Onan E125H, E140H User Manual
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1/96
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Redistribution or publication of this document,
by any means, is strictly prohibited.
Before operating the engine, read the Operator’s Manual and
become familiar with it and the equipment. Safe and efficient
operation can be achieved only if the equipment is
properly operated and maintained.
The following symbols, found throughout this manual, alert you
to potentially dangerous conditions to the operator, service per-
sonnel, or the equipment.
This symbol warns of immediate hazards
which will result in severe personal injury or death.
<.74341
practice which can result in severe personal injury or
death.
/.:9354
practice which can result in personal injury or product or
property damage.
Fuels, electrical equipment, batteries, exhaust gases and
moving parts present potential hazards that can result in severe
personal injury. Take care in following these recommended
procedures. All local, state and federal codes should be
consulted and complied with.
<.74341
use in any type of aircraft. Use of this engine in aircraft can
result in engine failure and cause severe personal injury or
death.
GENERAL
This symbol refers to a hazard or unsafe
This symbol refers to a hazard or unsafe
This engine is not designed or intended for
• Provide appropriate fire extinguishers and install them in
convenient locations. Use an extinguisher rated ABC by
NFPA.
• Make sure that all fasteners on the engine are secure and
accurately torqued. Keep guards in position over fans,
driving belts, etc.
• If it is necessary to make adjustments while the engine is
running, use extreme caution when close to hot exhausts,
moving parts, etc.
• Used engine oils have been identified by some state and
federal agencies as causing cancer or reproductive
toxicity. When checking or changing engine oil, take care
not to ingest, breathe the fumes, or contact used oil.
• Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol or
drug that makes the operation of equipment unsafe.
BATTERIES
• Before starting work on the engine, disconnect batteries
to prevent inadvertent starting of the engine. Disconnect
negative (–) cable first.
• DO NOT SMOKE while servicing batteries. Lead acid bat-
teries give off a highly explosive hydrogen gas which can
be ignited by flame, electrical arcing or by smoking.
• Verify battery polarity before connecting battery cables.
Connect negative (–) cable last.
PROTECT AGAINST MOVING PARTS
• Do not wear loose clothing in the vicinity of moving parts,
such as PTO shafts, flywheels, blowers, couplings, fans,
belts, etc.
• Keep your hands away from moving parts.
FUEL SYSTEM
• DO NOT fill fuel tanks while engine is running.
• DO NOT smoke or use an open flame in the vicinity of the
engine or fuel tank. Internal combustion engine fuels are
highly flammable.
• Fuel line must be of steel piping, adequately secured, and
free from leaks. Piping at the engine should be approved
flexible line. Do not use copper piping for flexible lines as
copper will work harden and become brittle enough to
break.
• Be sure all fuel supplies have a positive shutoff valve.
• Benzene and lead, found in some gasoline, have been
identified by some state and federal agencies as causing
cancer or reproductive toxicity. When checking, draining
or adding gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.
EXHAUST SYSTEM
• Exhaust products of any internal combustion engine are
toxic and can cause injury, or death if inhaled. When
operating the engine in a confined area, make sure the
ventilation system is operating properly.
• DO NOT use exhaust gases to heat a compartment.
• Make sure that your exhaust system is free of leaks. Make
sure that exhaust manifolds are secure and are not
warped by bolts unevenly torqued.
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, a poisonous gas that
can cause unconsciousness and death. It is an odorless and
colorless gas formed during combustion of hydrocarbon fuels.
Symptoms of carbon monoxide poisoning are:
• Dizziness • Vomiting
• Headache • Muscular Twitching
• Weakness and Sleepiness • Throbbing in Temples
If you experience any of these symptoms, get out into fresh air
immediately, shut down the unit and do not use it until it has
been inspected.
The best protection against carbon monoxide inhalation is
proper installation and regular, frequent inspections of the
complete exhaust system. If you notice a change in the sound
or appearance of exhaust system, shut the unit down immediately and have it inspected and repaired at once by a competent
mechanic.
