Kohler CV1000- Manuals
Kohler CV1000– User Manual in PDF format online.
Manuals:
User Manual Kohler CV1000
Summary
Contents Section 1. Safety and General Information ............................................................................. Section 2. Tools & Aids ............................................................................................................. Section 3. Troubleshooting .........
1.1 1 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. Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and und...
1.2 Section 1Safety and General Information ¡ȱȱȱȱęȱȱ severe burns. ȱȱęȱȱȱȱ ȱȱengine is hot or running. WARNING Explosive Fuel! ȱȱ¡¢ȱĚȱȱits vapors can explode if ignited. Store gasoline only in approved containers, in well vent...
1.3 Section 1 Safety and General Information 1 A. Model No. C V 980 S B. Spec. No. Command Engine Version Code S = Electric Start C. Serial No. Year Manufactured CodeCode Year 37 2007 38 2008 39 2009 CV940-0001CV960-0001CV980- 0001CV1000-0001 Complete Spec Number (Incorporating Model No. with Variat...
1.4 Section 1Safety and General Information SAE 10W30 A PI SER VICE SJ 5W-20, 5W-30 R E C O M M E N D E D S A E V I S C O S I T Y G R A D E S 10W-30 Kohler 10W-30 °F -20 0 20 32 40 60 80 100 °C -30 -20 -10 0 10 20 30 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W...
1.7 Section 1 Safety and General Information 1 ¹Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly. *HQHUDO6SHFL¿FDWLRQVï Power (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.) CV940...........
1.8 Section 1Safety and General Information Carburetor, Intake Manifold, and Air Cleaner ȱȱȱȱ Torque Using Sequence in Two Stages ................................................. ęȱȱŗŜǯşȱȉȱǻŗśŖȱǯȱǯǼ ȱ ȱ ę¢ȱȱŘŘǯŜȱȉȱǻŘŖŖȱǯȱǯǼ Carburetor/Air Cleaner ...
1.9 Section 1 Safety and General Information 1 ĞȱȱȱȱǻȱȱǼ Running Clearance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 in.) Flywheel End Main Bearing Journal O.D. - New ..............................................
1.11 Section 1 Safety and General Information 1 ŶȱȱŗŗȱȱǻŖǯŚřřȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯ Top Compression Ring-to-Groove Side Clearance .................................... 0.04/0.08 mm (0.0015/0.0031 in.) Middle Compression Ring-to-Groove Side...
1.12 Section 1Safety and General Information Tightening Torque: N·m (in. lb.) + or - 10% Property Class Noncritical Fasteners Into Aluminum SizeM4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35) M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 1...
1.13 Section 1 Safety and General Information 1 English Fastener Torque Recommendations for Standard Applications Grade 2 or 5Fasteners IntoAluminum Size8-32 2.3 (20) 2.8 (25) --------- 2.3 (20) 10-24 3.6 (32) 4.5 (40) --------- 3.6 (32) 10-32 3.6 (32) 4.5 (40) --------- --------- 1/4-20 7.9 (70) 13...
2.1 Section 2 Tools & Aids 2 Section 2 Tools & Aids Tools Description Source/Part No. Ğȱ¢ȱȱȱĞȱ¢ǯ ȱȱȬŞŘŚŖś ĞȱȱȱǻǼȱȱȱȱĞȱǯ ȱȱȬŞŘŚŗŝ ¢ȱ ȱȱȱȱȱȱȱ¢...
2.2 Section 2Tools & Aids Tools (Continued) Description Source/Part No. ¢ȱȱĞȱȱȱȱȱ¢ȱĞǯ ȱŘśȱŝŜŗȱřŞȬ ȱ¢ȱȱȱȱȱȱ¢ǰȱ¡ȱǯȱȱȱȱȱȱǻǼȱȱ¢ǯ ȱŘśȱŚśśȱŖŗȬȱŘ...
2.3 Section 2 Tools & Aids 2 Aids Description Source/Part No. ĞȱȱǻȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬ ȱ ȱǻ Ȧȱ ŜŜŗǼ ȱŘśȱřśŝȱŗŗȬ ȱ ȱǻȬǼ Ȭ ȱȱȱȱǻȱǼ ȱȱśŘȱřśŝȱŖŗȬ ȱȱȱȱǻȱĞǼ...
