Service Manual
Contents
1. BREAK IN OPERATION An engine that has been completely overhauled with new piston rings valves and connecting rods should be thoroughly broken in before being placed into service Good bearing surfaces and running clearances between the various parts can be estab lished only by operating the engine under reduced speed and loads for a period of time 6 1 To break in the engine 1 Run the engine at 2500 rpm without a load for 10 minutes 2 Run the engine at 3 000 rpm for 10 minutes 3 Run the engine at 3 600 rpm for 10 minutes 4 Run the engine with a load of 8 HP at 3 600 rom for 30 minutes 5 Run the engine with a load of 16 HP at 3 600 rpm for 30 minutes While the engine is being tested check for fuel and oil leaks Make final carburetor adjustments and regulate the engine operating speed After the first 20 hours of normal operation change the oil and oil filter PRE ASSEMBLY Inspect and pre assemble the engine subassem blies prior to replacing in crankcase Crankcase 1 Replace oil pump filter in bottom of crankcase Figure 5 16 2 Insert ball and relief valve spring into bottom of crankcase Tighten plug to specified torque Torque the relief valve plug between 10 9 and 18 1 ft Ibs 11 8 14 7 N m 3 Replace the governor lever shaft and secure with a snap pin and washer 4 Replace the oil drain valve if removed and the oil filter Cylinder Heads Valves and Rocker Arms2. A GOVERNOR SPRING M6 FLANGE BOLT 3 pcs lt SPEED AND CHOKE STEP 7 2 LINKAGE MOUNTING BRACKET SPEED CONTROL SOLENOID OPTIONAL FLANGE BOLT FIGURE 5 3 5 3 9 Disconnect the spark plug wires and the wiring ground wires secured with flanged bolts to each ignition coil Cut the cable ties securing wires to the manifold Remove the coils se 12 Remove the red white blue wire terminal from cured with 2 M6 bolts the oil pressure switch Remove the oil pres sure switch if necessary Disconnect the yellow 10 Pull out the connector under the relay attached wire at the starter to the cylinder baffle NOTE For re assembly purposes torque the M6 coil bolts between 5 1 and 6 5 6 9 11 Remove the relay the wire holder and the two 8 8N m IGNITION PLUG M6 BOLT TERMINAL AND WASHER SPARK PLUG CAP M6 BOLT AND WASHER IGNITION PLUG L TERMINAL SPARK CYLINDER BAFFLE STEP 10 11 amp 12 GROUND TERMINALS Not on all models 5777 S lt ELBOW CARS NKY Ag ERES IRE eg WITCH RELAY and CONNECTOR Not on all models WIRE HOLDER IGNITION COILS FIGURE 5 4 5 4 13 Remove all four cylinder baffles secured by 6 NOTE For re assembly purposes torque the bolts M8 manifold nuts between 12 3 to 13 7 ft Ibs 14 Remove the spark plugs if necessary plot tee Nm 15 Rem
3. Service Manual Performer Series OHV220 983 0500B 12 00 v 3 3 Wa gt A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS iii General Information 1 1 Manual 5 vacuo ve eT ke vh bese eh ETER EE 1 2 Mode Iul ee SERA AE PTT 1 2 How to Obtain Service 1 2 Performance CUNE 1 3 Specifications Ee Ne A 2 1 Performer OHV220 Engine Specifications 2 1 Dimensions and Clearances 2 2 ElectricaL Specifications RER ERR 2 8 Assembly Specifications 2 8 Engine oil Recommendation 2 8 Torque Specifications culi auk Re 2 8 Engine Troubleshooting 3 1 Engine Systems 4 1 tee WEE 4 1 Lubrication System EE 4 1 octet Mare oe hastens 4 2 KEE SSES Ee SE ER 4 3 Charging System EE 4 4 Staning MER 4 7 E
4. Assembly Assembly is the reverse of disassem bly Apply grease to the shift fork hinge and prongs and the splines on the armature shaft Torque mounting bolts as specified in Section 2 page 2 8 BATTERY CUSTOMER CONNECTION FIGURE 4 4 STARTING SYSTEM DIAGRAM 4 7 SHIFT LEVER DUST COVERS SOLENOID BRUSH amp BRUSH SPRING PINION STOPPER PINION ASSY THROUGH BOLT ARMATURE THRUST WASHERS FIGURE 4 5 STARTER ASSEMBLY Solenoid Inspection 2 Disconnect the spark plug cable so that the en gine will not start Bypass the start circuit with a jumper between the start and the positive bat tery terminal on the solenoid Figure 4 6 If the engine cranks the solenoid and starter are probably okay If the engine does not crank go to Step 3 For typical wiring connections at the starter sole noid refer to Figure 4 6 Before removing a starter because the engine does not crank 1 Make sure the battery is fully charged the con 3 Bypass the starter solenoid with a jumper be nections are clean and tight and the battery cables are in good condition If it is necessary to reconnect the battery connect the positive battery cable first 4 8 tween the motor and the positive battery ter minal on the solenoid Figure 4 6 If the motor responds it is probably okay and it may only be necessary to replace the solenoid POSITIVE TERMINAL START TERMINAL MOTO
5. belts pulleys ing the engine in a confined area etc e floorcare 1 General Information Introduction This manual deals with specific mechanical and electrical information needed by engine mechanics for troubleshooting servicing repairing or over hauling the engine The Parts Manual contains detailed exploded views of each assembly and their individual piece part numbers and names for ordering replacement parts Features of the Performer OHV220 engine are e Overhead valve arrangement enables high power and low fuel and oil consumption V twin four stoke design Air cooled and gasoline fueled The light weight and compact design make it easy to install and utilize for many applica tions Carrier Spark Plug steel crankshaft and high load bearing offer durability Pressure lubrication system and large capac ity air cleaner enhance reliability of the en gine The combustion chamber shape along with a tuned exhaust valve system enhances the low exhaust emission and provides high torque at low speed A steel crankshaft and high load bearing offer dura bility The pressure lubrication system and large ca pacity air cleaner enhance reliability of the engine The illustrations and procedures presented in each section apply to the Performer OHV220 Engine The blower housing side of the engine is the front end Right and left sides are determined by viewing the engine from the front The No 1
6. e Clean valves and wash cylinder head thor oughly e Remove carbon and gum deposits from the valves seats ports and guides e Inspect valves valve seats and valve guides e Replace valves that are badly burned pitted or warped e Valve guides should be replaced when valve ROCKER stem clearance exceeds specifications Re SPRING fer to the DIMENSIONS AND CLEARANCES ETAINER tables in Section 2 for clearance specifica COLLET tions VALVE If clearance has been exceeded draw valve VALVE guides out and press new guides in After SPRING replacing valves and guides lap valves in place until a uniform ring shows around the WASHER face of the valve 1 Insert an oil seal to the intake valve guide only Figure 6 1 2 Apply oil to washer valve spring and valve stem Place cylinder head on flat table and install washer valve spring valve and spring retainer Figure 6 1 EXHAUST INTAKE 3 Install rocker arm and shaft Pistons and Connecting Rods FIGURE 6 1 1 Install the oil control ring first then the second D Arrange gaps of piston rings as shown in ring and top ring Using a piston ring spreader Figure 6 5 expand rings just far enough to slip over piston and into the correct groove Use care not to dis Compression rings may have a dot or the word tort ring Figure 6 2 top on one side of the ring to indicate which side faces the top of the piston Unmarked pis
