ ȱ clearance is 0.25 mm (0.010 in.). Figure 10-56. Torquing Valve Cover Screw. 10.15 10 Section 10 Reassembly Install Spark Plugs ȱ ŗǯȱ ȱ ȱ®ȱŗŖȱǻȱǼȱ ȱǯ Cup ȱ Řǯȱ ȱȱȱȱ0.76 mm (0.030 in.)ǯ ȱ řǯȱ ȱ ȱȱȱȱȱ24.4-29.8 N·m ǻŗŞȬŘŘȱĞǯȱǯǼǯȱȱȱŗŖȬśŝǯ Valve Spring Figure 10-59. Installing Valve and Spring to Cup. Spring Figure 10-57. Installing Spark Plugs. Install Oil Filter Housing Assembly ȱȱȱęȱȱȱȱ ¢ǯȱȱȱŗŖȬśŞȱȱŗŖȬŜřǯ Figure 10-60. Installing Spring into Housing. Oil Filter Housing Valve Spring Cup Spring Nipple ȱ ǯȱ ȱȱȱęȱǰȱȱȱȱ ȱ ȱȱȱȱȱǯȱȱ ȱŗŖȬŜŗǯ ȱ ǯȱ ȱȱȱȱȱȱȱǯȱȱ ȱśȦŗŜȄȱ Ȧȱȱȱȱ18.0 N·m (160 in. lb.)ǯȱȱȱŗŖȬŜŘȱȱŗŖȬŜřǯ Cup Figure 10-58. Oil Filter Housing Components. ȱȱǯȱ ȱȱȱȱȱȱȱǰȱȱ ȱȱȱȱȱȱȱ ȱȱȱȱȱ¢ȱǯȱȱȱȱ ŗŖȬśşǯ ȱ ǯȱ ȱȱȱȱȱȱęȱǯȱ ȱȱŗŖȬŜŖǯȱ Figure 10-61. Installing Cup. 10.16 Section 10 Reassembly Nipple Cup (with Spring and Valve) Řǯȱ ȱȱęȱȱ¢ȱȱȱ ȱȱŞȱ¡ȱȱ ǯȱȱȱȱȱ ȱȱĚȱȱȱȱȬȱȱ ȱǯȱȱȱ ȱȱ24.4 N·m (216 in. lb.)ǯȱȱȱŗŖȬŜśǯ Mounting Screw Housing Figure 10-62. Installing Nipple into Cup and Oil Filter Housing. Oil Filter Housing Figure 10-65. Torquing Oil Filter Housing. ȱ řǯȱ ȱȱęȱ¢ȱȱȱ ȱȱȱ ȱȱȱ¢ǰȱȱȱȱȱ ȱŜǯ Install Intake Manifold ȱ ŗǯȱ ȱ ȱȱȱȱȱȱ ȱȱȱ ȱȱȱ ȱȱ Ě¢ ȱǯȱȱȱŗŖȬŜŜǯȱ Figure 10-63. Torquing Nipple into Housing. Installation ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱ ȱ ȱȱȱȱǯȱȱȱȱ ȱ ȱȬȱȱȱȱȱ ȱȱ ȱȱȱęȱǯȱȱȱŗŖȬŜŚǯ 10 Notches Figure 10-66. Installed Intake Manifold Gaskets. O-Rings Around Dowel Pins Figure 10-64. O-Rings Installed on Crankcase for Oil Filter Housing. 10.17 Section 10 Reassembly Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱ ȱȱȱȱȱȱȱȱ ǯȱȱȱȱ ȱȱ ȱǰȱ ęȱȱ16.9 N·m (150 in. lb.)