2.4 Section 2Tools & Aids Special Tools You Can Make Flywheel Holding Tool ȱĚ¢ ȱȱȱȱȱȱȱȱȱȱȱĚ¢ ȱȱȱȱ ȱȱȱŘȬŗǰȱȱȱȱȱȱȱȱ ǯ ȱ ŗǯȱ ȱȱȱȬěȱ ǰȱȱȱȱ¡ȱ ȱȱȱȱȱȱȱ ...
3.1 3 Section 3 Troubleshooting Troubleshooting Guide When troubles occur, be sure to check the simple ȱ ǰȱȱęǰȱ¢ȱȱȱȱȱȱconsidered. For example, a starting problem could be ȱ¢ȱȱ¢ȱȱǯ ȱȱȱȱȱȱȱȱȱ ǯȱ...
3.2 Section 3Troubleshooting Engine Overheats ȱ ŗǯȱ ȱȦȱǰȱȱęǰȱȱȱ shrouds clogged. ȱ Řǯȱ ¡ȱȱǯȱ řǯȱ ȱȱȱǯȱ Śǯȱ ȱȱȱǯȱ śǯȱ ¢ȱǯȱ Ŝǯȱ ȱȱ¡ǯ Engine Knocks ȱ ŗǯȱ ¡ȱȱǯȱ Řǯȱ ...
3.3 Section 3 Troubleshooting 3 ȱȱȱȱȱȱȱȱȱȱthe engine is reassembled and placed into operation. ȱȱȱȱȱȱȱ¢ȱȱ ȱȱȱȱȱȱǯ Basic Engine Tests Crankcase Vacuum Test ȱȱȱ...
3.4 Section 3Troubleshooting Leakdown Test Results ȱȱȱȱ ....................................................... ȱȱ¢ȱ ǯȱȱȱ¡ȱ¢ ............................................................. ȱ¡ȱȦȱǯ...
4.1 4 Section 4 Air Cleaner and Air Intake System Paper Element InnerElement Inlet Screen Air Cleaners General These engines utilize a Heavy-Duty style air cleaner as shown in Figure 4-1, consisting of a cylindrical ǰȱĴȱȱȱȱȱȱmanifold. The air cleaner housing cont...
4.2 Section 4Air Cleaner and Air Intake System EjectorArea CylinderShroud 4. Do not wash the paper element and inner element or use compressed air, this will damage ȱǯȱȱ¢ǰȱȱȱȱelements with new genuine Kohler elements as required. Handle the new elements carefully; ...
5.1 5 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¡ȱȱǯȱȱȱ¢ȱȱ...
5.2 Section 5Fuel 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 ...
5.3 Section 5 Fuel System and Governor 5 Self-RelievingChoke Fuel Shut-OffSolenoid Bowl Drain Screw Slow Jets Bowl Vent Low Idle Fuel Adjustments(With Limiters) Fuel Pump General These engines use either a pulse style fuel pump, or optional remote-mounted electric fuel pump ¢ǯȱȱȱśȬŗȱ...
5.4 Section 5Fuel 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. ȱ Ȋȱ ȱȱȱȱȱȱęȱ ȱǰȱȱ gasoline. • Make sure the fuel ta...
5.5 Section 5 Fuel System and Governor 5 Fuel Shut-OffSolenoid High Altitude Operation ȱȱȱȱȱȱȱŗśŖŖȱȱǻśŖŖŖȱĞǯǼȱȱǰȱȱȱ¡ȱȱȱȱover-rich. This can cause conditions such as black, ¢ȱ¡ȱǰȱęǰȱȱȱȱȱpower, poor f...
5.6 Section 5Fuel System and Governor Lean Rich Adjust to Midpoint Lean Rich Adjust to Midpoint Left Side Right Side Carburetor Adjustments Adjustment DZȱ ȱȱȱȱȱ¢ȱ Ğȱȱȱȱ ȱǯ The carburetor is designed to deliver the correct fuel-to-air mixture to...
5.7 Section 5 Fuel System and Governor 5 Governed Idle System ȱȱȱȱ¢ȱȱȱȱȱȱdesired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. ȱȱ¢ȱȱȱ ȱȱgovernor lever and the governed id...