7. the fuel line could become a path for cranking current e LPG leaks into an inadequately ventilated space can lead to explosive accumulations of gas LPG sinks when released into the air and can accu mulate inside basements and other below grade spaces Precautions must be taken to prevent gas leaks and the accumulation of gaseous fuel in the event of a leak e The fuel line must have a manual shutoff valve unless the highest fuel level in the supply tank is lower than the connection at the engine ENGINE EXHAUST IS DEADLY BATTERY GAS IS EXPLOSIVE e Wear safety glasses and do not smoke while e Learn the symptoms of carbon monoxide poi servicing batteries soning in this Manual e When disconnecting or reconnecting battery cables always disconnect the negative bat ue tery cable first and reconnect it last to reduce arc gine is started and after every eight hours of op eration If the exhaust noise changes shut down IS the engine immediately and have it inspected MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Inspect the exhaust system every time the en e The integral exhaust system must not be modi fied in any way Do not wear loose clothing or jewelry near mov ing parts such as PTO shafts fans belts and pul leys e Do not use engine cooling air to heat a room Keep hands away from moving parts e Make sure there is ample fresh air when operat e Keep guards in place over fans
8. A Install the second ring with punched mark ton rings can be installed either way REESEN 2 Apply oil to the small end of connecting rod and piston pin Position the piston on its respective B Top ring can be placed either way rod and install the pin C As for oil ring rails should be placed on 3 To secure the pin place retaining rings on each and below the expander side of the pin 6 2 COMBINATIO RING FIGURE 6 2 Main bearing cover and governor gear 1 Insert washers onto governor gear shaft 2 Insert governor gear along with sleeve into governor gear shaft Figure 6 3 RE ASSEMBLY PROCEDURES Crankshaft 1 Install crankshaft into crankcase Figure 6 4 NOTE Apply adequate oil to bearing portion of crankcase For easy installation put crankcase on box or wood blocks 6 3 WASHER 2 pcs GOVERNOR GEAR SHAFT SLEEVE GOVERNOR GEAR THRUST BEARING MAIN BEARING COVER FIGURE 6 4 Pistons and Connecting Rods 1 Install each piston and connecting rod assem bly into cylinder by using a piston ring compres sor to hold piston rings A The 1 mark on the connecting rod for 1 cylinder and 2 mark for 2 cylinder should face towards the flywheel when in serted Figure 6 5 B Apply enough oil to piston rings connect ing rod bearings large end and cylinder bore before assembly ALIGNMENT MARK
9. Reassembly Procedures by 1 M10 flange bolt for specific inspection and reassembly instructions Torque the oil relief plug between 10 9 and 18 1 11 8 14 7 M6 FLANGE BOLT 4 pcs OIL SEAL M8 FLANGE BOLT 2 pcs OIL PUMP COVER STARTER SOLENOID OIL FILTER 10 32 FLANGE BOLT 1 pc OIL PUMP FILTER STEEL BALL GOVERNOR LEVER i SHAFT SPRING relief valve GASKET aluminum 2 PLUG oil relief FIGURE 5 16 6 Engine Reassembly PRECAUTIONS 1 Clean parts thoroughly before reassembly A Make sure the piston cylinder crankshaft connecting rod and bearings are particu larly clean 2 Scrape off all carbon deposits from cylinder head top of piston and piston ring grooves 3 Check lips of oil seals Replace any oil seal where the lip is damaged Apply grease to the lip before reassembly 4 Replace all gaskets with new ones 5 If necessary replace keys pins bolts nuts etc 6 Torque bolts and nuts to specification Refer to the TORQUE SPECIFICATIONS Table Section 2 7 Apply oil to rotating and meshing parts 8 Check and adjust clearances and end plays where specified in this section SPECIAL TOOLS No special tools are required for disassembly of the engine Metric size sockets and wrenches will be needed A ring spreader will be needed to install pistion rings and a ring compressor will be used to install the pistons
10. fed to the engine through the pilot outlet and the by pass When idling the fuel is fed mainly from the pilot outlet MAIN SYSTEM The main system feeds the fuel to the engine during medium and high speed opera tion Fuel is metered by the main jet and fed to the main nozzle Air metered by the main air jet is mixed with the fuel through the emulsion tube and the mixture is atomized out of the main bore Then it s mixed again with the air taken through the air clean er into an optimum fuel air mixture which is sup plied to the engine CHOKE The choke is used for easy start up when the engine is cold When the starter is operated with a choke valve fully closed the negative pressure applied to the main nozzle increases and draws more fuel thus easily starting the engine PILOT AIR JET MAIN AIR JET NEEDLE VALVE EMULSION TUBE SHUT OFF VALVE fi i FUEL gt FUEL INLET MAIN NOZZLE PIPE THROTTLE VALVE BY PASS H Le T i MIXTURE MAIN JET TAMPER CAP PILOT JET PILOT OUTLET FIGURE 4 2 CARBURETOR SYSTEM 4 3 SHUT OFF VALVE fuel shut off valve prevents engine run on when the engine is turned off When the e
11. oil and grease thoroughly from the crankshaft and flywheel center hole 4 Install flywheel to crankshaft and tighten fly wheel nut with spring washer and washer Tighten the flywheel nut to the specified torque 6 8 Torque the M18 nut between 61 5 and 68 7 ft Ibs 83 3 93 1N m Ignition Coils Cylinder Baffles 1 Install the ignition coils onto crankcase Finger tighten the M6 bolts and washers 2 Using a feeler gauge adjust the gap between the coil and flywheel between 0 012 0 021 0 3 0 5mm 3 Tignten bolts the the specified torque Torque the 2 M6 bolts between 5 1 and 6 5 ft Ibs 6 9 8 8N m 4 Connect wiring from the stop diodes to the pri mary terminals on the ignition coils Figure 6 15 5 Secure wires with cable ties and route wire bundles between the number 2 cylinder and the oil filter housing THICKNESS GAUGE IGNITION COIL Ee Vrs Lea lt STOP DIODE FIGURE 6 15 6 Replace all four cylinder baffles secured with M6 flange bolts Refer to Figure 5 5 Carburetor 1 Place a new gasket onto the intake manifold and install carburetor Tighten the bolts to the specified torque Torque the 2 M8 flange bolts between 12 3 and 13 7 ft Ibs 16 7 18 6N m Governor Lever Control Solenoid 1 Attach governor rod and rod spring between the governor lever and carburetor throttle lever Insert the governor lever on governor lever sha
12. Cycle V Twin Cylinder Horizontal Shaft Overhead Valve Rated Output 20 5 HP 3600 rpm 15 3 kW 3600 Continuous Output 16 0 HP 3600 rpm 11 9kW 3600 Bore x Stroke 3 15 x 2 56 80 mm x 65 mm Displacement 39 90 cu in 653 cc Lubrication Oil Type Oil Capacity Full Pressure with Full Flow Spin On Filter Automobile Engine Oil SAE Class SE or Higher See Engine Oil Recom mendation 1 64 qt 1550 cc Charging System 12 volt 15 amp Dry Weight 96 9 Ibs 44 kg Dimensions LxWxHx 12 5 x 19 0 x 19 0 317 mm x 477 mm 475 mm Direction of Rotation CCW as Viewed from the PT shaft side Cooling System Forced Air Cooling Ignition System Spark Plug Type Flywheel Magneto Solid State NGK BP6ES BRP6ES Champion N9YC or RN9YC Gap 0 023 0 027 in 0 6 0 7 mm Governor System Centrifugal Fly Weight Air Cleaner Double Element Assembly 2 1 DIMENSIONS AND CLEARANCES ITEM STANDARD MAXIMUM inches mm inches mm Cylinder Head Flatness 0 002 or less 0 05 or less seat Intake 0 028 0 039 width O 2 Exhaust 0 7 1 0 SEDES TS Valve guide inside 0 2376 0 2383 diameter 6 035 6 053 Cylinder Rebore when the Inside diameter 31056 JAA 80 000 80 019 diameter reaches 0 004 0 1 1st 3 159 3 160 3 159 3 160 Rebo
13. ES or 6 CHAM PION N9YC or RN9YC 3 Torque spark plugs as specified below 6 7 TORQUE NOTES New Plugs between 8 7 and 10 8 ft Ibs 11 8 14 7 Nm Used Plugs between 16 6 and 19 5 ft Ibs 22 5 26 5 BREATHER COVER M6 FLANGE BOLT 2 pcs FIGURE 6 12 Charge Coil 1 Install charge coil with the wires routed at the 2 o clock position Figure 6 13 CHARGE COIL WIRES AT o KO Pen ANA ie 2 FLANGE BOLT 7 gem St STARTER NO 9 w FIGURE 6 13 2 Tighten the bolts and washers gradually in an even pattern to the specified torque Figure 6 13 Torque the 4 M5 bolts between 13 2 and 30 in Ibs 1 5 3 4N m Starter Motor 1 Install starter and solenoid assembly Tighten the flange bolts to specified torque Torque the 2 M8 bolts between 12 3 and 13 7 fi Ibs 16 7 18 6N m Intake Manifold 1 Place a stainless steel gasket onto both 1 and 2 cylinder heads and install intake manifold onto engine studs Secure with flange nuts to the specified torque Torque the 2 M8 flange nuts between 12 3 and 13 7 ft Ibs 16 7 18 6N m M8 FLANGE NUT 2 pcs MANIFOLD GASKET Ne NUT 2 pcs MANIFOLD GASKET FIGURE 6 14 Flywheel 1 Remove the M18 nut and washers from the ta pered end of the crankshaft 2 Place woodruff key in the keyway of crank shaft 3 Wipe off