KEEP THE UNIT AND SURROUNDING AREA CLEAN
• Make sure that oily rags are not left on or near the engine.
• Remove all unnecessary grease and oil from the unit.
Accumulated grease and oil can cause overheating and
subsequent engine damage and present a potential fire
hazard.
E-8
Table of Contents
Redistribution or publication of this document,
by any means, is strictly prohibited.
TITLE PAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS INSIDE FRONT COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2. TOLERANCES AND CLEARANCES 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3. ASSEMBLY TORQUES 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4. TROUBLESHOOTING 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5. FUEL SYSTEM 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Removal / Installation 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor (Beginning Spec C)5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor (Prior to Spec C)5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impulse Fuel Pump 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Arm5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnecting and Reclamping the Choke and Throttle Cables5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Adjustments5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Maintenance5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6. ELECTRICAL SYSTEM 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 VDC Output System6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Connections6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7. STARTING SYSTEM 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recoil Starter7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Shift Starter7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8. LUBRICATION SYSTEM 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Oil Pressure8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Relief Valve8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9. ENGINE BLOCK ASSEMBLY 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Compression Test 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Removal9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Rocker Cover9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Valve Lash9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Rocker Arms9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Pushrods and Ta ppets 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Disassembly/Assembly9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearcase9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor9-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancer Shafts 9-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Camshaft9-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Release System 9-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston / Connecting Rod9-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block9-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Bearings9-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Oil Seals9-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
ii
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 1. Introduction
Redistribution or publication of this document,
by any means, is strictly prohibited.
This is the service manual for the Model E125H and
E140H engines. These are 1-cylinder, 4-stroke
cycle, spark-ignited, overhead-valve (OHV), air-
cooled engines. Table 1-1 summarizes other in-
formation about these engines.
TABLE 1-1. USEFUL ENGINE INFORMATION
FEATURE
Rated Power
at 3600 rpm
Displacement 389 cm3(23.7 inch3)
Bore 84.2 mm (3.31 inch)
Stroke 70 mm (2.76 inch)
Compression Ratio 8.5:1
Minimum Cylinder
Compression Test
Pressure
Lubricating Oil
Capacity (with filter)
Minimum Lubricating
Oil Pressures at
1500/3300 rpm
(Beginning Spec D)
Minimum Lubricating
Oil Pressures at
1500/3300 rpm
(Prior to Spec D)
Ignition Timing
(not adjustable)
MODEL
E125H
12.5 bhp 14.0 bhp
483 kPa (70 psi)
0.95 litre
(1 quart)
New: 80/138 kPa (13/20 psi)
Worn: 62/103 kPa (9/15 psi)
New: 21/96 kPa (3/14 psi)
Worn: –/28 kPa (–/4 psi)
23° BTDC
MODEL
E140H
In this manual, the flywheel end is considered the
front of the engine. Right and left sides are determined by viewing the engine from the front.
Section 2. Tolerances and Clearances and Sec-
tion 3. Assembly Torques provide information nec-
essary for proper reassembly of the engine. They
are referenced throughout the manual.
Section 5. Fuel System, Section 6. Electrical System, Section 7. Starting System and Section 8. Lu-
brication System cover service of major subsys-
tems of the engine.
Section 9. Engine Block Assembly covers the com-
plete overhaul of the engine block assembly.
See the separate Operator’s Manual for engine op-
eration, maintenance and storage and for fuel and
lubricating oil recommendations.
See the separate Parts Manual for part identification
numbers and required quantities and for exploded
views of the engine subassemblies. Genuine Onan
replacement parts are recommended for best
results. When ordering parts, always give the
complete model and serial numbers appearing on
the engine nameplate. See Table 1-2 for a breakdown of the engine model number.
TABLE 1-2. ENGINE MODEL NUMBER
E
| || |||
1 2 3 4 5 6
140 H – N /11152 A
1. Model Letter
2.Rated Power—“140” designates 14.0 bhp
(brake horse power) and “125”, 12.5 bhp.
