Guardian Gtv/gth-990/760 ohvi series User manual

Owner’s

Manual

• SAFETY

• ASSEMBLY

• OPERATION

• TROUBLESHOOTING

• PARTS

• WARRANTY

GTV/GTH-990/760

AUTHORIZED DEALER SUPPORT:

SERIES ENGINES

1-800-333-1322

THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS, WHICH, IF NOT FOLLOWED,

COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOU AND OTHERS. READ AND

FOLLOW ALL INSTRUCTIONS IN THE MANUAL BEFORE ATTEMPTING TO OPERATE THIS UNIT.

SERVICE INFORMATION

Service on this engine within and after the warranty

period can be performed by any authorized service

dealer. Service technicians are factory trained and

capable of handling all service needs.

When contacting an authorized service dealer about

parts and service, always supply the complete model

number and serial number of your unit as given on its

data plate decal. See the illustration below for the

location of the decal.

The warranty for this engine is included in the owner’s

manual.

This engine meets the U.S. EPA and California

emissions regulations. To ensure that your

engine continues to meet these regulations,

refer to the following information and

instructions in this owner’s manual.

TABLE OF CONTENTS

GENERAL INFORMATION

Service Information ..................................................................2

Engine Identification Decal Location ........................................2

Oil and Fuel Information............................................................3

Engine Emission Compliance Period ........................................3

SAFETY

Rules for Safe Operation ..........................................................4

Before Operating ......................................................................4

While Operating ........................................................................5

OPERATION & MAINTENANCE

Before Starting the Engine ........................................................6

Starting the Engine ................................................................6-7

Stopping the Engine..................................................................7

Low Pressure Shutdown System ..............................................7

Restarting the Engine................................................................7

Maintenance Schedule..............................................................7

MAINTENANCE

General Maintenance Recommendations ................................8

Service and Adjustments ........................................................10

Carburetor Adjustments ..........................................................10

Adjusting Valve to Rocker Arm Clearance..............................11

Storage Instructions ................................................................11

Product Specifications ............................................................11

Oil Capacities ..........................................................................11

Service Parts ..........................................................................12

Troubleshooting ......................................................................12

Notes ......................................................................................13

WARRANTY

California Emission Control Warranty Statement....................15

Emission Control System Warranty ........................................16

Generac Engine Warranty ......................................................17

MAINTENANCE RECORD ..................................18

GTV/GTH - 990/760 OHVI SERIES ENGINES

OIL AND FUEL INFORMATION

NOTE: Be sure to read these instructions carefully before

attempting to start or operate this equipment. Using old or

improper oil or fuel can cause engine damage.

CAUTION: Any attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in engine damage.

CAUTION: This engine is shipped from Generac Power

Systems without oil. Check oil level before starting Engine. If

you start the engine without oil, the engine will be damaged

beyond repair and will not be covered under warranty.

RECOMMENDED OIL TYPE

Using the proper type and weight of oil in the crankcase is

extremely important. Check the oil before each use and change

the oil regularly. Failure to use the correct oil, or using dirty oil,

can cause premature engine wear and failure.

Use only high quality detergent oil rated with API service

classification SF, SG or SH. The recommended oil weights

include the following:

• During summer months: SAE 30. An acceptable substitute is

SAE 10W-30. After first oil change, synthetic oil is

acceptable.

• During winter months: SAE 5W-30, Synthetic 5W-20 or 5W-

30. DO NOT USE SAE 10W-40.

See Oil Capacities chart (Page 11) for oil capacities. Use no

special additives. Make sure that the unit is level when filling

with oil. DO NOT OVERFILL.

RECOMMENDED BATTERY

Servicing of the battery is to be performed or supervised by

personnel knowledgeable of batteries and the required

precautions. Keep unauthorized personal away from batteries.

Use only 12 volt negative (-) ground batteries with a minimum

rating of 675 cold-cranking amps at -17.8C (0 F).

WARNING: Damage will result to the engine starter if a

battery rated less than 675 cold-cranking amps is used.

BATTERY CABLES

Using battery cables that are too long or too small in diameter

may cause a decrease in voltage which leads to a starting

problem due to voltage drop. Use a cable size “2” for length 0”

to 10 feet. See Figure A for battery cable connections.

RECOMMENDED FUEL TYPE

Use clean, fresh, regular UNLEADED gasoline with this

engine.