14. MAIN BEARING SPACER 0 014 0 36mm Thickness with gasket tightened CRANKSHAFT GEAR CRANKCASE FIGURE 6 8 Main Bearing Cover 1 Place an oil seal guide onto PTO shaft to avoid Oi d damaging the main bearing cover oil seal Make sure the governor lever shaft and the oil pump filter are installed in the crankcase Place gasket onto the mating surface of crank case Using a soft hammer tap the cover until it touches the crankcase mating surface Make sure the governor gear and camshaft gear are properly engaged Lubricate the oil seal lip and bearing surfaces and install main bearing cover Tighten bolts gradually in an even pattern to the specified torque Torque the 10 M8 flange bolts between 12 3 and 13 7 16 7 18 6N m Rotate crankshaft slowly and check for smooth operation and side clearance Pump and Cover Apply oil to inner and outer rotors of oil pump and position them on the crankshaft Position an o ring in onto crankcase Figure 6 9 Grease the oil seal and install on the oil pump cover 6 5 4 Install the oil pump cover with arrow mark pointing upwards INNER ROTOR ARROW MARK D 77608 OY 2 AR OUTER ROTOR FLANGE BOLT FIGURE 6 9 Cylinder Heads NOTE Inspect the dwell pin and replace if damaged 1 Place new head gaskets onto crankcase 2 Install 1 and 2 cylinder heads Tighten
15. ONENT CLEARANCE End play between 0 006 0 013 crankshaft and camshaft 0 152 0 330mm Clearance between crank 0 014 case and bearing cover 0 36mm Clearance between rocker 0 003 0 004 arm and valve stem end 0 085 0 115mm Clearance between 0 012 0 020 ignition coils and flywheel 0 3 0 5mm ENGINE OIL RECOMMENDATION SAE EXPECTED AMBIENT TEMPERATURES ED 32 F 0 C and higher 30 10 to 100 12 C to 38 C 0 F to 80 18 C to 27 C AE 20 F to 50 28 C to 10 C 5W 30 2 8 After the first 20 hours of operation the initial oil and oil filter should be replaced Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Thereafter change the oil every 100 hours of opera tion and change the oil filter every 200 hours TORQUE SPECIFICATIONS ITEM TORQUE Breather cover 26 4 43 2 in Ib 2 9 4 9 N m Carburetor bolts 12 3 13 7 ft Ibs 16 7 18 6 Nm Charge coil 13 2 30 in Ibs 1 5 3 4 N m Connecting rod bolts 16 3 19 9 ft lbs 22 1 27 0 Nim Cylinder head bolts 24 6 30 4 ft lbs 33 3 41 2 Nm Flywheel nut 61 5 68 7 ft Ibs 83 3 93 1 N m Ignition coil 5 1 6 6 6 9 8 8 N m Intake manifold nuts a
16. R TERMINAL C FIGURE 4 6 STARTER SOLENOID TERMINALS 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 4 9 Pinion Inspection Service Refer to Figure 4 7 Replace the pinion assembly if the pinion teeth and armature shaft splines are worn or damaged Check the over running clutch by rotating the pinion clockwise and counterclockwise Replace the pinion assembly if it does not turn smoothly counterclockwise or lock clockwise Cleaning the pinion over running clutch in liquid cleaning solution will result in starter damage PINION FIGURE 4 7 CHECKING OPERATION OF THE PIN ION OVER RUNNING CLUTCH OIL PRESSURE RED gt RED SWITCH WHITE FUEL T Di BLUE CARBURETOR SOLENOID JE 2 BYPASS STOP DIODE 9 d RELAY T YELLOW 5 BLAC 3 m BLAC d
17. S PISTON RING COMPRESSOR N CONNECTING ROD FIGURE 6 6 Tappets and Camshaft TOP RING 1 Grease tappets and insert into their original position Push tappets in all the way to avoid damage to the camshaft Ld RING GAP DIAGRAM OIL RING 2 Lubricate bearing surfaces of the camshaft Install camshaft into the crankcase aligning the timing mark on the camshaft to the timing mark on the crankshaft gear See Figure 6 7 Incorrect alignment will cause FIGURE 6 5 engine malfunction 2 Temporary install the key and flywheel on the crankshaft then turn crankshaft to BDC bot IN CAMSHAFT tom dead center Lightly tap the top of the pis Be GEAR ton until large end of the rod meets the pin on the crankshaft 3 Match the alignment marks on the connecting rod cap to connecting rod and clinch together Figure 6 6 Tighten the connecting rod bolts to the specified torque CRANKSHAFT Torque the 2 M8 bolts between 16 3 and 19 9 ft lt GEAR Ibs 22 1 27 0 N m 4 Check for free movement of piston and FIGURE 6 7 necting rod by turning crankshaft slowly 3 Adjust the side clearance A Measure the end play of crankshaft and camshaft Adjust end play between 0 006 and 0 013 0 152 0 330mm using the proper spacer B Spacer Calculation Refer to Flgure 6 8 A 0 014 B 6 4 READING 2 HEIGHT GAUGE CRANKSHAFT
18. S St GRAY CUSTOMER CHARGE CONNECTION COIL VOLTAGE GREEN GREEN REGULATOR FUSE BLACK RED AS BLACK a d cO 000 CONTROL a STARTER SOLENOID a Deeg _ SOLENOID BLACK d BATTERY 12V 30 AH FIGURE 4 8 ENGINE WIRING DIAGRAM 6 PIN RED 5 RED D tc tc FUEL CARBURETOR ee RUNZS BYPASS DIODE DIODE STOP 5 WHITE e c DIODE o BLAC m CUSTOMER PRESSUR 8 al 5 gt GREEN LA IGNITION CHARGE YELLOW COILS COIL VOLTAGE REGULATOR BLACK CUSTOMER BLACK CONNECTIONS d Sc _L STARTER anon BLACK 12V 30 AH FIGURE 4 9 ENGINE WIRING DIAGRAM 4 PIN 4 10 5 Disassembly When complete engine disassembly is necessary first remove all complete assemblies Individual as semblies such as the fuel pump starter and the car buretor can be disassembled and repaired at anoth er time Suggestions e f you are uncertain about linkages wiring or hose connections label or tag items before removing them e Have small boxes on hand to hold disas sembled parts by group e Prevent loosing and misplacing parts by tem porarily assembling each group of disas sembled parts e Clean parts in washing fluid if necessary Most solvents are flammable and can cause severe personal injury or death if used improperly Follow the manu facturer s recommendati
19. W ROCKER ARM LIFT HOOK E M6 FLANGE BOLT 4 pcs GASKET rocker arm M10 FLANGE BOLT 4 pcs CYLINDER HEAD 2 20 Disassemble the breather assembly secured 19 Remove the intake and exhaust valves Do not reuse the intake valve stem oil seal Each time the valves are removed from the cylinder block a new seal must be used when the valve is reinstalled to the 1 cylinder head with 2 M6 flange bolts A CAUTION Removing a valve after installing NOTE For reassembly purposes torque the valve stem seal can cause seal damage Do not breather cover flange bolts between 26 4 and allow valve stem groove to come in contact with 43 2 in Ib 2 9 4 9 the valve stem seal after installation SPRING RETAINER VALVE COLLET 6 VALVE SPRING SPRING RETAINER VALVE e COLLET VALVE SPRING BREATHER COVER M6 FLANGE EXHAUST BOLT 2 pcs VALVE INTAKE VALVE FIGURE 5 7 5 7 FIGURE 5 8 5 8 Improper flywheel removal can cause gear case damage Do not use any tools to pry against the gear cover when removing the flywheel 21 Remove the flywheel with the blower unit at tached by A Remove the M18 nut lock washer and plain washer from the crankshaft B Using a universal flywheel puller pull the flywheel away from the gear ring C Repla