3.Shaft Orientation—“V” designates vertical
shaft and “H”, horizontal shaft.
4. Engine Fuel—“N” designates gasoline, “L”,
LPG and “D”, dual fuel.
5. Optional Equipment Code—designates muffler, fuel tank, electric starter, etc. or combina-
tions thereof.
Section 4. Troubleshooting provides a way to sys-
tematically locate engine problems.
IMPROPER SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN SEVERE PERSONAL IN-
JURY AND EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM
6.Spec Letter—designates production modifications.
WARNING
ELECTRICAL AND MECHANICAL SERVICE.
1-1
1-2
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 2. Tolerances and Clearances
All dimensional tolerances and clear-
ALLOWABLE
ances are in millimetres (inches) at 21 ° C
(70° F) unless otherwise indicated.
LIMIT
Redistribution or publication of this document,
by any means, is strictly prohibited.
FACTORY SPECIFICATION
MINIMUM MAXIMUM
CYLINDER BLOCK
Cylinder Bore I.D.
Standard 84.200
(3.3150)
.25 Oversize 84.450
(3.3248)
.50 Oversize 84.700
(3.3347)
Cylinder Bore Ta per – – 0.10
Cylinder Bore Out-of-Round – – 0.05
CAMSHAFT
Lobe Height, Diameter Over Nose
E125 Intake 34.23
(1.348)
E125 Exhaust 34.53
(1.359)
E140 Intake 35.09
(1.381)
E140 Exhaust 35.09
(1.381)
End Clearance 0.10
(0.004)
Journal Bearing O.D. 17.975
(.7077)
Journal Bearing Clearance (in gearcase) 0.01
(.0004)
BALANCER SHAFTS
End Clearance (Both Shafts) 0.10
(0.004)
Journal Bearing O.D. 21.875
(0.8612)
Journal Bearing Clearance (in gearcase) 0.02
(0.0008)
84.225
(3.3160)
84.475
(3.3258)
84.725
(3.3356)
34.55
(1.360)
34.85
(1.372)
35.41
(1.394)
35.41
(1.394)
0.20
(0.008)
17.990
(.7083)
0.05
(.0020)
0.20
(0.008)
21.890
(0.8618)
0.056
(0.0022)
84.325
(3.3199)
84.575
(3.3297)
84.825
(3.3396)
(0.004)
(0.002)
33.73
(1.328)
34.03
(1.340)
34.59
(1.362)
34.59
(1.362)
0.25
(0.010)
17.93
(.7059)
0.08
(.0031)
0.25
(0.010)
21.83
(0.8594)
0.08
(0.0031)
2-1
All dimensional tolerances and clear-
Redistribution or publication of this document,
by any means, is strictly prohibited.
FACTORY SPECIFICATION ALLOWABLE
ances are in millimetres (inches) at 21 ° C
(70° F) unless otherwise indicated.
CRANKSHAFT
Stroke 70
Connecting Rod Journal O.D.
Standard 33.475
(1.3179)
.25 Undersize 33.225
(1.3081)
.50 Undersize 32.975
(1.2982)
End Clearance 0.10
CONNECTING ROD
Pin Bore I.D. 20.015
(0.7880)
Large Bore I.D.
