Generac Power Systems GTV-760, Service Manual

Page 1: ... PartNo OE2Oal fr SERVICE MANUAL F J 1 POWER P O Box 297 Phone 262 473 5514 P ntedinlJ s A GiENEFIAC SYSTEMS INC Whitewater Wl 53190 GTV 1990 760 V TWIN OHVIENGINE Fax 262 472 6505 FirslEdition lssued bi xrxx ...

Page 2: ...ossiblyknow oI and advisethe sewicetrade of all conceivable pro eduresot methods by which a servicemight be per formed nor ot any possiblehazardsand or resultsot eachprocedure ormethod We havenotundertaken any suchwideevaluation There ore anyonewho usesa Procedureor method not recommendedby the manu acturermust irst satislyhimselfthat neitherhissa ety nor the product ssatety will be endangeredby t...

Page 3: ...ECTION 12 PISTON RINGS ANDCONNECTING RODINSPECTION ANDASSEMBLY SECTION 13rENGINE ASSEMBLY A WORD ABOUT SPECIALTOOLS Manyot theprccedurcs depicted in thismanualrcquitethe useof special tools Some of the toolsreouiredareavailable asGenetac pattsandate listedassuchin this manual ATTENTION cenerac Power Systems does notapprove orauthorizethe use olthese eng ines onAllTerrain Vehicles AW s go carts mot...

Page 4: ...alesa ly efficiently andreliablyonly ifitisproperly oper atedandmaintained Manyaccrdents ar caused byfailing to tolow simpe andfundamentalrules or precauttons Generac cannot possiby anticipate every possible circ m nancethat mightinvolve a hazard Thewarninqs in this manualand ontags anddecals affixed totheequipmeni arc therelore noi all inclusive tf you usea procedure work method oroperating techn...

Page 5: ...heequipmentor injure yourself Donotoperate theengine fanerthanihespeed necessary to operate theequipment Donotruntheengine at high speed whennotoperating theequipment This engine requires anadequate flowof cooingairfor its contrnued proper operation Never operale theequlpment inside anyroomor enclosure where thefreeflow ol cool ingairintoandoutof theequipment mightbeobnructed Withouisufficienl coo...

Page 6: ...7A DISPLAC EMENT 99 cc CBMPRESSlEN RAT D 8 5 1 LUBPICAIIIN SYSTEI l rUI L PAES UO 7 D V LO I PPE SLPfSI LIIE i IGNlIIUN SYSTEI I ELICTPDNIC SPEAKfRLESS CYL NDER CAST IRDN SLEf VL S I A R T I N GS Y S T E M ELECTRIC START IIL CAPACITY C030ml V FILTEP 1750nl V B FILTER VE GHT 454 a Dtbs ...

Page 7: ...DIMENSIONS AND FEATURES ...

Page 8: ...DIMENSIONS AND FEATURES ...

Page 9: ...DIMENSIONS AND FEATURES P N OC2965A P N OC2955C P N OC2965t ...

Page 10: ...calburetor The fuelairmixturc flowsthrcugh theopen intake valve intothecylinder Whenthepistonreaches BDC theintake stokeisover CrcNrT oN AND powER Bythetimethepiston reaches TDC combustion isakeady inprogress Theintake andexhaustvalves remain closed asthe exprnding gases of combustion forcethepiston downwad DEXHAUsr Theexhauststroke beginswhen thepiston hasrcached BDC andhasstartedits upwardmoveme...

Page 11: ... arcgasolinesblendedwith alcoholsot etheE Ex essiveamountsof theseblendscandamage the luel systemor causepertormanceprcUem Do not usegaso Iine which contains Methanol lf any undesirable operatingswptoms occu usegasolinewith a lower pe aentageof alcoholor ethei It isalsorecommended thatgasolin bepurchased in small quantities notmorethan a30daysupply FRESH gasollne min imizes qumdeposits andalso u i...

