Onan Elite E125V User manual

ONAN E125 V, E140V ENGINE SERVICE MANUAL
Table of Contents – Page 1 of 3
SAFETY PRECAUTIONS
GENERAL
BATTERIES
PROTECT AGAINST MOVING PARTS
FUEL SYSTEM
EXHAUST SYSTEM
EXHAUST GAS IS DEADLY
KEEP THE UNIT AND SURROUNDING AREA CLEAN
SUPPLEMENT 965-1053
PURPOSE
SERVICE MANUAL 965-0764 REVISIONS
CARBURETOR (BEGINNING SPEC E)
SECTION 1. GENERAL INFORMATION
SECTION 2. SPECIFICATIONS
SECTION 3. DIMENSIONS AND CLEARANCES
SECTION 4. ASSEMBLY TORQUES
SECTION 5. ENGINE TROUBLESHOOTING
SECTION 6. MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
ENGINE INSPECTION
AIR CLEANER AND ELEMENT WRAPPER
OIL CHANGE
OIL FILTER CHANGE
COOLING
VALVE CLEARANCE
SPARK PLUG
SECTION 7. LUBRICATION
OIL CHANGE
OIL FILTER CHANGE
OIL LEVEL CHECK
OIL PRESSURE
OIL PRESSURE RELIEF VALVE
OIL PUMP
DISASSEMBLY
ROTOR LOBE CLEARANCE
OUTER ROTOR AND PUMP BODY CLEARANCE
ROTOR AND COVER CLEARANCE
ASSEMBLY
SECTION 8. ELECTRICAL
IGNITION SYSTEM
SPARK PLUG
IGNITION COIL
IGNITION TIMING
FLYWHEEL ALTERNATORS
ALTERNATOR OUTPUT TESTS

ONAN E125 V, E140V ENGINE SERVICE MANUAL
Table of Contents – Page 2 of 3
SECTION 9. FUEL
GASOLINE CARBURETOR
DISASSEMBLY
INSPECTION/SERVICE
ASSEMBLY
CO ADJUSTMENT
IMPULSE FUEL PUMP
INSPECTION/SERVICE
FUEL PUMP REMOVAL
FUEL PUMP INSTALLATION
LPG FUEL SYSTEM
GOVERNOR ADJUSTMENTS
1. GOVERNOR LEVER ADJUSTMENT
2. IDLE SPEED ADJUSTMENTS
3. CHOKE ADJUSTMENT
4. SPEED CONTROL CABLE ADJUSTMENT
AIR CLEANER
FOAM WRAPPER ELEMENT
PAPER ELEMENT
SECTION 10. STARTING
RECOIL STARTER
110 VAC STARTER
SOLENOID SHIFT STARTER
SOLENOID
ARMATURE
COMMUTATOR AND MICA
STARTER BODY
BRUSHES
OVERRUNNING CLUTCH
SECTION 11. ENGINE BLOCK ASSEMBLY
INTRODUCTION
ENGINE DISASSEMBLY/ASSEMBLY
SUGGESTED DISASSEMBLY ORDER
SUGGESTED ASSEMBLY PROCEDURE
OPERATION
COMPRESSION TEST
FLYWHEEL
DISASSEMBLY
SERVICE/INSPECTION
ASSEMBLY
VALVE COVER
ROCKER ARM
DISASSEMBLY
INSPECTION/SERVICE
ASSEMBLY
CYLINDER HEAD
DISASSEMBLY
ASSEMBLY