CAUTION: Do not overfill the fuel tank. Always

allow room for fuel expansion.

WARNING: Never fill the fuel tank indoors. or when

the engine is running or hot. Do not light a cigarette or

smoke when filling the fuel tank.

ENGINE EMISSION COMPLIANCE PERIOD

For non-hand held engines: The Emissions Compliance Period

referred to on the Emissions Compliance label indicates the

number of operating hours for which the engine has been

shown to meet Federal emission requirements.

For engines less than 225 cc displacement, Category

C = 125 hours, B = 250 hours, and A = 500 hours.

For engines 225 cc or more, Category C = 250 hours,

B = 500 hours, and A = 1000 hours.

C-20 -10 10 20 30 40

100

806040200F -20

-30 Temperature Range of Expected Use

Synthetic 5W-20, 5W-30

10W-30, SAE 30

Battery

Positive(+)

Starter

Contactor

Typical Battery

Ground

Figure A - Battery Cable Connections

GTV/GTH - 990/760 OHVI SERIES ENGINES

If you do not understand any portion of this manual, contact

Generac or your nearest Generac Authorized Service Dealer

for starting, operating and servicing procedures.

Throughout this publication and on tags and decals affixed to

the engine, DANGER, WARNING and CAUTION blocks

are used to alert you to special instruction about a particular

operation that may be hazardous if performed incorrectly or

carelessly. Observe them carefully.

These safety warnings cannot eliminate the hazards that they

indicate. Strict compliance with the special instructions while

performing the service plus “common sense” are major

measures to prevent accidents.

The following definitions apply to DANGER, WARNING,

CAUTION and NOTE blocks found throughout the manual.

These safety symbols indicate the following:

DANGER: After this heading you can read handling,

installing, operating or servicing instructions that, if not

strictly complied with, will result in personal injury.

WARNING: After this heading you can read

handling, installing, operating or servicing instructions

that, if not strictly complied with, may result in personal

injury.

CAUTION: After this heading you can read

instructions for handling, installing, operating or

servicing the engine that, if not strictly complied with,

may result in damage to equipment and/or property.

NOTE: After this heading you can read explanatory

statements that require special emphasis.

These symbols indicate the following:

Points out important safety information that, if not

followed, could endanger personal safety and/or

property of yourself and others.

Potential explosion hazard.

Potential fire hazard.

ᏘPotential electrical shock hazard.

RULES FOR SAFE OPERATION

Study these RULES FOR SAFE OPERATION carefully

before operating or servicing this equipment. Become familiar

with the OWNER’S MANUAL and with the engine. The

engine can operate safely, efficiently and reliably only if it is

properly operated and maintained. Many accidents are caused

by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible circumstance

that might involve a hazard. The warnings in this manual and on

tags and decals affixed to the equipment, are therefore, not all-

inclusive. If you use a procedure, work method or operating

technique Generac does not specifically recommend, you must

satisfy yourself that it is safe for you and others. You must also

make sure the procedure, work method or operating technique

that you choose does not render the engine to be unsafe.

DANGER: Do not tamper with the engine governed

speed. High operating speeds are dangerous and

increase the risk of personal injury or damage to the

equipment. Operating at low speeds with heavy load may

shorten the engine’s life.

BEFORE OPERATING

• Gasoline is highly FLAMMABLE and its vapors are

EXPLOSIVE. Do not permit smoking, open flames,

sparks or heat in the area while handling gasoline. Avoid

spilling gasoline on a hot engine. Comply with all of the

laws regulating storage and handling of gasoline.

• Store gasoline and other fuels only in containers

designed and approved for the storage of such

materials.

• Add gasoline in a clean, well-ventilated area. Wipe up

any spilled gasoline immediately.

If gasoline has been spilled, let it dry completely before

starting the engine.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

WARNING:

GTV/GTH - 990/760 OHVI SERIES ENGINES

• Do not overfill the fuel tank. Always allow room for fuel

expansion. If the tank is overfilled, the fuel can flow onto a

hot

engine and cause a FIRE or an EXPLOSION.

• Allow at least two (2) feet of clearance on all sides of the

engine, even while operating it outdoors, or you could

damage the engine.

• Thoroughly inspect the engine for loose or damaged

parts before each use. Do not use the engine until

adjustments or repairs are made.