20. alve not functioning Check throttle shaft and linkage adjust governor lever Low fuel flow to carburetor Faulty fuel cut off valve or wiring Engine idles too high Adjust or replace control solenoid Idle unstable Check govenor linkage and springs Incorrect valve clearance Check and adjust Low compression laniti coil s fault Check and replace Insufficient output 9 5 y P Improper gap between coil and fly Check and adjust wheel Charge coil is demagnetized Replace charge coil Fuel system problems Check system Low air intake Clean air cleaner elements Check throttle valve for full opening 3 2 Cooling air flow obstructed Check air inlet and cylinder baffle and clean out improper engine Overheating Lean air fuel mixture Ge for plugged passages in carbu Excessive back pressure of exhaust Check clean or replace muffler and system spark arrestor if equipped Engine is overloaded Change to rated load Cil is leaking Loose drain valve or gasket Filter not properly installed Check and replace gaskets if neces Bearing cover bolts are loose sary Bearing cover gasket is worn or damaged Oil is diluted Piston oil rings are faulty Replace piston rings Piston rings worn siezed or making Hone cylinders and install oversize poor contact piston rings Piston and cylinder are worn Valve stem is worn Replace valve guides Oil level is too high Adjust oil level Cylinder breather is faulty Replace breather cov
21. arge or replace battery Poor battery terminal connections Check and clean terminals replace if damaged Faulty solenoid switch Check repair or replace Faulty starter motor Repair or replace starter Crankshaft has seized Check crankshaft bearings and crank shaft bearing surface A piston and cylinder have seized Check pistons and cylinder bores No fuel in system Refill Starter operates but engine does not start Faulty starter motor Poor connection or discontinuity of Check wire connections and ignition ignition system wires coils for shorts Slow cranking RPM caused by a faulty starter motor or low battery volt age at starter oe ag batey Bad connection between battery and Clean or repair starter motor Low engine speed while cranking bearing Improper engine oil 3 1 Bad connection between battery and Clean or repair ground Starter motor has worn brushes or Repair or replace starter motor Replace with recommended engine oil Problem Possible Cause Spark plug Improper gap No insulator Carbon deposits Ignition coil Ignition system 2 malfunctions No insulation or discontinuity Check for grounded wire and replace Bad connection or discontinuity of Replace coil s ignition coil Improper air gap between ignition coil Check and adjust and flywheel Carburetor Fuel system malfunc tions Flooding The floats are sticking Clogged or damaged Disassemble and clean Throttle v
22. ast five seconds While holding the pressure gauge level with the pump outlet record pressure gauge reading Shut the engine off and remove the pressure gauge hose from the fuel pump outlet Connect the fuel outlet line to the fuel pump Replace the fuel pump if test readings are not within values specified in Table 4 1 TABLE 4 1 PULSE PUMP TEST SPECIFICATIONS PUMP INLET VACUUM Minimum PUMP OUTLET PRESSURE Minimum 2 6 inches of mercury High Idle 2 6 inches 1 7 psi of mercury CARBURETOR Low Idle 1 7 psi The engine is equipped with a down draft carburetor with a float controlled fuel system and fixed main jet Carburetors are calibrated carefully for sure starts good acceleration low fuel consumption and suffi cient output FLOAT SYSTEM Fuel flows from the fuel tank into the float chamber through a needle valve When the fuel rises to a specific level the float rises When its buoyancy and fuel pressure are balanced the needle valve closes to shut off the fuel thereby CHOKE VALVE AIR AIR VENT HOLE l keeping the fuel at a predetermined level Fuel va pors are sucked into the combustion chamber through air vents in the carburetor body See Figure 4 2 PILOT SYSTEM The pilot system feeds the fuel to the engine during idle and low speed operation Fuel is fed through the main jet to the pilot jet where it is metered and mixed with the air from the pilot air jet The fuel air mixture is
23. bolts gradually in an even pattern to the specified torque Torque the 4 M10 flange bolts between 24 6 and 30 4 ft Ib 33 3 41 2 N m on each cylinder head Push Rods 1 Rotate the crankshaft until the tappets are at their lowest position 2 Loosen the rocker arm adjustment setscrews 3 Insert the push rods into the concave end of the tappet With the valve spring depressed Insert the other end of the push rod into the concave part of the rocker arm adjustment screws 4 Temporally tighten the adjusting screws Valve Clearance Adjustment NOTE Temporally place the flywheel in position for easier operation 1 Rotate crankshaft clockwise to the TDC top dead center of compression stroke by match ing the mark on the flywheel with the 1 mark on 1 cylinder head Figure 6 11 2 Loosen locknut on rocker arm and turn adjust ing screw to adjust the clearance between rocker arm and valve stem end Figure 6 10 Valve Clearance 0 004 0 085 0 115 mm Cold condition 2 CYLINDER 3 Tighten locknut to the specified torque Torque the 2 M8 locknuts between 7 2 and 10 1 9 8 13 7 on each rocker arm set 4 Adjust valve clearance on the 2 cylinder side in the same manner 5 Rotate crankshaft several times and check the valve clearance again Make final adjustments to each valve if necessary FEELER FIGURE 6 11 Rocker Arm Covers Insta
24. ce the crankshaft washers and nut 22 Pound out the woodruff key on the crankshaft NOTE For reassembly purposes torque the crank shaft nut between 61 5 and 68 7 ft Ibs 83 3 93 1 N m FIGURE 5 9 STEP 23 24 25 THREADS 23 Remove the gear ring 24 Remove the charge coil secured by 4 M6 bolts and washers NOTE For reassembly purposes torque the charge coil bolts between 13 2 and 30 in lIb 1 5 3 4 N m 25 To avoid damage to the oil seal wrap the threaded portion of the crankshaft with electri cal tape 26 Remove the 10 M8 bolts securing the gear case cover to the engine body Tap the cover gently with a soft faced hammer to loosen it Be careful not to damage the gear cover oil seal 27 With the gear cover removed the governor gear can be removed CRANKSHAFT NUT M18 LOCK WASHER WASHER M5 BOLT AND WASHER 4 pcs BLOWER FLYWHEEL RING GEAR FIGURE 5 11 5 9 GOVERNOR SLEEEVE GOVERNOR GEAR WASHER 2 pcs GOVERNOR GEAR SHAFT GASKET M8 FLANGE BOLT 10 pcs MAIN BEARING COVER FIGURE 5 12 28 Line up the timing marks of the camshaft gear and the crankshaft gear then pull out the cam shaft 5 10 29 Using a marker identify the position and loca tion of each tappet before removing 4 CAMSHAFT XS GEAR CRANKSHAFT GEAR FIGURE 5 14 30 Remove the ridge from the top of eac
25. cylinder is on the right the No 2 cylinder is on the left Figure 1 1 Oil Fill Cap Dip Stick Speed Control Solenoid Optional Air Cleaner Carrier Spark Plug Oil Filter PTO Shaft Regulator d Oil Drain Valve Blower Housing FRONT VIEW Starter Motor amp Solenoid REAR VIEW FIGURE 1 1 PERFORMER OHV220 ENGINE 1 1 major repair an overhaul is necessary trained experienced mechanic should either do the job or supervise and check the work of the mechan ic assigned to the job to ensure that all dimensions clearances and torque values are within the speci fied tolerances About this Manual Use the table of contents for a quick reference to the separate engine system sections Section 2 contains the specifications for the OHV220 engine for fluids torques clearances and tolerances The troubleshooting guide in Section 3 provides a quick reference for locating and correcting engine troubles Section 4 describes various engine system opera tions and contains electrical diagrams for the e Engine Wiring e Charging System e Starter System Section 5 describes the engine disassembly proce dure when performing a major overhaul The proce dure provides step by step instructions for removal and disassembly of engine components Section 6 describes inspection and assembly in structions for engine components MODEL NUMBER Use only Genuine Onan replaceme