ONAN E125 V, E140V ENGINE SERVICE MANUAL
Table of Contents – Page 3 of 3
SECTION 11. ENGINE BLOCK ASSEMBLY –CON’T
VALVE SYSTEM
TAPPETS
DISASSEMBLY
INSPECTION/SERVICE
VALVE STEM AND VALVE GUIDE CLEARANCE:
VALVE GUIDE REPLACEMENT:
ASSEMBLY
VALVE SPRING:
VALVE FACE AND SEAT GRINDING
INSPECTION/SERVICE
VALVE SEAT WIDTH:
VALVE SEAT CUTTING:
VALVE CLEARANCE:
OIL BASE
DISASSEMBLY
ASSEMBLY
GOVERNOR
BALANCING SHAFTS
DISASSEMBLY
OIL BASE BEARING TO SHAFT CLEARANCE:
ASSEMBLY
CRANKSHAFT AND CAMSHAFT
DISASSEMBLY
INSPECTION/SERVICE
CRANKSHAFT JOURNAL:
CAMSHAFT LOBE HEIGHT:
OIL BASE BEARING TO CAMSHAFT CLEARANCE:
ASSEMBLY
COMPRESSION RELEASE SYSTEM
PISTON, PISTON PIN, RINGS, CONNECTING ROD
DISASSEMBLY
PISTON INSPECTION
PISTON INSPECTION:
PISTON PIN HOLE INSIDE DIAMETER:
PISTON PIN OUTSIDE DIAMETER:
PISTON RING AND RING GROOVE CLEARANCE:
CONNECTING ROD SMALL END INSIDE DIAMETER:
CONNECTING ROD TO CRANKSHAFT JOURNAL OIL CLEARANCE:
CONNECTING ROD SIDE CLEARANCE:
ASSEMBLY
CYLINDER BLOCK
CLEANING
INSPECTION
REBORING THE CYLINDER
HONING CYLINDER (USING PRECISION HONES)
DEGLAZING CYLINDER BORE
BALL BEARINGS
OIL SEAL

El25V, El40V
Elite Series
Printed in U.S.A.
965-0764
Spec A-C
6-94

Safety Precautions
Before operatingtheengine, readthe Operator'sManualand
become familiarwith it and theequipment.
Safe andefficient
operatloncanbeachievedonly
If the equipment Is
properly operated and maintained.
Thefollowingsymbols,foundthroughoutthismanual, alertyou
topotentiallydangerousconditionsto theoperator,serviceper-
sonnel,or
the equipment.
Thls symbol warns of immediate hazards
whlch will result in severe personal Injury or death.
WARNING This symbol refers to a hazard or unsafe
practicewhlchcanresult in severepersonalInjury or
death.
CAUTION) This symbol refers to a hazard or unsafe
practlce whlch can resultInpersonal Injury or productor
property damage.
Fuels, electrical equipment, batteries, exhaust gases and
movingpartspresentpotentialhazardsthatcanresultinsevere
personal injury.Takecare infollowing these recommended
procedures.
All local, state and federal codes should be
consultedand compliedwith.
WARNING Thlsengineis not designed or Intended for
use Inany typeofaircraft. Use of this engine Inaircraftcan
resultIn engine failureandcause severe personalinjuryor
death.
GENERAL
Provideappropriatefire extinguishersand installthem in
convenientlocations. Use an extinguisher ratedABC by
NFPA.
Makesurethatallfastenersonthe enginearesecureand
accurately torqued. Keep guards in position over fans,
drivingbelts, etc.
If itisnecessaryto makeadjustmentswhile the engineis
running,use extremecautionwhencloseto hotexhausts,
movingparts, etc.
Usedengineoilshavebeen identifiedby somestateand
federal agencies ascausing cancer or reproductive
toxicity. Whencheckingor changingengineoil, takecare
not
to ingest,breathethe fumes, orcontactusedoil.
Do not work on this equipment when mentally or
physically fatigued,or after consuming any alcohol or
drugthat makesthe operation of equipmentunsafe.
BATTERIES
Beforestartingwork on the engine, disconnectbatteries
to preventinadvertentstartingof the engine. Disconnect
negative cable first.
DONOTSMOKEwhileservicingbatteries.Leadacidbat-
teriesgive
off ahighlyexplosivehydrogengaswhichcan
be ignitedby flame,electrical arcingor by smoking.
Verifybattery polarity before connecting battery cables.
Connectnegative cable last.
PROTECT AGAINST MOVING PARTS
Do notwear loose clothingin the vicinity of movingparts,
such asPTO shafts,flywheels,blowers,couplings, fans,
belts, etc.
Keepyour handsaway from movingparts.
FUEL SYSTEM
DO NOT fill fuel tanks while engine isrunning.
DONOTsmokeor useanopenflameinthevicinityof the
engine or
fuel tank. Internalcombustionenginefuelsare
highlyflammable.
Fuelline must be ofsteelpiping, adequately secured, and
free from leaks.Pipingatthe engineshouldbe approved
flexibleline.Donotuse copperpipingfor flexiblelines
as
copper will work harden and become brittle enough to
break.
Be sure all fuel supplies have a positiveshutoff valve.
Benzeneand lead, found in somegasoline,havebeen
identifiedbysome stateandfederalagenciesascausing
cancer or reproductivetoxicity. When checking, draining
or adding gasoline, take care not toingest, breathethe
fumes, or contact gasoline.
EXHAUST SYSTEM
Exhaust productsof any internalcombustionengine are
toxic and can causeinjury, or death
if inhaled. When
operatingthe engine in a confined area, make sure the
ventilationsystem is operatingproperly.
DO NOT use exhaustgasesto heata compartment.
Makesurethatyour exhaustsystemisfreeof leaks.Make
sure thatexhaust manifolds are secure and are not
warpedby boltsunevenlytorqued.
EXHAUST GAS IS DEADLY!
Exhaustgasescontaincarbonmonoxide,apoisonousgasthat
can cause unconsciousnessand death. It is anodorlessand
colorlessgas formedduringcombustionof hydrocarbon
fuels.
Symptomsof carbonmonoxidepoisoningare:
Dizziness Vomiting
Headache
0 MuscularTwitching
Weaknessand Sleepiness ThrobbinginTemples
If youexperienceany ofthesesymptoms,get out intofresh air
immediately, shutdown the unit and do not
use it until it has
beeninspected.
The best protection against carbon monoxide inhalation is
proper installation andregular, frequent inspections of the
completeexhaustsystem. Ifyou notice a change
in thesound
or appearance of exhaust system,shut the unitdown immedi-
atelyandhaveitinspectedandrepairedat once byacompetent
mechanic.
KEEP THE UNIT AND SURROUNDING AREA CLEAN
Makesurethatoily ragsare not left onor near the engine.
Remove all unnecessary grease and
oil from the unit.
Accumulatedgrease and oilcan cause overheatingand
subsequentengine damage and presenta potentialfire
hazard.
E-8