• Check the oil level in the engine before each use.

• Inspect the engine periodically. Repair or replace all

damaged or defective parts immediately.

• Inspect fuel system frequently for leaks or damage.

Repair or replace any damaged or leaking component

immediately. Never attempt to change, alter or modify

the engine fuel system in any way that might affect

safety or compliance with applicable codes and

standards.

WHILE OPERATING

• This engine was designed and manufactured for specific

applications. Do not attempt to modify the equipment or

use it for any application for which it was not designed.

• Generac Power Systems does not approve or authorize

the use of these engines on All Terrain Vehicles (ATV’s),

go-carts, motorbikes, aircraft products, personal

watercraft, or vehicles intended for use in competitive

events. Use of these engines in such applications could

result in property damage, serious injury (including

paralysis), or even death.

• Engine exhaust gases contain DEADLY carbon

monoxide gas. This dangerous gas, if breathed in

sufficient concentrations, can cause unconsciousness or

even death. Operate this equipment only in the open air

where adequate ventilation is available.

• Do not insert any object through the cooling slots of the

engine. You could damage the equipment or injure

yourself.

• Do not operate the engine faster than the speed

necessary to operate the equipment. Do not run the

engine at high speed when not operating the equipment.

• This engine requires an adequate flow of cooling air for its

continued proper operation. Never operate the equipment

inside any room or enclosure where the free flow of cooling

air into and out of the equipment might be obstructed.

Without sufficient cooling air flow, the engine quickly

overheats, damaging the engine or nearby property.

• Do not smoke around the engine. Wipe up any fuel or oil

spills immediately. Never leave oily or fuel soaked rags

around the engine. Keep the area around the engine clean

and free of debris.

• Keep hands, feet, clothing, etc., away from moving parts of

this engine.

• Never operate the engine (a) in the rain; (b) in any enclosed

compartment; (c) if the engine speed changes; (d) if the

engine sparks; (e) if flame or smoke is observed while the

engine is running.

• Never work on this engine or handle any electrical device

while standing in water, while barefoot, or while hands or feet

are wet. DANGEROUS ELECTRIC SHOCK will

result.

GTV/GTH - 990/760 OHVI SERIES ENGINES

OPERATION AND MAINTENANCE

It is the owner’s/operator's responsibility to perform all safety

checks; to make sure that all maintenance for safe operation is

performed promptly; and to have the engine checked by an

authorized dealer periodically. Normal maintenance service and

replacement of parts are the responsibility of the

owner/operator and, as such, are not considered defects in

materials or workmanship within the terms of the warranty.

Individual operating habits and usage contribute to the need for

maintenance service.

Proper maintenance and care of your engine assures a

minimum number of problems and keeps your operating

expenses at a minimum. See your authorized dealer/distributor

for service aids and accessories.

BEFORE STARTING THE ENGINE

Perform the following tasks before trying to start the engine:

CHECKING AND ADDING ENGINE OIL

NOTE: When adding oil to the engine crankcase in the future,

use only high quality detergent oil rated with API service

classification SF or SG SAE 30 weight. Use no special

additives.

Select the oil’s viscosity grade according to the expected

operating temperature. Do not use SAE 10W-40.

• Above 40°F, use SAE 10W-30 or SAE 30.

• Below 40°F, use synthetic 5W-20 or 5W-30.

Check your engine oil level frequently to avoid possible

damage from running low on oil.

• Place engine on a level surface.

• Clean area around oil fill and remove oil fill cap and

dipstick. (Figure 1 or figure 2)

• Wipe dipstick clean. Reinstall and check oil level on dipstick.

• Slowly fill engine with oil through the oil fill opening

until it reaches the full mark on the dipstick. Stop filling

occasionally to check oil level. DO NOT OVERFILL.

• Install dipstick. Install oil fill cap and finger tighten

securely.

• Check engine oil level before starting each time thereafter.

ADDING FUEL

1. Fill the fuel tank using clean, fresh regular UNLEADED

gasoline.

STARTING THE ENGINE

1. Open the fuel shut-off valve, (if equipped).

2. Move choke control to CHOKE or START Position.

3. Push throttle to FAST position (if equipped). Operate the

engine with the throttle in FAST position.

4. Turn key to START position (hold until engine starts, but

not more than 5 seconds). To prevent damage to starter,

allow starter to cool for one minute between attempting to

restart.