26. er assembly Ignition sytem faulty Ignition system wiring is poor Check wiring and connections Improper or damaged spark plug s Clean or replace Fuel system malfunction Lean air fuel mixture Check for plugged carburetor Carburetor damaged Disassemble and clean Fuel lines clogged or damaged Clean or replace Pre ignition Vacuum leak Replace gaskets Cylinder head Carbon deposit in combustion Remove and clean out carbon chamber Cylinder head gasket leaking Replace gasket Valve system Improper valve clearance Adjust valve lash Valve heat deterioration Replace or regrind Valve spring deterioration Replace springs 3 3 High oil consumption Ignition system Improper spark plug gap or dam Clean adjust or replace aged plug Faulty ignition coil Replace coil s Damaged or poor connection of Check connections or replace wires ignition wires Fuel system Engine misfire Lean air fuel mixture due to clogged Disassemble and clean carburetor carburetor Improper gasoline or water Replace gasoline and filter infiltration Engine valves Valves are deteriorated or out of Adjust or replace valves adjustment Valve spring is faulty Replace springs 3 4 4 Engine Systems INTRODUCTION This section presents an overview of the following OHV220 engine systems e Lubrication System e Fuel System e Electrical System e Starting System LUBRICATION SYSTEM Oil and Filter Change Refer to Periodic Maintenance in the Op
27. erator s Manual for oil and filter change intervals and proce dures Pressure Lubrication All engines use an oil pump to provide a constant flow of oil to the engine parts The oil supply collects OIL FILTER CAMSHAFT in the bottom of the crankcase A relief valve is used to control oil pressure Oil Pump Operation A large trochoid type oil pump is driven directly by the crankshaft delivering pressurized oil to the jour nal and pin portions of crankshaft camshaft etc A cartridge type oil filter is located in the bottom of the crankcase Through this cartridge oil filter oil is forced onto rotating parts such as journal and pins of the crankshaft and camshaft Oil is fed through the oil pump filter into the oil pump The oil pressure is adjusted by the relief valve after discharging from oil pump Oil is then splashed onto the cylinder piston and the cylinder head valve system See Figure 4 1 A by pass valve is incorporated into the cartridge type oil filter In the event the oil filter element be comes clogged the engine oil is fed through the by pass valve into the crankcase oil passage CRANKSHAFT FIGURE 4 1 LUBRICATION SYSTEM 4 1 Relief Valve The relief valve is located on the bottom of the crankcase It is non adjustable and normally does not require maintenance However each part of the relief valve is replaceable Oil Pressure Switch The oil pressure switch is mounted on the same ho
28. ft Figure 6 16 Finger tighten the M6 lock ing bolt washer and square nut 2 Reinstall the speed and choke linkage mount ing bracket and secure with 3 M6 flange bolts 3 Attach one end of the governor spring on the speed control link and the other end on the fifth hole of the governor lever Figure 6 17 GOVERNOR SHAFT LOCKING BOLT LEVER FIGURE 6 16 4 Attach the choke control rod and the return spring between the choke control lever on car buretor and the choke control link Figure 6 17 5 Replace the speed control solenoid to the gear case cover Adjust Governor 1 Push the speed control lever clockwise to the high speed position and tighten the nut 2 Make sure the governor lever is pulled by the governor spring and the carburetor valve is ful ly open 3 Turn governor shaft counterclockwise all the way and tighten lock bolt to secure the lever on the shaft Figure 6 18 Follow the adjustment procedures for the carbure tor in Section 6 of the Operator s Manual CHOKE CONTROL RETURN ROD 29 ke SPRING Bs E L CO SH 0 5 2 LINK ke et GOVERNOR SPRING 5 2 d v E lt gt SPEED CONTROL LINK FIGURE 6 17 FIGURE 6 18 Blower Housing Fuel Pump 1 Attach blower housing to crankcase and se cure evenly with 8 M6 flange bolts 2 Install fuel pump and
29. h cylinder 31 After removal mark the location of each piston with a ridge reamer before removing the piston and rod assembly so they can be returned to their respective cylinders Remove the piston and connecting rod by NOTE For purposes of reassembly torque the connecting rod bolts between 16 3 and 19 9 ft lb A removing the 2 M8 connecting rod bolts Peer 32 Use apiston ring spreader to remove the piston B take off the connecting rod cap rings 33 Remove the m18 nut and washers securing the C push the connecting rod upwards and re crankshaft in position and remove crankshaft move with piston A Retain the spacer on the crankshaft PISTON RING SET PISTON PIN CONNECTING lt PISTON ROD amp RING SET PISTON M8 CONNECTING CONNECTING ROD BOLT 2 pcs ROD CONNECTING ROD CAP M8 CONNECTING ROD BOLT 2 pcs 33 CRANKSHAFT FIGURE 5 15 5 11 34 Remove the remainder of the engine crank E Twist off the canister oil filter case parts NOTE For reassembly purposes torque the A Remove the starter and solenoid secured starter mounting bolts between 12 3 and 13 7 ft by 2 M8 flange bolts Ibs 16 7 18 6 N m B Remove the oil pump assembly secured Torque the oil filter bolt to 9 ft Ibs 12 3 N m by 4 M6 flange bolts C Remove the governor lever shaft secured with a snap pin and washer D Remove the inner oil pump filter secured Refer to the next section
30. ing ad vance system is contained within the magneto coils and is not serviceable nor can the individual elec tronic components be replaced Low Speed Ignition Timing Control Circuit Automatic Advancing Control Circuit Signal Transistor gt ELECTRONIC ADVANCING FLYWHEEL MAGNETO SYSTEM IGNITION TIMING B Power Transistor Primary Coil Secondary Coil Spark Plug Signal Transistor STEP ADVANCING 500 1000 2000 ENGINE REVOLUTION 3000 FIGURE 4 3 MAGNETO SYSTEM Ignition Timing The ignition timing is preset at the factory and is not adjustable Spark Plugs Check or replace spark plugs as recommended in the Periodic Maintenance Schedule in the Opera tor s Manual Replace spark plugs that show signs of fouling or electrode erosion Battery Inspection Battery gas is explosive Wear safe ty glasses and do not smoke while servicing batteries Lead acid batteries give off a highly explosive hydrogen gas which can be ignited by flame electrical arcing or smoking 4 5 Check battery cells with a hydrometer The specific gravity reading should be between 1 260 and 1 290 at 77 F 25 C If one or more cells are low on water add distilled water and recharge Keep the battery case clean and dry An accumulation of moisture or dirt will ac celerate discharge and battery failure Keep the battery terminals clean and tight Push the cable terminal down flush with or slightl
31. ions are secure 2 Reconnect the battery positive terminal first 3 Connect the fuel supply hose to the supply Note To prevent fuel from flooding the carbure tor the valve must be closed when the engine is not running 4 Refill engine oil and start the engine After oil lu bricates the oil passages and oil filter turn off engine and recheck the oil level Starting the engine without oil will cause severe engine damage Always keep the engine oil level between the Full and Add marks on the dipstick Overcranking the engine can cause starter damage Do not engage start er for longer than 30 seconds If engine does not start allow 5 minutes for starter to cool between cranking intervals Crankcase pressure can blow hot engine oil out the fill tube causing se vere burns Always stop the engine before removing the oil fill cap or the oil gauge NOTE Total engine oil capacity is about 1 64 qt 1 551 Use API classification or higher grade gine oil Onon ONAN CORPORATION 1400 73RD AVENUE N E MINNEAPOLIS MN 55432 FAX 763 528 7229 ONAN IS A REGISTERED TRADEMARK OF ONAN CORPORATION CUMMINS IS A REGISTERED TRADEMARK OF CUMMINS ENGINE COMPANY