Supplement 965-1053
Date:1-95
lnsert with-
Title: El 25V/E140V Service Manual
Number (Date):965-0764(6-94)
PURPOSE
This Supplement transmits the revisions to the Service Manual necessary for covering Spec €engines. Note
that the nameplate on a Spec
E engine will have the statement: “This engine meets 1995-1998 California
emissions regulations for
ULGEengines.”
To satisfy California emissions regulations Spec E engines have internal engine modifications and precision-
manufactured carburetors with tamper-resistant fuel mixture jets.
It should therefore be noted that, other than
installing the optional high-altitude jet (Figure 9-3a), fuel mixture adjustments should not
be attempted. Nor
shouldthecarburetor be overhauled.Instead,amalfunctioningcarburetor(see
EngineTroubleshooting)
should bereplaced.
California users should note that unauthorized modifications or replacement of fuel, exhaust, air intake, or
speed control system components that affectengineemissions are prohibited by California regulations and that
the optional high-altitude main jetisnot intended for use in California. Modification, removal or replacement of
the generator set labelIsalso prohibited.
SERVICE MANUAL 965-0764 REVISIONS
1. Insert this cover sheet behind the front cover of the manual.
2.On Page 1-1 of the manual add the following note at the bottom of the page: “See the Operator’s Manual
for fuel and engine oil recommendations and the Periodic Maintenance Schedule.”
3. On Page 9-1 ofthe manual add “(Does not Apply to Spec E and Later)” to the subheadings “Disassembly”
and “Inspection/Service”.
4. On Page 42 of the manual add “(Does Not Apply to Spec E and Later)” to the subheading “Assembly” and
to the heading “CO Adjustment”.
5. insert the attached page (9-2-1) between Page 9-2 and Page 9-3 of the manual.
Attachment: Page
9-2-1.
Page 1 of 1

SECTION
1
2
3
4
5
6
7
8
9
10
TITLE PAGE
SafetyPrecautionsinsidecover
General Information 1-1
Specifications2-1
DimensionsandClearances 3-1
Assembly Torques 4-1
EngineTroubleshooting5-1
Maintenance
Lubrication
Electrical
Fuel
Starting10-1
Engine
Block Assembly11-1
WARNING
INCORRECTSERVICEORREPLACEMENTOFPARTSCAN
RESULT IN SEVERE PERSONAL INJURY AND/OR EQUIPMENT
DAMAGE.SERVICEPERSONNELMUSTBEQUALIFIED
TO
PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