5. A) If the engine FAILS TO START, go to Step 6.

B) If the engine STARTS, go to Step 7.

6. Push the choke lever to the HALF CHOKE

POSITION. Repeat step 4

• If the engine STILL FAILS TO START, repeat

Steps 1-5.

OPERATION

Figure 1 - Oil Fill Check

FILL/

CHECK

DRAIN

CHECK FILL

Figure 2 - Oil Check and Oil Fill

GTV/GTH - 990/760 OHVI SERIES ENGINES

7. Move the choke lever to the OFF POSITION by

pushing it in or move choke control to RUN position.

Allow engine to warm up for two minutes..

NOTE: for cold weather starting: make sure the proper engine

oil is being used (see page 3).

STOPPING THE ENGINE

1. Remove load from engine.

2. Move throttle to SLOW position.

3. While still running, allow engine to cool for two minutes.

4. Turn key to OFF position.

5. Close fuel shut-off valve (if equipped).

LOW PRESSURE SHUTDOWN SYSTEM (OPTIONAL)

The engine is equipped with a low oil pressure sensor that

shuts down the engine automatically when the oil pressure

drops below 8 psi. If the engine shuts down by itself and the

fuel tank has enough gasoline, check the engine oil level.

INITIAL STARTUP

A delay built in the shutdown system allows oil pressure to

build during starting. The delay allows the engine to run for

about 10 seconds before sensing oil pressure.

SENSING LOW PRESSURE

If the system senses low oil pressure during operation, the

engine shuts down. The engine will not continue to run until 8

psi of oil pressure is reached.

RESTARTING THE ENGINE

If you try to restart the engine within (five) 5 seconds after it

shuts down, the engine may NOT start. The system needs 10

seconds to reset.

NOTE: If you restart engine after a shutdown and have not

corrected the low oil pressure, the engine will run for

about 10 seconds as described above, and then it will stop.

OPERATION

MAINTENANCE SCHEDULE

Every Every Every Every

8 Hours 25 Hours 50 Hours 100 Hours

or Daily Season Season Season

Check Oil Level •

Change Oil Note 1

Change Oil Filter Note 1

Service Air Filter

Replace or Clean •

Spark Plug

Clean Spark •

Arrestor Screen

Adjust Valve •

Clearance

NOTE 1: Change oil and filter after first 8 hours of operation and then

every 100 hours thereafter. Change sooner when operating under a heavy

load or in a dusty or dirty environment or in high ambient temperature.

NOTE 2: Service more often when operating in dirty or dusty conditions.

Replace standard filter element (Figure 7) every 50 hours. Replace canister

style filter (Figure 8) every 500 hours.

Foam

Pre-Filter

if equipped

Filter

(Note 2)

MAINTENANCE SCHEDULE

The owner/operator is responsible for making sure that all

periodic maintenance tasks are completed on a timely basis;

that all discrepancies are corrected; and that the equipment is

kept clean and properly stored. Never operate a damaged or

defective engine.

CAUTION: Disconnect the spark plug wires from

the spark plugs, and place the wires where they

cannot come in contact with the spark plugs before

working on this engine.

GTV/GTH - 990/760 OHVI SERIES ENGINES

GENERAL MAINTENANCE

RECOMMENDATIONS

CHECKING THE OIL LEVEL

See the BEFORE STARTING THE ENGINE section on

page 6 for information on checking the oil level. The oil level

should be checked before each use, or at least every eight

(8) hours of operation. Keep the oil level maintained.

CHANGING THE OIL AND OIL FILTER

Your engine is equipped with an oil filter. Change the oil and

filter after the first eight (8) hours of operation. Change

the oil and oil filter every 100 hours thereafter. If you are

using this engine under dirty or dusty conditions, or in

extremely hot weather, change the oil more often.

Use the following instructions to change the oil while the engine

is still warm:

1. Clean the area around the oil drain plug, remove the plug

and drain the oil completely into a suitable container

(Figure 1 or figure 3).

2. When the oil is drained, install and tighten the oil drain plug.

3. When changing the oil filter, use the

following instructions:

A) Locate filter (Figure 4 or figure 5).

B) Place a suitable container beneath the oil filter and turn

the filter counterclockwise to remove the filter.