32. light or arcing switch or equipment or other source of ignition near the work area or areas sharing ventilation Operate the engine at an idle for five minutes until the carburetor is full of fuel Shut the engine off and remove the fuel supply line from the fuel pump Connect a vacuum gauge to the fuel pump inlet using a piece of fuel hose with clamps Start the engine and allow to idle for at least five seconds Record the vacuum gauge reading Move the throttle control to the high idle posi tion Wait at least five seconds and record the vacuum gauge reading Shut the engine off and remove the vacuum gauge hose from the fuel pump inlet Connect the fuel inlet line to the fuel pump Shut the engine off and remove the pressure gauge hose from the fuel pump outlet Connect the fuel outlet line to the fuel pump Benzene and lead in some gaso lines have been identified by some state and federal agencies causing cancer or reproductive toxicity Do not to ingest inhale or contact gasoline or its vapors Remove the fuel outlet line from the fuel pump Connect a pressure gauge to the fuel pump outlet using a piece of fuel hose with clamps Start the engine and allow to idle for at least five seconds While holding the pressure gauge level with the pump outlet record pressure gauge reading Move the throttle control to the high idle posi tion and allow the engine to run for at le
33. ll each rocker arm cover using new gaskets Attach lift hooks to the upper bolts on each cover Tighten bolts to the specified torque Torque the 4 M6 flange bolts between 24 4 and 43 2 in Ibs 2 9 4 9 N m on each cover Breather Plate and Cover The crankcase breather prevents pressure from building up in the crankcase It also prevents oil contamination by removing moisture or gasoline vapors and other harmful blow by materials from the crankcase These vapors are routed to the car buretor where they are mixed with incoming air and burned in the combustion chamber A sticky breath er valve can cause oil leaks high oil consumption rough idle reduced engine power and a rapid formation of sludge and varnish within the engine 1 Attach breather plate breather valve and breather cover to crankcase using the proper gaskets 2 Position the breather plate so the reed valve is opens away from the cylinder head Figure 6 12 3 Tighten the breather cover bolts to the speci fied torque Torque the 2 M6 flange bolts between 24 6 and 43 2 in Ibs 2 9 4 9 N m NOTE Over tightening the bolts will result in gasket damage Replace torn or damaged gas kets if necessary Replace the breather if it s broken or cracked or if the crankcase pressure is indicated by oil leaks at the seals or excessive oil in the air cleaner housing Spark Plugs 1 Reinstall the spark plugs to each cylinder 2 Use type NGK BP6
34. mounting bracket onto the blower housing Connect fuel hose to the carburetor and pulse hose to the crankcase Air Cleaner 1 Connect breather hose to air cleaner base 2 Install air cleaner base onto carburetor 3 Connect breather hose to 1 cylinder head 4 Place air cleaner element along with urethane form onto base 5 Install air cleaner cover and secure with knob Oil Pressure Switch and Oil Filter 1 Install oil pressure switch into the elbow con nector on crankcase Tighten to the specified torque Torque the pressure switch between 4 3 and 7 2 fi Ibs 5 9 9 8N m 2 Apply a thin coat of oil to the rubber gasket on the oil filter canister Hand tighten about 3 4 turns after the gasket touches the crankcase Torque the oil filter to approximately 9 ft lbs 12 3N m GROUND TERMINALS Not on all models PRESSURE SWITCH RELAY and WIRE CONNECTOR HOLDER Not on all models FIGURE 6 19 Wiring 1 Attach the wire holder relay and connector and ground terminals to the engine crankcase under the 1 cylinder baffle Figure 6 19 2 Route the ground wires and connector wires threw the wire holder 3 Secure the wires to the intake manifold with cable ties 4 Attach the spark plug wires onto each plug 5 Route wire bundle up through the cable holder mounted on the Control Solenoid FINAL CHECKS 1 Check for loose bolts and nuts Make sure all electric wiring connect
35. mp Main bearing cover bolts 12 3 13 7 ft lbs 16 7 18 6 Oil filter 9 ft Ibs 12 3 Oil pressure switch 4 3 7 2 ft lbs 5 9 9 8 Nm Used Oil relief plug 10 9 18 1 ft lbs 11 8 14 7 N m Rocker arm nut 7 2 10 1 ft Ibs 9 8 13 7 N m Rocker arm cover 26 4 43 2 in lbs 2 9 4 9 N m Spark plug new 8 7 10 9 ft lbs 11 8 14 7 Nm 16 6 19 5 ft lbs 22 5 26 5 Nm Starter motor bolts 12 3 13 7 ft Ibs 16 7 18 6 Nm 3 Engine Troubleshooting Many troubleshooting procedures present hazards that can result in severe per sonal injury or death Only qualified service per sonnel with knowledge of fuels electricity and machinery hazards should perform service pro cedures Review the safety precautions on the inside cover page Poor connection of key or starter switch wiring Discontinuity between key switch or start switch and starter motor Possible Cause AWARNING Hot engine parts can cause severe burns Always allow the engine time to cool before performing any maintenance or service Refer to other sections within this manual or the Op erators Manual for procedures to test adjust repair or replace engine components Check repair or replace Replace wiring Discontinuity between battery and Replace battery cables starter motor Starter does not operate Weak or low charged battery Ch
36. ndard Time Monday through Friday Or send a fax to Onan using the fax number 1 612 574 8087 Incorrect service or parts replace ment can result in severe personal injury death and or equipment damage Service personnel must be qualified to perform electrical and or mechanical service PERFORMANCE CURVE The power curve shown in Figure 1 2 conforms to SAE internal combustion engine standard test code J1349 The continuous rated output is the output of an en gine at optimum governed speed which is prefera ble for engine life and fuel consumption When the The maximum torque is the torque rated on the out engine is installed the rated output should be lower put shaft while the engine is running at maximum than shown output per revolution N m kgf m 45 4 59 35 3 57 TORQUE gt MAXIMUM TO MAXIMUM HORSEPOWER CONTINUOUS RATED HP i e oc a oc RECOMMENDED HORSEPOWER RANGE 5 6 7 2000 2400 2800 3200 3600 REVOLUTION gt r p m FIGURE 1 2 OHV220 PERFORMANCE CURVE 1 3 1 4 Redistribution or publication of this document by any means is strictly prohibited 2 Specifications PERFORMER OHV220 ENGINE SPECIFICATIONS This Manual contains SI metric equivalents that follow immediately in parentheses Engine Type after the U S customary units of measure 4
37. ngine Disassembly 5 1 Engine Reassembly 6 1 i i P PP Hn 6 1 Special TOD S EE utra 6 1 Break In Operation ewe WENNER a eR pace cam Ete o 6 1 gio ccs DTE 6 1 He assembly Procedures 6 3 eler 6 10 Safety Precautions Thoroughly read the OPERATOR S MANUAL be fore operating the engine Safe operation and top performance can be obtained only with proper operation and maintenance The following symbols in this Manual alert you to po tential hazards to the operator service person and equipment alerts you to an immediate hazard which will result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death GENERAL PRECAUTIONS e Keep ABC fire extinguishers handy e Make sure all fasteners are secure and torqued properly e Keep the engine and its compartment clean Ex cess oil and oily rags can catch fire Dirt and gear stowed in the compartment can restrict cooling air e Before working on the engine disconnect the negative battery cable at the battery to pre ven