Page 12: ...uq figurc 1 1 o fill Check Remove dipnick andrefitlslow yw th newoilofproper 5 r vr eclassification andviscosity grade R f I to fu markon dipstick Whencheck ngoil evet dipst ckmustbealltheway inforaccurate readtngs Start andrunengine to check foroilleaks CHANGE Ot FLTER Replace oilf lter very I 00hours Befo re nstalt nqnewI rer ightly oilfiltergalketwithfresh clean engine oit Screw fiier onbyhandu...

Page 13: ...cketif necessary SERVICE DUAL ELEMENTAIR CLEANERS Remove andservice foampre c eanerevery 25hours orevery season whichever occurs firn setuice canridge every 50hou6 or ev ry season whichever occurs first SERVCE CAN STER AIR CLEANERS Clean theairfilterelemen s with compressed airevery 50 hours orevery season whichever occurs first Replace theair ilterelementG every 500hou6orif damaged Note The air c...

Page 14: ...dandeach spark plug Stadandrunengine at topnolo dspeed Nowground onespark plug Fig ret 7 The engineshould continue torunontheother cylinder Repeatthis testwiththeothercylnderlf theengine willnotcontinue to runwhenmaking thistest thecylinder thatlsNOT grounded isnotfunctioning and orthe spark plugisfouled Installa new spa plugbefore prcceeding f miss contn es problem may becarburetion orcompression...

Page 15: ... ONE CYL NDE R 1 Spark plug a a fouled5park plugmayindicate thatcarburetor isout of adjustment 2 Leak inspark plugwire 3 Headgasket 4 lntakemanifod a A leak ateiiherend oftheintake maoifold wlllonlyaffecl onecylinder notboth 5 Valves 6 RLngs 8 Cylinder NOTE A twin cylindetenginewi runwe ononecylin deraslong asthepower rcquircdfor theappli ation does not exceedthe powet produced by the one cylinder...

Page 16: ...ld nothave a heavy starting load 3 Check remote control assembly for proper adjustment 4 Check interlock system forshorted wires loose orcorrcded connections or defective modules orswitches ENG INIWON T STOP 1 Check equipment ignition stopswjtch 2 Check for loose or disconnected equipment stopswtcn 3 checkground wireharness onengrne a See Section 2 fortestProcedure V BRATION 1 Unitloadoutof balanc...

Page 17: ...ontaining a permanent magnet NOTE fhe magnetoignition synem rcquiresa minimum of 350RPMto ptoduce a consistentspa ARMATURES ARMATURE TESTING Thecondition oflheignition armatures canbeaccu tely diag nosedusingan ignitiontestet Generac P N0C5969 as descbedin Trcubleshoot n9 inSection 1 REMOV NG ARMATURES 1 Remove spark plugleads 2 Remove intake manifodandcovelintake pofts 3 Remove rotating screen an...

Page 18: ...ut Caution Flywheel pulle bolts maydamage lighting coilif turnedintoo ar cautionrDo NoTstrikellywheelwith a hardobjed or a m taltool asthismayGuseflywheelto shat ter in operation Alwaysuseapprovedflyl vheel Figure 2 5 RenovingFl heel INSPECT FLYIVHEEL KEY KEWVAYS FLYIVHEELAND CRANKSHAFT Check flywheel keyfor damage Check fly vheel or cracks orkeluaydanrage Alsocheck crankshaft keylvays andtaper fo...

Page 19: ...heengine killwires conslst ofagrcund wirewithadiodefor each armatureand aseparate wireforthecarbu retor solenoLd Theengine killwires areconnected to thewirlngharness pro vided bytheequipment manulacturer See engine wirediagram Page 6 3 TESTiNG GROUND WIRES Usea DigitalMultimeter Figure 2 9 to testthe ground wires The iollowing testwllbemade withthemeter intheDiode Ten IntheDiode Test position them...