ǰȱę¢ȱȱ 22.6 N·m (200 in. lb.)ǰȱȱȱȱ ȱ ȱȱŗŖȬŜŞǯ Figure 10-69. Lower Oil Cooler Hose Details. Řǯȱ ȱȱȱȱ¢ȱȱȱ ȱȱȱ ȱȱȱŜȱ ǯȱȱ ȱȱ ȱȱȱȱȱȱ 10.7 N·m (99 in. lb.)ȱȱ ȱǰȱȱ7.3 N·m (65 in. lb.)ȱȱȱǯȱȱȱŗŖȬŝŖǯ Figure 10-67. Installing Intake Manifold. Cylinder 1 Cylinder 2 3 4 1 2 Figure 10-70. Installing Backing Shroud Assembly. Figure 10-68. Intake Manifold Torque Sequence. ȱ řǯȱ ȱȱȱȱȱȱȱ ȱȱȱǯȱȱ ȱ¡ȱȱ ȱĚȱȱĚȱȱȱȱȱȱ ȱȱĴȦǯȱ Install Backing Shroud Assembly ȱ ŗǯȱ ȱȱ¢ǰȱȱȱ ȱȱȱȱ ȱȱȱęȱȱȱȱȱȱ ȱȱ¢ǯȱȱ ȱȱȱ ȱȱ ǯȱȱȱŗŖȬŜşǯ DZȱ ȱȱȱȱȱ ȱ¢ǰȱȱȱȱȱȱ ȱǻ¡Ǽȱȱȱȱ ȱǯȱ 10.18 Install Stator, Wiring Harness, and 5HFWL¿HU5HJXODWRU ȱ ŗǯȱ ¢ȱȱȱ ȱĚ®ȱǻ®ȱȱ śşŘŚŗȱȱǼȱȱȱȱȱǯ ȱ Řǯȱ ȱȱȱȱȱȱȱ ȱȱȱȱȱȱĴǰȱȱ ȱȱ ęȬȱȱȱȱǯȱŗȱǯ řǯȱ ȱȱȱȱ ȱ¡ȱĚȱ ȱȱ 6.2 N·m (55 in. lb.)ǯȱȱȱŗŖȬŝŗǯ ȱ Śǯȱ ȱȱȱ ȱȱȱ ȱȱ ȱȱȱȱ¢ǯȱȱȱ ŗŖȬŝŗǯ Section 10 Reassembly Tabs ŝǯȱ ȱȱęȬȱȱȱȱ ȱ ȱȱȱęȱȃǯȄȱĴȱȱ ȱȱȱȱȱ ȱȱ ǰȱȱ ȱȱȱ ȱȱ 2.0 N·m (18 in lb.)ǯȱȱȱȱȱȱ ęȬǯȱȱȱŗŖȬŝŚǯ Ground Lead Mounting Screws 5HFWL¿HU Regulator Figure 10-71. Installing Stator. śǯȱ ȱȱȱȱȱȱȱȱȱƸȱ ȱȱȱȱȱȱȱȱȱ ȱ ȱȱȱǯȱȱȱ ȱȱȱȱȱȱȱȱ ȱȱȱȱǯȱ Plug )LJXUH,QVWDOOLQJ5HFWL¿HU5HJXODWRU Install Flywheel WARNING: Damaging Crankshaft and Flywheel Can Cause Personal Injury! ȱȱȱȱȱȱĚ¢ ȱȱȱ ȱȱȱĞȱȦȱĚ¢ ǯȱȱȱ¢ȱ ȱ¡ȱȱǰȱȱȱȱȱȱ ¢ǰȱȱȱȱȱȱ ȱȱȱ ǯȱ ¢ȱȱȱȱȱ ȱȱ ȱȱ ȱȱȱĚ¢ ǯ B+ Lead Figure 10-72. B+ Charging Lead Details. ȱ Ŝǯȱ ȱȱ ȱȱȱȱ ȱȱ ȱȱȱȱȱ¢ǯȱȱ ȱŗŖȬŝřǯ DZȱ ȱȱȱĚ¢ ȱȱȱ ȱĞȱȱȱȱĚ¢ ȱȱ ȱǰȱ¢ǰȱȱ¢ȱȱȱ¢ȱ ǯȱȱȱȱȱȱ ȱȱĚ¢ ȱȱȱȱȱȱ ȱ ȱȱ¡ȱĚȱ ȱȱ ȱȱęǯ Molded Clips Figure 10-73. Installing Wiring Harness. Figure 10-75. Clean and Dry Taper of Crankshaft. 