38. ngine is on the valve is activated and the plunger is pulled in to open the main jet When the engine is off the power source to the valve is off The plunger is pushed out by the return spring and stops the fuel flow to the main jet Carburetor Replacement Do not adjust the fuel mixture rebuild or overhaul the carburetor A malfunctioning carburetor should be replaced Before replacing a carburetor howev er make certain that e All other necessary engine and generator ad justments and repairs have been performed e The carburetor is actually malfunctioning see Section 3 Engine Troubleshooting Unauthorized modifications or re placement of fuel exhaust air intake or speed control system components that affect emis sion on California certified engines are prohib ited by law in the State of California To remove the carburetor remove the air cleaner disconnect the fuel line choke and throttle link ages and unbolt the carburetor from the intake manifold When reinstalling the carburetor always use a new gasket Readjust the choke and throttle cables and engine speed as instructed in the Oper ator s Manual Speed Control Solenoid Optional The speed control solenoid monitors the rate of the load and automatically adjusts the engine to the ap propriate idle speed The solenoid is faulty if the idle does not pull to low Replace the solenoid 4 4 CHARGING SYSTEM Magneto The ignition system contain
39. nt parts to for quality and the best possible repair and overhaul re sults Whenever contacting an dealer or distributor for in formation parts or service always provide the mod el number and the serial number marked on the nameplate of the engine See Table 1 1 for an explaination of the engine model number 1 2 TABLE 1 1 ENGINE MODEL NUMBER Model Letter Performer Number of Cylinders and Rated Horse Power A 220 designates 2 Cylinders at 20 HP Engine Fuel Type and Engine Type Gas Industrial Engine Type Overhead Valves Engine Specific Model Number Model Nomenclature Revsion HOW TO OBTAIN SERVICE When the Performer 220OHV requires service contact the nearest dealer or distributor Factory trained Parts and Service representatives are ready to handle your service needs If you are unable to locate a dealer or distributor consult the Yellow Pages Typically our distributors are listed under GENERATORS ELECTRIC or ELECTRICAL PRODUCTS For the name of your local Cummins Onan or Onan only distributor in the United States or Can ada call 1 800 888 ONAN this automated service utilizes touch tone phones only By entering your area code and the first three digits of your local tele phone number you will receive the name and tele phone number of the distributor nearest you For outside North America call Onan Corporation 1 612 574 5000 7 30 AM to 4 00 PM Central Sta
40. on sources near the battery Do not jump start a frozen battery 6 Turn ignition switch to start engine Overcranking the engine can cause starter damage Do not engage start er for longer than 30 seconds If engine does not start allow 5 minutes for starter to cool between cranking intervals STARTING SYSTEM Starter Normally the starter requires little or no service oth er than possible brush replacement However if through accident or misuse the starter requires ser vice or overhaul the following provides the informa tion necessary to perform this service Functional Operation When the engine is turned ON low electric current flows through the coil of the solenoid and the coil is excited The plunger is pulled and higher cur rent S flows through the starter See Fig 4 4 ELECTRIC STARTER SOLENOID STARTER MOUNTED Starter Service When starting the engine note the starter motor ac tion The pinion gear should mesh quickly with the flywheel ring gear and spin the engine Once the en gine starts and the solenoid opens the starter should disengage and stop If the starter cranks the engine slowly or not at all check the start circuit components Failure to crank is usually caused by a low battery charge defective battery cables cor roded or poor connections or low temperatures Af ter checking these variables and the starter contin ues to crank slowly remove and repair the starter
41. ons when clean ing parts Special Tools Both American and metric size sockets and wrenches will be needed A ring spreader will be needed to remove and install pistion rings For pull ing the flywheel a universal type puller can be used as shown below FIGURE 5 1 FLYWHEEL PULLER 5 1 Preparation 1 Remove the fuel supply line Benzene and lead in some gas olines have been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not to ingest in hale or contact gasoline or its vapors 2 Disconnect exhaust and battery cables nega tive cable first Arcing can ignite explosive hy drogen gas given off by batteries causing severe personal injury Arcing can occur if the negative battery cable is connected and a tool being used to connect or discon nect the positive battery cable acciden tally touches the frame or other grounded metal part of the set To prevent arcing al ways remove the negative cable first and reconnect it last 3 Disconnect the electrical connector between the engine and accessory 4 Remove the engine from its mountings and place upright in a well lit and ventilated work area 5 Drain the engine oil Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Disassembly Procedures The following pages desc
42. ove the intake manifold secured by 4 M8 flange nuts CYLINDER BAFFLE 3 di lt M6 FLANGE BOLT 2 pes Se 6 FLANGE BOLT 3 pcs M8 FLANGE NUT 2 pcs MANIFOLD GASKET STEP 13 14 SPARK PLUG INTAKE MANIFOLD CYLINDER BAFFLE 1 NUT 2 pcs STEP 15 MANIFOLD GASKET SPARK PLUG M6 FLANGE BOLT 3 pcs M6 FLANGE BOLT 3 pcs CYLINDER BAFFLE 2 FIGURE 5 5 5 5 16 17 Remove rocker arm covers secured with 4 M6 bolts each Before removing the rocker arms and shafts turn the flywheel to dead center TDC with the mark T adjusted to number 1 or 2 in scribed on the cylinder head Figure 6 11 Use a permanent marker to mark the original posi tion of each push rod rocker arm and valve for reassembly M6 FLANGE BOLT 4 pcs LIFT HOOK ROCKER ARM X GASKET COVER rocker arm N N N ADJUSTING SCREW GASKET 1 FIGURE 5 6 M10 FLANGE BOT 4 pcs o N e S M8 NUT 2 pes amp 2 ROCKER 18 Remove the cylinder head from the engine body secured with 4 M10 flange bolts each NOTE For reassembly purposes torque the cylinder head flange bolts between 24 6 and 30 4 ft lb 33 3 41 2 Torque the rocker arm nuts between 7 2 and 10 1 fi Ibs 9 8 13 7 Torque the rocker arm cover bolts between 26 4 and 43 3 in Ibs 2 9 4 9 N m ARM 7 ADJUSTING SCRE
43. ribe and illustrate engine disassembly Disassembly Procedures 3 Remove the breather tube from the 1 cylinder head secured with a hose clamp 1 After the oil has been drained remove the dip stick and dip stick tube 4 Remove the fuel pump with mount Disconnect the fuel hose to carburetor and pulse hose 2 Remove the air cleaner cover elements and 5 Remove the blower housing secured with 8 base secured with 3 10 32 cap screws M6 flange bolts CLEANER 2 FUEL HOSE gt 10 32 e 3 FUEL PUMP SCREWS 3 pcs MOUNTING mm zu 9 CLEANER BRACKET ELEMENT S gt OIL FILL TUBE PULSE HOSE ech OIL LEVEL GAUGE AND TUBE M6 FLANGE BOLT 8 pcs X75 OIL DRAIN VALVE FIGURE 5 2 5 2 6 Remove the speed and choke control linkage 8 Remove the carburetor secured by 2 M8 and mounting bracket bolts 7 Disconnect the wiring harness under the speed NOTE For reassembly purposes torque the control solenoid Remove the speed control so carburetor bolts between 12 3 and 13 7 ft Ibs lenoid and the governor lever if required 16 7 18 6 M8 FLANGE BOLT 2 pcs CHOKE CONTROL ROD RETURN SPRING GASKET carburetor 1 2 STEP 6 6 1 LINK Ma P biet WASHER GOVERNOR LEVER ea E SE SPRING GOV ROD g M6 BOLT WASHER 1 jh us Ju M6 SELF LOCK NUT 1 pc LINK
44. ring 80 250 80 269 80 250 80 269 2nd 3 169 3 170 Reboring 80 500 80 519 Roundness after reboring 0 004 0 01 Cylindricity after reboring 0 0006 0 015 2 2 STANDARD MAXIMUM inches mm Piston 3 148 3 149 STD 79 968 79 988 3 145 79 878 KH 1st outer 3 158 3 159 1 1 E Piston size at skirt E diameter 80 218 80 238 3199 80 128 in thrust direction 2nd 1 3 168 3 169 80 468 80 488 3 164 80 378 iameter 0 0002 0 0035 Top 0 05 0 09 0 006 0 15 Ring groove side 0 0012 0 0028 clearance pol and 0 03 0 07 0 006 015 09922 DO 0 006 0 15 0 057 0 175 Piston pin hole 0 8262 0 8269 20 989 21 002 0 8281 21 035 Piston pin outer di ameter 0 8264 0 8268 20 991 21 000 0 8251 20 960 Clearance between piston and cylinder at skirt area 0 0005 0 0020 0 012 0 051 0 0098 0 25 2 3 STANDARD MAXIMUM inches mm inches mm Piston continued Top 0 0079 0 0157 2nd 0 2 0 4 0 0591 1 5 Piston ring end gap Oil 0 0079 0 0276 Ring 0 2 0 7 0 0591 1 5 Connecting Rod Large end inner diame