5.8 Section 5Fuel System and Governor 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 repla...
5.9 Section 5 Fuel System and Governor 5 Figure 5-14. Float and Inlet Needle Details. ȱ Ŝǯȱ ȱȱĚȱȱȱȱ ȱȱȱ seat and carburetor body. Install the new pivot ȱȱȱĚȱȱȱȱ ȱȱ ȱȱ ǯȱȱȱśȬŗśǯ Figure 5-15. Installing Float...
5.11 Section 5 Fuel System and Governor 5 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 Ĵ...
5.12 Section 5Fuel System and Governor 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 n...
5.13 Section 5 Fuel System and Governor 5 śǯȱ ȱȱ ȱ¡ȱǻ¢ȬǼȱȱȱȱ ȱȱĞȱȱ ȱȱȱȱlever from the carburetor housing. Save the bushing to use as a driver for installing the new bushing. Discard the old lever. ȱ Ŝǯȱ ȱȱǯǯȱȱȱȱ...
5.15 Section 5 Fuel System and Governor 5 GovernorLever GovernorCross Shaft GovernedIdle Spring Linkage GovernorSpring Governor General The governor is designed to hold the engine speed constant under changing load conditions. Most ȱȱȱ ȱȱȱĚ¢ ȱȱ...
5.16 Section 5Fuel System and Governor Hold Lever in"Full Throttle"Position High Speed (RPM)Adjustment Screw 3. Stop when the desired RPM speed is obtained. Figure 5-37. Adjusting High Speed RPM (Air Cleaner Removed for Clarity).
6.1 6 Section 6 Lubrication System SAE 10W30 A PI SER VICE SJ 5W-20, 5W-30 R E C O M M E N D E D S A E V I S C O S I T Y G R A D E S 10W-30 Kohler 10W-30 °F -20 0 20 32 40 60 80 100 °C -30 -20 -10 0 10 20 30 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W-20 or 5W...
6.2 Section 6Lubrication System Oil Drain Plug Drain Plug Operating Range 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 th...
6.3 Section 6 Lubrication System 6 ȱ řǯȱ ȱȱȱȱȱȱȱ21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ. ȱ Śǯȱ ȱȱǰȱ ȱ ȱȱȱȱȱ ¢ǰȱȱȱȃȄȱȱȱȱǯȱȱȱȃȱ¢ȄȱȱȱŜǯŗǯȱ ¢ȱȱȱȱ ȱȱȱȱȱȱǯ ȱ śǯȱ ...
6.5 Section 6 Lubrication System 6 Installation ȱȱ¢Ȝȱȱ ȱȱȱȱȱȱȱȱǯȱȱȱŜȬŗŘǯȱȱȱȱȱ ȱȱ¢Ȝȱȱȱȱȱȱ ȱȱ1/8-27 N.P.T.F. pipe plug. ȱȱȱ ǰȱ ȱȱDZȱ ŗǯȱ ¢ȱȱ...
7.1 7 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: • Spark Plugs ȱ Ȋȱ Ĵ¢ȱȱȱ¢ • Electric Starter ȱ Ȋȱ ȱȱ¢ȱǻȱȱǼȱ Spark ...
7.3 Section 7 Electrical System and Components 7 DC Voltmeter Battery Battery General ȱŗŘȬȱĴ¢ȱ ȱŚŖŖȱȱȱȱǻǼȱȱgenerally recommended for starting in all conditions. ȱȱ¢ȱĴ¢ȱȱĞȱĜȱȱȱapplication is started only in warmer temperatures. ȱ...
7.4 Section 7Electrical System and Components Molex Plug(Some Models) ȱȱ ȱěȱ¢ȱȱȱ¢ȱȱȱǯȱȱ¢ȱȱȱȱȱ ȱ£ȱȱȱǯȱȱěȱȱȱ¢ȱȱȱȱ ¢ȱȱȱȱȱǯ The ¡ȱȱ¢...
7.5 Section 7 Electrical System and Components 7 Kill Switch or ‘‘Off’’ Position of Key Switch IgnitionModules Spark Plug Magnet Flywheel (0.28/0.33 mm)0.011/0.013 in. Air Gap L1 D1 C1 T1 P S Spark Plug L2 SCS Figure 7-5. Capacitive Discharge (CD) Ignition Module Schematic. Figure 7-4. Capacitive Di...