10.19 10 Section 10 Reassembly Figure 10-76. Clean and Dry Flywheel Hub. Figure 10-78. Installing and Torquing Flywheel Fastener. Install Ignition Modules ȱ ŗǯȱ ȱȱĚ¢ ȱȱȱȱȱ ¢ȱ ȱȱȱȱǯ ȱ Řǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱ ȱȱȱ ¢ȱȱ¢ȱǻǼǯȱȱȱȱȱ ȱȱ ȱ¢ȱǻǼǯȱȱȱ ȱ ȱȱ ȱȱȱupǰȱȱȱȱ ǻǯŗǼȱȱȱȱ ȱȱȱȱ ȱȱǯȱĴȱȱęȬȱ ȱȱȱȱȱ ǯȱȱȱŗŖȬŝşǯȱ Figure 10-77. Installed Flywheel Key. DZȱ ȱȱȱĚ¢ ȱ¢ȱȱȱ ¢ȱȱȱ¢ ¢ǯȱȱĚ¢ ȱȱ ȱȱȱȱȱȱ¢ȱȱȱ ¢ȱǯ Clip Kill Lead ȱ ŗǯȱ ȱȱ ěȱ¢ȱȱȱ¢ ¢ȱȱȱ Ğǯȱȱȱȱȱ¢ȱȱ¢ȱ ȱȱȱ ȱȱĞȱǯ ȱ Řǯȱ ȱȱĚ¢ ȱȱȱĞȱȱ ȱȱȱĞȱȱ ěȱ¢ǯȱ ȱ řǯȱ ȱȱ¡ȱĚȱ ȱȱ ǯ Figure 10-79. Ignition Module Mounting Details. ȱ Śǯȱ ȱȱĚ¢ ȱȱ ȱȱȱȱȱ ȱȱĚ¢ ǯȱȱȱ¡ȱĚȱ ȱ ȱȱĚ¢ ȱȱȱĞȱȱ ŜŝǯŞȱȉȱǻśŖȱĞǯȱǯǼǯȱȱȱŗŖȬŝŞǯ ȱ řǯȱ ȱȱȱȱȱȱ ¢ȱȱȱ Ě¢ ȱȱȱȱȱȱ ȱȱȱ ȱȱȱǯ ȱ Śǯȱ ȱȱĚ¢ ȱȱȱȱȱ ¢ȱȱȱȱǯ 10.20 Section 10 Reassembly śǯȱ ȱȱ0.30 mm (0.012 in.)ȱĚȱȱȱ ȱȱȱȱȱȱǯȱ ȱȱŗŖȬŞŖǯȱȱȱȱȱȱ ȱȱȱȱȱĴǯȱȱȱ ȱ ȱȱ ȱȱȱȱȱȱȱ ȱȱȱȱǯ Feeler Gauge Figure 10-80. Setting Ignition Module Air Gap. ,QVWDOO2XWHU&\OLQGHU%DIÀHV ŗǯȱ ȱȱȱ¢ȱĝǯȱȱȱ ȱȱȱȱȱȱȱȱ ȱȱȱȱĝǯȱȱȱȱ ȱȱ ǯȱȱȱŜȱȱ ȱ ȱȱȱȱȱ¢ȱȱ ȱ¡ȱȱȱȱĝȱȱ 4.0 N·m (35 in. lb.) ȱȱǰȱȱ 2.0 N·m (17.7 in. lb.) ¢ȱĞǯȱȱ ȱŜȱ ȱȱȱȱ¢ȱȱȱ ȱȱ10.7 N·m (95 in. lb.) ȱ ȱǰȱ ȱ7.3 N·m (65 in. lb.) ȱȱǯ Cylinder %DIÀH Mounting Screws Ŝǯȱ ȱȱ ȱȱ6.2 N·m (55 in. lb.)ȱȱ ȱ ǰȱȱ4.0 N·m (35 in. lb.)ȱȱȱǯ ȱ ŝǯȱ ȱȱŚȱȱŜȱȱȱȱȱ ǯȱ Şǯȱ ȱȱĚ¢ ȱȱȱǰȱȱ ȱȱ ȱȱȱȱȱ ǯȱȱȱȱȱȱȱ ȱȱǯȱȱȱȱ ȱȱȱ ȱȱȱȱ¢ǯȱȱȱDZȱ 0.280/0.330 mm (0.011/0.013 in.)ǯ )LJXUH,QVWDOOLQJ2XWHU&\OLQGHU%DIÀHV Mounting Screws ȱ şǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱŗŖȬŞŗǯ 10 Molded Clip )LJXUH,QVWDOOLQJ&\OLQGHU%DIÀH,QQHU Screws. Figure 10-81. Lead Routing Details. 10.21 Section 10 Reassembly Install Oil Cooler ŗǯȱ ȱȱ ȱȱȱȱ ȱȱȱ ęȱȱȱȱȱǯȱȱ ȱ ȱ ǯȱȱȱŗŖȬŞŚǯ ȱ ȱ ȬȱȱȱȱȱǼǯȱ ȱȱȱ¡ȱȱȱȱȱȱ ȱȱȱȱĚ¢ ǯȱȱȱȱ ȱ9.9 N·m (88 in. lb.)