C) Coat the gasket of a new filter with engine oil. Turn

the new filter clockwise until the gasket contacts

the filter adapter, then tighten an additional 3/4 turn.

4. Remove the oil fill cap and insert a clean funnel into the oil

fill opening. Fill the crankcase with the recommended oil

until the oil level is at the full point on the dipstick.

Approximately 2366ml (2.5 qt.) are required when changing

an oil filter. POUR SLOWLY.

5. When the crankcase is filled to the proper level, install and

tighten the oil fill cap. Start engine to fill oil filter,

recheck/correct oil level.

CLEANING INTAKE SCREEN

Clean intake screen and oil cooler fins after each use or as

needed.

SERVICING THE AIR CLEANER

Your equipment’s air cleaner system is one of the most

important items to maintain. The engine will not run properly and

may be damaged if it is run with a dirty air cleaner system.

Service or replace the paper air filter per schedule on page 7.

Service or replace the filter more often if the engine is operated

under dusty or dirty conditions. Clean the foam pre-filter (if

equipped) every 25 hours of operation, or sooner

under dusty or dirty conditions.

Figure 3 & 4 - Drain Plug and Oil Filter

DRAIN

Figure 6 - Clean Intake Screen & Oil Cooler Fins

INTAKE SCREEN

Figure 5 - Oil Filter

FILTER

OIL

COOLER

FINS

GTV/GTH - 990/760 OHVI SERIES ENGINES

Use the following instructions to clean or

replace the air cleaner components. Locate your

engine configuration (Figure 7 or figure 8) and

follow the instruction.

CAUTION: Never run this equipment without the

complete air cleaner system installed on the engine.

This could result in premature wear to the engine.

OPTION 1

To clean or replace foam pre-cleaner:

• Remove air cleaner cover, then foam pre-filter.

• Wash pre-cleaner in soapy water. Squeeze pre-filter dry

in clean cloth (DO NOT TWIST).

• Clean air cleaner cover before re-installing it.

To service or replace paper air filter:

• Remove air cleaner cover; then remove foam pre-filter

(service if necessary) and remove paper filter.

• If the filter is too dirty, replace it with a new one. Dispose

of the old filter properly.

• Clean air cleaner cover then slip pre-cleaner over filter.

Next insert new paper filter into the base of the air

cleaner. Re-install air cleaner cover.

OPTION 2

1. Remove air cleaner cover.

2. Empty dust out of cover.

3. Gently pull filter out of air cleaner housing.

4. Clean inside of housing with damp cloth.

5. Push new air cleaner into housing.

6. Reinstall the air cleaner cover.

NOTE:To order a new air filter, please contact the nearest

authorized service center at 1-800-333-1322.

REPLACING THE SPARK PLUG

Use Champion RC14YC, NGK BKR4E or equivalent spark plugs.

The correct air gap is 0.76 mm (0.030 in.). Replace the plugs

every 100 hours of operation or once each year, whichever

comes first. This will help your engine to start easier and run

better.

1. Stop the engine and pull the spark plug wire off of the

spark plug.

2. Clean around the spark plug and remove it from the

cylinder head.

3. Set the spark plug gap (Figure 9) to 0.76mm (0.030 in.).

Install a correctly gapped spark plug into the cylinder head.

Figure 7 - Air Cleaner

Figure 8 - Canister Style Air Cleaner Components

Figure 9 - Setting Spark Plug Gap

COVER

AIR FILTER

ELEMENT,

PRIMARY

HOUSING

AIR FILTER

ELEMENT,

SAFETY

GTV/GTH - 990/760 OHVI SERIES ENGINES

CLEANING SPARK ARRESTOR SCREEN

If the engine exhaust muffler has a spark arrestor screen,

inspect and clean the screen every 100 hours of operation

or once each year, whichever comes first.

NOTE:If you use your engine on any forest-covered, brush-

covered or grass-covered unimproved land, it must have a

spark arrestor. The spark arrestor must be

maintained in good condition by the owner/operator.

Clean and inspect the spark arrestor screen as follows:

Inspect the screen and replace if it is torn, perforated or

otherwise damaged. DO NOT USE a defective screen. If the

screen is not damaged, clean it with a commercial solvent.

If the spark arrestor is found to be damaged or defective, replace it.