7.6 Section 7Electrical System and Components ǯȱ ȱȱȱȱǰȱȱȱ¢ȱ ȱȱȱȱǯȱȱȱ¢ȱ ǰȱwires, connections, safety interlocks, etc. ǯȱ ȱȱȱȱȱȱȱ associated with the ignition or electrical ¢ȱȱȱǯȱȱ...
7.7 Section 7 Electrical System and Components 7 Troubleshooting DSAI Ignition Systems ȱȱȱ¢ȱȱȱȱȱȱȱȱȱȱȱȱǯȱȱȱ¢ȱȦȱȱȱǰȱȱǰȱǰȱȱȱȱȱ¢ȱȱǯȱ...
7.8 Section 7Electrical System and Components ȱ Řǯȱ ȱȱȱǰȱȱȱȱ ȱśśŖȬŜŖŖȱǰȱȱȱǻǼȱȱǯ ȱ řǯȱ ȱȱȱȱȱȱȱ¢ȱȱ ¢ȱȱȱȱ¢ǯ ǯȱ ȱȱ¢ȱȱȱȱȱȱ engine runs p...
7.9 Section 7 Electrical System and Components 7 Battery Charging System General Most engines are equipped with a 15, 20, or 25 ampȱȱ¢ǯȱȱȱŝȬşȱȱŝȬŗřǯȱ DZȱ ȱȱ ȱȱȱ avoid damage to the electrical system and components: ȱ Ȋȱ ȱȱȱ...
7.13 Section 7 Electrical System and Components 7 Stator ȱȱȱȱȱȱȱȱȱĚ¢ ǯȱ ȱȱȱȱȱŞȱȬȱȃ¢ȄȱȱȱŗŖȱȬȱȃ¢Ȅȱȱȱreplacement is necessary. 5HFWL¿HU5HJXODWRU ȱęȬȱȱȱȱȱȱȱ...
7.15 Section 7 Electrical System and Components 7 Troubleshooting Guide 15/20/25 Amp Battery Charging Systems ȱȱȱȱȱȱĴ¢ȱȱȱȱĴ¢ȱȱȱȱȱȱǰȱȱȱȱ¢ȱȱȱ ȱȱȱȱ¢ȱȱ ȱȱĴ¢ǯ NOTE: ¢ȱ£...
7.16 Section 7Electrical System and Components DC Voltmeter 5HFWL¿HU5HJXODWRU FlywheelStator Ammeter Battery (-) (+) Figure 7-20. Connections for Testing Charging System. Electric Starting Motors ȱȱȱȱĞȱȱȱȱǯȱȱȬ¢ȱȱĞȱȱȱtypica...
7.19 Section 7 Electrical System and Components 7 DriveEnd Cap Screw Plunger Spring Lever Plate Plug Solenoid Frame & Field Brush Holder Nut CommutatorEnd Plate Screw Bolt Collar Retaining Ring Stop Drive Armature Washer Tube ȱ Şǯȱ ȱȱȱȱȱȱȱȱȱ ȱȱȱȱ...
7.20 Section 7Electrical System and Components Wear Limit Length7.6 mm (0.300 in.) Mica Insulation Commutator O.D. Inspection Drive Pinion ȱȱȱȱ ȱDZ ǯȱ ȱȱȱȱȱ ȱȱ damage. ǯȱ ȱȱ ȱȱȱȱȱȱ mechanism for nicks, or...
7.21 Section 7 Electrical System and Components 7 Brush Replacement ȱȱȱȱȱȱȱȱȱǻŚǼǯȱȱȱ ȱȱȱȱȱǰȱȱȱȱnecessary. ȱ ŗǯȱ ȱȱŗȬśȱȱȃȱ¢ǯȄ ȱ Řǯȱ ȱȱ ȱ ȱȱȱȱ ȱ¢ȱȱȱ...
7.22 Section 7Electrical System and Components řǯȱ ȱȱěȱȱǻǼȱ ȱȱȱ ȱȃěȄȱȱȱ ȱȱȱȦǯȱȱȱŝȬřşǯ Figure 7-39. Installing Thrust Washer. ȱ Śǯȱ ¢ȱȱȱȱȱȱȱȱȱȱȱ drive end cap, and install the armat...