ǯȱȱȱŗŖȬŞŜǯ ȱ řǯȱ ȱȱěȱ ȱ¢ȱȱȱȱ ȱȱȱȱ¡ȱǯȱȱ ȱȱ ȱȱ ȱȱȱ ȱȱ ®ȱǯȱŘŚřȱȱȱǯȱȱȱ ȱȱ9.9 N·m (88 in. lb.). ȱȱŗŖȬŞŜǯȱ Screws Hoses Special Washers Grass Screen Figure 10-84. Connecting Oil Cooler Hoses. Stiffener ȱ Řǯȱ ȱȱȱȱ ȱȱȱȱȱȱ ȱ¢ǯȱȱȱ ȱȱ ȱ ȱ ȱ ǯȱȱȱŗŖȬŞśǯ Mounting Studs Fan Screws Fan Mounting Screws Figure 10-86. Cooling Fan and Grass Screen Assembly Details. Install Electric Starter ȱ ŗǯȱ ȱȱȱȱȱȱȱ ȱ¡ȱ Ěȱ ǯȱȱȱŗŖȬŞŝǯ Figure 10-85. Installing Oil Cooler. Install Cooling Fan and Grass Screen ȱ Řǯȱ ȱȱ ȱ¡ȱĚȱ ȱȱ15.3 N·m (135 in. lb.)ǯ CAUTION: ȱȱ£ȱȱȬȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱ ¢ǯ ȱ ŗǯȱ ȱȱȱȱȱȱĚ¢ ǰȱ ȱȱȱǯȱ¢ȱȱȱ ȱȱ®ȱǯȱŘŚřȱȱȱȱȱ ȱȱȱȱȱ ǯȱȱ ȱ ȱȱ9.9 N·m (88 in. lb.)ǯȱȱȱŗŖȬ ŞŜǯ ȱ Řǯȱ ¢ȱȱȱȱȱ®ȱȱŘŚřȱȱȱ ¡ȱȱǰȱǻȱ ȱȱ ȱ 10.22 Mounting Screws Figure 10-87. Installing Electric Starter Motor. Section 10 Reassembly ȱ řǯȱ ȱȱȱȱȱǯȱȱȱ ŗŖȬŞŞǯ ȱ Řǯȱ ĴȱȱĴȱȱȱȱȱȱȱ ȱȱȱ¢ǯȱȱ ȱȱ ȱȱȱĴȱȱȱ ¢ǯȱȱȱŗŖȬşŖǯȱ Gasket (Tab "Up") Carburetor Throttle Linkage Figure 10-88. Connecting Leads to Starting Motor. ,QVWDOO9DOOH\%DIÀHV ȱ ŗǯȱ ȱȱ ȱ¢ȱĝȱȱȱ ȱ ȱȱ ǯȱȱ ȱȱȱ ęȱȱȱȱĝǯȱȱȱŜȱ ȱ ȱȱȱ¢ȱȱȱ10.7 N·m (95 in. lb.) ȱ ȱǰȱȱ7.3 N·m (65 in. lb.)ǰ ȱȱ ǯȱȱȱŜȱ ȱȱȱȱ ȱ ȱȱȱȱȱ3.9 N·m (35 in. lb.)ǯȱȱȱŗŖȬŞşǯ Valley %DIÀHV Choke Linkage Figure 10-90. Installing Carburetor onto Manifold. Install Governor Lever ȱ ŗǯȱ ȱȱȱȱȱȱȱĞȱ ȱȱȱĴȱȱ ȱȱȱ ǯȱȱȱȱȱȱȱȱȱ ǯ Governor Lever Mounting Screw Governor Cross Shaft Figure 10-91. Installing Governor Lever. )LJXUH,QVWDOOLQJ9DOOH\%DIÀHV Install Carburetor WARNING: Explosive Fuel! ȱ¢ȱȱȱȱȱȱȱȱ¢ǯȱ ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱȱȱȱȱȱȱȱ ¢ȱ ȱȱǯ ȱ ŗǯȱ ȱȱ ȱȱȱȱȱȱ ȱ ȱȱȱupǯȱȱȱȱȱ ȱȱȱǯ 10.23 10 Section 10 Reassembly Install Control Bracket and Air Cleaner Assembly ȱ ŗǯȱ ȱȱȱȱ¢ȱȱ ȱȱȱȱǰȱȱȱ ȱǯȱȱȱŗŖȬşŘǯ 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. ȱ Řǯȱ ȱȱ ȱȱȱ ȱȱȱȱ ȱǯ řǯȱ ȱȱȱȱ¢ȱȱȱȱ ȱȱǰȱĴȱȱȱ ȱǻ ȱȱ ȱȱǼǰȱȱęȱȱ ȱ¡ȱĚȱǯȱȱȱ ȱ ȱ ȱȱȱȱȱ ȱȱȱ Ȧȱȱȱȱȱȱȱ ǰȱȱȱȱ ȱ¡ȱĚȱ ǯȱ ȱȱȱȱǰȱȱȱȱ ȱ¡ȱĚȱȱȱ7.9 N·m (70 in. lb.) in ȱȱǰȱȱȱ ȱ¡ȱĚȱ ȱȱ9.9 N·m (88 in. lb.)ǯȱȱȱŗŖȬşřǰȱ ŗŖȬşŚǰȱȱŗŖȬşśǯ Mounting Screws Figure 10-95. Installing AIr Cleaner Mounting Screws . ȱ Śǯȱ ȱȱȱȱȱȱęĴȱȱȱ ȱȱȱȱȱȱȱȱȱ ȱǯ ȱ śǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱǯ ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱǯȱ ȱȱ ȱȱȱ ȱȱnew Ȭ ȱȱǯȱȱȱŗŖȬşŜǯ Breather Hose Port Ground Lead Location Vent Hose Mounting Nuts Figure 10-93. Installing Air Cleaner. 10.24 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. Install Throttle and Choke Linkages Install Fuel Pump ȱȱȱĴȦȱȱȱ ȱ ȱȱ¢ǰȱȱȱ ȱȱȱȱȱȱȱȱȱ ȱȱǯȱ On Control Levers: ȱ ȱ ȱAȱȱȱȱOuter Pullȱȱȱȱ ǯȱ ȱ ȱ ȱB ȱȱȱInner Pull ȱȱ ǯȱȱȱŗŖȬşŝȱȱŗŖȬşŞǯ ȱ ŗǯȱ ȱȱȱȱ ȱȱȱȱȱ ǰȱȱȱǯȱȱȱȱ ȱȱ4.0 N·m (35 in. lb.)ǯȱ Řǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱ ȱȱǯ ȱ řǯȱȱ ȱȱȱǰȱȱȱȱȱȱ ȱǯȱȱȱŗŖȬşşǯ ȱ ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱ ȱȱȱǯ Throttle Control Clamp Location Choke Control Clamp Location (A) Fuel Pump Outlet Hose Pulse Hose (A) Inlet Hose Links Connected Here 10 Figure 10-99. Fuel Pump Mounting and Hose Details. Figure 10-97. Throttle/Choke Linkage Details for "Outer Pull" Actuation. ȱ Řǯȱ ȱȱĴȱȱȱȱȱ ȱȱȱĴȱȱȱȱ ȱȱ ȱǯȱ 10.25 Section 10 Reassembly