Section 1 GeneralInformation
INTRODUCTION
Thismanualprovidesspecificmechanicaland
electrical information needed by engine mechanics
fortroubleshooting,servicing,oroverhaulingthe
engine.
Use the separate parts manual for parts identifica-
tionand for establishing their proper location on as-
semblies. The parts manual contains detailed ex-
ploded views of each assembly and the individual
piecepartnumbersandtheirpropernamesfor
ordering replacement parts.
The illustrations and procedures presentedineach
section apply to the engines listed onthecover. The
air cleaner side of the engineisthe front end. Right
and left sides are determined by viewing the engine
from the front.
If a major repair or an overhaulisnecessary, have a
trained and experienced mechanic perform the re-
pair and
see that all dimensions, clearances and
Use the table of contents for a quick reference tothe
separate engine system sections.
The troubleshooting guide is provided as a quick
referenceforlocatingandcorrectingengine
problems.
The wiring diagram shows how the electrical com-
ponents are interconnected.
The
Engine BIock Assembly section contains major
overhaulproceduresforstepbystepremoval,
torquevaluesarewithinthespecifiedtolerances.
disassembly,inspection,repair,andassemblyof
the engine components.
Use only Genuine Onan replacement parts to pro-
videqualityandthebestrepairandoverhaul
results.Whenorderingparts,alwaysusethe
complete model and spec number as well
as the
serial number shownon thenameplate.
TABLE 1-1. ENGINE MODEL IDENTIFICATION
1. Model letter designation.
2. BHP rating. Add a decimal one digitinfrom the
3. Designation (V = vertical shaft, H = horizontal
4. Engine fuel. (Example N
= gasoline, L = LP,
5. Factorycodefordesignatedoptionalequip-
6. Specification (spec letter) which advances with
right end. (Example 140
= 14.0)
shaft).
D
= Dual fuel)
ment,
if any.
factory production modifications.
INCORRECT SERVICE OR REPLACEMENT OF PARTS CANRESULT IN SEVERE PERSONAL IN-
JURYAND OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM
ELECTRICALAND/ORMECHANICALSERVICE.
\

Section 2. Specifications
Thesespecificationsare in customary U.S. units of measure with approximate metric equivalents following in
parentheses.
TABLE
2-1. SPECIFICATIONS
UNIT
OF SERIES
SPECIFICATIONMEASURE El 25V El 4OV
Number of Cylinders1 1
Bore mm 84.2 84.2
(in)(3.31)
(3.31)
(in)(2.76)(2.76)
(in3)
(23-7) (23-7)
Stroke mm 70.070.0
Displacement
Cm3 389389
Compression Ratio 8.5to18.5to
1
Power at kW 9.310.4
Rated
Speed (3600rpm) (BW (12.5)
(1 4.0)
OilCapacityLitres1.7
1 -7
With Fitter(Quarts)(1.75)(1.75)
CylinderCompressionkPa 483 or more
(Psi) (70 or more)
2-1

Section 3.
Dimensions and Clearances
All measurements given at room temperature of 70°F (21 "C). All measurements are giveninmillimeters with
approximate inch measurementsin parentheses. Measurements are for standard size parts. Refer to the
headings for notes
about which specs are covered, if the specis not listed the dimensions coverallspecs.
TABLE 3-1. DIMENSIONS AND CLEARANCES
CYLINDERBLOCK
Cylinder Bore Taper

DESCRIPTION
____- I
CAMSHAFT SPEC A AND B
Lobe- Height, Diameter Over Nose
El25 Intake
El25 Exhaust
E140Intake
El40 Exhaust
End Clearance
OilBase Bearing Clearance
CAMSHAFT BEGIN SPEC C
Lobe Height, Diameter Over Nose
El25 Intake
El25 Exhaust
El40 Intake
El40 Exhaust
End Clearance
Journal Bearing O.D.
Oil Base Bearing Clearance
-_---
34.3134.46 (1.351)(1.357)
34.6234.77 (1.363)(1.369)
35.1835.33 (1.385)(1.391)
35.1835.33 (1.385)(1.391)
0.10
0.20
(0.004)
(0.008)
.0.01
0.05
(0004)(-0020)
34.23
(1-348)
(1-359)
(1-381)
34.53
35.09
35.09
(1.381)
0.10
(0.004)
17.975
(.7077)
0.01
(.OOO4)
34.55
(130)
34.85
(1.372)
35.41
(1.394)
(1.394)
35.41
0.20
(0.008)
17.990
0.05
(.7083)
(.0020)
3-2
ALLOWABLE
LIMIT
33.81
(1.331)
34.12
(1.343)
34.68
(1.365)
34.68
(1-365)
0.25
(0.01
0)
.0.08
(.0031)
33.73
(1-328)
34.03
(1-340)
34.59
(1.362)
34.59
(1.362)
0.25
(0.01
0)
17.93
(. 7059)
0.08
(.0031)

