Generadores
Generadores
Generadores
0E2081
SERVICE
MANUAL
GTV – 990/760
V-TWIN
OHVI ENGINE
P. O. B ox 2 9 7 • W h i t ewa t e r, W I • 5 3 1 9 0
Phone: (262) 473-5514 Fax: (262) 472-6505
SECTION 2: IGNITION
SECTION 3: CARBURETION
SECTION 7: ALTERNATORS
SECTION 12: PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY
ATTENTION!
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.
1
RULES FOR SAFE OPERATION
If you do not understand any portion of this manual, con- RULES FOR SAFE OPERATION
tact Generac or your nearest Generac Authorized Service Study these RULES FOR SAFE OPERATION carefully before
Dealer for starting, operating and servicing procedures. operating or servicing this equipment. Become familiar with
Throughout this publication and on tags and decals affixed the OWNER’S MANUAL and with the engine. The engine can
to the engine, DANGER, WARNING and CAUTION blocks operate safely, efficiently and reliably only if it is properly oper-
are used to alert you to special instruction about a particu- ated and maintained. Many accidents are caused by failing
lar operation that may be hazardous if performed incorrectly to follow simple and fundamental rules or precautions.
or carelessly. Observe them carefully. Generac cannot possibly anticipate every possible circum-
These safety warnings cannot eliminate the hazards that stance that might involve a hazard. The warnings in this
they indicate. Strict compliance with the special instructions manual and on tags and decals affixed to the equipment, are
while performing the service plus “common sense” are major therefore, not all-inclusive. If you use a procedure, work
measures to prevent accidents. method or operating technique Generac does not specifically
recommend, you must satisfy yourself that it is safe for you
The following definitions apply to DANGER, WARNING, and others. You must also make sure the procedure, work
CAUTION and NOTE blocks found throughout the manual. method or operating technique that you choose does not
These safety symbols indicate the following: render the engine to be unsafe.
DANGER: After this heading you can read han- DANGER: Do not tamper with the engine gov-
dling, installing, operating or servicing instructions erned speed. High operating speeds are dangerous
that, if not strictly complied with, will result in and increase the risk of personal injury or damage
personal injury. to the equipment. Operating at low speeds with
heavy load may shorten the engine’s life.
WARNING: After this heading you can read han-
dling, installing, operating or servicing instructions BEFORE OPERATING
that, if not strictly complied with, may result in per- • Gasoline is highly FLAMMABLE and its vapors are EXPLO-
sonal injury. SIVE. Do not permit smoking, open flames, sparks or heat
in the area while handling gasoline. Avoid spilling gasoline
CAUTION: After this heading you can read instruc- on a hot engine. Comply with all of the laws regulating
tions for handling, installing, operating or servicing storage and handling of gasoline.
the engine that, if not strictly complied with, may • Store gasoline and other fuels only in containers designed
result in damage to equipment and/or property. and approved for the storage of such materials.
NOTE: After this heading you can read explanatory • Add gasoline in a clean, well-ventilated area. Wipe up any
statements that require special emphasis. spilled gasoline immediately. If gasoline has been spilled,
These symbols indicate the following: let it dry completely before starting the engine.
Points out important safety information that, if not • Do not overfill the fuel tank. Always allow room for fuel
followed, could endanger personal safety and/or expansion. If the tank is overfilled, the fuel can overflow
onto a hot engine and cause a FIRE or an EXPLOSION.
property of yourself and others.
• Allow at least two (2) feet of clearance on all sides of the
Ꮨ
• Check the oil level in the engine before each use.
Potential electrical shock hazard.
2
RULES FOR SAFE OPERATION
WHILE OPERATING
SERVICE INFORMATION
• This engine was designed and manufactured for specific Service on this engine within and after the warranty
applications. Do not attempt to modify the equipment or use period can be performed by any authorized service
it for any application for which it was not designed.
dealer. Service technicians are factory trained and
• Generac Power Systems does not approve or authorize the capable of handling all service needs.
use of these engines on All Terrain Vehicles (ATV’s), go-carts,
motorbikes, aircraft products, personal watercraft, or vehi- When contacting an authorized service dealer about
cles intended for use in competitive events. Use of these parts and service, always supply the complete
engines in such applications could result in property damage,
model number and serial number of your unit as
serious injury (including paralysis), or even death.
given on its data plate decal. See the illustration
• Engine exhaust gases contain DEADLY carbon monoxide below for the location of the decal.
gas. This dangerous gas, if breathed in sufficient concen-
trations, can cause unconsciousness or even death. Operate
The warranty for this engine is included in the
this equipment only in the open air where adequate venti-
owner’s manual.
lation 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 cool-
ing air into and out of the equipment might be obstructed.
Without sufficient cooling air flow, the engine quickly over-
heats, 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.
3
DIMENSIONS AND FEATURES
4
DIMENSIONS AND FEATURES
5
DIMENSIONS AND FEATURES
6
DIMENSIONS AND FEATURES
7
4-CYCLE ENGINE THEORY
If the engine is to run properly, four (4) events must occur in C IGNITION AND POWER
the proper sequence and at the correct time. These events are By the time the piston reaches TDC , combustion is already
(a) intake, (b) compression, (c) ignition and power, and (d) in progress. The intake and exhaust valves remain closed as the
exhaust. expanding gases of combustion force the piston downward.
A INTAKE
The piston is travelling from top dead center (TDC) to bottom
dead center (BDC). The cam has opened the intake valve. The
piston's downward movement in the cylinder creates a partial
vacuum in the cylinder. Air at atmospheric pressure is drawn
into the cylinder through the carburetor and is mixed with fuel
in the carburetor. The fuel-air mixture flows through the open
intake valve into the cylinder. When the piston reaches BDC,
the intake stroke is over.
D EXHAUST
The exhaust stroke begins when the piston has reached BDC
and has started its upward movement. The intake valve is
closed. The exhaust valve is open to let gases escape.
B COMPRESSION
As the piston reaches bottom dead center (BDC), both the
intake and exhaust valves are closed. The piston moves upward
toward TDC and the fuel-air mixture is compressed. Just before
the piston reaches TDC, ignition occurs.
8
SECTION 1: GENERAL INFORMATION
SECTION CONTENTS NOTE 1: Change oil and filter after first 8 hours of operation and then
PAGE every 100 hours thereafter. Change sooner when operating under a heavy
MAINTENANCE SCHEDULE ........................................... 1-1 load or in a dusty or dirty environment or in high ambient temperature.
FUEL AND OIL RECOMMENDATIONS.............................. 1-1 NOTE 2: Clean more often when operating in dirty or dusty conditions.
Gasoline .................................................................. 1-1 Replace canister style filter every 500 hours.
Lubrication ................................................................ 1-1 NOTE 3: Perform this task ONLY after first 50 hours of operation. Head
Recommended Oil Type.............................................. 1-1 bolts will NOT need further retorquing.
Change Oil ................................................................ 1-2 NOTE 4: Check valve lash and adjust if necessary after first 50 hours of
operation and every 100 hours thereafter.