Page 20: ...rness c lf meter displays OL diod isdefective open Replace ground harness 6 Nowrepeat test forterminal C Results must bethesame See Diode Failwe Diagnosis betow SPARK PLUG SPARK PLUG DIODE figute 2 11 lgnitionWhingHamess DIODE FAITURE DIAGNOSIS IGNITION KILLWIRE ENGINE GBOUND HARNESS POSITIVE Ii4ETEB TESTLEAD NEGATIVE I 4ETER Figurc2 10 Testing GrcundWhe GROUND WIRE HARNESS SWITCH ON TURNED OFF CA...

Page 21: ...inkfrom carburetor 2 Disconnect fuefshutoffsotenoid byunboking theground w e fro themarlotd ardunptJgg rq thepo e wrre Note Wiressimply unplugfromthe solenoid on modets 04629 2 EW 04717 0 04717 1 04A06 0 04A57 0 O4a5 0 04a62 O 3 Disconnect breather tube 4 separateihrottle linkballjointfiom carburetor oyrorar ng theballsocket_ 5 Disconnect thefuelline 6 Removethe fournuts holding thecarburetorand p...

Page 22: ...overfor adjustment 12 Stairengifeanda owto w rm upfor _5min 13 Move speed controevertoslowspe d position an thod throttleeveragainst idtestopscrew 14 adjuststopscrew to maintain _t2O0RpM idte 15 5ow y pv p p6 s6nt or e er oro sob6doo or Donol exce d 4000RPN 1 Figute 3 4 Note The highspeed sc ewmay needadjusting to rcach tne speed ontrct stop without ex eeding 4OOO RpM l6 rL h rfa pepd Lolt ot r I ...

Page 23: ...r of cylinder 2to pumpthefuel tt iscapable of pfimingat 12 30 5 cm max lift Thepumphasa rraxouu tpressure of 5 psi lf afuelpumpotherthantheonedescribed above rsused thefuellinepressure atthecarburetor inletmustnotexceed 3 psi Pressures inexcess of 3 psimaycause anoverrichcaF buretor mfturethatwouldlead to engine damaqe Figute3 6 Fuel 33 ...

Page 24: ...NOTES p q ffi 34 ...

Page 25: ...r arm Lub cateallmoving parts whenreasserabling 1 Force gearassembly andgovernor spooloff of governor shaft 2 Remove anyremainlng plastic fromthenotchinthegov ernor5nan 3 Checkthat allthegovernor bearing pans toppLile oear ing andbottomplate arc ontheshafi andthat moves 4 Slidethe newgear assemblyand spoolontothe governor shaft Sllde untilthegear hooks intothenotchinthegov GOVERNOR ARM lf thegover...

Page 26: ...hing screw onthegovemor lever Rotate the governor armclockwise and holdgovernor lever inWOTposition Whileholding thisposition torque theclinching screw to 11 6 Nm 100in Ibs Check to make sure thatthethrottle travels fromWOT to idle lf it doesn t thegovernor needs to beresetagain Figurc4 5 Dynamic GovenorAdjustment DYNAMICGOVERNOR ADJUSTMENT Slartengine anda bw 10warr upfo 5 mi rures Move speed con...

Page 27: ...d control lever to high speed position Donotexceed 4000RPM Nol Thehigh speedscrewmayneedadjusting to rcach the speed ontrol stop without exceeding4000RPM 5 Wth thespeed controljn thehigh speed position adjust thehigh speed screw io obiain thedesired engine speed Figurc4 5 Dynamic GovenotAdjustnent 4 3 ...

Page 28: ...NOTES ...

Page 29: ...TAT C GOVERNOR A01UsTMENT _ _ _ 5 6 GENERAL INFORMATION compression testlng information and procedu res isdescrlbed Cylnders are numbered asshown inFgure 5 1 Figurc5 1 REMOVE CYLINDER HEADS Dsconnect exhaust systemfrom exhaust manifold Remove exhaust manifold faom englne Dsconnectchoke andthrottle control cables Remove spa p ugs 1 Removelhe parts depicted inFigure 5 2 a Discard gaskets andvalve co...