SERVICE AND ADJUSTMENTS

ENGINE SPEED

CAUTION: The engine speed was properly adjusted at

the factory and should require no additional adjustment. Do

not attempt to change engine speed. If you believe the

engine is running too fast or too slow, take your engine to

an authorized service center for repair and adjustment.

CHANGING THE ENGINE GOVERNED SPEED

WILL VOID THE ENGINE WARRANTY.

The operating speed of this engine is maintained by either a

mechanical, flyweight type or an electronic stepper motor

controlled governor. DO NOT try to adjust the governed

speed setting for the following reasons:

• Operating the engine at high engine speeds is dangerous

and increases the risk of personal injury or damage to the

equipment.

• Operating the engine at low engine speeds with heavy

loads may shorten the engine’s life.

CARBURETOR ADJUSTMENTS

The carburetor of your engine is pre-set at the factory. The

carburetor should not be tampered with because this will

VOID THE EMISSION CONTROL SYSTEM

WARRANTY. If you experience problems and your engine is

used at an altitude in excess of 5000 feet, contact the nearest

authorized dealer regarding high altitude setting changes.

ADJUSTING VALVE CLEARANCE

After the first 100 hours of operation, you

should adjust the valve clearance in the engine.

IMPORTANT: If you feel uncomfortable about doing this

procedure or you don't have the proper tools, please take your

engine in to the nearest service center to have the valve

clearance adjusted. This is a very important step to insure

longest life for your engine.

To adjust valve clearance:

• Make sure the engine is at room temperature.

• Make sure that the spark plug wires are removed from the

spark plugs and out of the way.

• Remove the four screws attaching the valve cover with

a 10 mm wrench or socket.

• Make sure the piston is at Top Dead Center (TDC) of its

compression stroke (both valves closed). To get the

piston at TDC, remove the intake screen at the front of

the engine to gain access to the flywheel nut. Use a large

socket and socket wrench to rotate the nut and hence the

engine. While watching the piston through the spark plug

hole. The piston should move up and down. The piston is

at TDC when it is up as high as it can go.

• Loosen the rocker jam nut. Use an 10mm allen wrench

to turn the pivot ball stud while checking clearance

between the rocker arm and the valve stem with a

feeler gauge. Correct clearance is 0.002-0.004 inch

(0.05-0.1mm).

NOTE: You must hold the rocker arm jam nut in place as you

turn the pivot ball stud.

Figure 10 - Valve Clearance Adjustment

GTV/GTH - 990/760 OHVI SERIES ENGINES

When valve clearance is correct, hold the pivot ball stud in place

with the allen wrench and tighten the rocker arm jam nut.

Tighten the jam nut to 174 in/lbs. torque. After tightening the jam

nut, recheck valve clearance to make sure it did not change.

• Install new valve cover gasket (Part number 0C2979).

• Re-attach the valve cover and torque to 4.8 to 5.5 ft. - lbs.

NOTE: Start all four screws before tightening or you will not

be able to get all the screws in place. Make sure the valve

cover gasket is in place.

• Re-attach the spark plug wire to the spark plug.

• Repeat the process for the other cylinder.

STORAGE INSTRUCTIONS

This engine should be started at least once a month and run for

at least 10 minutes. If this cannot be done and the

equipment must be stored for more than 30 days, use the

following guidelines to prepare it for storage.

WARNING: Never store the engine with the fuel in

the tank indoors or in an enclosed or poorly ventilated

area. Fumes can reach an open flame, spark, or pilot

light as on a furnace, water heater, or clothes dryer

and ignite.

1. Run the engine for about five (5) minutes to warm it.

NOTE: Alcohol-blended fuel, or “gasohol”, attracts moisture

which can lead to the separation and formation of acids during

storage. This acidic gas can damage internal engine parts.

Methanol, ethanol and grain alcohol all are forms of gasohol. If

you did use “gasohol,” drain the fuel tank, then run the engine

until it stops from lack of fuel.

WARNING: Drain the fuel into approved container,

outdoors, away from open flame. Be sure the engine is

cool.

NOTE: Using a fuel additive such as STA-BIL®fuel stabilizer,

or an equivalent, will prevent gum deposits from forming in the

engine’s fuel system.

2. While the engine is still warm, drain the oil from the

crankcase. Refill it with fresh oil. See BEFORE

STARTING ENGINE on Page 6 for oil

recommendations.