Change Oil Filter ........................................................ 1-2
Cleaning Intake Screen .............................................. 1-2 FUEL AND OIL RECOMMENDATIONS
Replace Spark Plugs .................................................. 1-3
GASOLINE:
Air Cleaner Maintenance .......................................... 1-3
We recommend the use of clean, fresh lead-free gasoline. A min-
Service Dual Element Air Cleaners .............................. 1-3
imum of 85 octane is recommended. The use of lead-free gasoline
Service Canister Air Cleaners...................................... 1-3
results in fewer combustion deposits and longer valve life.
TROUBLESHOOTING ..................................................... 1-3
Systematic Check ...................................................... 1-4 NOTE: Using a fuel additive such as STA-BIL® fuel stabi-
Check Ignition .......................................................... 1-4 lizer, or an equivalent, will prevent gum deposits from
forming in the engine’s fuel system.
Check Ignition (Engine Running) ................................ 1-4
Check Ignition (Fouled Plug or Other Causes) ............ 1-4 NOTE: Some fuels, called oxygenated or reformulated
Cylinder Balance Test ................................................ 1-4 gasolines, are gasolines blended with alcohols or ethers.
Excessive amounts of these blends can damage the fuel
Check Fuel ................................................................ 1-5
system or cause performance problems. Do not use gaso-
Check Compression ....................................................1-5 line which contains Methanol. If any undesirable
Cylinder Leakdown Test ............................................ 1-5 operating symptoms occur, use gasoline with a lower per-
Things Which Affect Both Cylinders .......................... 1-5 centage of alcohol or ether.
Things Which Affect One Cylinder ............................ 1-5 It is also recommended that gasoline be purchased in small
EQUIPMENT AFFECTING ENGINE OPERATION ................ 1-6 quantities, not more than a 30 day supply. FRESH gasoline min-
Hard Starting or Will Not Start .................................. 1-6 imizes gum deposits, and also will ensure fuel volatility tailored
Engine Won’t Stop .................................................... 1-6 for the season in which the engine will be operated.
Vibration.................................................................... 1-6
LUBRICATION:
Power Loss ................................................................ 1-6
Noise ........................................................................ 1-6 Oil has four purposes. It cools, cleans, seals and lubricates.
During normal operation, small particles of metal from the cylin-
MAINTENANCE SCHEDULE der walls, pistons, bearings and combustion deposits will
Every Every Every Every gradually contaminate the oil. Dust particles from the air also
8 Hours 25 Hours 50 Hours 100 Hours contaminate the oil forming an abrasive mixture which can
or Daily Season Season Season
cause wear to all of the internal moving parts of the engine,
Check Oil Level • if the oil is not changed regularly. Fresh oil also assists in cool-
Change Oil Note 1 ing. Old oil gradually becomes thick and loses its cooling ability
Change Oil Filter Note 1 as well as its lubricating qualities.
Foam Filter RECOMMENDED OIL TYPE:
Service Air Filter Pre-Filter (Note 2)
if equipped Using the proper type and weight of oil in the crankcase is
Replace or Clean • extremely important. Check the oil before each use and change
Spark Plug the oil regularly (see Figures 1-1, 1-2 & 1-3). Failure to use the
Clean Spark • correct oil, or using dirty oil, can cause premature engine wear
Arrestor Screen and failure.
Adjust Valve Note 4 Use only high quality detergent oil rated with API service clas-
Clearance sification SF, SG or SH. The recommended oil weights include
Retorque Head Bolts Note 3 the following:
1-1
SECTION 1: GENERAL INFORMATION
• During summer months: SAE 30. An acceptable substitute CHANGE OIL FILTER:
is SAE 10W-30. After first oil change, synthetic oil is
Replace oil filter every 100 hours. Before installing new filter,
acceptable.
lightly oil filter gasket with fresh clean engine oil. Screw filter
• During winter months: SAE 5W-30, Synthetic 5W-20 or 5W- on by hand until gasket contacts filter adapter. Tighten 3/4 to
30. DO NOT USE SAE 10W-40. one full turn farther, Figure 1-3.
Start and run engine at idle for 30 seconds and stop engine.
Recheck oil level and add if required. Restart engine and check
10W-30, SAE 30 for oil leaks.
F -20 0 20 40 60 80 100
C -30 -20 -10 10 20 30 40
Temperature Range of Expected Use
CHANGE OIL:
The crankcase oil capacity is about 2030 ml (2.1 qt.) with the
oil filter. Without the filter, the oil capacity is 1750 ml (1.8 qt.).
Use no special additives. Make sure that the unit is level when DRAIN
filling with oil. DO NOT OVERFILL.
IMPORTANT: DO NOT OVERFILL. Check and maintain oil
level regularly. Change oil and filter after first eight (8)
hours of operation. Figure 1-2. Oil Drain
FILL / CHECK
Figure 1-3. Oil Filter
1-2
SECTION 1: GENERAL INFORMATION
tions are not carefully followed, dirt and dust which should be
INTAKE collected in the cleaner, will be drawn into the engine. These
SCREEN particles are highly abrasive and will cause the piston rings and
cylinder bore to wear quickly. As the rings and cylinder bore
become worn, these abrasive particles enter the crankcase
OIL
and contaminate the oil, forming an abrasive mixture which
COOLER
FINS will cause wear on all of the internal moving parts.
The air cleaner on every engine brought in for a check up
or repair should be examined and serviced. If the air cleaner
shows signs of neglect, show it to the customer before clean-
ing. Instruct the customer on proper care, to assure long
engine life.
Note: Replace air cleaner gaskets and mounting gaskets
that are worn or damaged, to prevent dirt and dust from
Figure 1-4. Clean Intake Screen & Oil Cooler Fins entering engine due to improper sealing. Replace bent
air cleaner mounting bracket if necessary.
REPLACE SPARK PLUGS:
SERVICE DUAL ELEMENT AIR CLEANERS:
Replace spark plugs every 100 hours of operation or every
Remove and service foam pre-cleaner every 25 hours or every
season, whichever occurs first. Replace spark plugs if elec-
season, whichever occurs first. Service cartridge every 50 hours
trodes are burned away, or the porcelain is cracked. Set spark
or every season, whichever occurs first.
plug gap at .76 mm (.030") for all models. Torque spark plugs
to 20.0 Nm (180 in. lbs.). SERVICE CANISTER AIR CLEANERS:
Clean the air filter element(s) with compressed air every 50
hours or every season, whichever occurs first. Replace the air
filter element(s) every 500 hours or if damaged.
Note: The air cleaner assemblies on some equipment
may have been supplied by the equipment manufac-
turer. See the equipment manufacturer’s owner’s manual
for service information specific to that product.
TROUBLESHOOTING
Most complaints concerning engine operation can be clas-
sified as one or a combination of the following:
1. Will not start
2. Hard starting
Figure 1-5. Setting Spark Plug Gap 3. Lack of power
GENERAC C h a m p i o n 4. Runs rough
Spark Plug Type Part No. Part No.
5. Vibration
Resistor Plug 072347 RC12YC
6. Overheating
AIR CLEANER MAINTENANCE:
7. High oil consumption
WARNING: NEVER OPERATE ENGINE WITH AIR
Note: What appears to be an engine malfunction may be
CLEANER ASSEMBLY OR AIR CLEANER CARTRIDGE
a fault of the powered equipment rather than the engine.
REMOVED. FIRE MAY RESULT.
