Lfm3250 927 0251 Onan CCKB (20HP Tractor) Engine Major Service Manual & Parts W 1116 Supl (06 1974)

User Manual: 927-0251 Onan CCKB (20HP Tractor) Engine Major Service manual & Parts w-927-1116 supl (06-1974)

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.

MAdOR

SERVICE

MANUAL

AND PARTS CATALOG
,PRO?E’I?TY
f?~
?

.

FOR

ONAN
20 HP CCKB ENGINE

DO NOT R~MfJIYE

FOR
GARDEN TRACTOR
SERVICE

●

,.
)’

BASIC MODELS

.

CCKB-MS/24201+

?

CCKB-MS/2440H
CCKB=MS/2733J
...
,,
,
.% J

.,.

FORM NUMBER

927–0251

ISSUE OATE

6HJ74

SAFETY PRECAUTIONS
Always use an appropriately sized, approved
double-throw transfer switch with any standby
generator set. DO NOT PLUG PORTABLE OR
STANDBY SETS DIRECTLY
INTO A HOUSE ‘
RECEPTACLE
TO
PROVIDE
EMERGENCY
POWER. It is possible for current to flow from
generator into the utility line. This creates extreme hazards to anyone working on lines to
restore power.

The following symbols in this manual signal @potentiallydangerous conditions to the operator or equipment. Read this manual carefully. Know when these
conditions can exist. Then, take necessary steps to
protect personnel as well as equipment.

Onan
uses this
symbol
throughout this manual to
warn of possible serious personal injury.

IEQiim

Use extreme caution when working on electrical
components. High voltages cause injury or death.

This symbol refers to possible
equipment damage.

Follow all state and local electrical codes. Have all
electrical installations performed by a qualified
licensed electrician.

Fuels, electrical equipment, batteries, exhaust gases
and moving parts present potential hazards that could’
result in serious, personal injury. Take care in following these recommended procedures.
●
●

Use Extreme Caution Near Gasoline, Gaseous
Fuel And Diesel Fuel. A constant potential explosive or fire hazard exists.
Do not fill fuel tank near unit with engine running.
Do not smoke or use open flame near the unit or
the fuel tank.

Lead acid batteries emit a highly explosive
hydrogen gas that can be ignited by electrical
arcing or by smoking.
●

Have a fire extinguisher nearby. 6e sure extinguisher is properly maintained and be familiar
with its proper use. Extinguishers rated ABC by
the NFPA are appropriate for all applications.
Consult the local fire department for the correct
type of extinguisher for various applications.
s

Guard Against Electric Shock
Remove electric power before removing protective shields or touching electrical equipment. Use
rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
around electrical equipment. Do not wear damp
clothing (particularly wet shoes) or allow skin
surfaces to be damp when handling electrical
equipment.
Jewelry is a good conductor of electricity and
should- be removed when working on electrical
equipment.

Exhaust Gases Are Toxic
Provide an adequate exhaust system to properly
expel discharged gases. Check exhaust system
regularly for leaks. Ensure that exhaust manifolds
are secure and not warped.

Be sure all fuel supplies have a positive shutoff
valve.
Fuel lines must be of steel piping, adequately
secured and free from leaks. Do not use copper
piping on flexible lines as copper becomes
hardened and brittle. Use black pipe on natural
gas or gaseous fuels, not on gasoline or diesel
fuels. Piping at the engine should be approved
flexible line.

Do Not Smoke While Sewicing Batteries

,
c“

Be sure the unit is well ventilated.
●

Keep The Unit”And Surrounding

Area Clean.

Remove all oil deposits. Remove all unnecessary
grease and oil from the unit. Accumulated grease
and oil can cause overheating and subsequent
engine damage and may present a potential fire
hazard.
Dispose of oily rags. Keep the floor clean and dry.
●

Protect Against Moving Parts.
Avoid moving parts of the unit. Loose jackets,
shirts or sleeves should not be permitted because
of the danger of becoming caught in moving
parts.
Make sure all nuts and bolts are secure. Keep
power shields and guards in position.
If adjustments must be made whiie the unit is
running, use extreme
caution
around hot
manifolds, moving parts, etc.
Do not work on this equipment when mentally or
physically fatigued.

i
\.

These parts apply to the ONAN engines used in Garden Tractor service and will
give better service than those previously listed. Use these parts in place of
those listed in the main parts catalogs 927-02S1 and 927-1103.
.,.
Parts are not illustrated as they are similar in’”appearanceto those in the
.....
parts catalog.
CYLINDER BLOCK GROUP
REF. NO.

QTY. USED

BEARING, CRANKSHAFT
101-0450
2
101-0450-02
2
101-0450-10
2
101-0450-20
2
101-0450-30
2

15

*

PART NO.

PART DESCRIPTION

*Standard
.002” Undersize
.010” Undersize
.020” Undersize
.030” Undersize

- These standard bearings included in replacement cylinder block assembly
listed in main parts catalog.

CRANKSHAFT, FLYWHEEL, CAMSHAFT & PISTON GROUP
REF. NO.
11

PART NO.

QTY. USED

PART DESCRIPTION

PISTON AND PIN (Includes Retaining Rings)
112-0136
Standard
2
112-0136-05
.005” Oversize
2
112-0136-10
.010” Oversize
2
112-0136-20
2
.020” Oversize
112-0136-30
.030” Oversize
2
112-0136-40
.040” Oversize
2

ONAN INDUSTRIAL ENGINES
FOR TRACTOR APPLICA’I’ION

“.”’
,, .,.
\

CCKB
SERIES

.

●

TABLE

OF CONTENTS

PAGE

TITLE
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifieatians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and ClearcrneeS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly
Engine

.,
---

Oil

Torques

System

Fuel

ignition
Starting
Engine

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System

Governor

Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . .

System
and

Battery

System

Charging.

. . ..o

Disassembly
Catalog

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. ..+.....*

2
3
4
4
5
6
8
11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . ..00

. . . . . . . . . . . . . . . . . . . . . . ...0

..o””o

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...000

EngineWiringDiagram-CCKB-MS/z420

. . . . . . . . . . . . . . . . . . . . . . . ..*.o

EngineWiringDiagram-CCKB-MS/2440

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

WE SUGGEST THAT THIS BOOK BE KEPT HANDY,
EITHER FOR MAKING ADJUSTMENTS OR ORDERING
PARTS.

:;
22
32
48
49

-—

GENERAL INFORMATION

SERVICE MANUAL

MODEL DESIGNATION

This

Identify
your model by referring
to the MODEL
and
SPEC (specification)
NO. as shown on the unit nameplate.
Always
use this number and the engine
serial
number when making reference
to your engine.

Onan
service
manual
contains
information
for
proper servicing
and overhauling
CCKB engines
begin
Spec H. Onan recommends
reading
the entire
manual to

better
understand
the CCKB
engine
before
performing
any work on the unit. The information
will enable you to
maintain
and service
the engine
which
can not only
result
in better
operation,
but long unit life as well.
Because
correct
diagnosis
is an utmost
part of repair,
a troubleshooting
chart is included.

How

interpret MODEL and SPEC NO.
CCKB

- MS /

2420 J

TTTT

NOTE: Flywheel
end of engine is considered
the front.
Left and right sides are determined
looking at front of
engine.

12.34

This symbol is used to warn of
possible equipment damage.

~;

uses
this
symbol
throughout the text to warn of
possible injury or death.
When contacting
the factory
supply
the complete
model
as shown
on the nameplate
TION”
following).

to

~:

about
the engine
always
number
and serial
number
(see
“MODEL
DE SIGNA-

Factory
Specific

code
Type:

for

general

identification

purposes.

S - MANUAL STARTING
MS - ELECTRIC
STARTING
Factory
cede
for optional
equipment
supplied.
Specification
(Spec Letter)
advances
with factory
production
mod ificat ion.

If your engine
needs service
or repair,
contact
an Onan
Service
Center.
Trained
mechanics
will assure
expert
repair service
on your Onan engine.

@El
TO A VOID POSSIBLE
PERSONAL
INJURY
OR
EQUIPMENT
DAMA GE, AN AUTHORIZED
SERVICE REPRESENTATIVE
MUST PERFORM ALL
SERVICE.

2

SPECIFICATIONS

,,’ -,

Engine Manufacturer
Engine Ensign
.
Horsepower
. . .
Displacement
. .
Bore . . . . . . .
Stroke
. . . . . .
Crankshaft
. . . .
Valves
. . . . .
Bearings(MainandRod)
Lubrication
System
Oil Capacity
. .
(With Filter)
.
BatteryChargingSystem

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TUNE-UP

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Onan

Opposed
two cylinder,
four cycle,
L head and air cooled
. .
19-1/2 hp @ 3600 rpm 20 hp max. @ 3900rpm
49.8 cu. in.
. . . . . . . . . . . . . . . . . . . .
3-1/4 inch
. . . . . . . . . . . . . . . . . . . .
3 inch
. . . . . . . . . . . . . . . . . . . ..
Ductile
lmrr
. . . . . . . . . . . .. Horizont=d.
Mechanical
. . . . . . . . . . . . . . . . . . .
Sleeve
. . . . . . . . . . . . . . . . . . . .
Pressure
Feed
. . . . . . . . . . . . . . . . . . .
3-1/2 Quarts
. . . . . . . . . . . . . . . . . . . .
4 Quarts
. . . . . . . . . . . . . . . . . . . .
Flywheel
Alternator
. . . . . . . . .
12Volt,15Amp,
Flywheel
Alternator
or 12Volt,20Amp,

SPECIFICATIONS
MAXIMUM

MINIMUM
Valve Tappet Adjustment
Intake
. . . . . . .
Exhaust
. . . . . .
Breaker
Point Gap (Full
Spark Plug Gap
. . . .
Ignition
Timing Advance

.

. . . . . . . . .
. . . . . . . . .
Separation)
. .
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(Engine
Running)

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.008
.017

.006
.015

.020
.025

20° BTC

DIMENSIONS

AND CLEARANCES

All c Iearances given at room temperature of 70° F.
All

dimensions

in inches unless

otherwise

specified.
Maximum

Minimum

Valve Stem in Guide –Intake.
Valve Stemin
Guide –Exhaust.
Valve Seat Interference
Width...
Valve Face Angle
. . . . . .
Valve Seat Angle
. . . . . . .
Crankshaft
Main Bearing
. . .
Crankshaft
End Play
. . . . .
Camshaft
Bearing
. . . . . . .
Camshaft
End Play
. . . . . .
Rod Bearing
. . . . . . . . . .
Connecting
Rod End Play
. . .
Timing Gear Backlash
. . . . .
Oil Pump Gear Backlash
. . .
Piston to Cylinder,
Conformat ic
ring -90 °frompin)
Clearance..
Piston
Pin in Piston
. . . . .
Piston
Pin in Rod . . . . . . .
Piston
Ring Gap in Cylinder..
Crankshaft
Main Bearing Journal
Crankshaft
Rod Bearing
Journal
Cylinder
Bore - Standard
Size.

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Type (Measured
below
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. . . . . . . . . . . .
. . . . . . . . . . . .
. . . . . . . . . . .
– Standard
Size
. .
– Standard
Size
. . .
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oil-cent
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rolling
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0.0010

0.0025

0.0025
1/32

0.0040
3/64
440
450

0.0038
0.012
0.0030

0.0025
0.006

0.0015
0.003
0.0005
0.002
0.002
0.002

0.0023
0.016

0.0025

0.0045

Thumb

0.003
0.005

Push

Fit

0.0006
0.023

0.0001
0.010
1.9992
1.6252
3.249

2.0000
1.6260
3.250

ASSEMBLY TORQUES

ASSEMBLY TORQUES

TORQUE

SPECIFICATIONS

Assembly
torques
as given here require
the use of a
torque
wrench.
These
assembly
torques
will assure
proper tightness
without danger of stripping
the threads.
If a torque
wrench
is not available,
you will have to
estimate
the degree of tightness
necessary
for the stud,
nut or screw
being installed
and tighten
accordingly.
Be careful
not to strip the threads.
Check all studs,
nuts and screws
often.
Tighten
as needed
to prevent
them from working
loose.