7.25 Section 7 Electrical System and Components 7 VOM Leads 12 volt Test LeadsMomentaryConnection Only Solenoid Test Procedure Solenoid Shift Style Starters ȱȱȱȱȱȱȱȱȱȱȱĴȱȱȱ ȱȱterminal. Remove the mounting hardware and se...
7.26 Section 7Electrical System and Components Test 4. Solenoid Hold-In Coil/Contact Continuity Test. ȱȱȱȱȱȱȱȱ¡Řȱǰȱȱconnect the two ohmmeter leads to the two large post ǯȱȱȱȱȱǻřǼȱȱȱȱ¢ǯȱȱȱŝȬśŚǯȱȱȱ...
8.1 8 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...
8.2 Section 8Disassembly Cylinder Shroud Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter ȱ ŗǯȱ ȱȱȱęȱȱȱǯȱȱȱ ȱȱȱęǯȱȱȱŞȬŘǯ Figure 8-2. Removing Oil Filter. 2. Remove the dipstick and one of the oil drain plugs. Figure 8-3. ...
8.3 Section 8 Disassembly 8 3. Remove the lower mounting screw and pull the ȱęȱȱȱȱȱǯ Figure 8-7. Removing Oil Fill Tube. Remove Electric Starter Motor 1. Disconnect the leads from the starter. ȱ Řǯȱ ȱȱ ȱ¡ȱĚȱ ȱȱǯȱ ȱȱŞȬŞǯ Figure 8-8. Remo...
8.4 Section 8Disassembly Remove Fuel Pump WARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱȱǯȱȱȱ¢ȱȱȱǰȱȱ ȱǰȱȱǰȱ ¢ȱȱȱȱĚǯȱȱȱęȱȱȱȱ ȱȱȱȱȱȱr...
8.5 Section 8 Disassembly 8 Figure 8-15. Removing Control Bracket. ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱ ȱȱȱȱĞǯȱȱȱŞȬŗŜǯ Figure 8-16. Removing Governor Lever. Remove Carburetor WARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ...
8.6 Section 8Disassembly NOTE: New clamps are recommended any time disassembly is performed, or if clamps have been loosened (expanded) several times. )LJXUH5HPRYLQJ9DOOH\%DIÀHV 2. Remove the four screws securing each of the ȱ¢ȱĝȱȱǯȱȱȱŞȬŘŖǯ )LJXUH5HPRYLQJ2XWHU&\OLQG...
8.7 Section 8 Disassembly 8 Figure 8-24. Removing Oil Filter Housing. ȱȱ ȱ¢ȱȱȱȱęȱȱassembly requires individual servicing. ȱ ǯȱ ȱȱȱȱȱȱȱȱęȱ ȱȱȱśȦŗŜȈȱȱ ȦǯȱȱȱŞȬŘśǯ Figure 8-25. Removing Nipple. ȱ ǯ...
8.8 Section 8Disassembly Remove Grass Screen and Cooling Fan ȱ ŗǯȱ ȱȱ ǰȱĴȱ ǰȱȱ¡ȱ ȱȱȱȱǰȱěǰȱȱȱȱȱȱĚ¢ ǯȱȱȱŞȬŘşȱȱŞȬřŖǯ Figure 8-29. Removing Grass Screen Fasteners. Figure 8-30. Removing Cooling Fan and He...
8.9 Section 8 Disassembly 8 Wiring Harness MoldedClips 2. Remove the mounting screws securing the ęȬȱȱȱȱȱassembly. Note the location of the ground lead. ȱȱęȬȱȱȱȱǰȱit may remain mounted to the backing shroud ¢ǯȱȱȱŞȬ...
8.10 Section 8Disassembly 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 Figure 8-38. Removing Valve Covers. Remove Cylinde...
8.11 Section 8 Disassembly 8 Figure 8-42. Removing Hydraulic Lifters. Figure 8-43. Match Numbers on Cylinder Barrel and Heads. 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 ...
8.12 Section 8Disassembly 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. 4. Repeat the above procedure for the other cylinder hea...
8.13 Section 8 Disassembly 8 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 Remove Camshaft ȱ ŗǯȱ ȱȱĞȱȱȱǻȱǼǯȱȱ ȱŞȬśř...