3. Remove spark plug and pour about 1/2 ounce (15ml) of

engine oil into the cylinder. Crank slowly to distribute oil.

CAUTION: Avoid spray from the spark plug hole when

cranking the engine slowly.

4. Install the spark plug. Do not connect the spark plug wire.

5. Clean the dirt, oil and grease from the cylinder, cylinder

head, fins, blower housing, rotating screen and muffler area.

6. Close the fuel shut-off valve.

OTHER STORAGE TIPS

1. Do not store gasoline from one season to another.

2. Replace the gasoline can if it starts to rust. Rust and/or dirt

in gasoline can cause problems.

3. Store the equipment in a clean and dry area.

PRODUCT SPECIFICATIONS

MODEL GTV-GTH-990 GTV-GTH-760

Bore 90mm 90mm

Stroke 78mm 60mm

Valve Clearance 0.05–0.10mm 0.05–0.10mm

(.002–.004 in) (.002–.004 in)

Displacement 992cc 763cc

Maximum Tilt Angle 15° 15°

While Operating

Weight (44.5 kg.) (98 lbs.) (44.5 kg.) (98 lbs.)

OIL CAPACITIES

MODEL GTV 990 & 760 GTH 990 & 760

Oil Capacity with Oil 2030 ml (2.1 qt.) 1750 ml (1.8 qt.)

Filter

Oil Capacity without 1750 ml (1.8 qt.) 1470 ml (1.5 qt.)

Oil Filter

GTV/GTH - 990/760 OHVI SERIES ENGINES

Engine will not start; or starts 1. Dirty air cleaner. 1. Clean or replace air cleaner.

and runs rough. 2. Out of gasoline. 2. Fill fuel tank.

3. Stale gasoline. 3. Drain fuel tank and & carburetor and fill

with fresh fuel.

4. Spark plug wire not 4. Connect wire to spark plug.

connected to spark plug

5. Bad spark plug. 5. Replace spark plug.

6. Water in gasoline. 6. Drain fuel tank & carburetor; fill with fresh

fuel.

7. Overchoking. 7. Put choke knob to No Choke position.

8. Low oil level. 8. Fill crankcase to proper level.

9. Excessive rich fuel mixture. 9. Contact Authorized Service Facility.

10. Intake valve stuck open or closed. 10. Contact Authorized Service Facility.

11. Engine has lost compression. 11. Contact Authorized Service Facility.

Engine shuts down 1. Out of gasoline. 1. Fill fuel tank.

during operation. 2. Low oil level. 2. Fill crankcase to proper level.

3. Fault in engine. 3. Contact Authorized Service Facility.

Engine lacks power. 1. Dirty air filter. 1. Replace air filter.

2. Engine needs to be serviced. 2. Contact Authorized Service Facility.

Engine “hunts” or falters. 1. Choke is opened too soon. 1. Move choke to halfway position until

engine runs smoothly.

2. Carburetor is running too rich 2. Contact Authorized Service Facility.

or too lean.

3. Governor or speed control system 3. Contact Authorized Service Facility

out of adjustment.

TROUBLESHOOTING

SERVICE PARTS

MODEL GTV-GTH-990 & GTV-GTH-760

Spark Plug (Champion RC14YC) P/N 0E7585

Spark Plug (NGK BKR4E) P/N 0E6037

Oil Filter (Black) P/N 070185B

Oil Filter (Yellow) P/N 070185C

Air Cleaner Element P/N 0D9723

Air Pre-cleaner P/N 0D4511

Air Filter, Primary (Canister Style, large) P/N 0E3557

Air Filter, Safety (Canister Style, small) P/N 0E3656

GTV/GTH - 990/760 OHVI SERIES ENGINES

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with

Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*

New engines must be designed, built and equipped to meet stringent anti-smog standards for the state of California and the

federal government. Generac will warrant the emission control system on your engine for the periods of time listed below provided

there has been no abuse, neglect, unapproved modification or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair

your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on engines are warranted for two years as hereinafter noted. If, during such warranty period,

any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs

or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory

supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance

on your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure

the completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or

responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or

unapproved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a

problem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service

Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System

Warranty (ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the

“Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also

provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there

is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in

circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the

Generac Warranty describe important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty

service, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner

shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product

to/from the inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or

losses incurred while the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the

following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190 15

GTV/GTH - 990/760 OHVI SERIES ENGINES

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:

(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new

engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months

thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or

equipment, and to each subsequent purchaser/owner, that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their

respective authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-

related part to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.