Connecting
Rod Bolt . . . . . . . . . . . . . . . . .
Oil Pump
. . . . . . . . . . . . . . . . ........
Oil Base Mounting Screws
. . . . . . . . . . . . .

27-29
7-9
43.48

Rear Bearing
Plate Screws . . . .
Gear Case Cover
. . . . . . . . . .
Starter Mounting Bracket
to
Oil Base Screws . . . . . . . . .
Other 5/16 “Cylinder
Block Nuts
hlagneto Stator Screws . . . . . . .
Rotor to Flywheel
Screws
. . . .
Flywheel
Capscrew
. . . . . . . .
Cylinder
Dead bolts
. . . . . . . .
Spark Plugs . . . . . . . . . . . . . .
Valve Cover Capscrews
. . . . . .
Manifold Screws . . . . . . . . . . .
Fuel Pump Mounting sCrews
. . .
Carburetor
Mounting Stud Nuts . .

. . . . . . . . .
. . . . . . . . .

2(I .25
10-13

. .
.
. .
. .
. .
. .
. .
. .
. .
. .
. .

43.48
10-12
15-20
5
35-40
29-31
20-25
4.8
15-20
5- 6
8-12

Ft. - Lb.

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‘.

ENGINE TROUBLESHOOTING

,. ...

r.

GASOLINE
ENGINE
TROUBLESHOOTING
GUIDE
.

‘,..

1~1

10

10 I

I

I

1 I

I

I

I

1 ].[

I

I

IOlolol

I r]

Ie 1.1

I

I

I

1

I I

Rich

Fuel

Mixture

or Choke

Stuck

g
I Leak)ng

ton

.

rd”,,~

,Ierr,,

worn

●

Water Passages
m–. –.
7––.

lii!!iii!ill!!-ll!!if~~~
●

,

w

WC

water

ICL

Valve

Faulty
Oirty

Oil
Oil

011 Too
Oi I Level
Oil

Too

or Pump
Restricted

VI!

L?.=

Rellef

”,ca,

PumD

u’lugc

Stuck
Pump

or Filter
Light
Low
Heavy

or Diluted

Seal

O!ls SYSTEM
Never remove oil level indicator cap
with the engirre rurrning, because hot
oil will blow out of the tube causing possible
injury.

EisEil

CRANKCASE OIL
Change

crankcase

oil

every

only when engine
is warm.
oil fill at 25 operating
hours.)

.s0

operating

(Exception:

hours
Drain

and
initial

When changing
oil, fill the crankcase
to the FULL
mark (Figure
1) with a good quality
(API) SE oil (gasoline operation
only) of the viaccsity
specified
on the
nameplate.
If SE oil is not available,
SD or SD/CC
oil may be used.
When add ing oil between
to the oil in the crankcase
viscosity
and brand.

changes,
in API

For
temperatures
above
30”F,
use
temperatures
below 30° F, use 5W30.

use oil identical
designation,
SAE

SAE

30

In extremely
dusty conditions
or in very cold
change oil at least every 25 hours of operation.

oil;

for

weather,

FIGURE

T

-KEEP CRANKCASE
OIL AT THIS
LEVEL
NEVER OPERATE
ENGINE WITH --OIL SELOW THIS
LEVEL.

FIGURE
OIL

FILTER

1. OIL

2.

ENGINE

OIL

FILTER

Do not overfill crankcase.
service
DS oil. Do not
of motor oil.

Emzi
nor grades

Do not use
mix brands

FULL

Remove hose clamp, breather
hose, breather
cap clamp
and insulator
halves
to release
breather
cap and valve
assembly.
Wash cap and valve assembly
and the baffle
in a suitable
solvent
and reinstall.
See Figure 3.

LOW

ALWAYS REPLACE CAP
TIGHTLY OR OIL LEAKAGE MAY OCCU@ AT
OIL SEALS.

LEVEL

CRANKCASEEREATtl ER

INDICATOR

waREATH

Change
the crankcase
oil filter every
100 hours.
Remove the filter
by turning
counterclockwise,
using a
filter
wrench.
Coat the rubber gasket
on the base of
filter
iightly
with oil. Add the rubber
strip
provided
with the filter to prevent air loss in the area indicated
(Figure
2). It is advisable
to wipe dry the drip pan
located
below the filter.
Install
the filter
finger-tight
plus 1/4 to 1/2 turn.

CAP AND VALVE -A
—cLAMP

!

““O”’RING
SCREEN
BREATHER TUBE —1

CRANKCASE
BREATHER
The engine
is equipped
with an insulated
ball check
valve for maintaining
crankcase
vacuum.
Inspect
every
200 hours. NO maintenance
is generally
required.
Should
the crankcase
become
pressurized,
“as evidenced
by
oil leaks at the seals
or around the cap of the oil level
indicator,
disassemble
and clean as follows:

FIGURE

6

3.

CRANKCASE

BAFFLE

BREATHER

OIL

PUMP

To remove the oil pump,
intake cup assembly,
as

it is necessary
to detach
illustrated
in Figure
4.

-------

the
CRANKCASE
ON LEFT

. . . .

TURNED~
SIDE -

Check the oil pump thoroughly
for worn parts.
Oil the
pump to prime it before reinstalling.
Except
for gaskets
and suction
cup, the component
parts of the pump are
not available
individually.
Install
a new pump assembly
if required.

.

If new oil pump gaskets
are installed,
they should
be
the same thickness
as those removed.
A gasket
kit with
various
thickness
gaskets
is available.

.\
FIGURE

4.

OIL

pUMp

ASSEMBLY

FUEL 5iW’$i$TEM

CARBURETOR

(Figure

5)

Carburetor

The carburetor
has an idle fuel adjustment
(A), a main
fuel adjustment
(B), and a low speed stop adjustment
(C). The idle fuel adjustment
affects
engine operation
at low speed or idle position.
The main fuel adjustment
affects
operation
under load (high speed).
Under normal
circumstances,
factory
carburetor
adjustments
should
not be disturbed.
If either
A or B has been disturbed
turn needles
(counterclockwise)
off their
seats
1 to
1-1/2 turns to permit initial
starting.

Carburetor Idle Fuel
1.
2.
3.

4.

Do not force the needle against
its seat; doing so will damage it.

m

5.

Adjustment:

Run the engine
at least
10 minutes
to warm it up.
Move speed control
on tractor
to slow position
so
engine
is running at approximately
1200 rpm.
Turn idle needle
(A) out (counterclockwise)
until
engine
begins
to slow down or run unevenly
(rich
mixture).
Remember
this position.
Turn idle needle back in (clockwise)
past the position where the engine runs smoothly
until it begins
to slow down or run unevenly
(lean mixture).

Back the needle
halfwa~
between
provide
a smooth

out to a position
the two positions.
running
idle.

approximately
This
should

Main

(Load)

Fuel

unevenly
with a load applied,
may need adjustment.

If engine runs
adjusting
needle

Adjustment:

the main

1. Start

engine
and allow it to warm up.
Set idle adjustment
so engine runs smoothly.
(See
Idle Fuel Adjustment).
Carburetor
in on governor
mechanism
to slow engine
3. Push
speed to about 400 to 500 rpm.
4. Release
governor
mechanism
to a How engine
to
accelerate.
If engine
accelerates
evenly
wit bout
hes itat ion, main adjustment
is correct.
If not, turn
needle
(B) outward
about 1/2 turn and again release governor
mechanism.
Continue
this procedure
until engine
accelerates
evenly
and without
hesitation
after releasing
the governor.
tends
to hunt (alternate
increase
and
5. If engine
open
main
fuel
adjusting
decrease
of speed),
needle
a little
more. Do not open more than 1/2
turn beyond
maximum power point.
2.

CARBURETOR
1.
2.
3.
4.
5.
6.

Remove
Remove
Lift out
seat.
Remove
Remove
and pull
Remove
out the

DISASSEMBLY

the main jet assembly
and bowl.
the float pin and float. See Figure 6.
the fuel inlet valve and unscrew
the valve
the no-load
adjusting
needle.
the throttle
plate
screws
and the plate
out the throttle
shaft.
the choke plate screws
and plate and pull
choke shaft.

i &#-–

FUEL

INLET

‘~c:~;EToR

Y

o
B

A914
Rev.

FIGURE

5.

MAIN
FUEL
ADuJUSTMEIUT

CARBURETOR

ADJUSTMENTS

FIGURE

6.

FLOAT

ASSEMBLY

4’:

Cleaning
and Repair: To clean
the carburetor,
soak all
components
thoroughly
in a good carburetor
cleaner
following
the cleaner
manufact urer’s
instruct ions.
Be
sure
all carbon
is cleaned
from the carburetor
bore,
especially
in the area of the throttle
valve.
Blow out
the passages
with compressed
air. If possible,
avoid
using wire to clean out the passages.

Check
the adjusting
needles
and nozzle
for damage.
If the float is loaded with fuel or damaged,
replace
it.
The float should
fit freely on its pin without
binding.
Invert the carburetor
body and measure
the float level
(Figure
7). If necessary,
bend the small
lip that the
intake valve rides on to adjust
float level.
Check the choke
play and replace

and throttle
if necessary.

shafts

for excessive

BEND

side

TAB

FUEL

PUMP

The engine
uses a diaphragm-type
fuel pump. If fuel
does
not reach
the carburetor,
check
the fuel pump
before dismantling
it.

1. Disconnect

the fuel line at the carburetor.
the engine
slowly
by hand and observe
whether
fuel comes from the line at the carburetor.

2. Crank

Be sure to direct the fuel flow
rnto a container
so gas does not
on ignition wires.

EEiiia
spill
3.

If there
is enough
fuel in the tank, and
between
the tan~ and the pump is open
pump fails,
repair
or replace
it.

diaFailure
of the pump is usually
due to a leaking
phragm, valve or valve gasket,
a weak or broken spring,
to
or wear in the drive linkage.
If the operator
chooses
repair
the pump rather
than install
a new one, use
complete
repair kit. Refer to Parts Catalog.
Fuel

Pump

1. Remove

THIS DIMENSION
SHOULD BE
1/8’’ -3/16”

,

-“.

)-

I

A913

FIGURE

CARBURETOR
1.

7.

FLOAT

ADJUSTMENT

ASSEMBLY

Install
the throttle
shaft
and plate,
using
new
screws
and lockwashers.
Install
with bevel mated
to the carburetor
body. On plates
marked with the
letter
C, install
with the mark on the side toward
the idle port when viewed from the flange
end of
the carburetor.
To center
the plate,
back off the
top screw,
close
the throttle
lever and seat the
plate by tapping
it with a small screwdriver.
Then
tighten
the two screws.
the choke shaft and plate.
Center the plate
2. Install
in the same manner as the throttle
plate (step 1).
Use new screws
and lockwashers.
the fuel inlet valve seat and valve.
3. Install
the float, float pin and float spring.
Center
4. Install
the pin so the float bowl does not ride against
it.
the float level with the carburetor
casting
5. Check
inverted.
See Figure 7.
the bowl ring gasket,
bowl and bowl nut.
6. Install
Make sure that the bowl is centered
in the gasket
the float spring
is in place and tighten
the main
jet assembly
securely.
Turn in until it seats
and
back out 1 to 1-1/2 turns.
the idle adjusting
screw finger tight.
Then
7. Install
back out 1 to 1-1/2 turns.

the line
but the

Reconditioning:

fuel lines
and mounting
screws
holding
pump to engine.
mark with a file across
a point
2. Make an indicating
at the union of the fuel pump bolt and cover.
This
mark
will
assure
proper
reassembly.
Remove
assembly
screws
and remove
upper pump body.
3. Turn pump body over and remove valve plate screw
and washer.
Remove
valve retainer,
valves,
valve
noting their position.
springs
and valve
gasket,
Discard
valve
springs,
valves
and valve retainer
gasket.
4. Clean
pump body thoroughly
with solvent
and a
fine wire brush.
the pump cover with the diaphragm
sur5. Holding
face
up, place
the new valve
gasket
into
the
in
cavity.
Assemble
the valve spring
and valves
the cavity.
Reassemble
the valve
retainer.
Lock
in position
by inserting
and tightening
fuel pump
valve retainer
screw.
pump body assembly
in a clean
place and
6. Place
rebuild
the lower diaphragm
section.
bracket,
press down on the dia7. Holding mounting
turn
phragm
to compress
spring
under
it, then
bracket
900 to unhook
diaphragm
so it can be
removed.
with a solvent
and a fine
8. Clean mounting bracket
wire brush.
the diaphragm
fuel pump rod spring,
dia9. Replace
phragm gasket,
stand new spring in casting,
position diaphragm,
compress
spring
and turn 90° to
reconnect
diaphragm.
10. Hold bracket,
then
place
the pump cover
on i
(make sure that indicating
marks are in line) and
insert
the four screws.
DO NOT TIGHTEN.
With
the hand on the mounting
bracket
only, push the
pump lever to the limit of its travel
and hold in
this
position
while
tightening
the four screws.
This
is important
to prevent
stretching
the diaphragm.
11. Mount the fuel pump on engine,
using new mounting
gaskets.
Connect
~he fuer lines.