45. s a flywheel magneto with automatic advancing characteristics This sys tem is free from start up failure due to dirty burnt or a corroded point surfaces because there are no points The electronic automatic advancing provides easy starts and stable high performance at operating speed by advancing the ignition timing to the most suitable point THEORY Refer to Figure 4 3 Revolution of the fly wheel generates electricity on the primary side of the ignition coil and the base current 1 to the pow er transistor Current 11 turns the power transistor on and the electric current 72 flows During low idle after the flywheel reaches the igni tion point the low speed ignition timing control cir cuit runs the base current 13 turning the signal tran sistor A on This allows the current 11 to bypass as current 74 The power transistor turns off and the current 12 is abruptly shut resulting in high voltage generated in the secondary coil producing sparks at the spark plugs During high speed operation the advancing control circuit operates the ignition timing to run base cur rent 15 turning the signal transistor B on This al lows current 1 to bypass as current 16 The power transistor turns off and the current 12 is abruptly closed resulting in high voltage generated in the secondary coil producing sparks at the spark plugs The engine timing advances relative to the engine speed controlled by this circuit This tim
46. st 0 0034 0 0045 Valve clearance CH Ga 0 085 0 115 o Valve spring Free length 3 1 5551 89 5 Tappet Outer stem diameter 0 03528 0 3533 8 960 8 975 0 3516 8 93 Inner guide diameter 0 3543 0 3549 9 00 9 015 0 3575 9 08 0 0010 0 0022 Tappet guide clearance 0 025 0 055 P 37 Valve seat angle Cut 45 ut angle 0 028 0 039 0 079 2 0 Contact width b 0 7 1 0 2 6 STANDARD inches mm MAXIMUM inches mm Rocker Arm Shaft diameter 0 4719 0 4722 11 986 11 994 0 4693 11 92 Rocker arm hole 0 4727 0 4734 0 4752 12 07 diameter 12 006 12 024 0 0005 0 0015 Arm shaft clearance AN 0 012 0 038 0 0059 0 15 2 7 ELECTRICAL SPECIFICATIONS COMPONENT RATING Voltage Regulator 12V 15 Amp Output Ignition Coil Resistance Primary 7 8 Ohms Secondary 7 8 Ohms Charge Coil Nominal Output 12V 15 Amp Resistance 9 ohms Ignition coil air gap 0 012 0 020 0 3 0 5 mm Fuel Pump Inlet vacuum At low idle 2 6 of mercury Outlet pressure 1 7 psi At high idle Inlet vacuum minimum measure ments 2 6 of mercury Outlet pressure 1 7 psi ASSEMBLY SPECIFICATIONS COMP
47. t starting e Use caution when making adjustments while the engine is running hot moving or electrically live parts can cause severe personal injury or death e Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors e Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not to ingest inhale or contact gasoline or its vapors e Do not work on the engine when mentally or physically fatigued or after consuming alcohol or drugs e Carefully follow all applicable local state and federal codes This engine is not designed or in tended for use in aircraft Such use can lead to engine failure severe personal injury or death FUEL IS FLAMMABLE AND EXPLOSIVE e Keep flames cigarettes sparks pilot lights electrical arc producing equipment and switches and all other sources of ignition well away from areas where fuel fumes are present and areas sharing ventilation e Do not fill the fuel tank while the engine is run ning Fuel lines must be copper or steel tubing or pip ing adequately secured and free of leaks e Use approved flexible fuel hose for connections at the engine Do not use copper tubing as a flex ible connector vibration will cause it to work harden and break Use non conductive hose if
48. ter Clearance between crankpin and inner diameter Small end inner diameter Clearance between piston pin and inner diameter Large end side clearance 120 1 5354 1 5361 39 000 39 016 1 5394 39 100 0 0012 0 0024 0 030 0 060 0 0079 0 2 0 8272 0 8277 21 010 21 023 0 8299 21 080 0 0004 0 0013 0 010 0 032 0 0047 0 12 0 0039 0 0157 0 1 0 4 0 0394 1 0 2 4 STANDARD mm MAXIMUM inches mm Crankshaft Crankpin outer diameter Journal diameter 1 5337 1 5343 38 956 38 970 1 5315 38 90 D1 1 77102 1 77165 44 984 45 000 D2 1 77110 1 77154 44 986 44 997 Camshaft Cam height internal and external Journal outer 1 4213 1 4291 36 1 36 3 1 4154 35 95 0 7861 0 7866 0 7854 19 950 diameter D 19 967 19 980 Valve 0 2350 0 2356 Valve stem outer Intake 5 970 5 985 0 2303 5 85 diameter 0 2346 0 2352 7 Exhaust 5 960 5 975 0 2303 5 85 Clearance between valve stem and Intake prem 0 0118 0 30 valve stem guide 1 Exhaust VR 0 0118 0 30 0 060 0 093 2 ITEM STANDARD MAXIMUM inches mm inches mm Valve continued Intake TARA Exhau
49. using as the oil filter If oil pressure becomes low while flowing to the oil pump the switch will trigger a shutdown condition Crankcase Breather The crankcase breather prevents pressure from building up in the crankcase It also prevents oil contamination by removing moisture or gasoline vapors and other harmful blow by materials from the crankcase These vapors are routed to the car buretor where they are mixed with incoming air and burned in the combustion chamber A sticky breather valve can cause oil leaks high oil consumption rough idle reduced engine power and a rapid formation of sludge and varnish within the engine Replace the breather if it s broken or cracked or if the crankcase becomes pressurized indicated by oil leaks at the seals or excessive oil in the air clean er housing FUEL SYSTEM The fuel system consists of a fuel pump carburetor fuel filter shut off valve and control linkage Fuel Pump A diaphragm type fuel pump is mounted on the front of the engine The pump is operated by vacuum pressure inside the crankcase The fuel pump is not serviceable and should be re placed if faulty Fuel Pump Test Procedure Before testing make certain the fuel pump vacuum and fuel line connections are tight and free of leaks 10 11 12 4 2 Ignition of fuel can result in se vere personal injury or death Thoroughly clean up any spilled fuel Do not smoke or allow any flame spark pilot
50. y below the top of the battery post After making connections coat the terminals with a light application of petro leum jelly or grease to retard corrosion Always disconnect the negative cable first and reconnect it last to reduce the risk of arcing and explosion Jump Starting Occasionally it may be necessary to jump start charge a weak battery using a charged booster battery If jump starting is necessary the following procedure is recommended to help prevent starter damage battery damage and personal injuries 1 Disconnect engine load 2 Use a battery of the same voltage 12V as is used with your engine 3 Attach one end of the positive booster cable red to the positive terminal of the booster battery Attach the other end on the positive cable to the positive terminal of your engine battery Electrical arcing can cause se vere personal injury Do not allow positive and negative cable ends to touch 4 6 4 Attach one end of the negative booster cable black to the negative terminal of the boost er battery Attach the other end of the negative cable to a solid chassis ground on your engine Jump starting in any other manner may result in damage to the battery or the electrical sys tem Jump starting a battery incor rectly can cause either battery to explode resulting in severe personal injury or death Do not allow any spark flame pilot light lit cigarette or other igniti
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