If equipment is suspect, see equipment affecting engine
A properly serviced air cleaner protects internal parts of the operation.
engine from dirt and dust particles in the air. If air cleaner instruc-
1-3
SECTION 1: GENERAL INFORMATION
CHECK IGNITION:
If spark does not occur look for:
• Shorted ignition/kill wire
• Two closed diodes in ground wire harness
• Incorrect armature air gap
• Armature failure
1-4
SECTION 1: GENERAL INFORMATION
If the RPM loss is greater than 75 RPM this indicates that the EXAMPLE:
grounded cylinder with the least RPM loss is the weakest of Cyl. #1 Cyl. #2 Diff.
the two cylinders. Look to that cylinder for a problem. Eng. #1 165 PSI 160 PSI 5 PSI
Eng. #2 175 PSI 155 PSI 20 PSI
Example:
If compression is poor, look for:
Engine RPM - Both Cylinders = 3400 RPM
• Insufficient valve clearance
Engine RPM - #1 Cylinder Grounded = 3300 RPM
• Loose cylinder head bolts
Engine RPM - #2 Cylinder Grounded = 3100 RPM • Blown head gasket
Conclusion: #1 cylinder is weakest of the two cylinders. • Burned valves, valve seats and/or loose valve seats
• Warped cylinder head
• Warped valve stems
• Worn bore and/or rings
• Broken connecting rods
1-5
SECTION 1: GENERAL INFORMATION
VIBRATION:
1. Unit load out of balance - remove and balance.
2. Mounting bolts loose - tighten.
POWER LOSS:
1. Bind or drag in unit- if possible, disengage engine and oper-
ate unit manually to feel for any binding action.
2. Unit load has excess drag.
NOISE:
1. Engine coupling or pulley - an oversize or worn coupling
can result in knocking, usually under acceleration. Check
for fit or tightness.
2. Equipment needs lubrication.
1-6
SECTION 2: IGNITION
SPECIFICATIONS FOR
GTV-990/760 OHVI V-TWIN ENGINE
MODEL SERIES................................................ GTV-990/760
ARMATURE AIR GAP .............................. 0.20 TO 0.30 MM Figure 2-1. Removing Armature
(0.008" TO 0.012")
FLYWHEEL NUT TORQUE INSTALL ARMATURES:
FT. LBS. ........................................................................ 150
FLYWHEEL NUT TORQUE 1. Turn flywheel so magnet is away from armature.
NM .............................................................................. 203 2. Install ground wire onto tab terminal on armature.
See Section 1 For Spark Plug Maintenance And Specifications
Note: Make sure wires are routed over armature mount-
ing posts and away from flywheel.
GENERAL INFORMATION
Generac GTV-990/760 OHVI V-Twin engines use a magneto
ignition: an ignition armature with a self-contained transistor
module (no moving parts). Two magneto ignition armatures
are used, with a flywheel containing a permanent magnet.
NOTE: The magneto ignition system requires a minimum
of 250 RPM to produce a consistent spark.
ARMATURES
ARMATURE TESTING:
The condition of the ignition armatures can be accurately diag-
nosed using an ignition tester, (Generac P/N 0C5969) as
described in "Troubleshooting" in Section 1.
REMOVING ARMATURES:
1. Remove spark plug leads. Figure 2-2. Installing Armature
2. Remove intake manifold and cover intake ports. 3. Assemble armature to engine, Figure 2-2.
3. Remove rotating screen and blower housing. a. Mounting holes in armature are slotted. Push armature
away from flywheel as far as possible and tighten one screw
to hold armature in place.
2-1
SECTION 2: IGNITION
FLYWHEEL
REMOVE FLYWHEEL:
1. Remove flywheel nut and washer, Figure 2-4.
2. Remove fan retainer and fan.
4. Reinstall flywheel nut. Turn nut down flush with top of Figure 2-5. Removing Flywheel
threads.
INSPECT FLYWHEEL KEY, KEYWAYS, FLYWHEEL AND
5. Install flywheel puller. CRANKSHAFT:
6. Tighten puller screws equally until flywheel loosens, Check flywheel key for damage. Check flywheel for cracks
Figure 2-5. or keyway damage. Also check crankshaft keyways and taper
for damage, Figure 2-6. Replace crankshaft, if damaged.
2-2
SECTION 2: IGNITION
3. Install washer and flywheel nut. See “Typical 12 Volt Wiring Diagram”, Page 6-3.
a. Torque flywheel nut to 204.0 Nm (150 ft. Ibs.), Figure 2-7. TESTING GROUND WIRES:
4. Assemble fan and retainer to flywheel, Figure 2-8. Use a Digital Multimeter (Figure 2-9) to test the ground
a. Torque screws to 21.7 Nm (192 in. Ibs.). wires.
The following test will be made with the meter in the Diode Test
position.
In the Diode Test position, the meter will display the forward
voltage drop across the diode(s). If the voltage drop is less than
0.7 volts, the meter will "Beep" once as well as display the volt-
age drop. A continuous tone indicates continuity (shorted diode)
An incomplete circuit (open diode) will be displayed as "OL."
2-3
SECTION 2: IGNITION
2-4
SECTION 3: CARBURETION
SECTION CONTENTS
PAGE
CARBURETOR TYPES ..................................................... 3-1
CARBURETOR REMOVAL................................................ 3-1
CLEANING CARBURETOR .............................................. 3-1
CARBURETOR INSTALLATION ........................................ 3-2
STATIC GOVERNOR ADJUSTMENT.................................. 3-2
FUEL PUMP .................................................................... 3-3
CARBURETOR TYPES
There are four types of carburetors used on Generac OHVI
V-twin engines:
1. Keihin two-barrel, side-draft on Models EVT-04198-0, EVT-
04629-0, EVT-04629-1, EVT-04630-0, EVT-04741-0,
EVT-04772-0, EVT-04797-0, 04807-0, 04861-0, 0D3358,
0E0038. Figure 3-1.
2. Deni two-barrel, side draft on Models EVT-04174-0, 04198-
1, 04629-2, 04806-0, 0E3342.
3. Nikki two-barrel, side-draft on Models EVT-04712-0, EVT-
04717-0, 04717-1, EVT-04739-0, 04857-0, 04858-0,
04862-0, 0D7675, 0D9033.
4. Nikki single-barrel, side-draft on Model 0D9708.
3-1
SECTION 3: CARBURETION
IDLE
CLINCHING
SCREW
PLENUM
CARBURETOR WOT
PLENUM GASKET
GASKET
Figure 3-3.
10. Reinstall choke link in carburetor and clip the link into the
bellcrank.
Figure 3.5.
11. Perform a static governor adjustment.
12. Start engine and allow to warm up for 5 minutes. STATIC GOVERNOR ADJUSTMENT
1. Loosen the clinching screw on the governor lever.
13. Move speed control lever to slow speed position and hold
throttle lever against idle stop screw. 2. Hold governor lever in WOT position and rotate the gov-
ernor arm clockwise.
14. Adjust stop screw to maintain ~1200 RPM idle.
3. While holding this position, re-torque the clinching screw
15. Slowly move speed control lever to high speed position.
to 11.3 Nm (100 in-lbs.).
Do not exceed 4000 RPM.
4. Check to make sure that the throttle travels from WOT to
IDLE. If it doesn't, the governor needs to be reset again.
3-2
SECTION 3: CARBURETION
FUEL PUMP
The fuel pump supplied with the engines is a pulse pump.