AIR

CLEANER

EE!KI
and score

NEVER
run engine
removed.
Dirt will
the cylinders.

To gain access
screw and pull

to air cleaner
out air cleaner

with air cleaner
enter carburetor

element,
loosen
inlet cover.

thumb

Under
normal
conditions
clean
filter
element
every
50 hours by blowing
out with low pressure
compressed
air. Replace
element
every
200 hours.
Check
or replace
more often if tractor
is operating
in dusty
or
dirty conditions.

FILTER
ELEMENT
LOOSEN
—

\

TO

w , V*

I

1

FIGURE

THUMB
SCREW
REMOVE

0

8.

AIR

CLEANER

;‘“
J:,

‘t<

GOVEW+!X!2R
SYSTEM

,.”
,,

ADJUSTMENTS
If governor
ing:

(Figure

requires

Low Speed Adjustment:

anical)
speed.

is

required

9)

1.

readjustment,

to

observe

A tachometer
accurately

the

(electric
set
the

foHow2.

or mechgovernor

3.

Use a screwdriver

to adjust
low speed stop
screw
(Figure
9) so engine runs at 1200 (t 100)rpm when
throttle
is held closed.
Readjust
carburetor
idle mixture
so engine
runs
smoothly.
Check
adjustment
made in step
1 and readjust
minimum
idle speed
if necessary.

THESE
TWO
SURFACES
SHOULD
TOUCH
WHEN
THROTTLE
IS IN
FULL SPEED
POSITION
A

\.
uSE

IzEE3

90°

PLIERS

TO

C&wL~v
AVOID

l\

@

::1 P
. SWIVEL

PLATE

.
FIGURE

9.

GOVERNOR

ADJUSTMENTS

High

1.
2.

3.

Speed and Cable

Adjustment:

Move engine
speed
control
on tractor
to “fast”
position.
With speed
control
in “fast”
position,
the speed
control
cable
should
be holding
governor
swivel
plate
against
stop
on
governor
base
plate
(Figure
9).
If speed
adjustment
is necessary,
remove
cable
clip and loosen
swivel
screw.
Hold end of cable
housing
1/8 inch from base
plate
mounting
edge
and using a 900 pliers
reinstall
cable clip.

Bending
the base
plate
will cause
misalignment
between swivel plate and
the edge of base plate.

EEEcI

4. Back

off from “fast”
posit ion on throttle
cent rol
arm until
inner cable
moves
forward
about
1/16
inch.
plate against
the stop edge and
5. Hold the swivel
tighten
the swivel
screw.
Recheck
to see if control pulls swivel plate against
the base plate.
running,
loosen
stud adjusting
nuts
6. With engine
and turn toward spring
(left) to increase
or away
from spring
(right)
to decrease
the high speed.
Tighten
nuts and check speed.
at no load should
be 3850 (f 100) rpm.
7. Top speed
CLEANING
Inspect

or wear.

the governor

Clean

otlen

linkage,

in dusty

springs,
etc.
conditions.

for binding

Ka’w’mml Ar’+m BATTERY CHARGING

BREAKER

POINTS

To
maintain
maximum
efficiency
from
change the breaker
points every 200 hours
Proceed
as follows:
1,
2

3.

4.
5.

6.
7.

2. Clean

the engine,
of operation.

Remove
the two screws
and the cover
on the
breaker
box.
Remove
the two spark
plugs
so engine
can be
easily
rotated
by hand.
If plugs
have not been
changed
within
the last 100 hours,
replace
them
with new ones after setting
the breaker
points.
Remove the two mounting screws
(A) and pull the
points out of the box- just far enough so screw (B)
can be removed.
See Figure
10. Replace
points
with
a new set but do not completely
tighten
mounting
screws
(A).
Remove and replace
condenser
with a new one.
Rotate
the engine
clockwise
(facing
flywheel)
by
hand until points
are fully open. Turn screw (C)
until
point
gap measures
.020 inch with a flat
thickness
gauge.
Tighten
mounting
screws
and recheck
gap.
Timing.
Proceed
to Ignition

3.
4.

5.
6.

off the timing mark on the timing bracket
(located
on rear bearing
plate) and also clean the
200 mark on the front clutch.
(For safety
turn off
front clutch and if possible
remove belt from front
clutch
pulley. )
Start engine and check for alignment
of these two
marks.
If misaligned,
loosen
the mounting
screws
on
breaker box (Figure
10) and move breaker box left
to advance,
or to the right to retard the timing,
Tighten
breaker
box screws
and recheck
timing.
Replace
breaker box cover and any other hardware
removed.

Ignition

NOT E: Each time rrew breaker points are installed,
place a drop of oil on the point’s
pivot point
(Figure 10).

-

Engine Not Running

Connect
a continuitytest
lamp set across the ignition breaker
points.
Touch
one test prod to the
breaker
box terminal
to which the coil lead is
connected
and touch the other test prod to a good
ground on the engine.

2.

Turn
crankshaft
against
rotation
(counterclockwise) until the points close.
Then s lowly turn the
crankshaft
with rotation
(clockwise).
As the points begin to open the light will flicker
or go out. At this time the ‘timing marks should be
aligned.
If not, adjustment
is necessary.
Align timing marks and loosen breaker box screws
(Figure
10). Move breaker box to the left (advance)
or to the right (retard) until the light flickers.
Tighten the breaker box screws and recheck timingl

3.

4.

PLACE DROP OF OIL ON PIVOT POINT
WHENEVER
NEW POINTS ARE
INSTALLED.

Timing

1.

5.

SPARK

PLUGS

Remove
both spark plugs and install
new
100 hours. Use Champion
H-8 or equivalent.
be sure spark plug gap is set at .025 “.
REFER

ones every
Check to

s

APPROXIMATE

TIMING

TO ADVANCE

OR RE;ARD~

I

4

FIGURE

IGNITION

10.

BREAKER
& TIMING

POINTS
ADJUSTMENT

TIMING

Ignition Timing – Engine Running
Always

check

or if noticing

timing
after
poor engine

replacing
ignition
points
performance.
Proceed
as
SPARK
0.025’”

follows:
1“
\

1.

To accurately
check
the ignition
timing,
use a
timing light when engine
is running.
Connect
the
timing
light
according
to its manufacturer’s
instructions.
Either spark plug can be used as they
fire simultaneously.

FIGURE

13

I 1. SPARK

PLUG

GAP

GASOLINE

“PLUG GAP

IGNITION COIL
To test
primary
and secondary
ignition coil .proceed
as follows:

windings

within

Keep the battery
of moisture
will
battery
failure.

the

1. Use a Simpson 260 VOM or equivalent.
2. Place back lead on ground (-) terminal

of coil and
Primary
resis-

case
lead

clean and dry. An accumulation
to a more- rapid discharge
and

,/-

(

Keep the battery
terminals
clean and tight. After making connections,
coat the terminals
with a light application of petroleum
jelly or grease to retard corrosion.

red lead to positive
(+) terminal.
tance should read 3.87 - 4.73-ohms.
resistance
setting
on ohmmeter.
Place
3. Change
ohmmeter
leads
inside “of spark
plug cable
holes
(Figure
12).
Secondary
resistance
should
read
12,60015,400-ohms.
4. If any of the above conditions
are not met, replace
coil. Refer to Parts Catalog for correct part number.

Check
battery
cells
to make sure they are filled
to
appropriate
level
adding
distilled
water
as required.
Check
specific
gravity
in each cell.
Specific
gravity
shald
be 1,280 at 80° F; if not, recharge
battery
to
bring it up to this level.

This

engine uses a 12 volt, negative
system.
Alternator
must be
connected
to battery at all times when engine is running. Do not reverse battery cables. Damageto regulator
or [gnition coil could result if cables are reversed.

=&round

NOT E: Poor contact at the battery cable connections
is often a source ot’ trouble. Make sure battery .-

11.svolt

3700
Draw

60 A Max.

AMMETER

sWITCH

~

1

I

FIGURE

28.

TESTING

FIELD

COILS

FOR

OPENS
BATTERY

8.

Inspection
of Brushes:
When brushes
are worn more
than .3 “ they are to be replaced.
Figure 29 shows
the wear limit. See that the brushes
move smoothly
in the brushholders.

WEAR

LINll TT

u
–____

T
.55”

.3”

,
FIGURE

29.

BRUSH

WEAR

-L

~
=
~
~—

MvEOTLETRv

“

RPM
ND ICATOR

.—

LIMIT

FIGURE

20

,,
(’
‘~.

31.

STARTER

MOTOR

WIRING

NOTE: The conductor for this test should be large
enough and as short as possible,
If anything is
wrong in the previous test, inspect the following
items:

.-

o Annealed brush springs
e Improperly seated brushes
●
●
●

STARTING
MOTOR

\

●

J

FIGURE

FIGURE

,/

(..

33,

32.

●

BATTERY

2.

BATTERY

ADJUSTING

CONNECTIONS

PINION

CLEARANCE

Insufficient
armature “end play
Shorted, open or grounded armature
Grounded or open field coil
Poor electrical
connection
Dirty commutator

To adjust
pinion
clearance,
connect
the battery
to the starting
motor as shown in Figure 32. This
will allow the pinion of the starting
motor to slide
and stop.
In this
state,
measure
the clearance
between the end of the pinion and pinion stop when
the pinion is pushed lightly toward the commutator
end. Clearance
should be .02 “ to :06 “. Adjust for
proper clearance
by removing the magnetic
switch
attaching
screws
and select
the proper thickness
of the fiber packings
shown in Figure 33.

,-

ENGINE DISASSEMBLY

If engine
disassembly
is necessary,
first
remove all
the complete
assemblies
(e.g. manifold
with carburetor
and cartridge
air cleaner.
Individual
assemblies,
as the
car buretor, ” can be removed
and serviced
later,
if
necessary.
Any special
assembly
instructions
for a
particular
group are included
in the applicable
section.
When
reassembling,
check
each
section
for these
special
assembly
instructions
or procedures.

(-.

Do not drop the flywheel.
A broken fin will destroy
balance.
Always use a steel key for mounting the
wheel,

the
fly-

Emit’

Do not use a screwdriver
or similar
tool or pry behind the flywheel against
the gearcase.
The gearcase cover is die-cast material
and will break if undue pressure
is applied in this
manner.

FLYWHEEL
To remove
the flywheel,
turn the flywhe”el mounting
screw
outward
about two turns and use Onan puller
420-0100

to pull the flywheel

(Figure

34).