8.14 Section 8Disassembly 2. Carefully remove the connecting rod and piston ¢ȱȱȱ¢ȱǯȱȱȱŞȬśŜǯ Figure 8-56. Removing Piston/Connecting Rod Assemblies. 3. Repeat the above procedures for the other connecting rod and piston assembly. Remove Crankshaft ŗǯȱ ¢ȱȱ...
8.15 Section 8 Disassembly 8 Remove Lifter Feed Chamber Cover and Gaskets ȱ ŗǯȱ ȱȱȱ ȱȱȱĞȱȱ chamber cover, and gaskets. Carefully separate ȱȱȱȱǯȱȱȱŞȬŜŖǯ Figure 8-60. Removing Lifter Feed Chamber Cover Components. Remove Flywheel and ...
9 9.1 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 & Ext...
Section 9Inspection and Reconditioning 9.2 45 ° High Point from Fillet Intersections This Fillet AreaMust Be Completely Smooth Minimum The Fillet Must Blend Smoothly with the Bearing Journal Surface NOTE: If the crankpin is reground, visually check to ȱȱȱęȱȱ¢ȱ ȱthe c...
Section 9 Inspection and Reconditioning 9 9.3 11 mm (0.433 in.) Measure 11 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin accomplished at a drill speed of about 250 RPM and ŜŖȱȱȱǯȱĞȱȱȱȱȱhone, proceed as follows: ȱ ŗǯȱ ȱȱȱȱ...
Section 9Inspection and Reconditioning 9.4 Feeler Gauge 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 ȬȬȱȱȱ...
Section 9 Inspection and Reconditioning 9 9.5 EXHAUST VALVE INTAKE VALVE A B C D D F E G H F E G H INT EXH Figure 9-6. Valve Details. ȱȱȱȱȱ ȱȱ¢ȱȱfuel consumption may be symptoms of faulty valves. ȱȱ¢ȱȱȱȱĴȱȱ ȱǰȱ...
Section 9Inspection and Reconditioning 9.8 Valve Seat Cutter Pilot Valve Guides ȱȱȱȱȱ ȱ¢ȱęǰȱȱ ȱnot 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-val...
Section 9 Inspection and Reconditioning 9 9.9 Overheated or Deteriorated Oil Scored Piston and Rings Abrasive Scratched Rings Stuck, Broken Rings Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter the combustion chamber ...
Section 9Inspection and Reconditioning 9.10 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....
Section 9 Inspection and Reconditioning 9 9.11 Figure 9-12. Piston Ring Installation. ȱ ŗǯȱ ȱȱȱǻĴȱ ǼDZȱȱȱ expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Middle Compression Ring (Center Groove): Install the center ring using a piston ...
Section 9Inspection and Reconditioning 9.12 Oil Pan Assembly InspectionInspect 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 ǻȱȱȱŗ...
Section 9 Inspection and Reconditioning 9 9.13 O-Ring 3 2 1 4 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. Figure 9-16. O-Ring Installed in Oil Pump Housing. 5. Lightly lubricate the I.D. of the inlet seal with oil ...
10.1 10 Section 10 Reassembly General NOTE: Make sure the engine is assembled using ȱęȱȱǰȱȱǰȱȱǯȱȱȱȱęȱȱȱȱȱ ȱȱǯȱ ¢ȱȱ ȱǯȱ¢ȱȱȱȱȱȱȱȱȱȱ...
10.2 Section 10Reassembly ȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯ ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱ ǯȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱĴȱȱȱǯȱȱ...
10.3 Section 10 Reassembly 10 Oil Seal Seal depth 1.5 - 2.0 mm (0.059 - 0.078 in) CrankcaseSurface 12.66 mm(0.498 in.) Crankcase Surface GovernorGear Shaft Figure 10-6. Installed Main Bearing. Install Governor Shafts, Seal, and Governor Gear ȱȱȱĞǰȱǰȱȦȱȱȱ ȱ...