It uses crankcase vacuum pulses drawn from the valve cover
of cylinder #2 to pump the fuel. It is capable of priming at
12" (30.5 cm) max lift. The pump has a max outlet pressure
of 1.5 psi.
If a fuel pump other than the one described above is used,
the fuel line pressure at the carburetor inlet must not exceed
3 psi. Pressures in excess of 3 psi may cause an over rich car-
buretor mixture that would lead to engine damage.
TO
CARBURETOR
INLET
FUEL FROM
TANK
PULSE LINE
3-3
NOTES
3-4
SECTION 4: GOVERNOR CONTROLS AND GOVERNOR
SECTION CONTENTS 1. Force gear assembly and governor spool off of governor
PAGE shaft.
MECHANICAL GOVERNOR ........................................... 4-1
2. Remove any remaining plastic from the notch in the gov-
GOVERNOR .................................................................. 4-1
GOVERNOR ARM .......................................................... 4-1 ernor shaft.
STATIC GOVERNOR ADJUSTMENT ................................ 4-2 3. Check that all the governor bearing parts (top plate, bear-
DYNAMIC GOVERNOR ADJUSTMENT .......................... 4-2 ing, and bottom plate) are on the shaft, and that it moves
smoothly.
MECHANICAL GOVERNOR
4. Slide the new gear assembly and spool onto the governor
DISASSEMBLE:
shaft. Slide until the gear hooks into the notch in the gov-
1. Drain the oil from the engine. ernor shaft.
2. Remove any rust, nicks, or burrs from the crankshaft.
GOVERNOR ARM
3. Remove the 4 oil cooler screws. If the governor arm does not move freely, or if the arm feels
4. Disconnect the wiring from the oil pressure switch. loose in the bushings, it may need replacing. If wear is noticed,
change the governor arm, governor gear assembly (gear and
5. Remove the governor lever from the shaft. flyweights), spool, and bushings as needed. Lubricate all
6. Separate the ball joint on the swinging arm. moving parts when reassembling.
7. Remove all of the crankcase bolts and slide the crankcase
cover off.
Note: Watch the swinging arm bracket so that it doesn't
hook on the sheet metal.
8. Discard the crankcase gasket & oil passage seal.
GOVERNOR
Both the spool and the flyweights must move freely for the
governor to work properly. Check for wear on the spool and
flyweights. If wear is noticed, change the governor gear
assembly (gear and flyweights), spool, and governor arm.
Lubricate all moving parts when reassembling.
4-1
SECTION 4: GOVERNOR CONTROLS AND GOVERNOR
8. Slide the arm in until the thrust washer is tight. 6. Reconnect the ball joint on the swing arm.
9. Slide the lower bushing down and into it’s holder, then install 7. Place the governor lever on the governor arm, with the
the upper e-clip. spring in the 4th hole out.
1. Clean any old gasket material from the crankcase and 9. Reconnect the ground wire to the oil pressure switch.
cover mating surfaces. 10. Reattach the oil cooler to the blower housing.
2. Be sure that the new oil passage o-ring is in place.
STATIC GOVERNOR ADJUSTMENT
3. Put a new gasket on the crankcase. 1. Loosen the clinching screw on the governor lever.
4. Slide the crankcase cover back on the crankcase. 2. Rotate the governor arm clockwise and hold governor
Note: Hold the governor arm in the counter-clockwise lever in WOT position.
position while installing. Also, make sure that the swing- 3. While holding this position, torque the clinching screw to
ing arm bracket goes in place. 11.3 Nm (100 in. lbs.).
5. Start all of the crankcase bolts, and then torque them to 4. Check to make sure that the throttle travels from WOT to
35 ft. lbs., following the proper torque sequence. IDLE. If it doesn't, the governor needs to be reset again.
6 10 8
Figure 4-3.
4-2
SECTION 4: GOVERNOR CONTROLS AND GOVERNOR
IDLE
3. Adjust stop screw to maintain 1200 RPM idle.
4. Slowly move speed control lever to high-speed position.
CLINCHING Do not exceed 4000 RPM.
SCREW
Note: The high-speed screw may need adjusting to reach
WOT
the speed control stop without exceeding 4000 RPM.
5. With the speed control in the high-speed position, adjust
the high-speed screw to obtain the desired engine speed.
4-3
NOTES
SECTION 5: CYLINDER HEAD AND VALVES
SECTION CONTENTS
PAGE
GENERAL INFORMATION ............................................... 5-1
REMOVE CYLINDER HEADS............................................ 5-1
Remove Rocker Arms ................................................ 5-2
DISASSEMBLE CYLINDER HEAD...................................... 5-2
INSPECT AND REPAIR .................................................... 5-3
Reface Valves and Seats ............................................ 5-3
ASSEMBLE CYLINDER HEAD .......................................... 5-4
INSTALL CYLINDER HEAD .............................................. 5-5
ADJUST VALVE CLEARANCE .......................................... 5-5
REASSEMBLE ................................................................ 5-5
STATIC GOVERNOR ADJUSTMENT.................................. 5-6
Figure 5-1.
GENERAL INFORMATION
Compression testing information and procedures is described REMOVE CYLINDER HEADS
in “Troubleshooting” in Section 1. Disconnect exhaust system from exhaust manifold. Remove
Cylinders are numbered as shown in Figure 5-1. exhaust manifold from engine. Disconnect choke and throttle
control cables. Remove spark plugs.
1. Remove the parts depicted in Figure 5-2.
a. Discard gaskets and valve cover seals.
6
3 8
1 FINGER GUARD
2 ROTATING SCREEN 5
3 INTAKE MANIFOLD
ASSEMBLY
2
4 OIL COOLER
5 BLOWER HOUSING 1
4
6 UPPER WRAPPER
7 LOWER WRAPPER
8 VALVE COVER
Figure 5-2.
5-1
SECTION 5: CYLINDER HEAD AND VALVES
BALL STUD
ROCKER ARM
Figure 5-4. Remove Cylinder Head
JAM NUT
Figure 5-3.
5-2
SECTION 5: CYLINDER HEAD AND VALVES
TELESCOPING
GAUGE
5-3
SECTION 5: CYLINDER HEAD AND VALVES
Exhaust Valve
Figure 5-12. Check Valve Springs 5. Compress valve spring and install keepers (Figure 5-15).
Figure 5-13. Install Valve Stem Seals 7. Set guide plate in place and loosely install rocker arm
assemblies (ball stud, rocker arm and jam nut).
2. Install valves (Figure 5-14).
8. Repeat Step 7 for other head.
5-4
SECTION 5: CYLINDER HEAD AND VALVES
A
B
C
REASSEMBLE
1. Install cylinder wrappers.
TORQUE SEQUENCE FOR HEADS: a. Torque M5 screws to 2.8 Nm (25 in. lbs).
b. Torque M6 screws to 4.5 Nm (40 in. lbs).
A-B-C-D-E-F
2. Install spark plugs.
Figure 5-16. a. Torque to 20 Nm (180 in. lbs.).
3. Install exhaust manifold.
ADJUST VALVE CLEARANCE
1. Set No. 1 cylinder at TDC, compression stroke. a. Torque screws to 19 Nm (14 ft. lbs.).
a. Adjust rocker arms and check clearance (Figure 5-17). 4. Install blower housing.
a. Torque screws to 4.5 Nm (40 in. lbs).