TABLE 3-3. DIMENSIONS AND CLEARANCES
DESCRlPTlON FACTORY SPECIFICATION
MINMAX
PISTON SPEC A AND B
Piston Skirt O.D.
90 deg to Pin, 26.5 from Top of Piston
84.09 84.1 2
(3.31 1) (3.312)
.25
Oversize 84.3484.37
(3.320)(3.322)
50 Oversize 84.5984.62
(3.330)(3.331)
PinBore I.D.
PISTON BEGIN SPEC C
Piston Skirt O.D.
deg to Pin, from Top of Piston 26.5 90
20.000 20.01 0
(0.7874) (0.7878)
84.0984.1
2
(3.31 1 ) (3.312)
.25
Oversize 84.3484.37
(3.320)(3.322)
50 Oversize 84.5984.62
(3.330)(3.331)
PinBore I.D. 20.00420.01 2
(0.7876)(0.7879)
PISTON PIN SPEC A AND B
PistonPin O.D. 20.000 20.005
(0.7874)(0.7876)
Clearance inPiston .005 .010
(.0002)(0.0004)
Clearance inConnecting Rod .010.025
(0.004) (0.001 0)
PISTON PIN BEGIN SPEC C
PistonPin O.D.
20.000 20.005
(0.7874) (0.7876)
Clearance in Piston .....................-.001.012
(.OooO) (0.0005)
Clearance inConnecting Rod .010 .025
ALLOWABLE
LIMIT
20.020
(0.7882)
20.022
(0.7883)
19.990
(0.7870)
0.30
(0.001 2)
(0.001
4)
.035
19.990
(0.7870)
0.03
(0.001 2)
.035
3-3

TABLE 3-4. DIMENSIONS AND CLEARANCES
DESCRIPTION
PISTON RINGS
Top Compression Ring Thickness
Second Compression Ring Thickness
Top Compression Ringto Ring Groove
Clearance
Second Compression Ring to Ring Groove
Clearance
Top Compression Ring End Gap
Second Compression Ring End Gap
Oil Ring Side Rail Gap
INTAKE VALVE
ValveStem O.D.
Valve Guide I.D.
Valve Stemto Guide Clearance
El 25V Valve Lash
El40V Valve Lash
Face Angle
INTAKE VALVE SEAT
SeatWidth
SeatAngle
EXHAUST VALVE
ValveStem O.D.
Valve Guide I.D.
Valve Stemto Guide Clearance
FACTORY SPECIFICATION
1.47
(.058)
1.47
(.058)
0.03
(0.001)
(0.001)
0.03
1.49
(.059)
1.49
(.059)
0.08
(0.003)
0.08
(0.003)
0.25
0.51
(0.010)(0.020)
(0.01
0) (0.020)
(0.01
5) (0.055)
0.25 0.51
0.381.40
6.960
6.975
(0.2740) (0.2746)
7.000 7.015
(0.2756) (0.2762)
0.03
0.06
0.075
0.15
45"
(0.001)(0.002)
(-003)
(-006)
7.940 7.960
(0.31 26) (0.31 34)
8.000 8.015
(0.3150) (0.31 56)
0.04
0.08
(.003)
ALLOWABLE
LIMIT
1.42
t.056)
1.42
(-056)
0.13
(0.005)
0.13
(0.005)
1.oo
(0.039)
1.oo
(0.039)
1.80
(0.071)
(0.004)
0.25
0.25
(0.01 0)
(0.01 0)
1.7
(.067)