Standard 33.500
(1.3189)
.25 Undersize 33.250
(1.3091)
.50 Undersize 33.000
(1.2992)
Large Bore Clearance 0.015
(0.0006)
Side Clearance on Crankshaft 0.40
PISTON
Piston Skirt O.D. 90 Degrees to Pin and
26.5 mm (1.043 inch) from Top of Piston
Standard 84.09
.25 Oversize 84.34
.50 Oversize 84.59
Pin Bore I.D. 20.004
(0.7876)
(2.76)
(.004)
(0.016)
(3.311)
(3.320)
(3.330)
70
(2.76)
33.485
(1.3183)
33.235
(1.3085)
32.985
(1.2986)
0.20
(.008)
20.025
(0.7884)
33.525
(1.3199)
33.275
(1.3100)
33.025
(1.3002)
0.050
(0.0020)
1.10
(0.043)
84.12
(3.312)
84.37
(3.322)
84.62
(3.331)
20.012
(0.7879)
LIMIT
–
–
–
–
0.25
(0.010)
20.071
(0.7902)
–
–
–
0.100
(0.0040)
1.50
(0.059)
–
–
–
20.022
(0.7883)
2-2
All dimensional tolerances and clear-
FACTORY SPECIFICATION
ALLOWABLE
ances are in millimetres (inches) at 21 ° C
(70° F) unless otherwise indicated.
LIMIT
Redistribution or publication of this document,
by any means, is strictly prohibited.
MINIMUM MAXIMUM
PISTON PIN
Piston Pin O.D. 20.000
(0.7874)
Clearance in Piston Pin Bore –.001
(.0000)
Clearance in Connecting Rod Pin Bore .010
(0.0004)
20.005
(0.7876)
.012
(0.0005)
.025
(0.0010)
PISTON RINGS
Top Compression Ring Thickness 1.47
(.058)
Second Compression Ring Thickness 1.47
(.058)
Top Compression Ring to Ring Groove
Clearance
Second Compression Ring to Ring
Groove Clearance
0.03
(0.001)
0.03
(0.001)
Top Compression Ring End Gap 0.25
(0.010)
Second Compression Ring End Gap 0.25
(0.010)
Oil Ring Side Rail Gap 0.38
(0.015)
1.49
(.059)
1.49
(.059)
0.08
(0.003)
0.08
(0.003)
0.51
(0.020)
0.51
(0.020)
1.40
(0.055)
INTAKE VALVE
Valve Stem O.D. 6.960
(0.2740)
Valve Guide I.D. 7.000
(0.2756)
Valve Stem to Valve Guide Clearance 0.03
(0.001)
6.975
(0.2746)
7.015
(0.2762)
0.06
(0.002)
Valve Lash 0.15
(.006)
Face Angle 45" –
INTAKE VALVE SEAT
Seat Width 1.1
(.043)
Seat Angle 45" –
19.990
(0.7870)
0.03
(0.0012)
.035
(0.0014)
1.42
(.056)
1.42
(.056)
0.13
(0.005)
0.13
(0.005)
1.00
(0.039)
1.00
(0.039)
1.80
(0.071)
–
–
0.10
(0.004)
0.25
(0.010)
1.7
(.067)
2-3
All dimensional tolerances and clear-
FACTORY SPECIFICATION
ALLOWABLE
ances are in millimetres (inches) at 21 ° C
(70° F) unless otherwise indicated.
LIMIT
Redistribution or publication of this document,
by any means, is strictly prohibited.
MINIMUM MAXIMUM
EXHAUST VALVE
Valve Stem O.D. 7.940
(0.3126)
Valve Guide I.D. 8.000
(0.3150)
Valve Stem to Valve Guide Clearance 0.04
(.002)
7.960
(0.3134)
8.015
(0.3156)
0.08
(.003)
Valve Lash 0.15
(.006)
Face Angle 45" –
EXHAUST VALVE SEAT
Seat Width 1.1
(0.043)
Seat Angle 45" –
VALVE SPRINGS—INTAKE AND EXHAUST
Valve Spring Free Length (Approx.) 43.5
(1.713)
Valve Spring Length
Valve Closed 32.6
(1.28)
Valve Open 23.2
(0.91)
Spring Load (Valve Closed Length) 12.6 kg
(27.7 lb)
Spring Load (Valve Open Length) 26.4 kg
(58.2 lb)
14.6 kg
(32.1 lb)
28.4 kg
(62.7 lb)
VALVE ROCKER ARM
Rocker Arm Bore I.D. 12.000
(0.4724)
Rocker Arm Shaft O.D. 11.973
(0.4714
Rocker Arm to Rocker Shaft Clearance 0.016
(0.0006)
12.018
(0.4718)
11.984
(0.4718)
0.045
(0.0018)
–
–
0.10
(.004)
0.25
(0.010)
1.7
(0.067)
–
–
–
–
24.9 kg
(55 lb)
–
–
0.15
(0.0059)
2-4
All dimensional tolerances and clear-
FACTORY SPECIFICATION
ALLOWABLE
ances are in millimetres (inches) at 21 ° C
(70° F) unless otherwise indicated.