-

GEAR COVER
After removing
the
tap the gear cover
loosen
it.

flywheel
key and mounting
screws,
gently with a soft-faced
hammer to

When installing
the gear cover, make
sure that the pin in the gear cover
the governor cup correctly (see below).

EziiEcI

engages

Turn the governor cup so that the metal lined hole is
at the three o’clock
position.
The smooth side of the
governor yoke must ride against
the governor cup. Turn
the governor arm and shaft clockwise
as far as possible
and hold in this position
until the Rear cover is in‘Be “careful not to
stalled
flush against
the crankcase.
damage the gear cover oil seal. Adjust the roll (stop)
pin to protrude
to a point 3/4 inch from the cover
mounting
surface.
See Figure 36.
FIGURE

34.

ONAN

FLYWHEEL

- ‘(
-

PULLER-

GOVERNOR

ARM
R

SHAF

NOR
YOKE
Side

cup)
SEAL
IF

FEELER

ENTER

BALL

FALLEN

FIGURE

35.

GEAR

COVER

ASSEMBLY

WILL

HOLE

1/29’,

HAS
OUT

(’\.

GOVERNOR

CUP

\Vith the gear cover removed,
the governor
cup can be
taken off after removing
the snap ring from the camshaft center
pin. Catch “the flyballs
while sliding
the
cup off. See Figure 36,

t--k

WHEN
GOVERNOR
IS PROPERLY
AS SE ME LEO
THE
DIMENSION
SHOWN
ON
ORAWING
wlLL
BE AS
INDICATED

CENTER

#“,;,,
The camshaft
may be pressed
out of the gear by use of
a hollow tool or pipe which will fit over the camshaft
center
pin. Do not press on the center
pin or damage
it in any way. The governor ball spacer
is a press fit
to the camshaft
gear.

CAMSHAFT
GEAR

..
‘?’

*

When pressing
a camshaft
gear onto the camshaft,
be
sure the gear is started
straight
and that the key is
properly in place. When replacing
the cam gear on units
having
automatic
spark advance
mechanisms,
remove
the spark advance
mechanism
and put blocks
beside
the pins to avoid damage when pressing
on cam gear.
Install
the governor cup assembly
before installing
the
camshaft
and gear in the engine.

PIN

sr+AP

RINGJ

GOVERNOR

GOVERNOR

b

CUP

3 Al
‘

>?.-/

Each timing gear is stamped
with an O mark near the
edge.
The gear teeth must mesh so that these
marks
coincide
exactly
when the gears are installed
in the
engine (Figure
37). Be sure, when installing
the camshaft gear and shaft assembly,
that the thrust
washer
is properly in place behind
the camshaft
gear. Replace
the camshaft
retaining
washer
and lock ring to the
crankshaft.

‘,

FLYBALL

Iwiiii
[W?&d

“em
FIGURE

36.

The camshaft
gear is pres=ed
on and keyed
to the
camshaft.
The camshaft
and gear must be removed as
an assembly
aft,er first removing
the crankshaft
gear
lock ring and washer.
Before
removing
the camshaft
and gear assembly,
remove the cylinder
head and valve
Remove
the operating
plunger
for the
assemblies.
breaker points.
Remove the fuel pump and tappets.

GOVERNOR

CUP

Replace
any flyball that is grooved or has a flat spot.
If the arms of the ball spacer
are worn or otherwise
damaged,
replace
the entire
timing
gear . set.
The
governor
cup must spin freely on the camshaft
center
pin [vithout excessive
looseness
or wobble.
If the race
surface
of the cup is grooved or rough, replace
it with
a new one.
\~hen installing
the governor
cup, tilt the engine
the gear is up, put the flyballs
in place and install
cup and snap ring on the center pin (Figure
36).

so
the

The camshaft
center pin extends
out 3/4 inch from the
end of the camshaft.
This distance
provides
an in-andout travel distance
of 7/32 inch for the governor
cup,
as illustrated.
Hold the cup against
the fly balls when
measuring.
If the distance
is less (the engine may race,
especially
at no load), remove the center pin and press
a new pin in only the required
amount.
Otherwise,
grind off the hub of the cup as required.
The camshaft
center piri cannot be pulled outward nor removed without damage.
If the center
pin extends
out too far, the
cup will not hold the flyballs
properly,

,.
;
[

TIMING

GEARS

If replacement
of either
the crankshaft
gear or the
camshaft
gear becomes
necessary,
install
both gears
new, never one only. Use a gear pulling ring (Onan No.
420-0248)
to remove
the crankshaft
gear. Be sure to
remove the snap ring first.

FIGURE

37.

TIMING GEAR REMOVAL
AND INSTALLATION

CYLINDER
HEADS
The ‘cylinder
heads should
be tightened
in the order
designated
per Figure 38 to a torque of 5 foot-pounds,
then 10 foot-pounds,
etc. until all are torqued
to 29
to 31 foot-pounds,

/

f

“’VEF7
i,

.0 I

I0.

5=====

6

NO.1 CYLlNDF41

FIGURE

NO.2

3B. HEAD

BOLT

CYL8NDSR

FIGURE

TIGHTENING

40.

VALVE

FACE

AND

SEAT

ANGLES

SEQUENCE

VALVES

The valve face
45°.
This
1°
seating
surface
valve seat.
The
valves
minimizes
life (Figure 40).

Properly
seated
valves
are essential
to
good engine
performance.
The cylinder
head is removable
for valve
servicing.
Do not use a pry to loosen
‘the cylinder
head.
Rap sharply
on the edge
with
a soft-faced
hammer, taking care not to break any cooling
fins. A
conventional
type valve spring lifter may be used when
removing the valve spring locks, which are of the split
type. Clean “all carbon deposits
from the cylinder
head,
piston
top, valves,
guides,
etc.
If a valve
face is
burned
or warped,
or the stem worn,
install
a new
valve.

from the
assemblies.

valve

(-’
...

The valves
should not be hand lapped,
if at all avoidable, since the sharp contact
may be destroyed.
This
is especially
important
where
stellite
faced
valves
and seats
are used. Valve faces should be finished
in
a machine to 440. Valve seats should be ground with a
45° stone
and the width of the seat band should be
1/32 to 3/64 of an inch wide. Grind only enough to
assure
proper seating.

Worn valve stem guides
may be replaced
from inside
the valve chamber.
See Figure
39. A seal is provided
behind
the intake
valve
guides
only.
The smaller
diameter
of the tapered
valve guides must face toward
the valve head.
Tappets
are also replaceable
after first removing the valve

angle is 440. The valve seat angle is
interference
angle
results
in a sharp
between
the valve and the top of the
interference
angle method of grinding
face deposits
and lengthens
valve

Remove all grinding
compound
from engine
parts
and
place
each valve
in its proper location.
Check each
valve for a tight seat,
using an air pressure
type testing tool. If such a tool is not available,
make pencil

chamber,

I
NOTE

-

USE

AUTOMOTIVE
TO

ADJUST

A

THE

NOTE

STANDARD

TYPE

-

SEE

VALVE

TAPPET

WRENC

TAPPETS.

I
I

L

FIGURE

39.

CCKE

VALVE

L_

1

SYSTEM

..

marks at intervals
across
the valve face and observe
it’ the marks rub off uniformly when the valve is rotated
part of a turn against
the seat.
Lightly
oil the valve
removed.
Adjust
the

stems
valve

PISTONS AND RINGS
Whenever there is a noticeable
wear ridge at the top of
each cylinder,
remove
the ridge with a ridge reamer
before removing
the pistons.
If ridge is -not removed,
the rings
can catch
the ridge when pushing
out the
pistons
and cause a ring land fracture
(Figure
42).

and reassemble
all parts
Tappet
clearance
(see

Adjust ment).
The positive
type valve
rotocoils
serve
to prolong
valve life and decrease
valve repairs.
Check the rotocoils periodically
by removing
the cylinder
heads and
cranking
the engine.
When functioning
properly,
the
valve is rotated a fraction
of a turn each time it opens.
If rotocoils
are faulty,
install
new ones.

TAPPET

WEAR

-—
—

ADJUSTMENT

To correct
the valve
clearance,
screw
as needed
to obtain
the
screw is self-locking.

PISTON

turn the adjusting
right clearance.
The

AND
TABLE

EXHAUST
OF

.. ..-. .

FIGURE

42.

PISTON
BREAK

WEAR

,WITH
RING

RIDGE

LARGE
WEAR
OR
RING
LAND.

ON CYLINDER

WALL

To remove the piston
and connecting
rod assemblies,
turn the crankshaft
until a piston
is at the bottom of
the stroke.
Remove
the nuts from the connecting
rod
bolts.
Lift the rod bearing
cap from the rod and push
the rod and piston assembly
out the top of the cylinder
with the handle
end of a hammer.
Be careful
not to
scratch
the
crankpin
or the
cylinder
wall when
removing
these
parts.

VALVES

CLEARANCES)

S

REk40v
ING
RIDGE
COULD

To adjust
the valves
on the right hand cylinder,
crank
the engine
over one complete
revolution
and again
line up the correct
timing
marks.
Then
follow
the
adjustment.
given
for the valves
of the. left hand
cylinder.

(SEE

LAND

CYLINDER
WALL

The engine
is equipped
with adjustable
tappets.
To
make a valve
adjustment,
remove
the valve
covers.
Crank the engine
over slowly
by hand until the left
hand intake
valve,
when facing
the flywheel,
opens
and closes.
Continue
about 1/4 turn until the correct
timing marks align.
This
should
place
the left hand
piston at the top of its compression
stroke,
the position it must be in to get proper valve adjustment
for
the
left
hand
cylinder.
Clearances
are
shown
in
Dimensions
and Clearances
section.
For each valve,
the gauge should
just
pass
between
the valve
stem
and valve tappet
(Figure 41).

INTAKE

RING

RIDGE”

/

NOTE:
bearings

Keep the connecting
with their respective

rod bearing
rods.

caps

and

The pistons
are fitted with two compression
rings
and
one oil control
ring with an expander.
Remove ‘these
rings
from the piston
using
a piston
ring spreader.
Clean
the piston
ring grooves
with a groove cleaner
or the end of a broken ring filed to a sharp point (see
Figure
43). All passages
should
be cleaned
with a
non-caustic
solvent.
Clean the rod bore and the back
of the connecting
rod bearings
thoroughly.

..
-1’
(,
FIGURE

41.

ADJUSTING

Mark each piston
to make sure the rod will be assembled on the piston from which it was removed.
Remove
the piston pin retainer
from each side and push the pin
out .

TAPPETS

25

Improper
width rings or excessive
ring side clearance
can result
in ring breakage.
New rings in worn ring
contact
grooves
don’t
have
good
cylirider
wall
(Figure
45).
Replace
pistons
showing
signs of bad scoring
or burring,
excessive
skirt
clearance,
wavy or worn ring
lands,
fractures
or damage
from detonation.
Replace
piston
pins showing
fractures,
scored
bores or bores
out of round more than 0.002 inch.

CYLINDER
WALL

FIGURE

45.

NEW

RING

PISTON

... ...-—.

IN

RING

WORN

GROOVE

Use a new piston pin to check the pin bushing
should
connecting
rod for wear. The clearance
and Clearances
section.
shown in Dimensions

B21

FIGURE

43.

CLEANING

RING

in the
be as

f’
ix....

GROOVES

Inspect
the pistons
for” fractures
at the ring lands,
skirts
and pin bosses.
Check for wear at the ring land
using
new rings
and a feeler
gauge
as showrr
in
section
and Clearances
Figure 44. See Dimensions
for proper side clearance
measurement
and ring groove
widths.

Before
installing
new rings on the piston,
check the
ring gap by placing
each-ring
squarely
in its cylinder
at a position
corresponding
to the bottom of its travel
(see Figure 46). The gap between
the ends of the ring
and Clearances
section.
Rings
is given in Dimensions
which are slightly
oversize
may be filed as necessary
to obtain the correct
gap, but do not use rings which
require
too much filing.
Standard
size
rings
may be
used
on .005 inch oversize
pistons.
Other oversize
rings must be used with corresponding
oversize
pistons.