Adjusting Governor ȱ ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱ¢ȱȱȱȱȱȱ ȱȱĞǯȱȱȱŗŖȬŗŖŖǯ 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. Řǯȱ ȱȱȱ toward ȱȱ ȱȱȱȱ ȱȱǻ ȬȱĴǼȱȱȱ ȱǯȱȱȱŗŖȬŗŖŗǯȱ ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱȱȱ ȱĞȱȱȱȱĞȱ ȱǻ ȱ ȱȱǼȱȱȱȱȱ ȱǰȱȱȱ ȱ¡ȱȱȱ7.3 N·m (65 in. lb.)ǯȱȱȱŗŖȬ ŗŖŗǯȱ Governor Idle Spring (Color) High Speed (RPM) Clear 1200 - 1550 RPM Black 1551 - 1800 RPM Governor Spring (Color) High Speed (RPM) Orange 3000 - 3100 RPM Red 3101 - 3300 RPM Green 3301 - 3750 RPM Purple 3751 - 3900 RPM Figure 10-103. Governor Spring/RPM Chart. Install Oil Sentry™ (If Equipped) Move and Hold Towards Carburetor Hex Nut ȱ ŗǯȱ ¢ȱȱȱ ȱĚ® ǻ®ȱǯȱ śşŘŚŗȱȱǼȱȱȱȱȱȱȱ ¢™ȱ ȱȱȱȱȱȱŗȦŞȄȱȱȱ ȱȱǯȱȱȱŗŖȬŗŖŚǯȱȱȱ 10.1 N·m (90 in. lb.)ǯ Lift/Rotate Clockwise Figure 10-101. Adjusting Governor. Śǯȱ ȱȱȱȱȱȱȱǯȱ ȱȱȱȱǻ ȱȱȱ Ǽǰȱȱȱȱȱȱȱȱȱȱ ȱǯȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱ ǯȱȱȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱȱȱ ȱȱȱȱ¢ȱĝǯȱȱȱŗŖȬŗŖŘǯ 10.26 Oil Pan Pressure Switch Figure 10-104. Oil SentryTM Pressure Switch Location. Section 10 Reassembly ȱ Řǯȱ ȱȱȱ ȱȱȱȱȱ¢™ ǯ Mounting Screws Install Blower Housing and Cylinder Shrouds ŗǯȱ ȱȱȱǰȱ ȱȱ ȱ ȱȬ ǰȱȱȱǯȱȱ ȱȱ ȱ ȱ ǯȱȱȱ ȱȱ4.0 N·m (35 in. lb.)ǯȱȱȱŗŖȬŗŖśǯ ȱ Řǯȱ ĴȱȱĞȱȱǻȱǼȱȱȱ ȱȱ ȱȱ ǯȱȱȱ ȱ ȱ9.9 N·m (88 in. lb.)ǯȱȱȱŗŖȬŗŖśǯ Cylinder Shrouds Figure 10-107. Installing Cylinder Shrouds. Oil Fill Tube Lift Bracket Lower Mounting Screw ,QVWDOO0XIÀHU ŗǯȱ ȱȱȱȱǻȱǼǯȱĴȱȱ ĝȱȱȱ ȱȱȱ¡ȱĚȱȱ ȱȱ¡ȱǯȱȱȱ¡ȱĚȱ ȱȱ24.4 N·m (216 in. lb.)ǯ ȱ Řǯȱ ȱ¢ȱĴȱ ȱȱǯȱ ȱŜȱ ȱȱ9.9 N·m (88 in. lb.), and M8 ȱȱ24.4 N·m (216 in. lb.)