Page 30: ...ure S 3 3 Remove headboltsandcylinder head Figure 5 4 a Discard gasket 4 Repeat Steps 1 3forothercylinder head DISASSEMBTE CYLINDER HEADS I Piace a shopragorshortsection of rubberfuelline under valves inside combunion chamber to holdvalve in ptace whileconrpressing sprlng 2 lold downvalve sprngretainer byhandor witha vatve spflng compressor Figure 5 5 Remove thefollowing a Valve spring keepers b V...

Page 31: ...ybereconditioned using avalve seai cutter lf valve seatk widerthan dimensjon showninFigure 5 9 a narrcwing cuttershould beused to ensure thatconEcrarea of valve seatiscentered onfaceof valve Figure 5 tO a usea 60 cutterto narrow seat frombottomanda i5 cuttertonarrow seat fromtop Figure 5 9 Note fi valve seatis looseor uacked rcpla e cytinder 60 CUTTEF 15 CUTTER Figurc5 9 ValveSeatDinensions 2 Valv...

Page 32: ...stallValves Place ashopragorshodsection oi rubber fue neunder valves insdecornbustion chamber to hod vavein place whilecompressing sp ing lnnaI vavesprings andvalve sprinq retalners overvalve Figure5 12 Check Valve Spings ASSEMBLE CYLINDER HEAD l lnstallnewvalv stemseals a Oi innersurface andlipofvi vestemseal b Pressrealonto intake valveguide bushing unllltbottoms Figure 513 5 Compress valve sprl...

Page 33: ... andEX0 0762mm 003 b Torquejam nutandballstud to 19Nm 14ft lbs 2 Repeatfor No 2cylinder 3 Inslallvalve covers withnewgaskets Figure 5 18 a Torque nutsto 6 8Nm 5ft lbs REASSEMBIE 1 lnstall cylinderwtappers a ToqueM5scre 6 to 2 8Nm 25in lbs b Torque M6screws to 4 5Nal 40in lbs 2 Install spark plugs a Torque to 2l Nm 15 5 ft lbs 3 Install exhaust manifold a Torque scewsto 32 5Nm 24ft lbs 4 Install bl...

Page 34: ... throttleandchokecontrolcables andcheckfor proper operation 6 lnstallrotatingscrcen a Torque screws to 1 9Nm 17in Tbs 7 Install fingerguard a lf engineisequipped withsocket headscrews torque screws to 4 5Nm 40in lbs b lf engine isequipped withfingerscrews tightenscrevls byhand to approximately 1 3Nm 12in lbs 8 Assemble aircleanet WARNINGT Before starting or running engine static adjustment o the g...

Page 35: ...STARTER N4OTOR SPINS 8UT DOES NOICRANK ENGINE a Sticking pinion geardueio di t b Damaged pinion oring gear c Battery fauryor damaged d Incorrect rotation duetoreveBed motor polariv a lmolors rotate countercockwlse viewed rompiniongear e Damaged solenoid sTARTER IVIOTOR SPINS BUTWLL NOT STOP a Defective starter switch b solenoid stuck engaged TEST EQUIPMENT Thefolowingisalistofequipment recommended...

Page 36: ...each studtermlnal onthe solenoid Figure 6 3 10 Attach oneendofjumper lead to positive terminalon bat tery 11 Touch jumper wireto tabterminalon solenoid a AnaudibTe Cllck should beheard asthesolenoid switch closes b Metershould make a continuoustone continuity Figurc6 3 Testing Solenoid BATTERY INFORMATION A 12voltbattery isused to operate 5tader rnoto6on Gen erac OHVL v twin engines For best start...

Page 37: ...t sparks caused byaccd ntagfounding Tlghten conne torssecurely 4 Connect negative termlnal to negative battery teminal Tighten connectors 5ecurcly a Use atapercharge automatically reduces charge rate b Fillnon sealed batterycelk withdistilled watefafter charg ing forbatteries thathave beeninseNice Note ll battery get5 Hot to the touchor is spifting acid gassing ex essively unplug charyer peiodi al...