RING IN
R BORE

FIGURE

44.

INSPECTING

RING

LANDS

FIGURE

46.

w

FITTING

PISTON

GAGE

-(”
‘k.,..
RINGS

Rings

of the tapered
or identified
ring must be installed
end of the piston.

one side,

/“
“,,

type are usually
marked
top on
in some other manner and the
with this mark toward the closed

Space each ring gap one third of the way around the,
piston
from the preceding
one, with no gap directly
in line with the piston.
pin.
The bottom piston
ring
groove should
be fitted
with an expander
and an oil
control
ring and the two upper
grooves
fitted
with
compression
rings:
If a chrome faced ring is used, it
will be in the top groove. The oil control ring is selected for best performance
in regard to the correct
unit
pressure
characteristics.
The piston
is fitted
with a full-floating
type piston
pin. The pin is kept in place by two lock rings in the
piston,
one at each side. Be sure these lock rings are
properly
in place before installing
the piston and conand
necting
rod in the engine.
Refer to Dimensions
Clearances
section
for the correct
piston-to-cylinder
clearance.

CONNECTING

RODS
The connecting
rods should
be serviced
at the same
time the pistons
or rods are serviced.
Rods must be
removed
with the piston.
Replaceable
bushings
and
bearings
Catalog
section
for
are
used.
See Parts
available
undersize
and standard
size bearings.

(’

Proper
clearance
is obtained
by replacing
bushing
and the bearings.
The rod bearings
cision
size and require
no reaming.

FIGURE

the pin
are pre-

CYLINDER
1.

Place
a piece of correct
size Plastigage
cap the full width of the bearing
insert
off center
(Figure 47),

2.

Make
so that

3.

in the bearing
about 1/4 inch

4.

~.. .

CLEARANCE

BLOCK

Make a thorough
check for cracks.
Minute cracks
may be detected
by coating
the suspected
area
with a mixture of 25% kerosene and 75% light motor
oil.
Wipe the part dry and immediately
apply a
coating
of zinc oxide (white
lead)
dissolved
in
wood ~lcohol.
If cracks
are present,
the white
coating
will become
discolored
at the defective
area.
Inspect
the cylinder
bore for scoring.
Check the
Welsh plugs for a tight, even fit and the fins for
breakage..
Check the cylinder
bore for taper,
out of round
and wear with a cylinder
bore gauge,
telescope
gauge
or inside
micrometer
{Figure
48). These
measurements
should
be taken
at four places
–
the top and bottom of piston -ring travel.
Record
measurements
taken lengthwise
at the top
and bottom of the piston travel as follows:
a.

Rotate
the crank
about 30° from bottom dead center
and reinstall
the bearing cap. Tighten
the bolts to the
Torques and Special
torque specified
in the Assembly
Tools section.
Do not turn the crankshaft,

,{.

MEASURING
BEARING
WITH PLASTIGAUGE

Inspection:

Install
the connecting
rods and caps with raised
lines
(witness
marks) aligned and with the caps facing toward
the oil base.
The rod and cap numbered
2 fits on the
crankshaft
journal
nearest
the bearing
pla~e. Coat the
crankshaft
journal
bearing
surfaced
with
oil before
installing
the rods. Crank the engine
by hand to see
that the rods are free. If necessary,
rap the connecting
rod cap screws
sharply
with a soft-faced
hammer to
set the rod square on the journal.
Checking
Bearing
Clearance
with
Plastigage:
certain
that all parts are marked or identified
they are reinstalled
in their original positions.

47.

b.

Remove
the bearing
cap. Leave
the flattened
Plastigage on the part to which i! has adhered
and compare
the widest
point with the graduations
on the Plastigage envelope
to determine
bearing clearance.

c.

27

Lengthwise
of the block,
measure
and record
as “A” the diameter
of the cylinder
at the top
of the cylinder
where the greatest
ring wear
occurs.
Also,
lengthwise
of the block,
measure
and
diameter
at the
record
as ‘ ‘B” the cylinder
piston
skirt travel.
Crosswise
of the block, measure
and record “as
“C” the diameter
of the top of the cylinder
at
the greatest
point of wear.

Repair:
1.

2.

3.

4.
5.

6.

7.

8.

9.
FIGURE

48.

METHODS
BORE

OF

A hone can be used to rebore a cylinder
(Figure
49). Remove stock to 0.002 inc% undersize
of finish
bore with coarse
hone (100 grit),
then complete
honing with finish
hones (300 grit).
Anchor
the block
solidly
for either
vertical
or
horizontal
honing.
Use either
a drill
press
or
heavyduty
drill which operates
at approximately
250 to 450 rpm.
Lower the hone into “the cylinder
until it protrudes
1/2 to 3/4 inch past the end of the cylinder.
Rotate
the adjusting
nut until the stones
come in contact
with the cylinder
wall at the narrowest
point.
Turn the hone by hand. Loosen
the adjusting
nut
until the hone can be turned.
Connect drill to hone and start drill. Move the hone
up and down in the cylinder
approximately
40
cycles
per minute. Usually
the bottom of the cylinder must be worked out first because
it is smaller.
Then when the cylinder
takes a uniform diameter,
move the hone up and down all the way through the
bore. Follow the hone manufacturer’s
recommendations for wet or dry honing and oiling the hone.
Check the diameter
of the cylinder
regularly
during
honing:
A dial bore gauge is the easiest
method
but a telescoping
gauge can be used. ” Check the
size at six places
in the bore; measure
twice at
at the top, middle and bottom at 90° angles.
When the cylinder
is approximately
0.002
inch
within the desired
bore, ch-ange to fine stones
and
finish the bore. The finish should not be smooth
but as shown in Figure 50. The crosshatch
formed
by the scratching
of the stones
should
form an
angle of 230. This can be achieved
by moving the
hone up and down in the cylinder
about 40 cycles
per minute.”
Clean
the cylinder
block thoroughly
with soap,
water and clean rags. A clean white rag should not
be soiled
on the wall after cleaning
is complete.
Do not use a solvent
or gasoline
since they wash.
the
oil
from the
walls
but
leave
the
metal
particles,
”
Dry the crankcase
and coat it with oil.

CYLINDER

INSPECTION

d.

Measure and record as “D” the diameter
at the
bottom
of the cylinder
bore and crosswise
of
the block.
e. Reading
“A”
compared
to reading
“B”
and
reading
“C”
compared
to reading
“D”
indicates
cylinder
taper.
f . If cylinder
taper
exceeds
0.005 inch,
rebore
and hone to accommodate
the next oversize
piston.
Reading
“A” compared
to reading “C”
and reading
“B”
compared
to reading
“D”
or not the cylinder
is out of
indicates
whether
round. If the out of round exceeds
0.002 inch,
the cylinders
must be rebored
and honed for
the next oversize
piston.
A reboring
machine
is used when going to oversize
pistons.
The
following
repair data covers
honing to oversize
by use of a hone.

FIGURE

28

49.

HONING

CYLINDER

( .._

, ,~.,
...

PRODUCE
FOR

CROSS
FAST

HATCH
RING

SCRATCHES
AVOID

SEATING

FIGURE

50.

CORRECT

HONE

THIS

FINISH

FINISH

,CRANKSHAFT
Inspect
the bearing
journals.
If they are scored
and
cannot be smoothed
out by dressing
down, the bearing
journals
should be refinished
to use nearest
available
undersize
bearings
or a new crankshaft
should
be
installed.
If a worn main bearing
journal- cannot
be
fitted
with
an available
precision
type
undersize
bearing,
then refinish
it to the next undersize.
If a
-worn rod journal
cannot
be fitted
by installing
new
bearing
inserts
(forged
rod), then refinish
it to take
the corresponding
undersize
bearing insert available.

reduce
friction.
Place
the bearing
on the crankcase
over the bearing
bore with the lubricating
hole (front
only) in proper position.
Be sure to start the bearing
straight.
Press
the front bearing
in flush with the outside end of the bearing
bore. Press
the rear bearing
in until past the ignition
plunger hole.

PRECISION
TYPE
Do not line ream

-

or bore.

Whenever
making major repairs
on the engine,
inspect
the drilled
passages
of the crankshaft.
them to remove
any foreign
material
and to
proper lubrication
of the connecting
rods.

always
Clean
assure

. --— __________
ALIGN
HOLE
WITH

HOLE

~~
_____
BEARING,

IN

IN BEARING

BORE

,..-

\,
k..

or crankshaft
bearings
requires
complete
disassembly
of the engine.
Use a press or a
suitable
drive
plug to remove the bearings.
Support
the casting
to avoid distortion
and avoid damaging
the
bearing
bore during removal
and installation.
Use oil
on the bearings
to reduce friction
wherr installing
and
again lubricate
with oil after installing
(see Figure 51).
Use combination
bearing
driver 420-0324
to install
the
camshaft
bearings.
Camshaft
are precision
type
Replacement
camshaft
bearings
which do not require
line reaming or line boring
after
Coat the bearing
with lubricating
oil to
installation.

:

~k

~
)*J

7/329’
Y“?.
SIOE

CAMSHAFT

BEARINGS
Remova 1 of the camshaft

.,,,,.

—

,;l (LOCK
~:,7-7-TCALIGN
I . ‘,&,&
f
.\:

/j

,:

BEARING
HOLES

OIL

f

IN

).

&:/
ynl)~.~

WITH
SORE

THRUST
WASH ER

To
PRECISION

LOCK

PIN

CRANKSHAFT

51.

TYPE

Do not line ream
or
-. bore.
_—._

‘BEARING

FIGURE

OIL HOLES
BEARING

,T
j/

~,i

BEARING

PIN

INSTALLATION
CRANKSHAFT

BEARING

OF

CAM AND

BEARINGS

-

.

Crankshaft
New crankshaft
main bearings
are precision
type which
do not require line reaming or line boring after installfor standard
size and
ation. See Parts Catalog section
undersizes
available.

bearing
plate
420-0313.

Before putting in the main bearings,
expand the bearing
bore by placing the casting
in hot water or in an oven
heated to 200°F.
If practical,
cool the precision
bearing to shrink it.

plate must be removed
to replace
the oil seal
out from the inside

and

gear

cover

driver

When installing
the gear cover oil seal,
tap the seal
inward until rear (spring side) of casing
is 1 inch from
the mounting
face of the cover.
Install
new style,
thin
open face seal,
1-7/64 inches
from mounting
face ot’
cover.
When installing
the bearing
plate
oil seal,
tap the
seal into the bearing
plate bore to bottom against
the
shoulder
in the plate
bore. Use a seal expander,
or
place
a piece
of shim stock
around the end of the
crankshaft,
when replacing
the bearing
plate to avoid
Remove
the shim stock
as soon
damaging
the seal.
as the plate is in place.
Engines
equipped
with some types
of reduction
gear
assemblies,
do not use the rear oil seal. The reduction
gear assembly
is oiled directly
from the engine crankcase.
Refer to the instructions
Screened
on the case
of the reduction
gear assembly.

SEALS

The bearing
seal.
Drive

420-0181

Before
installing
the seals,
fill the space
between
seals
with a fibrous
grease
or stiff cup grease,
This
will improve sealing
(-see Figure 52).

For putting
in either
the front or rear main bearing,
using
instructions
following,
always
align
the oil
hole(s) in the bearing with the oil hole(s) in the bearing
bore. The oil passage
must be at least 1/2 open. The
cold oiled precision
bearing
should require
only light
taps to position
it. Install
the bearing
flush with the
inside
end of the bore.
If the head of a lock pin is
damaged,
use side cutters
or “Easy -Out’’tool
to remove pin. Then install
a new lock pin. Apply oil to the
thrust
washers
to hold in place
when the crankshaft
is installed.
The oil grooves
in the thrust
washer
bearings
must face the crankshaft.
Be sure two notches
fit over lock pins.

OIL

driver

its oil
using

~...