ǯ Figure 10-105. Oil Fill Tube and and Lift Bracket. ȱ řǯȱ ȱȱȱȱ ȱǯȱȱ ȱȱȱȱ ǯȱȱȱ ȱ ȱ4.0 N·m (35 in. lb.)ȱȱȱǰȱȱ 2.0 N·m (17.7 in. lb.) ¢ȱĞǯ ȱ ȱŗŖȬŗŖŜǯ Mounting Locations Flange Nuts (4) Underside View )LJXUH0XIÀHU,QVWDOODWLRQ ȱ řǯȱ ȱȱȱȱǻȱǼǯ Figure 10-106. Installing Blower Housing. ȱ Śǯȱ ȱȱ ȱ¢ȱȱȱȱ ȱȱȱ ǯȱȱȱ ȱ ȱ4.0 N·m (35 in. lb.)ȱȱȱǰȱ ȱ2.0 N·m (17.7 in. lb.) ¢ȱĞǯ ȱ ȱŗŖȬŗŖŝǯ 10.27 10 Section 10 Reassembly Install Oil Filter and Add Oil to Crankcase ȱ ŗǯȱ ȱȱȱȱǯȱȱȱŗŖȬŗŖşǯȱ ȱȱȱȱŘŗǯŚȱȉȱǻŗśǯŝȱĞǯȱǯǼǯ DZȱ ȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱ ęȱȱȱȱǯ Figure 10-111. Reinstall the Dipstick in Tube. Connect Spark Plug Leads ȱ ŗǯȱ ȱȱȱȱȱȱǯȱȱȱ ŗŖȬŗŗŘǯ Drain Plug (Starter Side Shown) Figure 10-109. Reinstall Oil Drain Plugs. ȱ Řǯȱ ȱȱ ȱȱęȱ ȱȱȱ ȱȱŜǯ ȱ řǯȱ ¢ȱȱȱęȱȱȱȱȱȱȱȱ ȱȱȱȱęȱȱȱȱęȱȱ ȱȱǯȱȱȱŗŖȬŗŗŖǯ ȱ Śǯȱ ȱȱȱęȱȱȱȱȱ ȱȱǰȱȱȱȱęȱȱ ȱřȦŚȬŗȱǯȱȱȱŗŖȬŗŗŖǯ Figure 10-112. Connect Spark Plug Leads. Prepare the Engine for Operation ȱȱȱ ȱ¢ȱǯȱȱ ȱȱȱȱǰȱȱȱȱȱȱ ǯ ȱ ŗǯȱ ȱȱȱ ȱȱȱ¢ǯ ȱ Řǯȱ ȱȱȱȱȱǰȱȱ¢™ ȱ ǰȱȱȱ ȱȱęȱȱǯ Figure 10-110. Installing and Tightening Oil Filter. ȱ śǯȱ ȱȱȱȱȱȱȱȱȱȃȄȱȱȱ ȱȱǯȱȱȱŗŖȬŗŗŗǯ 10.28 ȱ řǯȱ ȱȱȱ ȱȱȱǰȱ ǰȱȱ¢ȱȱǯȱȱȱȱ ȱȱȱȱȱȈ¢ȱ ȱȱȈȱȱȈȱ ¢Ȉȱǯ ȱ Śǯȱ ȱȱǰȱȱȱǰȱȱȱ ȱȱ ȱȱ¢ǯȱȱȱ ȱśǰȱȱȈȱ¢ȱȱȈǯ Section 10 Reassembly Testing the Engine ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱȱ ǯ ȱ ŗǯȱ ȱȱȱȱȱȱȱǯȱȱȱȱ ȱǯȱȱȱȱȱȱȱ ȱȱȱȱȱǻŘŖȱȱȱǼȱȱ ǯȱȱȱȱȱȱȱŘȬřȱǰȱ ȱśȬŜȱȱȱ ȱȱȱ ǯȱȱȱȱ¡ȱĴȱ ȱ¢ȱǻȱǼǯ Řǯȱ ȱȱȱȱȱȱǻǼȱ ȱȱĴǯȱȱȱȱ¡ȱ ȱȱȱȱ¡ȱřşŖŖȱȱǻȱ Ǽǯ 10 10.29 10.30 FORM NO.: ISSUED: REVISED: LITHO IN U.S.A. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 TP-2581 1/09