TABLE 3-5. DIMENSIONS AND CLEARANCES
DESCRIPTION
EXHAUST VALVE
(cont)
E125V Valve Lash
E140V Valve Lash
Face
Angle
EXHAUST VALVE SEAT
SeatWidth
SeatAngle
VALVE SPRINGS INTAKE AND EXHAUST
SPEC
A AND B
Valve Spring Free Length (Approx.)
Valve Spring Length
Valve
Closed
ValveOpen
Spring Load (Valve
Closed Length)
SpringLoad(ValveOpenLength)
VALVE SPRINGS INTAKE AND EXHAUST
BEGIN SPECC
Valve Spring Free LengthApprox
Valve Spring Length
Valve
Closed
ValveOpen
Spring Load (Valve Closed Length)
SpringLoad(ValveOpenLength)
0.075
0.15
(-006)
45"
(-003)
43.5
(1.71)
32.6
(1.28)
23.2
(0.91
)
5.67 kg 6.62 kg
(1 2.5
Ib) (1 4.6 Ib)
11 -52kg 13.43 kg
(25.4
Ib) (29.6 Ib)
43.5
(1.71)
32.6
(1.28)
23.2
(0.91)
12.6 kg 14.6 kg
(27.7
Ib)
(32.1 Ib)
26.4 kg 28.4 kg
(58.2
Ib)
(62.7 Ib)
0.25
0.25
(0.01
0)
(0.01 0)
1.7
(0.067)
10.21 kg
(22.5
Ib)
24.9 kg
(55 Ib)
3-5

-"--
DESCRIPTION
ROCKER ARM
Rocker Arm Inside Diameter
Rocker Arm Shaft O.D.
Rocker Armto Shaft Clearance
-__.__I-
LUBRICATING SYSTEM
Engine Oil Pressure
At Idling
At 3300 rpm
RotorLobeClearance
Outer Rotor to Pump
Body Clearance
Rotor and Cover Clearance
IGNITION SYSTEM
Spark Plug Gap
Ignition Timing (BTDC) Not Adjustable
Ignition Unit Core to Rotor Magnet
Clearance(AirGap)
ELECTRICAL SYSTEM
Commutator O.D.
Difference of Commutator O.D.'s
_--
Armature's Shaft to Bushing Clearance
MicaUndercut
BALANCE SHAFT
End Clearance (BothShafts).
AND CLEARANCES
FACTORY SPECIFICATION
MINMAX
-_I___-__
12.000 12.018
(0.4724) (0.471 8)
11.973 11.984
(0.4714 (0.471 8)
0.016
0.045
(0.0006) (0.0018)
-I_----*
3.0 psi or more
14.0 psi or more
0.15 or
less
( 0.006 or less)
0.120.19
(0.005) (0.007)
0.02
0.09
(0.001)(0.004)
0.890.891.02 (0.035)
(0.035) (0.040)
23"
0.50
(0.020)
28.0)
Less than' 0.05
(Less than 0.002)
0.020.07 (0.001)(0.003)
(1.102)
0.45
0.75
(0.01 8) (0.030)
0.10
0.20
(0.004)(0.008)
3-6
ALLOWABLE
0.15
(0.0059)
4.0 psi
0.20
(0.008)
0.25
(0.010)
27.00
(1.063)
0.016
(0.41)
0.20
(.008)
0.20
(0.008)
0.25
(0.01 0)