5. Install intake manifold with new gaskets.
a. Torque screws to 19 Nm (14 ft. lbs.).
b. Assemble governor link to carburetor.
6
3 8
1 FINGER GUARD
2 ROTATING SCREE 5
3 INTAKE MANIFOLD
ASSEMBLY
Figure 5-17. Adjust Valve Clearances 4
2
4
Valve Clearance (cold) IN and EX 0.0762 mm (.003“).
b. Torque jam nut and ball stud to 19 Nm (14 ft. lbs.). 7
8 VALVE COVER
2. Repeat for No. 2 cylinder.
3. Install valve covers with new gaskets, Figure 5-18.
a. Torque nuts to 6.8 Nm (5 ft. lbs.). Figure 5-19. General Assembly
5-5
SECTION 5: CYLINDER HEAD AND VALVES
IDLE
CLINCHING
SCREW
WOT
Figure 5-20. Static Governor Adjustment
5-6
SECTION 6: ELECTRIC STARTER
6-1
SECTION 6: ELECTRIC STARTER
6-2
SECTION 6: ELECTRIC STARTER
USE A TEMPERATURE
COMPENSATED
HYDROMETER
INSTALLATION:
1. Before installing battery, connect all equipment to be
operated.
2. Place battery in holder with flat base. Tighten holder down
evenly until snug. DO NOT overtighten.
3. Connect positive terminal to positive post FIRST to prevent
sparks caused by accidental grounding. Tighten connec-
tors securely.
4. Connect negative terminal to negative battery terminal. Figure 6-5. Checking 12 Volt Battery Cells
Tighten connectors securely.
TESTING BATTERY:
CHECKING BATTERY:
Set a digital multimeter to read DC Volts.
1. Physical check – clean if necessary.
Attach RED meter test lead to positive(+) battery terminal.
a. Corrosion
Attach BLACK meter test lead to negative (-) battery terminal.
b. Dirt With ignition switch “OFF,” press starter button. If ignition
c. Terminal and clamps (secure – good condition) switch and starter switch are the same switch, disconnect
2. Bring battery to full charge. wires from spark plugs and ground ignition using two Ignition
Testers. Turn switch to “START.” Meter should display 9 volts
WARNING: DO NOT exceed charge rate of 1/10 or more while cranking engine. If less than 9 volts is measured,
ampere for every ampere of battery rating. Consult replace battery.
battery manufacturer for maximum charge recom-
mendations. CAUTION: Do not crank starter motor for more than
15 seconds without allowing starter motor to cool
a. Use a taper charge (automatically reduces charge rate). at least 2 minutes.
b. Fill non-sealed battery cells with distilled water after charg-
ing (for batteries that have been in service). BATTERY RECOMMENDATIONS:
Note: If battery gets “Hot” to the touch or is spitting acid The battery size recommended is 525 CCA@0.
(gassing) excessively, unplug charger periodically.
BATTERY CABLE RECOMMENDATIONS:
3. With battery fully charged, check specific gravity readings
of each cell with a Battery Hydrometer and record read- These cable sizes are based on total length of cable from bat-
ings (Figure 6-5). All readings should be above 1.250 tery positive post to starter, plus ground return to battery
(compensating for temperature). If specific gravity read- negative post.
ings varied 0.50 or if all cells read less than 1.225, replace #4 AWG — 1.8 m (6 ft.) or less
battery.
#2 AWG — 3.7 m (12 ft.) or less
6-3
SECTION 6: ELECTRIC STARTER
Figure 6-6.
ENGINE
E
IR
EW
ANG
OR
TERMINAL 5 IR
E E
IR
ORANGE WIRE WN W TE W
D I
RO H RE
AR B W WI
A CK 422 LO
W
P 973 YE
L
TERMINAL 3 2
OPEN
TERMINAL 1
BROWN WIRE
TERMINAL 4
WHITE WIRE
TERMINAL 2
YELLOW WIRE
6-4
SECTION 6: ELECTRIC STARTER
SUPPLIED BY SP
CUSTOMER
BLACK
TO KILL IGNITION
T
SUPPLIED BY IM
CUSTOMER SUPPLIED BY
RED
CUSTOMER
12V SP
BATTERY
SM
SUPPLY 12V TO
OPTIONAL HIGH TEMP. SWITCH CRANK ENGINE SOLENOID
IM
CONNECT TO IGNITION KILL WIRE TO
KILL IGNITION ON HIGH TEMPERATURE.
CONNECT TO GROUND SIDE OF A LIGHT
OR BUZZER TO GROUND THE CIRCUIT OPTIONAL CHARGING SYSTEM
AND TURN THE LIGHT OR BUZZER ON SUPPLIED BY
WHEN THERE IS HIGH TEMPERATURE. CUSTOMER
SUPPLIED BY CUSTOMER
+ BATTERY
WHITE
CONNECT TO IGNITION KILL WIRE TO KILL WHITE
IGNITION ON LOW OIL PRESSURE. SUPPLIED BY
CONNECT TO GROUND SIDE OF A LIGHT OR STATOR CUSTOMER
BUZZER TO GROUND THE CIRCUIT AND
TURN THE LIGHT OR BUZZER ON WHEN
THERE IS LOW OIL PRESSURE.
KEY:
IM - IGNITION MODULE
VOLTAGE
LOP - SWITCH, LOW OIL PRESSURE REGULATOR
(CLOSES ON LOW PRESSURE)
SM - STARTER MOTOR
SW - SWITCH, START/STOP
SUPPLY 12V TO ALLOW FUEL FLOW
SP - SPARK PLUG
FS - FUEL SHUTOFF SOLENOID
6-5
NOTES
SECTION 7: ALTERNATORS
SECTION CONTENTS 4. Attach RED and BLACK test lead probes to AC output ter-
PAGE minals (white wires), as shown in Figure. 7-1. (Meter test
20 AMP REGULATED ALTERNATOR ............................... 7-1 clip leads may be attached to either AC output terminal.)
Alternator Output Test .............................................. 7-1
5. With the engine running at 3600 RPM output should be
Testing DC Output Charging Wire.............................. 7-1 no less than:
Testing Regulator-Rectifier.......................................... 7-2
26 Volts - 20 Amp System
20 AMP REGULATED ALTERNATOR
6. If no or low output is found. check for bare wires or any
The 20 amp regulated alternator system provides AC current
other obvious defects. If "shorted" leads are not visible,
through two output leads to the regulator-rectifier. The regu-
replace the stator.
lator-rectifier converts the AC current to DC, and regulates the
current to the battery. The charging rate will vary with engine TESTING DC OUTPUT CHARGING WIRE:
RPM and temperature.
A simple test may be performed to test the DC output charg-
The stator, regulator-rectifier and flywheel are NOT inter- ing wire circuit. If a problem exists in the wiring it can be
changeable with any other alternator system. corrected before testing regulator-rectifier.
WHEN CHECKING THE ALTERNATOR COMPONENTS, Leave stator wire harness disconnected from regulator-rec-
MAKE THE TESTS IN THE FOLLOWING SEQUENCE: tifier.
ALTERNATOR OUTPUT TEST: Equipment keyswitch must be in OFF position.