10.4 Section 10Reassembly Śǯȱ Ĵȱȱȱ¢ȱȱȱȱĞȱȱȱ ȱȱȱȃȄȱȱǯȱȱ ȱȱ ȱ ǯȱȱȱȱȱȱȱȱȬǰȱ¢ȱȱȱȱȱ ® ǯȱŘŜŜȱȱǰȱȱȱ ȱȱȱǯȱȱȱ ȱ...
10.6 Section 10Reassembly Figure 10-20. Torquing Connecting Rod End Cap Screws. ȱ Ŝǯȱ ȱȱȱȱȱȱȱ ȱȱȱȱ¢ǯ Install Camshaft ȱ ŗǯȱ ¢ȱ¢ȱĞȱȱǻȱ ȱǯȱ25 357 14-SǼȱȱȱȱȱȱǯȱȱȱĞȱ...
10.7 Section 10 Reassembly 10 OilSeal 3 mm (0.118 in.) ȱ śǯȱ ȱȱȱ¢ȱȱȱȱȱ ȱȱ¢ǯ Install Oil Pan Seal and Main Bearing Main Bearing ȱȱȱȱȱȱ ȱȱȱǰȱȱ ȱȱȱȱȱȱȱǯ ŗǯȱ ȱȱȱȱ...
10.8 Section 10Reassembly O-Ring 10 8 1 14 3 5 12 7 9 11 6 4 2 13 Install Oil Pan Assembly ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱǰȱ¢ǰȱȱȱȱ¢ȱȱȱȱǯȱȱȱ ȱȬȱȱȱȱǯȱȱȱŗŖȬŘŝǯ Figure 10-27. O-Ring Installed. Řǯȱ ȱȱ...
10.9 Section 10 Reassembly 10 Crankcase Filter Breather Hose Flange Nuts (4) Gasket Check Crankshaft End play ȱ ŗǯȱ ȱȱȱȱ ǰȱȱȱȱȱȱ ȱȱȱĞȱȱ¢ȱȱȱęȱȱȱȱŗǯȱ Figure 10-32. Checking Crankshaft End play. Install Brea...
10.10 Section 10Reassembly 1 3 4 2 ȱ řǯȱ ȱȱȱ¡ȱĚȱ ǰȱȱȱ ȱȱȱ ȱȱȱŗŖȬřśȱȱ5.7 N·m (51 in. lb.)ǯ Figure 10-35. Breather Assembly Fastener Torque Sequence. ȱ Śǯȱ ¢ȱȱȱ ȱȱȱȱȱ ȱ ȱȱȱȱȱȱ...
10.11 Section 10 Reassembly 10 DZȱ ¢ȱĞȱȱ ¢ȱȱ ȱȱȱȱȱȱȱ¢ǯȱȱ¡ȱĞȱȱȱȱȱȱĞȱȱȱȱȱ ȱȱȱĞȱȱȱȱȱȱȱȱȱǯȱȱ¢ȱȱȱȱȱȱ...
10.12 Section 10Reassembly Spacer Washers 2 2 4 5 5 4 1 3 3 1 No. 1 No. 2 Figure 10-43. Installing Valves with Valve Spring Compressor. Install Cylinder Heads ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱ¢ȱȱȱȱǯ ȱ Řǯȱ ȱȱȱ ...
10.13 Section 10 Reassembly 10 ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱ ¢ȱȱȱȱȱ¢ǯȱȱȱȱȱȱ¢ȱȱȱȱǯȱŘȱǻ Ǽȱȱȱȱȱ29.3 N·m (260 in. lb.)ǯȱȱȱŗŖȬŚŞǯ Figure 10-48. Installing Pipe Plug in Cylinder Heads. Ins...
10.14 Section 10Reassembly ȱȱDZȱ ȱ ǯȱ ȱ ȱȱȱȱȱȱȱ ȱ ȱǯ ȱ ȱ ǯȱ ¢ ¢ȱȱĞȱ ȱȱȱ ȱǛŗȱȱ ȱ ¢ǯ ȱ ȱ ǯȱ ȱȱȦȱȱȱȱȱ ȱ ȱ Ğȱȱȱ¢ȱȱȱǯȱȱ ȱ ȱ¢ȱȱǰȱȱȱ...
10.15 Section 10 Reassembly 10 Figure 10-53. Establishing the "0" Lash Point. Śǯȱ ȱȱȱȱĴȱȱȱȱǰȱ ȱȱǻǼȱȱȱȱfour (4)complete revolutions clockwiseǰȱȱȱĚȱȱnut (1/6 turn), or a total of 4-1/6 turnsǯȱ Figure 10-54. Setting Valv...