(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s Manual shall be

warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac

according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the

ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual shall be warranted

for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the

ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty

Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted

for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the

part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under

the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such

emissions-related part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a

Generac Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for diagnostic

costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under

warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected

demand for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty

maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac’s ECS Warranty

obligations.

(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac engine. Such use voids

this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for

failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey

market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

1.1) Gasoline carburetor assembly and its

internal components (if so equipped).

a) Fuel filter (if so equipped)

b) Carburetor gaskets

c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its

internal components (if so equipped).

a) Fuel controller (if so equipped)

b) Mixer and its gaskets (if so equipped)

c) Carburetor and its gaskets (if so equipped)

d) Primary gas regulator (if so equipped)

e) LP liquid vaporizer (if so equipped)

2) Air Induction System including:

a) Intake pipe/manifold

b) Air cleaner

3) Ignition System including:

a) Spark plug

b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) including:

a) Muffler gasket

b) Exhaust manifold

5) Crankcase Breather Assembly including:

a) Breather connection tube

*Generac engine types covered by this warranty statement include the following:

1) Utility

2) Lawn and Garden Equipment

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile (IM) Generator

GTV/GTH - 990/760 OHVI SERIES ENGINES

GENERAC POWER SYSTEMS’

TWO-YEAR LIMITED WARRANTY FOR GT SERIES ENGINES

For a period of 2 (two) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair

or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is

found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the

purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer.

All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This

warranty applies only to Generac GT engines sold and rated for GT engine applications, as Generac has defined GT engine applications.

This warranty pertains only to the GT engines utilized to power equipment within the lawn and garden industry. Examples include, but

are not limited to, portable generators, pressure washers, air compressors, welders, lawn tractors and mowers, snow blowers, edgers

and pumps. THIS WARRANTY IS NOT TRANSFERABLE.

WARRANTY SCHEDULE

GT engines bound for export outside of North America shall be warranted for a period of 1 (one) year for

consumer/personal applications and 90 (ninety) days for commercial applications.

CONSUMER/COMMERCIAL APPLICATIONS

• YEAR ONE - 100% (one hundred percent) coverage on part(s) and labor as listed (proof of purchase required):

Engine - All components

• YEAR TWO - 100% (one hundred percent) coverage on part(s) ONLY as listed (proof of purchase required):

Engine - All components

All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat Rate Manual

for engines. THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

•Generac engines that utilize non-Generac replacement parts.

•Costs of normal maintenance, adjustments, installation and start-up.

•Failures caused by any contaminated fuels, oils, or lack of proper fluid amounts.

•Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all

mechanical devices, the GT-Series engines need periodic part(s) service and replacement to perform well. This warranty will not

cover repair when normal use has exhausted the life of a part(s) or engine.

•Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,

lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

•Products that are modified or altered in a manner not authorized by Generac in writing.

•Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or

replacement of the defective part(s).

•Engines used for generators that are utilized as “Prime Power” in place of existing utility power where utility is present or in place of

utility power where utility power service does not normally exist.

•Failure due to misapplication.

•Telephone, cellular phone, facsimile, internet access or other communication expenses.

•Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty

period.

•Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.

•Rental equipment used while warranty repairs are being performed.

•Overnight freight costs for replacement part(s).

•Overtime labor.

•Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO

OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow

limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL

GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT

RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages,

so the above limitation may not apply to you. Purchaser/owner agrees to make no claims against Generac based on negligence.

This warranty gives you specific legal rights. You also may have other rights that vary from state to state.

GTV/GTH - 990/760 OHVI SERIES ENGINES

MAINTENANCE RECORD

Maintenance performed ______________________ Date __/__/__ Engine hours _____

GTV/GTH - 990/760 OHVI SERIES ENGINES

MAINTENANCE RECORD

Maintenance performed ______________________ Date __/__/__ Engine hours _____

GTV/GTH - 990/760 OHVI SERIES ENGINES

GENERAC POWER SYSTEMS, INC.

P.O. Box 297 • Whitewater, WI 53190

Part No. 0D8699 REV. C / PRINTED IN THE USA / 3.04

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