Section 4. Assembly Torques
Thetorquevalueslisted in Table 4-1 havebeenTighten allstuds, nuts andcapscrewsasspecified
determinedforspecificapplications.Theengine tokeepthemfromworkingloose.RefertotheParts
assemblytorquesgivenhere
will provideproperManualforthelocationofwashersandcapscrews.
tightness without danger of stripping threads.
All
threadsmustbeclean, rust free andlightly
lubricated.
TABLE 4-1. ASSEMBLY TORQUES
DESCRIPTION
Conn Rod Bolts
Oil
Base Bolts
Oil Pump Cover Screws
OilPump Screen Cover
Oil Drain Plugs
Oil Base Pressure
Line Plugs
LOPCO or Pipe Plug
Adapter Filter Head
Oil Filter
OilIndicator Cap
Cy1 Head
Bolts
NO. 1-5 Bolts
No.
6 Flange Bolt
Valve Lash Adj Nut
Valve Cover Bolts
Spark Plug
Air Deflector Bolts
Pulse Pumpto Deflector
Pulse Pump Spud
Int Elbow to Cy1
Hd Screws
Air Cleaner Pan to
Air
Deflector
Carb.toInt Elbow
Knob-Inner Air CLnr
Knob-Outer Air Clnr
Cy1 Air Hsg
Bolt
Exhaust Elbow Bolts
Muffler Bolts
Starter Bolts
Alternator Stator Screws
Stator Wire Clamp
Screw
Flywheel Nut
Ignition Coil
Bolt
Blower Hsg Bolts
Voltage
Reg Screws
Chaff Screen Bolt
Stationary Guard Bolt
Recoil Starter Cup Screw
Recoil Starter Bolts
Control Plate
Stud
Control Plate Pivot Bolt
Nut-Control Plate Stud
Governor
Arm Nut
Throttle Cable Clamp Screw
Nuts
M8x44 24-27
M8x
50 16-22
M6x 14
M6x 14
3/8” NPT
114"NPT7-11
1/8”NPT
3/416" 24-30
1.5-2
7-11
7-11
7-11
7-11
M1042-50 M8x50 16-22
M77-11 M6x257-11
M8x 11-20
10-24
M8x16
M6x 107-11
#102.3-2.8
18-20OILBASETORQUE 12-16-
58
5-8Torque
'A" twice.
Toque boltsin
clockwise
direction starting with "A" SEQUENCE
118" NPT
M8x
50
114" x .50"
M6x
85
M6x 10
M8
M8x
45
M8X95
M8x
40
M6x 25
M6x14
M18
M6 x 27
M6x20
114"
x .50”
M6x 10
M6x
20
M8x 16
M6x 12
M8
M8
M6
M6
1032"
7-11
11-16
6.7-8.1
10-15
Not
Specified
7-11
11-20
16-22
11-20
16-22
10-15
10-15
122-138
10-15
7-11
6.7-8.1
7-11
1.4-2
24-30
7-11
11-16
11-16
7-11
8.1-10.9
1.4-2
5-8
58
58
18-22 3/41Turnaftergskt
1.1-1.5(13-18LB*IN)contacts
base
Toque in sequence shown.
after
others are done.
Tighten every other bolt until
all bolts are tightened.
Retorque
the first bolt twice.
31-37Two bolts outside valve cover
12-16
(#2 & #4) To be retorqued
5-8
58
7-18
8-15
58
1.7-2.1 (20-25LB-IN
C-1138
5-8
8-12
5-6 (60-72L
7-11
Not
Specified
58
8-15
8-15
12-16
12-16
7-11
90-102
7-11
7-11
5-8
5-6 (60-72
LB_IN
58
1-1.5 (12-18 LB*IN)
18-22
5-8
8-12
5-8
68
a12
1-1.5 (12-18LB-IN
Tighten
twice (1-2-1)
contacts element
1-1/2-2turns after
cover
CYLINDER HEAD
TORQUE SEQUENCE
4-1

5-1

Section 6. Maintenance
PERIODICMAINTENANCESCHEDULE Neglectingroutinemaintenance will result in poor
performance and reduced engine life.
Keep an accurate logbook of maintenance, service,
and operating time: Follow a regular schedule of
inspectionandservice,basedonoperatinghours.
WARNING Incorrectserviceorreplacementof
parts can resultinseverepersonalInjuryand/or
UsethefactoryrecommendedPeriodicMainte- equipmentdamage. Servicepersonnelmust be
nance Schedule(basedon favorableoperating qualified to perform electricaland/ormechani-
conditions)toserveasaguidetogetlongandeffi- calservice.
cient engine life.
Regular service periods are recommended for nor-
WARNINGAccidental starting oftheengine
mal service and operating conditions. If the engine
can result in severe personal Injury or death.
isinan application with extreme temperatures, se-
DIsconnect the negative battery cable and
veredutycycles,etc.,serviceatmorefrequent spark plug wire before servicing the engine,
intervals. controls,or associatedequipment.
TABLE 6-1. PERIODIC MAINTENANCE SCHEDULE
Air Cleaner Element and
1 Check for fuel leaks. With engine running, visually and audibly check exhaust system for leaks.
2- Perform more often when running under severe operating conditions.
3- Required for initial break-in only.
4- Required for initial 100 hours, 200 hour interval thereafter.
X
X2
X