Page 38: ...tive C batteryterminal With ignitionswitch OFF press stanerbutton lf ignition switchand starterswitcharethesameswitch disconned wires fro nspafk plugs andground igntionusingtwo lgnition Testers Turnswitch to START Meter should display 9 volts ormorewhile cranking engine lf lessthan 9volts k measured replace battery EATTERY RECOMT 4ENDATIONS Thebattery sizerccommended is525CCA o EATTERY CAELE RECOM...

Page 39: ...utteminal 5 Withtheengine running at3600RPM outputshould be noLess man 26Volts 20AmpSystem 6 lf noo low oJtpJr r fould hec rorbare wi e5 o a y otherobvlous defects lf shoded leads afenotvisible replace thestator TESTING DCOUTPUT CHARGING WIREI Asimple testmaybeperformed totesttheDCoutputcharg ing wirecircuit lf a p oblemexists in the wi ingil canbe corrected before testing regulatoFrcctifier Leave...

Page 40: ...empropey connected staftthe engine 3 Erlng theengine upto normal operating speed andtest thebattery voltage again 4 lfthebattery voltage whiletheengine isrunnjng isgreater thanwhentheengine isstopped thecharging system is Note With the engine running the battery vottage should be 13 Volts BAITERIES Note SeeSection6 for baftery sizeand cabtesetection 7 2 ...

Page 41: ...heengineshuts downbyitselfandthefLrel tankhasenough gasoline check theengine oillevel A delaybLrlrinrotl_e l Jroowrsyste o so e engile applications allows oilprcssureto buidduingstading Thedelay allows lheengire lo J lro aboLl I0 econds befo e sensr g oilpressure f thesystem senses owoil pressure du ingoper aton theengine rhutsdown The engnewilnotcontinueto rununti 8 psiof oil pressure s reached l...

Page 42: ...GING THEENGINE OILANDFILTER RECOMMENDED OIL TYPE Using theproper Vpeandweightof oilrnthecrankcase is extremely rmponant Check theoilbeforc each use andchange theoilregularly Failure ro usethe corrcct oil orusing dirtyoil cancause premature engine wearandfaluae Ureonlyhighqua litydetergent oilrated withAp setuice rtae sficatjon Sl SGor SH Therecommended oilweights inctude thefollowing During summer...

Page 43: ...ng Flllthecrankcase withtherecommended oil untilthe oii levelisat thefull pointon the dipstick approximately 2030ml 2 Iqt are requredwhenchang ingtheoiland oilfilter POUR SLOWLY When thecrankcase Gfiliedtotheprope level installthe oilfill cap Startengine to ilioilfilter rechecucorrecr orl ottcootER some engines areequippedwth anoilcoolerTheo lcooter ismounted ontheblower housing Forced airfrom the...

Page 44: ...SECT ON 9 ENGINE DISASSEMBLY 8 4 ...

Page 45: ...Remove cylinder heads see Seclion 5 1 Remove thefollowing parts Figure 9 1 a Brcather Assembly b Alternator c Backplate d Starter Motor 2 Remove ctankcase cover a Discard gasket andO ring 3 Rotate c nkshaft andcamshaft untillimingmarks allgn andremove camshaft Figure 9 2 Note lf necessary place the engine flWheel sidedown to pfevent tappets ffom catching on the camshaft a Remove tappets Figwe9 1 R...

Page 46: ...linder Figure 9 4 a Reasse ble caoro rodlo prevenl nrercharg n9 5 Repeat or renraining cyllnder 6 Remove crankshafl Figure 9 5 ligwe 9 5 RenoveOankshalt 7 Remove oilpumpfrcmcrankcase cover Note clean all suiaces of gasketmateial Removeoil sealsand thotoughly dean componentsin solvent Orga nize components keeping pat s which are assemblies together Figute 9 3 Renove cj l shalt Fiqurc9 4 RenovePinon...