(.,

“[
Use

between

seals

improve seal.

GE

I

J

heavy fiber or
in space

cup grease

to

,REAR BEARING PLATE

THIS SURFACE SHOULD BE
CLEANED
OF
ALL
OLD
SEALING
COMPOUND
BEFORE
INSTALLING
SEAL.

DRIVE OR PRESS OIL
SEAL TO SHOULDER
OF THE PLATE BORE
GEAR COVER OIL” SEAL

FIGURE

52.

GEAR

REAR BEARING PLATE
OIL SEAL

COVER

AND

REAR

30

BEARING

PLATE

OIL

SEALS

.,

CRANKSHAFT
After
using

ENDPLAY

OIL

the
the

rear bearing
end plate
has been tightened
Torques
torque
recommended
in Assembly
and Special Tools section,
check the crankshaft
endplay as shown
in Figure
53. If there
is too much
and Clearances
section
for
endplay
(see Dimensions
minimum and maximum endplay),
remove the rear bearing end plate and replace
the gasket
with a thinner
gasket
from the gasket
kit.
For too little
endplay,
remove
the rear bearing
end plate
and replace
the
gasket
with a thicker
one. Reinstall
the
end plate
making
sure the thrust
washer
notches
line up with
the lock pins.
Torque
and recheck
endplay
of the
crankshaft.

PUMP

Check the oil pump thoroughly
for worn parts.
Oil the
pump to prime it before reinstalling
(Figure
54). Except
for gaskets,
the component
parts of the pump are not
available
individually.
The suction
cup is available
separately.
Install
a new pump as”sembly, if required.

CR

UNSCR
FRU4
I
To reas

~.,..

h-REAR

!~

1,

,,,,

~

BEARING
PLATE

,,,

~

)

Ik

pl!!!.,

MEASURE

.: ..,,.
,,, ,,:..
.:.
“’”J

FIGURE

53.

(Refer

o

FIGURE

!

MEASURING
EN DPLAY

EN DPLAY

HERE
to table

c I earan ces)

CRANKSHAFT.

of

54..

OIL

PUMP

PARTS CATALOG
This catalog applies to tractor
identified by a reference. Part
select the Parts Key No. that
models. Right and left engine

application CCKB Engines. Parts are arranged in groups of related items and are
illustrations are typical. Using the Model and Spec No. from the engine nameplate,
applies to your engine. This Parts Key No. represents parts that differ between
sides are determined by facing the blower end (front) of the engine.

INSTRUCTIONS

FOR ORDERING

For parts or service, contact the dealer from
Authorized Onan Parts and Service Center.

REPAIR PARTS

whom you purchased this equipment

To avoid errors or delay in filling your parts order, please furnish all information
Always refer to the nameplate
1. Always give the MODEL

-

or refer to your Neares

requested.

on your unit:
and SPEC NO. and SERIAL NO.

PARTS KEY TABLE
MODEL

AND SPEC NO.

CCKB-MS/2420
CCKB-MS/2440
CCKB-MS/2733

For handy
nameplate

reference,
information

PARTS KEY NO.

H
H
J

,+
,~,2]
3

(-.

insert YOUR engine
in the spaces above.

2. Do not order by reference number or group number; always use part number and description.
.3.

Give the part number, description and quantity needed of each item. If an older part cannot be identified,
return the part prepaid to your dealer or nearest AUTHORIZED
SERVICE STATION. Print your name and
address plainlyon the package. Write a Iettertothe same address stating the reason for returning the part.

4. State definite shimin~ instructions. Any claim for loss or damage to your unit in transit should be filed
promptly against’ ihe ~ransportation company making the delivery. Shipments are complete unless the
packing list indicates items are back ordered.
Prices are purposely omitted from this Parts Catalog due to the confusion resulting from fluctuating
import duties, sales taxes, exchange rates, etc.
For current parts prices, consult your Onan Dealer, Distributor or Parts and Service Center.

32.

“

costs,
c -.

P. 3.’3

-.
\. .

~

,’,.
., .,,
,.
.. . . .
.

..

p=:.

;.~,~

.,,

‘:.

,ke’
$@J
\\

>~j’ ““’:5

;.. .
.,
i,,.
=--’+%
‘ “’
30
I

‘

4 3

w

‘.

.:“

$-

.r

.7

THE

w————

vOLTAGE

REG.

uVASUSE130fUEARL’f
PR(XX.I~13N
AND

PART
..

MOQEL

IS AN ONA$J

:
-

‘“”

:
‘.*%
,.
.

;

. ...,.

,
.

..;.
:L~+
+

-.,

:.%?- .’..
‘:: ‘,..,

%,.
.,-,: ...
“;:..

.+.!:::
:’:”:’”,
., ...,.
.. .

. .-

..,,
... ,,,,,,+ ,.,,.
... ,..
.
.. ...
.

.

:.*

.

... ,,

..”,,

..”.

.“’. .-:’-“’

“,,
;.,,;

.-,

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,,.

,,..
. ..’..-

v

“’ -)

qil(il;’.

.

,.

*

“,,

26

27

I

.:

___
u “II

DRANKSHAFT, FLYWHEEL, CAMSHAFT
AND PISTON GROUP
-—.
----Htt.
PAH 1
UTY.
PART
NO.

NO.

USED

REF.
NO.

DESCRIPTION

1 50%

7

2
3
4
5

6

7
8
9
10
11

12
13
14

15

T
Ring, Camshaft Center Pin
150-0612
1
Cup, Governor
510-0015
5
Ball, Fly-Governor
134-0673
1
Gear, Ring -Flywheel
FLYWHEEL (Includes Ring Gear and Rotor)
134-2621
1
Key 1 (15 Amp. Alternator)
134-2642. “
Key 2 & 3 (20 Amp. Alternator)
105-rx%zE3033Z
j
Gear ~,
Timing (Includes
~t
GeeI@- i%-’iJ
hAIJtd
+)
105-0004
1
Washer, Camshaft Gear Thrust
515-0001
1
Key, Camshaft Gear Mounting
105-0238
1
Camshaft (Includes Center
Pin)
150-0075
1
Pin, Camshaft Center
PISTON AND PIN (Includes Retaining Rings)
l!.’-O*I79
‘2
Standard
11,~-o
2
.005” Oversize
112-0
-lo
2
.01 O“ Oversize
112-0
-20
2
.020” Oversize
1 I 2-o
-30
2
.030” Oversize
1 I 2-o K -40
2
.040” Oversize
112-0069
2
Pin, Piston
112-0003
4
Ring, Piston Pin Retaining
z.
114-0203
Rod Assembly, Connecting
(Forged) - Includes Bushing
and Place Bolts
RING SET, PISTON
113-0153
2
Standard
.005” Oversize
113-0153-05
2

PART
NO.

113ZXZ-10
113-0153-20
113-0153-30
113-0153-40
805-0010

OTY.
USED

Y

25

.01 0“ Oversize
.020” Oversize
.030” Oversize
.040” Oversize
Bolt, Place - Connecting
Rods (Special)
BEARING, CONNECTING
ROD
114-0188
4
Standard
114-0188-02
4
.002” Undersize
114-0188-10
4
.010” Undersize
114-0188-20
4
.020” Undersize
114-0188-30
4
.030” Undersize
114-0036
2
Bushing, Piston Pin Connecting Rod
526-0128
Washer, Flywheel Mounting
KEY, FLYWHEEL ~OUNTING
515-0098
1 #Key3
515-0002
Key l&2
1
104-0170
1
Screw, Flywheel Mounting
(Special)
515-0001
1 # Key, Crankshaft Gear
Mounting
518-0014
1
Lock, Crankshaft Gear Washer
104-0043
1
Washer, Crankshaft Gear
Retaining
Crankshaft (Replaces all SpeCS. (’
104-CilW13~
i 1

26
27
28

150-1257
150-0077
850-0055

16
17

18
19
20

21
22
23
24

2
2
2
4

Key

F

/

PART
DESCRIPTION

1
1
1

+ Spacer, Governor Fly Ball
~ Plate, Governor Fly Ball
Washer, Lock - Flywheel

~~

CYLINDER

BLOCK

GROU~

37

-F

;@
>
>.
-.

36

6a-

2

—14

34

5
r38
31

r

-o

s

/4

24
/

20

I

22

.

, ,/-

{’
,
“..

34

REF.
NO.
7

PART
NO.
110-1885

2
3
4
5

123-0954
123-0953
123-0865
509+? 117

6
7
8
9

110-0666
110-0867
517-0048
800-0512

10
11
12

509-0090
110-0892
110-0884

13

110-0883

14
15

16

123-0958
BEARING,
101-0450
101-0450-02
101-0450-10
101-0450-20
101-0450-30
104-0575

17
18

101-0115
101-0422

19

101-0367

20
21
22

509-0041
516-0072
110-0445

23
24

110-0904
526-0063

QTY.
USED

PART
DESCRIPTION

REF.

PART

QTY.

PART

NO.
——

NO.

-USED

DESCRIPTION

25

1

Block Assembly, Cylinder
(Includes Parts Marked ●)
Cap, Breather Tube
1
Tube, Breather
1
Baffle, Breather Tube
1
Seal, “O” Ring - Breather
1
Tube
Cover, Valve Compartment
2
Gasket, Valve Cover
2
●Plug, Camshaft Expansion
1
●Screw, Bearing Plate Mounting
5
(5/16-18 x 1”) - Replaces
Stud and Nut used on early
models
2
Seal, Intake Valve Stem
Gasket, Cylinder Head
2
Head, Cylinder - Right
1
(W? Cylinder)
Head, Cylinder - Left
1
(#1 Cylinder)
Screen, Breather Tube
1
CRANKSHAFT
‘Standard
2
.002” Undersize
2
.010” Undersize
2
.020” Undersize
2
.030” Undersize
2
●Washer, Crankshaft Bearing
2
Thrust
●Gasket Kit, Bearing Plate
1
‘Plate, Bearing (Excludes
1
Bearing)
●Bearing, Camshaft Front or
2
Rear (Precision)
1
●Seal, Bearing Plate
“pin, Main Bearing Stop
4
Nut, Bearing Plate Stud
5
(5/16-18) - Used on Early
Models
Rotocap, Valve
4
Washer, Copper - Valve
2
Compartment Cover

26
27

28

29

30
31
32
33

34

35

●

5

850-0045

1
120-0386
VALVE
Intake- Chrome Cobalt Alloy
110-1037
2
110-0860
2
Exhaust-Chrome
Cobalt Alloy
INSERT, VALVE SEAT-Chrome
Cobalt Alloy
11O-I3872
2
●Exhaust, Standard
110-0872-02
2
.002” Oversize
11O-O872-O5
2
.005” Oversize
110-0872-10
2
.010” Oversize
110-0872-25
.025” Oversize
110-1000
;
“Intake, Standard
110-1000-02
2
.002” Oversize
110-1000-05
2
.005” Oversize
110-1000-10
2
.01 O“ Oversize
110-1000-25
2
.025” Oversize
●GUIDE, VALVE
110-0902
2
Exhaust
110-1827
2
Intake
110-0539
4
Spring, Valve
123-0951
Clamp, Breather Cap
110-0639
Lock, Valve and Spring
;
Retaining
TAPPET, VALVE
115-0006
4
Standard
115-0006-05
.005” Oversize
SCREVV, HEX HEA’& CAP
110-0879
6
Cylinder Head
(5/16-18 X 1-1/4”)
114-0022
10
Cylinder Head
(5/16-18 X 1-3/4”)
Valve Compartment Cover
800-0012
2
(1/4-20 X 2-1/4”)
Waaher, Flat - Cylinder Head
526-0122
16
Screws
Hose, Breather
503-0582
;
503-0170
Clamp, Breather Hose
809-0035
Screw, Breather Ofamp
Insulator Half, Braather
123-0998
1
Tube
- Included

in Cylinder

40 l/o-3J3t

35

..

“Washer, Lock - Rear Bearing
Plate
●Tube, Crankcase Oil

Block Assembly.