ENGINEINSPECTION AIRCLEANERANDELEMENTWRAPPER
Refer to Air Cleaner, in section 9, for disassembly,
Checkthefuellinesandfittingsforleaks.
Do nottheand assembly procedures.
start engine until leaks are repaired.
OIL CHANGE
WARNING Breathing exhaust gases can result
in severepersonal injury
or death. Inspect the
Refer to OilChange, insection 7, for inspection and
exhaust system audibly and visualiy for leaks
service procedures.
daiiy and repair leaks immediateiy.
OIL FILTER CHANGE
Inspect the exhaust system for cracks and run the Refer to
Oil FilterChange, in 7, for inspection and
engine to check for leaks. Repair problems before service procedures.
allowing the engine to
be used.
COOLING
Examinetheaircleanercomponentsfordamage,Refer to Flywheel, insection 11, forinspectionand
properfit,etc.Repairorreplacecomponentsasserviceprocedures.
necessary.
VALVE CLEARANCE
Check-theoillevelwiththeengine off andtheequip- Refer to valve system, in section for inspection
ment on a level surface. If theoillevelisat or below and service procedures.
the fullmark on the dipstick, addoil of the proper
viscosity
(see Oil Change section) until the level
reaches the
full mark. Do not operate the engine
with the oil level
below the add or above the full Referto Spark Plug, insection 8, for inspection and
SPARK PLUG
mark. service procedures.

Section 7. Lubrication
A pump driven by one of the balancer shafts pro-
videspressurelubricationoftheconnectingrod
journal through drilled passages in the crankcase
and crankshaft. An oil hole inthe crank arm pro-
vides spray lubrication of the piston, cylinder walls,
and other crankcase components. The lubrication
system includes an oil pressure relief valve and full-
flow oil filter (Specs
B and C). Theoilpumpisacces-
sible by removing a coverinthe oil base.
WARNING Improper serviceor replacement of
parts canresultinsevere personalinjuryand/or
equipmentdamage. Servicepersonnel mustbe
qualified toperform electricaland/or mechani-
cal service.
WARNING Accidental starting of the engine
can result in severe personalinjury or death.
Disconnectthenegativebatterycableand
spark plug wires while servicing engine,
controls, or associated equipment.
OIL CHANGE
WARNING Crankcase pressure can blow out
hotoil,whichcan cause severe personalinjury.
Do not checkoil whilethe engineIs running.
WARNING Hot crankcaseoil can causeburns
if
it comesin contactwithskin. Wearprotective
clothingand keepfingers and hands clear when
drainingoil.
WARNING SomeStatesorfederalagencies
have determinedthatused engineoiliscarcino-
genicandcauses reproductive toxicity. Take
carenotto breathe, ingest or comeIntocontact
withused engineoil.
CAUTION Excess oil can causehigh oil con-
sumption,highoperating temperatures, andoil
foaming. Do not overfill crankcase.
Run the engine until it is thoroughly warm before
draining the oil. Stop the engine, place
a pan under
the drain plug and remove the plug (open the drain
cock). Replace the drain plug (close the cock) when
the oil has stopped draining. Refill with oil meeting
the API classification SG, SG/CD, or SG/CE and
having the proper viscosity for the ambient temper-
ature. See Table
7-1. Straight weight oilis recom-
mended for severe duty use and minimum oil con-
sumption at temperatures above
32" F (0" C).
TABLE 7-1. OIL VISCOSITY RECOMMENDATIONS
OIL FILTER CHANGE
WARNING Hot crankcaseoil can causeburns
if itcomesIncontactwithskin. Wearprotective
clothingand keepfingersand hands clear when
drainingoil.
CAUTION Excess oil can causehigh oil con-
sumption,highoperating temperatures, andoil
foaming. Do not overfill crankcase.
Spin the oil filter element off and discard it. Clean
the filter mounting surface and make sure a gasket
is insertedinthe new element. Apply a thin film of
new oil to the gasket. Spin the element down by
hand until the gasket just touches the mounting sur-
face. Then add another
1/2-3/4 turn. Do not over-
tighten. Fill with oil to the
FULL mark and start and
run the engine untilit iswarm. Check for oil leaks.
Check oil level.
7-1