LIMIT
Redistribution or publication of this document,
by any means, is strictly prohibited.
MINIMUM MAXIMUM
LUBRICATING SYSTEM
Rotor Lobe Clearance 0.15 or less
(0.006 or less)
Outer Rotor to Pump Body Clearance 0.12
(0.005)
Rotor to Cover Clearance 0.02
(0.001)
IGNITION SYSTEM
Spark Plug Gap 0.89
(0.035)
Magneto Coil to Rotor Magnet Clearance 0.25
(0.010)
STARTER MOTOR
Commutator O.D. 28.0
(1.102)
Difference of Commutator O.D.’s – 0.05
Armature Shaft to Bushing Clearance 0.02
(0.001)
Mica Undercut 0.45
(0.018)
0.19
(0.007)
0.09
(0.004)
1.02
(0.040)
0.40
(0.016)
(0.002)
0.07
(0.003)
0.75
(0.030)
0.20
(0.008)
0.25
(0.010)
0.25
(0.010)
–
–
27.00
(1.063)
0.016
(0.41)
0.20
(.008)
0.20
(0.008)
2-5
2-6
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 3. Assembly Torques
BOLT “A”
GEARCASE
GEARCASE
BOLTS
CYLINDER HEAD
Redistribution or publication of this document,
by any means, is strictly prohibited.
DESCRIPTION BOLT
SIZE
Connecting Rod Bolts M8 x 44 24-27 18-20
Gearcase Bolts
Oil Pump Cover Screws M6 x 14 7-11 5-8
Oil Pickup Tube M6 x 14 7-11 5-8
Oil Drain Plugs 1/4” NPT 7-11 5-8
Fuel Pump Pulse Line
Elbow
LOPCO or Pipe Plug 1/8” NPT 7-9.5 5-7
Adapter Filter Head 3/4”-16 47-54 35-40
Oil Filter – – – <Turn the oil filter 3/4-1 turn after gasket contacts base.
Cylinder Head Bolts
No. 1-5 Bolts
No. 6 Flange Bolt M8 x 50 16-22 12-16
Valve Lash Adjusting
Nut
Valve Rocker
Cover Bolts
Spark Plug M14-1.25 24-30 18-22
M8 x 35,
50, 75
1/8” NPT 7-9.5 5-7
M10 x 66,
86, 125
M7 7-11 5-8
M6 x 25 7-11 5-8
METRIC
(N-m)
16-22 12-16
42-50 31-37
ENGLISH
(LB-FT)
INSTRUCTIONS
<Torque the gearcase bolts in a clockwise direction starting
with bolt “A”. Torque bolt “A” twice.
<Torque the cylinder head bolts in sequence shown. Two
bolts outside valve cover (#2 & #4) to be retorqued after
others are torqued.
<Tighten every other valve rocker cover bolt until all bolts
are tightened. Torque the first bolt twice.
3-1
DESCRIPTION INSTRUCTIONSENGLISH
INTAKE SYSTEM
CYLINDER HEAD TORQUE SEQUENCE
ELECTRICAL
SHEET
NOTE: THESE TORQUE VALUES PROVIDE
Cylinder Air Housing
PROPER TIGHTNESS WITHOUT DANGER OF
Cylinder Air Housing
Bolt
STRIPPING THREADS. ALL THREADS MUST BE
CLEAN AND RUST-FREE. LIGHTLY OIL ALL
THREADS EXCEPT ON THE SPARK PLUG.