Temporarily, disconnect stator wire harness from regulator- 1. Insert RED test lead into receptacle in meter.
rectifier. 2. Insert BLACK test lead into receptacle in meter.
1. Insert RED test lead into receptacle in meter. 3. Rotate selector to (DC volts) position.
2. Insert BLACK test lead into receptacle in meter. 4. Attach RED test lead probe to DC output wire terminal,
3. Rotate selector to (AC volts) position. Figure 7-2.
5. Attach BLACK test lead probe to negative battery terminal.
CAUTION: ATTACH METER TEST LEADS TO AC
OUTPUT TERMINALS (WHITE WIRES) BEFORE START- 6. Turn equipment keyswitch to ON position. Meter should
ING ENGINE. IF STATOR IS GROUNDED (DEFECTIVE), display battery voltage.
AND METER TEST LEADS CONTACT CENTER DC 7. If meter does not display battery voltage, check for blown
OUTPUT PIN, ARCING MAY OCCUR WHICH MAY fuse or broken or shorted wires.
DAMAGE WIRING.
7-1
SECTION 7: ALTERNATORS
TESTING REGULATOR-RECTIFIER:
1. Using a digital multimeter, test the battery voltage while
the engine is NOT running.
2. With the charging system properly connected, start the
engine.
3. Bring the engine up to normal operating speed and test
the battery voltage again.
4. If the battery voltage while the engine is running is greater
than when the engine is stopped, the charging system is
working.
Note: With the engine running, the battery voltage
should be at least 13 Volts.
BATTERIES
Note: See Section 6 for battery size and cable selection
information.
7-2
SECTION 8: LUBRICATION SYSTEM
SECTION CONTENTS NOTE: If you restart engine after a shutdown and have
PAGE not corrected the low oil pressure, the engine may run
DESCRIPTION ................................................................ 8-1 for about 10 seconds as described above, and then it will
PROTECTION SYSTEMS stop.
Low Oil Pressure Switch ............................................ 8-1
HIGH TEMPERATURE SWITCH (OPTIONAL):
High Temperature Switch .......................................... 8-1
CHECKING THE ENGINE OIL LEVEL ................................ 8-1 This switch’s (not shown) contacts close if the temperature
CHANGING THE ENGINE OIL AND FILTER ...................... 8-2 should exceed approximately 140º C (284º F), initiating an
Recommended Oil Type.............................................. 8-2 engine shutdown. In certain applications, the equipment will
Oil Change Procedure ................................................ 8-2 automatically restart and the LED will reset once the temper-
OIL COOLER .................................................................. 8-3 ature has returned to a safe operating level.
DESCRIPTION
The Generac GTV-990/760 OHVI V-twins use a full pressure
lubrication system with an oil filter. The gerotor type oil pump
draws oil from a screened oil pickup in the sump and pumps
the oil through the oil filter.
The filtered oil flows through an oil galley in the sump and
is distributed to the main bearings, connecting rod bearings
and camshaft bearings. Engine oil pressure will vary with oil
viscosity, ambient air temperature differences, operating tem-
peratures and engine load. Follow the oil recommendation on
page 8-2 of this section.
Oil Pressure - @ 70° F (21 ° C):
OIL
15 - 50 psi (1.0 - 3.5 Bar) PRESSURE
OIL FILTER
SWITCH
A pressure relief valve limits the maximum oil pressure in the
system. Figure 8-1. Engine Protective Devices
8-1
SECTION 8: LUBRICATION SYSTEM
The crankcase oil capacity is about 2030 ml (2.1 qt.) with the
oil filter. Without the filter, the oil capacity is 1750 ml (1.8 qt.).
Use no special additives. Make sure that the unit is level
when filling with oil. DO NOT OVERFILL.
8-2
SECTION 8: LUBRICATION SYSTEM
3. When changing the oil filter, use the following instructions: OIL COOLER:
A) Locate oil filter (Figure 8-4). Some engines are equipped with an oil cooler. The oil cooler
is mounted on the blower housing. Forced air from the flywheel
B) Place a suitable container beneath the oil filter and turn
fan flows through the oil cooler fins dissipating heat from the
the filter counterclockwise to remove the filter.
engine oil.
C) Coat the gasket of a new filter with engine oil. Turn
The oil cooler fins should be cleaned every 100 hours and
the new filter clockwise until the gasket contacts the
checked periodically for debris and cleaned with compressed
filter adapter, then tighten an additional 3/4 turn.
air or a soft bristle brush.
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 2030 ml (2.1 qt.) are required when chang-
ing the oil and oil filter. POUR SLOWLY.
5. When the crankcase is filled to the proper level, install the
oil fill cap. Start engine to fill oil filter, recheck/correct oil
level.
8-3
NOTES
SECTION 9: ENGINE DISASSEMBLY
SECTION CONTENTS
PAGE
ENGINE DISASSEMBLY .................................................. 9-1 D
ENGINE DISASSEMBLY
Drain oil, remove oil filter and remove engine from equip- A
ment. Remove spark plugs. Remove flywheel, disconnect stop
switch wires at armatures and remove armatures (see Section
2). Remove cylinder heads (see Section 5).
1. Remove the following parts (Figure 9-1): B
Figure 9-2.
9-1
SECTION 9: ENGINE DISASSEMBLY
3. Rotate crankshaft and camshaft until timing marks align 5. Repeat for remaining cylinder.
and remove camshaft (Figure 9-3).
6. Remove crankshaft (Figure 9-5).
Note: If necessary, place the engine flywheel side down
to prevent tappets from catching on the camshaft.
a. Remove tappets.
Note: Remove any carbon or ridge at the top of the cylin-
der bores to prevent breaking rings when removing
piston and connecting rod assemblies.
4. Remove No. 2 connecting rod cap and push connecting
rod and piston assembly out of cylinder (Figure 9-4).
a. Reassemble cap to rod to prevent interchanging.
9-2
SECTION 10: CYLINDER & CRANKCASE COVER
SECTION CONTENTS NOTE: If cylinder bores are within specification and show
PAGE no signs of scoring or other damage, new piston rings
CHECK CRANKCASE.................................................... 10-1 may be installed providing the cylinder bores are recon-
Resizing .................................................................. 10-1 ditioned using a rigid hone with finishing stones, to
restore the proper cross hatch angle in the cylinder bores. The
Cylinder Finish ........................................................ 10-1
proper cylinder cross hatch ensures proper lubrication and
Cleaning .................................................................. 10-2 piston ring break in.
BEARINGS.................................................................... 10-2
Refer to "Cylinder Finish (Cross Hatch)” below for correct pro-
Check Mag Bearing ................................................ 10-2
cedure for installing cross hatch.
Remove Mag Bearing .............................................. 10-2
Install Mag Bearing .................................................. 10-3
Check PTO Bearing .................................................. 10-3
Remove/Install PTO Bearing...................................... 10-3
Install PTO Oil Seal .................................................. 10-4
Check Camshaft Bearings ........................................ 10-4
Oil Seals .................................................................. 10-4
CHECK CRANKCASE
Check crankcase for cracks, stripped threads or broken fins.
Check cylinder bores for damage or scoring.
1. Check cylinder head mounting surface for distortion with a
straight edge, Figure 10-1.
If mounting surfaces are distorted more than 0.1 mm (.004"),
Figure 10-2. Check Cylinder Bore
the crankcase must be replaced.