10.16 Section 10Reassembly Spring Install Spark Plugs ȱ ŗǯȱ ȱ ȱ ® ȱŗŖȱǻȱǼȱ ȱǯ ȱ Řǯȱ ȱȱȱȱ0.76 mm (0.030 in.)ǯ ȱ řǯȱ ȱ ȱȱȱȱȱ24.4-29.8 N·m ǻŗŞȬŘŘȱĞǯȱǯǼǯȱȱȱŗŖȬśŝǯ Figure 10-57. Installing Spark Plugs. Install Oil Filter Housing ...
10.17 Section 10 Reassembly 10 O-Rings AroundDowel Pins Figure 10-62. Installing Nipple into Cup and Oil Filter Housing. Figure 10-63. Torquing Nipple into Housing. Installation ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱ ȱ ȱȱȱȱǯȱȱȱȱȱ ȱȬȱ...
10.18 Section 10Reassembly 1 2 Cylinder 1 Cylinder 2 3 4 Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱ ȱȱȱȱȱȱȱȱǯȱȱȱȱ ȱȱ ȱǰȱęȱȱ16.9 N·m (150 in. lb.)ǰȱę¢ȱȱ22.6 N·m (200 in. lb.)ǰȱȱȱȱ ȱȱȱŗ...
10.19 Section 10 Reassembly 10 Figure 10-71. Installing Stator. śǯȱ ȱȱȱȱȱȱȱȱȱƸȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱǯȱ Figure 10-72. B+ Ch...
10.20 Section 10Reassembly Figure 10-76. Clean and Dry Flywheel Hub. Figure 10-77. Installed Flywheel Key. DZȱ ȱȱȱĚ¢ ȱ¢ȱȱȱ ¢ȱȱȱ¢ ¢ǯȱȱĚ¢ ȱȱȱȱȱȱȱȱ¢ȱȱȱ¢ȱǯ ȱ ŗǯȱ ȱȱ ěȱ¢ȱȱȱ¢ ¢ȱȱ...
10.22 Section 10Reassembly Install Oil Cooler ŗǯȱ ȱȱ ȱȱȱȱ ȱȱȱ ęȱȱȱȱȱǯȱȱ ȱ ȱǯȱȱȱŗŖȬŞŚǯ Figure 10-84. Connecting Oil Cooler Hoses. ȱ Řǯȱ ȱȱȱȱ ȱȱȱȱȱȱ ȱ¢ǯȱȱȱ ...
10.23 Section 10 Reassembly 10 ȱ řǯȱ ȱȱȱȱȱǯȱȱȱ ŗŖȬŞŞǯ Figure 10-88. Connecting Leads to Starting Motor. ,QVWDOO9DOOH\%DIÀHV ȱ ŗǯȱ ȱȱ ȱ¢ȱĝȱȱȱ ȱ ȱȱ ǯȱȱ ȱȱȱęȱȱȱȱĝǯȱȱȱŜȱ ȱ...
10.25 Section 10 Reassembly 10 Fuel Pump Outlet Hose PulseHose InletHose Figure 10-96. Installing Choke Link and Push-On Nut. Install Throttle and Choke Linkages ȱȱȱĴȦȱȱȱ ȱȱȱ¢ǰȱȱȱȱȱȱȱȱȱ...
10.26 Section 10Reassembly Oil Pan Adjusting Governor ȱ ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱ¢ȱȱȱȱȱȱȱȱĞǯȱȱȱŗŖȬŗŖŖǯ Figure 10-100. Brushed/Knurled Area. Řǯȱ ȱȱȱ toward ȱȱ ȱȱȱȱ ...
10.27 Section 10 Reassembly 10 Oil FillTube LiftBracket LowerMountingScrew Cylinder Shrouds MountingScrews ȱ Řǯȱ ȱȱȱ ȱȱȱȱȱ¢ ™ ǯ Install Blower Housing and Cylinder Shrouds ŗǯȱ ȱȱȱǰȱ ȱȱ ȱ ȱȬ ǰȱȱȱǯȱȱ ȱ...
10.29 Section 10 Reassembly 10 Testing the Engine ȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱǯ ȱ ŗǯȱ ȱȱȱȱȱȱȱǯȱȱȱȱ ȱǯȱȱȱȱȱȱȱȱȱȱȱȱǻŘ...
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