I

GEAR COVER, OIL BASE
AND OIL PUMP GROUP

Al

I

3

.
“.-.

9

/7

,,,
,

36

REF.
NO.

;--,
.

7-

PART
NO.

6
7

BEARING,

3

,4

5

8
9

GOVERNOR

“Key
1
510-0013
Key
1
510-0008
1
510-0014
●Ball,
COVER ASSEMBLY, GEAR
?(]3-0333
1
Key
103-0480
1
Key

3
l&2
Bearing - Governor
l&2
3- Complete

11
12
13
14

15

16

103-0011
123-0694
123-0191
102-0158
526-0065

1
1
1
“1
2

BASE, OIL
102-0770
1
1
102-0740
SCREW, HEX CAP
102-0455
4
800-0028

2

114-0022

4

800-0034

1

800-0007

2

Shaft

Assembly

Replace!

Parts Marked*)

Gasket, Gear Cover
Cap and Indicator, Oil Fill
Gasket, Oil Fill Cap
Gasket, Oil Base Mounting
Washer, Copper-Oil
Filter
Adapter Mounting
Key 3
Key l&2
Oil Base to Block
(3/8-16 X 1-1/4”)
Oil Filter Adapter Mounting
(5/16-18 X 1 “)
Gear Cover Mounting
(5/16-18 X 1 -3/4”)
Gear Cover Mounting
(5/16-18 X 2-1/4”)
Oil Pump Mounting
(1/4-20 X l“)

PART

QTY.

NO.

USED
—

19
20

WASHER,
850+050
850-0045
850-0040
505-0110
509-0040
516-0141

21
22

123-1149
141-0078

.1
1

23
24
25
26
27

122-0320
122-0323
122-0321
309-0237
120-0491

1
1
1
1
1

28

120-0648

1

29

801-0048

1

30
31
32
33

120-0140
120-0398
120-0161
526-0066

1
1
1
1

34

815-0046

2

35

‘821-0018

2

36

122-0347

1

18

SHAFT-LOWER

All Specs (includes
10

17

1
1

‘Seal, Oil - Governor Shaft
“Bearing, Governor Shaft Upper
ARM AND SHAFT ASSEM13LY, GOVERNOR
150-1422
1
“Key 3
150-1008
1
Key l&2
YOKE, GOVERNOR SHAFT
150-1187
1
● Key 3
150-0620
1
Key l&2
518-0129
1
Ring, Yoke Retaining Keyl &2
●Pin, Governor - Cup Stop
516-0130
1

2

509=
510-0013

REF.
NO.
——

PART
DESCRIPTION

:SXD

PART
DESCRIPTION

LOCK
4
5
2
1
;

011 Base Mounting (3/8” )
Gear Cover Mounting (5/16”)
Oil Pump Mounting (l/4’r)
Plug (3/8”), Oil Drain
“Seal, Gear Cover
Pin (5/16 x l-I/8”)
Gear Cover
Tube, Oil Fill
Gasket, Oil Fill Tube
Mounting
Adapter, C)il fill
Filter, Oil (Spin-on)
Gasket, Oil Filter Adapter
Switch, Oil Light
Pump, Oil Complete
(NOTE: Internal parts not
sold separately)
Intake, Oil Pump (Includes
Cup, Screen and Pipe)
Screw (3/6-24 x 3/4”) Oil By-Pass
Spring, Oil By-Pass Valve
Valve, Oil By-Pass
Gasket Kit, Oil Pump
Washer, Oil Pressure Relief
Valve
“Screw (8-32 x 3/8”),
Pan Head
Screw (1/4-20 x 5/8”),
Self Locking - Oil Fill
Tube Mounting
Gasket, Oil Filter

“ - Included in Gear Cover Assembly.

37

10

,12

1 1~
362,4
@. “
1
A am:

32

II
1,

e

4W

1“
. ‘ . ......
‘%

‘@

I ‘“’

13

7

28

FUEL
REF.
NO.
T
2

PART
NO.
——
149-1318
800-0054

QTY.
USED
1
2

3
4
5

149-0003
503-0669
502-0388

2
1
1

6
7
9

141-0689
503-0301
WASHER,
850-0030
850-0050

1
2

REF.
NO.
——

PART
DESCRIPTION
“ PumD. Fuel
Screw (3/8-16 x 2“) - Intake
Manifold Mounting
Gasket, Fuel Pump Mounting
Line, Fuel Pump to Carburetor
Elbow, Carburetor Inlet
(Restricted)
‘ Carburetor
Clamp, Rubber Hose

20
21

850-0030

2

10
11
12
13
14
16
17

850-0030
141-0281
153-0453
154-0951
154-0013
149-0045
518-0176
502-0313

2
1
1
1
2
1
2
3

18
19

502-0058
806-0009

1
2

520-0526
654-0017

QTY.

PART
DESCRIPTION

USED
2
2

Stud, Carburetor Mounting
Washer (5/16”), Shakeproof
Carburetor

LOCK
3
2

PART
NO.

Air Inlet Mounting (#lo)
Intake Manifold Mounting
(3/8” )
Air Cleaner Bracket
Mounting (#10)
Choke Bracket Mounting (3/8”)
Gasket, Carburetor Mounting
Bracket, Choke
Manifold, Intake
Gasket, Intake Manifold’
Spacer, Fuel Pump Mounting
Clip, Throttle Cable
Elbow, Street (2) Fuel Pump
(1) Carburetor
Tee, Carburetor Inlet
Screw (1/4-20 x 1-1/4”) Fuel Pump Mounting

22

868-0002

2

23

815-0199

3

.24
25
26

145-0398
140-0921
813-0097

1
1

27
28
29
30
31
32
33
34

140-1073
140-1094
140-1071
140-1135
503-0311
140-1075
140-1133
526-0234

2

35

815-0178

2

36

503-0004

1

“ - For Components,

38

2

1
1
1
1
1
1
1

I.T. -

Mounting

Nut (5/16-24), Jam Carburetor Mounting
Screw (10-32 x 5/16”),
Fillister Head - Air Inlet
Mounting
Adapter, Air Inlet
Gasket, Air Inlet
Screw (10-32 x 5/16”) Choke Bracket Mounting
‘
Clamp Assembly - Air Cleaner
Cover, Air Cleaner Inlet
Element, Air Cleaner
Cover, Air Cleaner Outlet
Clamp (2”), Air Inlet
Inlet, Air
Bracket, Air Cleaner
Washer, Flat - Air Cleaner
Bracket Mounting
Screw (10-32 x 5/8”) - Air
Cleaner Bracket Mounting
Clamo (1-7/8”), Air Inlet
Hose’
‘,

see separate

group.

-.

,,’

FUEL PUMP PARTS GROUP

;

.,

REF.
NO.

PART
NO.
149-1318
149-0526

(xv.
T
1

815-0148

1
4

815-0147

2

149-0096
149-0095
149-0562
149-0672
140-0539
149-0675
516-0113
149-0710

2
2
1
1
1
1
1
1
1

13

149-0858

1

14
15
16
17
18

149-1042”
509-0065
149-1044
149-0003
518-0129

1
2
1
1
1

4
5
6
;
9
10
11
12

PART

USED

DESCRIPTION
Pump, Fuel (Complete)
Repair Kit (Includes Parts
Marked ‘)
Body (Not Sold Separately)
Screw (#8-32 x 7/8”),
Machine
Screw (#6-32 x 5/8”),
Phillips - Retainer
‘Valve and Cage
●Gasket, Valve
●Diaphragm Assembly
“Spring
Retainer, Valve Cage
“Spring
Pin, Rocker Arm
Body (Not Sold Separately)
Link and Arm, Rocker (Sold
only as a set)
*Gasket, Diaphragm - Lower
Side
ALever, Primer
ASeal, “O” Ring
A Spring, Primer Lever
‘Gasket, Pump Mounting
A Ring, Retainer - Primer
Lever

“ - Parts Included in Repair Kit.
A - Not used Key 3.
;-

.

.’

,.

,,.

39”

.

CARBURETOR

REF.
NO.
——

PART
NO.

QTY.
USED

141-0689
141-0747

1.
1

141-0748

1

1
2
3

141-0281
141 -G708
141-0741
141-0698

1
1
1
4

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

141-0706
141-0705
141-0661.
141-0830
141-0696
141-0703
141-0702
141-0701
141-0700
141-0711
141-0713
141-0710
141-0077
141-0712
141-0742
141-0699
141-0697
141-0203
141-0709
141-0799

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

“ - Parts contained
f - Parts contained

,

PARTS GROUP

?.

PART
DESCRIPTION
Carburetor, Gasoline
Repair Kit (Includes Parts
Marked “)
Gasket Kit (Includes Parts
Marked E)
CGasket, Carburetor Flange
Bowl, Fuel
. Plate, ”Choke
Screw and Washer - Choke
and Throttle Plate
Mounting
Plate, Throttle
‘Retainer, Seal
Z’Seal, Rubber
“Valve Seat Assembly, Fuel
Washer, Fuel Valve Seat
“Shaft, Float
Float Assembly
VGasket,
Bowl to Body
Screw, Throttle Stop
Spring, Throttle Stop
Needle, Idle Adjusting
Spring, Idle Needle
f“Washer, Main Jet Assembly
Jet Assembly, Main
Shaft and Lever, Choke
Washer
~Seal, Felt
“Retainer, Felt Seal
Shaft and Lever, Throttle
“Spring, Float

&

17,

in Repair Kit.
in Gasket Kit.

,

,..,-

IGNITION

GROUP
-/’+’

REF.

‘u

4

NO.
—_
1
2
3
4
5
6
7

/12

,\

17

8

0

PA RT
NO.

QTY.
USED

1

160-0930
160-0150
160-0075
160-0002
509-0035
312-0069

1
1
1$
1
1~
1
1
1

167-0188

10

160-0043
160-0265

11

167-1464

PART

DESCRIPTION
“Cover, Breaker Box
“Gasket, Breaker Box Cover
“Cam, Point Gap Adjusting
.Point Set, Breaker
“’O”’Ring - Spark Plug Cables
“Condenser, Breaker Points
Clip, Spark Plug Cables
Gasket, Breaker Box Mounting
.Plunger

P

,-

.<.,

.!

y

—1
.. )
. .A< -’3
-&/>

d

2

14
15
16
17
18
19
’20
21
22
23
Z4
“ L5

2{

1

Cable (23-1,2”), Spark Plug Right Side
166-135#fl
(
Coil, Ignition [ ~~c!hb
YA#Z/
167-t463@~
;
Cable (19”), Spark Plug Left Side
160-0264
1
“ Guide. plunger
167-0241
2
Plug, Spark
160-0257
1
BOX Assembly, Breaker
(Includes Parts Marked “)
160-0428
1
‘Strap, Point Set to Terminal
Block
160-0349
1
.Block and Terminal Assembly
850-0040
2
.Washer (1/4’’ ),. Lock
802-0034
2
.. Screw(1/4-20 x 3/4”) -’
Breaker Box Mounting
334-0028
1
Wire, Lead
160-1165
1
Bracket, Timing
518-0049
3
%crew (8-32 x 1/4”) Brea er Box
14[”baY
z+~h
!
Parts included in 160-0257 Breaker Box Assembly.
.7~

L

P5u+?s@32tuz
ILL-u

l#9Y

2.

+ Whfhq~
t~p

”,’

trJ; L#

)ci’7.

. . ../-. .._.

Luk

iOVERNOR,

STARTER

AND

BLOWER

HOUSING

GROUP

23
31
&

,,..

(\.

‘= 42

REF.
NO.

.,

----‘..

——
1

2

870-0053

QTY.
USED
_
2

4

JOINT, BALL
150-0639
150-0939
LINK, GOVERNOR
520-0187
520-0623
870-0131

5
6

150-1386
870-0065

1
1

7
8

150-1385
870-0131

1
2

9
10
11

150-0147
150-0098
821-0009

1
1
1

12

815-0104

1

3

13
14

15
16
17
18

(,”

PART
NO.