MISC
Redistribution or publication of this document,
by any means, is strictly prohibited.
BOLT
SIZE
Pulse Pump to Air
Cleaner Pan
Intake Elbow to Cylinder
Head
Air Cleaner Pan to
Cylinder Block
Carburetor to Intake El-
bow
Air Cleaner Wingnut 1/4”-20 - - <Tighten 6 to 8 clicks after seating air cleaner.
Control Plate Screws M5 x 16, 30 7-9.5 5-7
Throttle Stop Screw
Bracket
Fuel Line Hold Down
Screw
Throttle Cable Clamp
Screw
Voltage Regulator
Screws
Starter Bolts M8 x 40 16-22 12-16
Alternator Stator
Screws
Ignition Coil Bolt M6 x 30 10-15 7-11
Connector-Wire Har-
ness to Blower Housing
Blower Housing Bolts M6 x 20 7-11 5-8
Blower Housing to Man-
ifold Bolt
Starter Cover Bolts 3/8” x 16 25-35 18-26
Chaff Screen Bolts M6 x 10 7-11 5-8
Stationary Guard Bolts M6 x 20 1-1.2
Recoil Starter Cup
Screw
Recoil Starter Bolts M6 x 12 7-11 5-8
Governor Arm Nut M6 8.1-10.9 6-8
Flywheel Nut M18 122-138 90-102
Oil Fill Tube M8x20 11-16 8-12
#10 2.3-2.8
M8 x 50 11-16 8-12
M8 x 16 11-16 8-12 <Tighten twice (1-2-1).
M6 x 85 10-15 7-11 <Tighten twice (1-2-1).
M5 x 10 2.7-5.4 2-4
#10-16 1.4-2
#10-32 1.4-2
1/4” x 50 6.7-8.1
M6 x 25 10-15 7-11
M4 x 12 1.4-2
M6 x 14 10-15 7-11
1/4”-20 7-11 5-8
M6x10 7-11 5-8
M8x16 11-16 8-12
METRIC
(N-m)
(LB-FT)
1.7-2.1
(20-25 lb-in)
1-1.5
(12-18 lb-in)
1-1.5
(12-18 lb-in)
5-6
(60-72 lb-in)
1-1.5
(12-18 lb-in)
1-1.5
(12-18 lb-in)
3-2
Section 4. Troubleshooting
Redistribution or publication of this document,
by any means, is strictly prohibited.
PROBLEM
Engine Does Not Start
• • Battery Connections Poor
• • Battery Low or Discharged
• • Starter Faulty
• Starter Solenoid Faulty
• • Spark Plug Gap Wrong
• • Magneto Coil Faulty
• • Spark Plug Wires Faulty
• • • • • • Magneto Gap Wrong
• • Fuel Ta nk Empty
• • • • • Fuel Mixture Too Lean
• • • • • Fuel Mixture Too Rich
• • • • Engine Flooded
• • • • • • Fuel Quality Poor
• • • • • Carburetor Dirty
• • • • • • • • Air Cleaner Dirty
• • • Fuel Filter Dirty
• • • • Fuel Pump Defective
• • • • • Valve Clearance Wrong
• • • • • • Valve Spring Broken
• • • • Piston Rings Worn or Broken
• • • • Head Gasket Blown
• • • • • • • • • • Oil Level Too Low
• • • • • • • • • • • Oil Viscosity Too Low or Diluted
• • Linkage Out of Adjustment
• • Linkage Worn or Disconnected
• • Linkage Binding
• • Governor Assembled Wrong
Engine Stops
Engine Cranks Slowly
• • • • • Bearing Clearance Wrong
• • Oil Viscosity Too High
Engine Misfires
• • • • • Valve or Valve Seal Leaking
• • Air Circulation Poor
• • Cylinder Cooling Fins Dirty
Engine Overheats
Engine Backfires
Governor Hunts
Black Exhaust
Blue Exhaust
Burned Valves
Connecting Rod Wear
• • • • • • Oil or Oil Filter Dirty
• • • • • • • Oil Pump Faulty
High Oil Pressure
Cylinder Wear
• • Oil Gauge Faulty
• • Relief Valve Stuck
Mechanical Noise
Low Oil Pressure
Piston Wear
Low Compression
Bearing Wear
Sticking Valves
Ring Wear
PROBABLE CAUSE
STARTING SYSTEM
IGNITION SYSTEM
FUEL SYSTEM
INTERNAL ENGINE
COOLING SYSTEM
LUBRICATING SYSTEM
THROTTLE/GOVERNOR
4-1
4-2
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 5. Fuel System
Redistribution or publication of this document,
by any means, is strictly prohibited.