Page 47: ... rc on ditioned using a igid hone with tinishing stones to rcstotetheprcpet oss hakh anglein the ylinderbotet The propercylindercrosshakh ensurcsNoper lubicatjon ahd pistonnng hrcakin Refer to Cylinder Finish Cross Hatch below forcorrect pro cedure for installing cross hatch TOP BOTTOIV Figurc10 3 Measute at SixPoinB RESZING Note Ovefsize kits are NOT available DO NOT borc ylinden CYLINDER FIN SH ...

Page 48: ...tt kercsene withholrunning wat rRepeatwashing andrinsing unlilallt ces oi hon n9grha gone Honing git ishighly abGsive andwillcause rapid weartoall ofthelnternal components oftheengine unless ii iscompletely Figwe 0 4 Cylinder Crcss CLEANING ITISMOSTIMPORTANT THATTHEENTIRE CYLINDER AND CRANKCASE BETHOROUGHLY CLEANED AFIERHONING Finwash thecylinderand crankcasecareiully inasolventsuch as kercsene or...

Page 49: ... sure thatthedankcase issupponed bytheseaboss 2 setthenewbeainginthecrankcase withthenotchup andthe oil holeslinedup withthe passages in the crankcase 3 carcfully slidethe bushing driverinto the beaingand press thebearing in untilit is0 25 1 27mm 01 05 belowthesu face 4 Remove anymaterial leftintheoilpassage 5 lnstall newoiLseal withsealing lipfacing ln a Press oilseal untilflushwithcrankcase 45 1...

Page 50: ...kcase covermustbereplaced Forveatical shaftengines thegero Mag Bearing RejectDimension 20 06mm 790 PfO Beafing Rejed Dimension 18 06mm 7rr O L SEALS Always installnew oilseals whenever engine i5dlsaslembled formajor servicinq orwhenrepaingbearings Lub cate 5eal ing edgeof oil sealwith cleanengineoil beforeassembly Alw ysuse thecorrect seal protectorto prevent damaging oi seal Figurc10 11 Chec ing ...

Page 51: ...CTION 10 CYLINDER CRANKCASE COVER 16 smm 0 65 2 16mm 18 504 1 183 5mm P 224 l Ol2mm1o 473 1lYP MATEHIAL WOOD 25 4mm I1 lx216mm 8 5 x 254mm 10 0 CLAMP THISENDINVISE 254mm 10 0 Figurc10 12 HoningFixtue 10 5 ...

Page 52: ...SECTION 10 CYLINDER CRANKCASE COVER 10 6 ...

Page 53: ... gearfor damage orwear lf threads keyways ortiminggear aredam agedorworn replace crankshaft Ch ck journats forscoring Ifjournals arescored replace crankshaft Check journa sfor wearseecrankshafr rejedt sizes Mag Intake obes Exhaust 4 745 o 1a4 1 221 1 221 17 93 nrm 19 93 mm 31 02 mm 31 02 mm ALL 1 648 534 I 490 a1 8s mm 37 85 mm 38 96 mrn FLYWHEEL KEY PTO JOUFNAL TIMING LOBES Figwe11 2 Che ing Cans...

Page 54: ...SECTION I I CRANKSHAFT CAMSHAFT ...

Page 55: ...35mm 0015 outof round it mustbereplaced DISASSEMBLE PISTON ANDCONNECTING ROD 1 Remove piston ringsusing ringexpander a fhen remove oil ring Figurc t2 t Renove Rjngs 2 Disassemble piston fromconnecting rod Figure t2 2 a Remove piston pinlocks b Piston pinisa slipfit in prston andconnecting rod Keep pGtons andconnecting rods together asanassembly Donotmix Figurc12 2 Remove pistoD pin Lock CHECKING P...