152-0197
WASHER, FLAT
526-0006
526-0196
526-0018
516-0059
150-1384
134-0589
HOUSING,
134-2871
134-2622

2
2
1
1
2

1
1
2
1
1
1

BLOWgR
1
1

“PART
DESCRIPTION

Nut (10-32), Lock - Governor
;od
Key 3
Key l&2
Key 3
Key l&2
Nut (10-32), Keps - Governor
Ball Joint
Arm, Governor Pivot
Nut (5/16-18), Lock - Governor
Arm Pivot
Bracket, Throttle Control
Nut (10-32) - Governor
Control
Stud, Governor High Speed
Spring, Governor High Speed
Screw (1/4-20 x 3/8”), Self
Locking - Governor Control
Arm
, Screw (8-32 x 5/16”),
Fillester Head - Governor
Control Swivel
Swivel, Governor Control
Governor Control Swivel (#1z)
Governor Linkage (#10)
Governor Arm Pivot (1/4”)
Key, Hair Pin - Governor
Control Swivel
Bracket, Governor Control
Housing, Cylinder Air - Left
Key 3
Key l&2

REF.
PART
NO.
NO.
——
19
HOUSING,
134-2760
134-2500
134-2094
20
134-2131
21
122-0345
22
520-0751

QTY.
USED
—CYLINDER
1
1
1
1
1
4
4

23

870-0232

27

WASHER, LC)CK
850-0040
2
3
850-0050
850-0050

28

29

MOTOR,
191-1052.
191-0922
191-0734
191-0864

30

191-0854

31

SCREW,
800-0051
800-0051
102-0455

32

821-0009

33

191-1076

PART
DESCRIPTION
Al~-RIGHT
Key 3
Key 2
Key 1
Baffle, Air - Key 1 & 2
Tube, Oil Filter Drain
Stud, Cylinder Air Housing
Mounting
Nut (1/4-20) - Cylinder Air
Housing Mounting

Control Bracket Mounting (1/4”)
Starter Motor Mounting
(3/8” ) - Key 3
5
Starter Motor Mounting
(3/8”) - Key 1 & 2
STARTING (For Components, See Separate Groups)
Key 3
1
Key 2
1“
1
Key 1
Spacer, Starter Motor
2
Mounting - Key 1 & 2
Bracket, Starter Motor
1
Mounting”- Key 1 & 2
HEX CAP
Starter Motor Mounting
3
(3/t3-16x 1-1/4”) - Key 3
Starter Motor to Bracket
2
(3/8-16 x 1-1/4”) - Key 1 & 2
Starter Bracket Mounting
3
(3/8-16 x 1-1/4”) - Key 1 & 2
Screw (1/4-20 x 3/8”),
2
Self Locking - Governor
Control to Blower Housing
Seal, Starter Air - Key 3
1

T.

(.
12

\

“,

.

I =-

‘a$4$

T’

%“

t
,.f

4

/
5

‘%

;

.
(“
\.L

REF.
NO.

PART
NO.

1-

~

QTY.
USED

2

191-0932

1
1

3

191-0886

1

4

813-0108

3

5

850-0030

3

6
7
9

323-0853
323-0851
191-1016

1
1

10

191-0938

1

1

PART
DESCRIPTION

Flywheel and Ring Gear
Stator & Harness Assembly
(15 Amp Alternator) - Key 1
Regulator - Rectifier Assembly Key 1
Screw (10-32 x 1-1/2”),
Round Head - Stator
Mounting
Washer (#1 O), Lock Stator Mounting
Connector
Connector
Stator & Harness Assemblv
(20 Amp Alternator) - Key
2&3
Rectifier Assembly - Key 2 & 3

REF.

PART

NO.

~.

11

QTY.
USED

12

191-0939
815-0181

1
4

15
16

167-0188
323-0879

1
1’

17

323-0882

1

18.

323-0881

1

19

323-0880

1

20
21

323-0496
323-0488

5
5

“ - See Crankshaft

PART
DESCRIPTION

Regulator Assembly - Key 2 & 3
Screw (10-32 x 1/2”) Regulator and Rectifier
Mo;nting
Clio, Stator Lead
Connector, Stator Leads
(2 Pins) - Key 2 & 3
Connector, Stator Leads
(3 Sockets) - Key 2 & 3
Connector, Rectifier Leads
(3 Pins) - Key 2 & 3
Connector, Regulator Leads
(2 Sockets) - Key 2 & 3
Pin, Connector - Key 2 & 3
Socket, Connector - Key 2 & 3

and Flywheei Group for part number.

/-

g8

/11

1

I

l—

16

A

C2 -)1 H
1A

19

~l.

13

.
0

20

I

18

12

(“””-191-0734

REF.
NO.
—
1

2
3
4
5
6
7
8
9
10
11
12
13
14
15

PART
NO.

STARTER

QTY.
USED

191-0734
191-0742

1

191-0743
191-0744
191-0745
191-0746
191-0747
191-0748
191-0749
191-0750
191-0751
191-0752
191-0753
191-0754
191-0755
191-0756

1
1
1
1
1
1
1
1
1
,.

1

1
1
1
1

MOTOR

PARTS GROUP - KEY 1

REF.
NO.

PART
DESCRIPTION

T

Motor Assembly, Starting
Yoke Assembly (Frame) Includes Parts Marked “
Armature
Clutch, Starter
Stop, Pinion
Ring
Washer, Plain
Bracket Assembly, Front
Lever Assembly
Spring, Lever (A)
Spring, Lever (B)
Holder, Spring
Bracket Assembly, Rear
Washer, Plain
Washer, Plain
Washer, Insulator

PART
NO.

17
18
19
20
21
22
23
24
25
26

191=
191-0758
191-0759
191-0760
191-0761”
191-0762
191-0763
191-0764
191-0765
191-0766
850-0050

27

800-0051

~

r

PART
DESCRIPTION

QTY.
USED

4
.4
2
3
1
11
1
4
4
2
2

“Brush
Spring, Brush
Bolt, Through
Screw, Machine P.H.
Switch Assembly, Solenoid
“Coil Assembly, Field
Bearing, Front
Bearing, Rear
“Pole Shoe
‘Screw, Pan Head
Washer, Lock - Starter Motor
Mounting
Screw, Hex Cap - Starter
Motor Mounting

‘ - Included in Yoke Assembly.

,..

[L

45

191-0922

STARTER

MOTOR

PARTS GROUP - KEY 2

REF.

PART

NO.
——

NO.

QTY.
USED

191-0922
191-0983
191-0984
191-1010

1

1
2
3
4
5
6
7

191-1011
191-0987
191-0988
191-0989

1
1
2
1

8
9
10
11
12

191-0990
191-0991
191-1007
191-1008
191-1009

1
1
4
2
1

13
14
15
16
17

191-0995
191-0996
191-0997
191-1005
191-1006

1
1
1
2
1

18

191-1001

1

1
1
1

-

PART
DESCRIPTION
Motor, Starting - Complete
Lever Assembly
Spring Set
Bearing, Rear Bracket
Assembly
Screw Set
Switch Assembly
Bolt, Through
Bracket Assembly, Front
(Includes Bearing)
Bearing, Front Bracket
Stopper Set, Pinion
SSpring, Brush
fBrush. N@ative
Bracket A;sembly, Rear
(Includes Bearing)
Clutch Assembly
Armature
Washer Set
Brush, Positive
Holder Assembly, Brush
(Includes Parts Marked E)
Field Coil Set (Includes
Positive Brush)

k. _

f - Parts included in 191-1006 Brush Holder Assembly.

..f
\.

46

191-1052

STARTER

MOTOR
REF.
NO.
——

PARTS GROUP - KEY 3
PART
NO.

QTY.
USED
_

1
1

2
3

191-1052
191-0983
191-0984
191-1010

4
5
6
7

191-1011
191-0987
191-0988
191-1086

1
1

8
9
10
11
12

191-0971
191-0991
191-1007
191-1008
191-1009

4
2
1

13
14
15
16
17

191-1087
191-1088
191-0997
191-1005
191-1006

1
1
1
2
1

18

191-1089

1

1

PART
DESCRIPTION
Motor, Starting - Complete
Lever Assembly
Spring Set
Beari;g, Rear Bracket
Assembly
Screw Set
Swdch Assembly
Bolt, Through
BracketAss>mbly,
Front
(Includes Bearing)
Bearing, Front Bracket
Stopper Set. Pinion
“Spring, Brush
“Bru&~, Negative
Bracket Assembly. Rear
(Includes Bearing)
Clutch Assembly
Armature Washer Set
Brush, Positive
Holder Assembly, Brush
(Includes Parts Marked “)
Field Coil Set (Includes
Positive Brushes)

1
1

2
1

1
1

. - Parts Included in 191-1006 Brush Holder Assembly,

SERVICE
NOTE:

For other

KITS

AND

MISCELLANEOUS

kits. refer to the group

for the

part in question.
REF.
NO.
——

PART
NO.
-168-0103
160-0836
168-0095
522-0267

OTY.
USED
—
1
1
1
1

PART
DESCRIPTION
Gasket Kit, Compfete Engine
Ignition Tune-Up Kit
Carbon Removal Gasket Kit
Kit, Overhaul

- CAmlON –
REGULXTORMUST BE
GROUNOLDTHROUGH

VR1

MOUNTING OOLTs
MOuKrED 8WIMD
OLM:R

VOLT

REG

UWXL

~

RFLT
M. ALm’
J2

ALT

q

SfATOR

JI

SI
=

.“Q*,

”

;

--

TO START SWITCH

--

TO BATTERY

--

TO OIL PRESS

--

To IGNITION

~

El

‘

F:y
~---j

-n

- .-—

T

-LIGHT

n

J .1
.
●

LIST REF

PARTs

REF OES
81
BT1
Elt2

PARTNO.

OTY
DESCRIPTION”
1
STARIERL SOLENOIO-Et/GINE
1
BATTERY.12 V
2
SPARKPLIM

GI

FNCINF
--------

WI
QIMc
.. . ..
. ..-

nlACOAM

w,r-l~

m-,-,

:;

1
I
1

CONNECTOR

SI
S2
TI

I
I
1

SW ITCH-LOW OIL PRESS
BREAKER & CAP ASSEMBLY
IGNITION CO IL-(ONAN)

VR1

1“

fl[GuLATOR-flfCT
IF IER-VOllAE

.

-

48

unmet

*.l WUI=L

--”r.

LLKD-m>f

,...

ALTERNATOR-FLYWHEEL
15 AsIP
CONN[C1OR

i-n .-n
L-i
Lu

C.-

.

.

----

1
i,

iWWAEI

MouKKD

OLWER

UHECL

JI
I

--

,-.

SI

I

=

TO BRTTERY

--

‘TO OIL PRESS LIGHT
TO IGNITION

@

TI

IL
;.
~~

RECT

REG

CRI

VRI

BL

--

. --

AA
xx
=sb
g-l=

-TO START SWITCH

A

‘&j”-’”
.-

-

El

C2
11
.
OTY
1
1
\
2

OISCRIPTION
STARTERL SOLE
NOiO-ENGINE
EATT[RY, 12 V
RECTIFIERRSSY
SPARKPLUG

G1

I

ALTERNATI)R-FLYIHEEL
20 AUP

JI

I

CONNECTOR

SI

I

S2
TI
VR

1
1
I

SWITCH-LOW”
OIL PRESS
6REAKERt CkF’ASSEUEIY
IGNITION COIL-( ONAN)
ffESUIATOR-V0L7Alc[

R[F 0[S
81
ETI
tRl
EIL2

/
~

-

\ --

ENGINE

WIRING

DIAGRAM

- MODEL

PARTtAO.

.

LIST REF

PARTS

E
CC KB-t4S/2440H

AND CC KB-MS!2733J



---

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Creation Date--Text             : Friday, March 05, 1999 4:03:37 PM
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