TOP
CENTER
BOTTOM
10-1
SECTION 10: CYLINDER & CRANKCASE COVER
It is recommended that the cylinder bores be reconditioned with hot running water. Repeat washing and rinsing until all traces
to restore the cross hatch when new piston rings are to be of honing grit are gone.
installed in a cylinder that is within specification. Be careful not
Honing grit is highly abrasive and will cause rapid wear to all
to hone oversize or it will be necessary to replace the crankcase.
of the internal components of the engine unless it is completely
Honing is done with a variable speed 1 /2", portable drill and removed.
a honing fixture. See Page 10-5 for dimensions to make a
honing fixture. Use two crankcase cover mounting screws to
fasten the crankcase to the honing fixture, Figure 10-5.
Clamp honing fixture and crankcase securely in a vise at a
convenient work height.
Place hone in middle of cylinder bore. Tighten adjusting
knob with finger until stones fit snugly against cylinder wall.
DO NOT FORCE. Cut a wood block and place inside cylinder
to prevent hone from extending further than 3/4" to 1" (19
mm to 25 mm) below cylinder bore. Place hone drive shaft in
chuck of portable drill and tighten. Be sure that cylinder and
hone are centered and aligned with the drill spindle.
NOTE: To produce the proper cross hatch finish use a drill
speed of approximately 200 RPM and 40-60 Hatch strokes
per minute. Lubricate hone liberally to prevent build up
on finishing stones.
Figure 10-5. Honing Cylinders
NOTE: Automatic transmission fluid is an acceptable
honing oil. Another acceptable honing oil can be made NOTE: When cylinder and crankcase have been thor-
by mixing 4 parts No. 30 weight oil with 1 part kerosene. oughly cleaned, use a clean white rag or napkin and
wipe the cylinder bore. If honing grit is present it will
appear as a gray residue on rag. If any honing grit is evi-
dent, re-wash and rinse entire cylinder and crankcase and
check again. When there is no trace of honing grit on rag,
the cylinder is properly cleaned. Then oil cylinder bore
to prevent rusting.
BEARINGS
CHECK MAG BEARING:
45º Check magneto bearing for damage. Damaged bearings
must be replaced. If not damaged, check for wear using a tele-
scoping gauge and caliper (see Figure 10-6). Measure at several
locations. If the measured diameter is larger than 38.25 mm
(1.506”), the bearing must be replaced.
Figure 10-4. Cylinder Cross The diameter of the crankshaft may also make it necessary
to replace the bearing. See Section 11 for the crankshaft mea-
CLEANING: surement details.
IT IS MOST IMPORTANT THAT THE ENTIRE CYLINDER AND REMOVE MAG BEARING:
CRANKCASE BE THOROUGHLY CLEANED AFTER HONING.
1. Remove seal.
First wash the cylinder and crankcase carefully in a solvent such as
kerosene or commercial solvent. Then thoroughly wash cylinder and 2. Place crankcase flat upon a press and remove bearing using
crankcase using a stiff brush with soap and hot water. Rinse thoroughly a bushing driver (Figure 10-7).
10-2
SECTION 10: CYLINDER & CRANKCASE COVER
2" MIN
44.5mm±0.1mm [1.752"±0.004"]
10-3
SECTION 10: CYLINDER & CRANKCASE COVER
TELESCOPING
GAUGE Figure 10-11. Checking Mag Side Camshaft Bearing
OIL SEALS:
Always install new oil seals whenever engine is disassembled
for major servicing or when repairing bearings. Lubricate seal-
ing edge of oil seal with clean engine oil before assembly.
Always use the correct seal protector to prevent damaging oil
seal.
10-4
SECTION 10: CYLINDER & CRANKCASE COVER
216mm [8.504"]
16.5mm [0.65"]
183.5mm [7.224"]
10.5mm [0.413"]
17mm [0.67"]
254mm [10.0"]
MATERIAL: WOOD
25.4mm [1"] x 216mm [8.5"] x 254mm [10.0"]
10-5
NOTES
SECTION 11: CRANKSHAFT & CAMSHAFT
MAG OIL
JOURNAL GALLERIES
PTO
FLYWHEEL JOURNAL
KEY
EXHAUST PTO
LOBES JOURNAL
11-1
NOTES
SECTION 12: PISTON, RINGS & CONNECTING ROD INSPECTION & ASSEMBLY
SECTION CONTENTS
PAGE
GENERAL INFORMATION.............................................. 12-1
DISASSEMBLE PISTON AND CONNECTING ROD .......... 12-1
CHECKING PISTON AND RINGS.................................... 12-1
CHECKING PISTON PIN AND CONNECTING ROD.......... 12-2
ASSEMBLE PISTON AND CONNECTING ROD ................ 12-2
ASSEMBLE PISTON RINGS TO PISTON .......................... 12-3
GENERAL INFORMATION
It is recommended that new piston rings be installed when-
ever the engine is disassembled for major servicing or overhaul,
providing that cylinder bores are within specification.
Remove any carbon or ridge at the top of the cylinder bore. Figure 12-2. Remove Piston Pin Locks
This will prevent breaking the rings when removing the piston
and connecting rod from the engine. Remove the connecting CHECKING PISTON AND RINGS
rod cap. Push the piston and connecting rod out through the If the cylinder is not going to be replaced and the piston shows
top of the cylinder. no signs of scoring, the piston should be checked. Carefully
remove carbon from ring grooves.
Measure cylinder bores before checking pistons and rings.
See Section 10. If cylinder bores are out of tolerance, it will not 1. Check side clearance of ring grooves using new rings, Figure
be necessary to check pistons and rings since a new crankcase 12-3. If a 0.10mm (.004”) feeler gauge for the compression
and piston assemblies will be used. rings or 0.20mm (.008”) for the oil ring can be inserted, the
ring groove is worn. The piston must be replaced.
If the cylinder bore is more than .075 mm (.003") oversize,
or .035 mm (.0015") out of round, it must be replaced.
12-1
SECTION 12: PISTON, RINGS & CONNECTING ROD INSPECTION & ASSEMBLY
Figure 12-4. Checking Ring End Gap CONNECTING ROD REJECT SIZE
Crankpin Bearing Piston Pin Bearing
39.09mm (1.539") 20.05mm (.7894")
CRANKPIN BEARING
Figure 12-5. Check Piston Pin Bore ASSEMBLE PISTON AND CONNECTING ROD
Lubricate parts with engine oil and assemble #1 piston and
CHECKING PISTON PIN AND CONNECTING ROD connecting rod, Figure 12-8.
1. Check piston pin, Figure 12-6.
1. Notch or casting mark on piston must be on flywheel side.
a. Replace if less than 19.97mm (.7862") or if it is .01mm
2. Number "1" on connecting rod must face PTO side (oppo-
(.0005") out of round.
site notch or casting mark on piston).
2. Check connecting rod bearings.
a. Install piston pin locks with needle nose pliers.
Note: If crankpin bearing is scored or worn the connect-
ing rod must be replaced. Lubricate parts with engine oil and assemble #2 piston and
connecting rod, Figure 12-9.
1. Notch or casting mark on piston must be on flywheel side.
2. Number "2" on connecting rod must face PTO side (oppo-
site notch or casting mark on piston).
a. Install piston pin locks with needle nose pliers.