Page 56: ... ing rcd must be tepla ed PISTON PINBEARING Figurel2 7 Check RodBeaingt ASSEMBLE PISTON AND CONNECTING ROD Lubric te parts withengine oilandassemble 1 piston and connecting rod Figure 12 8 l Notchor casting markonpistonmustbeonflywheeJside 2 Number 1 onconnecting rodmustfacePTO side oppo sitenotchorcasting markonpiston d l rstallpinon pi rlocGwithneedle rosepliers Lubricate parts withengine oiland...

Page 57: ...ngs 1 Installoilringexpander a Install lowerscraper ring a lnstall upper scraper ring 2 Install center compression ringwithchamfer up 3 Install topcompression rlng Note Top compression ng may be installed with eithet Fiourc12 Assenble l RodAndPiston Figurc12 9 Assenble S2RodAnd Pinon TOPCOMPAESSION R NG CENTEF COMPF SSION FING Figurct2 10 PistonRinglnstallatton 12 3 ...

Page 58: ...SECTION 12 PISTON RINGS CONNECTING RODINSPECTION ASSEMBLY 12 4 ...

Page 59: ...rings withRing Comprcssor Figure l3 2 a Place piston andringcompressor upside downonbench withprojedions oncomprcssor facing up b Tlghten ringcompressor evenly untilrings arefullycom pressed c Thenloosen ringcompressor veryslightly soth t com pressor can be rotatedon pistonskirtwhile holding connecting rcd Figure 13 2 d Remove connecting rodcap Figure13 2 ConprestingRings 2 Lubcate cylinder borcs ...

Page 60: ...ng markson cam shaftand cfankshaft gearand installcam shaft Figure 135 3 Atsemble governor spool io governor shafi a Makesure thatspoolengages flyweights b Install new O Lringincrankcase INSTALL CRANKCASE COVER Lubricate PTO andcamgearbearing 1 Rotate governor shaftsothatthe piddlerests againstthe cover Figure l3 6 Figute13 5 Rotating covehot Shaft 2 lnstall crankcase cover withnewgasket Note fi t...

Page 61: ...ayfrom fly r heelas faraspossible andtighten onescrew to hotd coilin place 5 Repeai forsecond coil Note Thesideshownin Figurc 13 9must faceup on both coilsot the engine will not fundion Noperly 6 lnsta I ground wireontotabterminal on ignition coils lmportant Make surcwircs arc routed over coil mount ing pos6 INSTAI t BREATHER 1 InseJt breather material 2 Instalbreather assembly andgasket 3 Torque ...

Page 62: ...rms and ballstuds withclean engine oil 2 Assemble ballstuds rccker arms jamnutsandguide plates tocylinder head Figu 13 l3 a Make surc thatthepush rods areintheproper location onthetappeti andtherocker arms 3 Loosen mounting screw somagnet willpullcoildownagainst thickness gauge a Torque screws to l2 2 Nm 9ft lbs 4 Rotate fll1 1 heelto emovethickness gauge 5 Repeat forsecond coil INSTATI CYLINDER H...

Page 63: ...allvalve cove6withnewgaskets Figure t3 15 a Torque bolts to 6 8Nm 5ft lbs GENERAT ASSEMBLY 1 Install Cylinder shields wrappers a Torque M5screws to 2 8Nm 25in lbs b Torque M6screws to 4 5Nm 40in lbs c Connect ignition 9rcundwireto ignitionkilterminalin backing plate Figurc13 15 lnttallValveCove s Figurc13 t4 AdjustValveCleannce rrncen cueno norelruo scneen INTAKE MANIFOLD ASSEMBLY orrcooren erowen...

Page 64: ...l intake manifold assembly a Toqueboltsto 19Nr 14ft lbs 9 Installfinger guard a lf engineisequipped withsocket headscrcws torque screws to 4 5Nm 40in lbs 10 Connect governor llnkage andspeed contrcl tinkage I1 Install spark plugs_ a Torque spark plugsto19Nm 14ft tbs ADJUST 6OVERNOR Note Referto Sedion 4 Page4 2 fot Stati covehor Adjustment WARNING BETORE STARTING ORRUNNING ENGtNE staticadjustment ...

Page 65: ...SECTION ...