WARNING
Improper service or replacement of
parts can result in severe personal injury and
equipment damage. Service personnel must be
qualified to perform electrical and mechanical
service.
WARNING
Accidental starting of the engine
can result in severe personal injury or death.
Disconnect the negative (–) battery cable and
spark plug wire before servicing the engine,
controls, or associated equipment.
WARNING
Ignition of fuel can result in severe
personal injury or death. Do not smoke or allow
any spark, pilot light, or arcing switch or equip-
ment near the fuel system or in areas with
shared ventilation.
Provide adequate ventilation when working on
the fuel system.
CARBURETOR REMOVAL/INSTALLATION
Before replacing or overhauling a carburetor, make
certain 1) that all other necessary engine and gener-
ator adjustments and repairs have been performed
and 2) that the carburetor is actually malfunctioning.
Carburetor Removal
Refer to Figure 5-1. Remove the air cleaner assem-
bly. Disconnect the governor linkage, fuel line, throt-
tle linkage, and choke control linkage. Remove the
carburetor assembly from the intake elbow.
Carburetor Installation
Install the carburetor assembly on the intake elbow.
Tighten the through bolts as specified in Section 3.
Assembly Torques. Connect choke control linkage,
throttle linkage, fuel line, and governor linkage.
Make sure the breather tube and rubber seal are
installed properly. Install the air cleaner assembly
as instructed in this section. Always use new gas-
kets when installing a carburetor.
Instructions for control cable and speed adjust-
ments follow in this section.
?AG@F;@9
E5D7IE
DG447D
E73>
3;D
5>73@7D
93E=7F
4D73F:7D
FG47
;@F3=7
7>4AI
53D4GD7FAD
3EE7?4>K
53D4GD7FAD
EGBBADF
FIGURE 5-1. CARBURETOR ASSEMBLY
5-1
CARBURETOR (BEGINNING SPEC C)
Redistribution or publication of this document,
by any means, is strictly prohibited.
Carburetor Replacement
Other than replacing the carburetor main fuel jet
(fixed-type) with the optional high-altitude jet (Fig-
ure 5-2), fuel mixture adjustments should not be at-
tempted. Nor should the carburetor be overhauled.
Instead, a malfunctioning carburetor should be re-
placed. See CARBURETOR REMOVAL / INSTAL-
LATION in this section.
Carburetor High-Altitude Jet (Optional)
If the engine is operated at an altitude above 5000
feet (1524 metres), it is recommended that the carburetor main fuel jet be replaced with the optional
high-altitude jet (which has a slightly smaller orifice).
5:A=7
>7H7D
F:DAFF>7
>7H7D
CAUTION
To avoid slipping and gouging the
main fuel jet, use a screwdriver with a 5/16 inch
(8 mm) wide blade.
;6>7 EB776
EFAB E5D7I
F3?B7D^D7E;EF3@F
B>G9 AH7D ;6>7
?;JFGD7 @776>7
?3;@ 8G7> <7F
$ZRW]V PVTLYQPO%
5-2
D7?AH7 F:7 8>A3F
4AI> 8AD 3557EE FA
F:7 ?3;@ 8G7> <7F
FIGURE 5-2. CARBURETOR
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