12-2
SECTION 12: PISTON, RINGS & CONNECTING ROD INSPECTION & ASSEMBLY
NOTCH OR
CASTING MARK
TOWARD
FLYWHEEL SIDE
CYLINDER #2
12-3
NOTES
SECTION 13: ENGINE ASSEMBLY
SECTION CONTENTS
PAGE
INSTALL CRANKSHAFT ................................................ 13-1
INSTALL PISTON AND CONNECTING ROD .................... 13-1
INSTALL CAMSHAFT .................................................... 13-2 RING
INSTALL OIL PUMP ...................................................... 13-2 COMPRESSOR
INSTALL CRANKCASE COVER ...................................... 13-2
INSTALL ALTERNATOR AND IGNITION COILS ................ 13-3
INSTALL BREATHER ...................................................... 13-3
INSTALL FLYWHEEL ...................................................... 13-3
ADJUST IGNITION COIL AIR GAP .................................. 13-4
INSTALL CYLINDER HEADS .......................................... 13-4
INSTALL ROCKER ARMS .............................................. 13-4
ADJUST VALVE CLEARANCE ........................................ 13-5
GENERAL ASSEMBLY.................................................... 13.5
ADJUST GOVERNOR .................................................... 13-6
INSTALL CRANKSHAFT
Lubricate mag bearing and lips of oil seal with engine oil and
install crankshaft. Figure 13-2. Compressing Rings
DEAD-BLOW
HAMMER
13-1
SECTION 13: ENGINE ASSEMBLY
TIMING MARKS
13-2
SECTION 13: ENGINE ASSEMBLY
a. The allen head crankcase bolt will need to be backed off. 2. Install back plate.
4. Torque screws in sequence shown to 47.5 Nm (35 ft. Ibs.), a. Torque screws to 10 Nm (7.4 ft. lbs.).
Figure 13-8.
Important: Route alternator wires through relief in back
5. Check crankshaft end play. If less than 0.05mm (.002”) plate. DO NOT pinch wires.
there may be an assembly problem. 3. Install starter motor.
a. Torque screws to 24.4 Nm (18 ft. lbs.).
4. Assemble ignition coils to engine, Figure 13-10.
a. Mounting holes in coil are slotted. Push coil away from
9 flywheel as far as possible and tighten one screw to hold
coil in place.
5. Repeat for second coil.
Note: The side shown in Figure 13-10 must face up on
both coils or the engine will not function properly.
6. Install ground wire onto tab terminal on ignition coils.
3
Important : Make sure wires are routed over coil mount-
ing posts.
TORQUE SEQUENCE FOR
CRANKCASE COVER:
1-2-3-4-5-6-7-8-9-10 1
6 10 8
Figure 13-8
INSTALL BREATHER
1. Insert breather material.
2. Install breather assembly and gasket.
3. Torque bolts to 6.8 Nm (5 ft. lbs.).
INSTALL FLYWHEEL
Important: Clean flywheel and crankshaft taper remov-
ing all oil, dirt or grease.
1. Insert flywheel key into crankshaft.
2. Assemble flywheel to crankshaft.
3. Install washer and flywheel nut.
Figure 13-9. Install Alternator 4. Torque flywheel nut to 204 Nm (150 ft. Ibs.), Figure 13-11.
13-3
SECTION 13: ENGINE ASSEMBLY
A
B
STUD
ROCKER ARM
NUT
Figure 13-12. Adjust Air Gap
13-4
SECTION 13: ENGINE ASSEMBLY
ADJUST VALVE CLEARANCE 3. Install valve covers with new gaskets, Figure 13-16
1. Set No. 1 cylinder at TDC (Top Dead Center), compression a. Torque bolts to 6.8 Nm (5 ft. lbs.).
stroke.
a. Adjust rocker arms and check clearance, Figure 13-15.
Valve Clearance (cold) IN and EX 0.076mm (.003")
b. Torque ball studs and jam nuts to 19 Nm (14 ft. Ibs.).
2. Repeat for No. 2 cylinder.
GENERAL ASSEMBLY
1. Install cylinder shields (wrappers).
a. Torque M5 screws to 2.8 Nm (25 in. lbs.).
b. Torque M6 screws to 4.5 Nm (40 in. lbs.).
Figure 13-15. Adjust Valve Clearance c. Connect ignition ground wire to ignition kill terminal in
backing plate.
6
3 8
1 FINGER GUARD
2 ROTATING SCREEN 5
3 INTAKE MANIFOLD
ASSEMBLY
2
4 OIL COOLER
5 BLOWER HOUSING 1
4
6 UPPER WRAPPER
7 LOWER WRAPPER
8 VALVE COVER
13-5
SECTION 13: ENGINE ASSEMBLY
ADJUST GOVERNOR
Note: Refer to Section 4, Page 4-2 for Static Governor
Adjustment.
13-6
SECTION 14: SPECIFICATIONS
COMMON SPECIFICATIONS
Armature Air Gap .008” – .012” (0.20 – 0.30 mm)
Crankshaft End Play .002” – .015” (0.05 – 0.40 mm)
Spark Plug Gap .030” (0.76 mm)
Valve Clearance (Cold)
– Intake .002” – .004” (0.05 – 0.1 mm)
– Exhaust .002” – .004” (0.05 – 0.1 mm)
14-1
SECTION 14: SPECIFICATIONS
TORQUE SPECIFICATIONS
Alternator (to cylinder) 10.0 Nm (7.4 ft. lbs.)
Air Cleaner Support Bracket 5.4 Nm (48 in. lbs.)
Armature 10.0 Nm (7.4 ft. lbs.)
Back Plate 4.5 Nm (40 in. lbs.)
Blower Housing 4.5 Nm (40 in. lbs.)
Breather 4.5 Nm (40 in. lbs.)
Carburetor (to manifold) 5.4 Nm (48 in. lbs.)
Connecting Rod 24.4 Nm (18 ft. lbs.)
Crankcase Cover 47.5 Nm (35 ft. lbs.)
Cylinder Head Bolts 29.9 Nm (22 ft. lbs.)
Cylinder Wrappers:
– M5 bolt 2.8 Nm (25 in. lbs.)
– M6 bolt 4.5 Nm (40 in. lbs.)
Exhaust Manifold 19 Nm (14 ft. lbs.)
Fan Retainer 21.7 Nm (192 in. lbs.)
Finger Guard:
– Hex Head Screws 4.5 Nm (40 in. lbs.)
– Finger Screws 1.3 Nm (12 in. lbs.) (Approximately)
Flywheel Nut 204 Nm (150 ft. lbs.)
Governor Lever (clinching screw) 11.3 Nm (100 in. lbs.)
Intake Manifold 19 Nm (14 ft. lbs.)
Oil Pump 12.2 Nm (9 ft. lbs.)
Rocker Arm Jam Nut 19 Nm (14 ft. lbs.)
Rotating Screen Screws 1.9 Nm (17 in. lbs.)
Spark Plug 19 Nm (14 ft. lbs.)
Starter Motor 24.4 Nm (18 ft. lbs.)
Valve Cover 6.8 Nm (5 ft. lbs.)
14-2
NOTES
NOTES
SECTION XX
Printed in U.S.A Copyright © 2001 • Generac® Power Systems, Inc.