kohler tableau de réglages atelier

5/12/2018 Kohler tableau de réglages atelier - slidepdf.com

http://slidepdf.com/reader/full/kohler-tableau-de-reglages-atelier 1/70

SPECS & TORQUES

SPECIFICATIONS & TOLERANCES TORQUE VALUE & SEQUENCES



Table of ContentsStandard Application Torque Recommendations……………………………………….…..3

K–Series Single Cylinder Engine Specifications & Tolerances………….………….…..4-5

K–Series Twin Cylinder Engine Specification & Tolerances…………………….…….…6-7

K–Series Single Cylinder Torque Values & Sequences for Fasteners………….………..8

K–Series Twin Cylinder Torque Values & Sequences for Fasteners…………….……….9

Magnum Single Cylinder Engine Specifications & Tolerances……………………….10-11

Magnum Twin Cylinder Engine Specifications & Tolerances…………………………12-13

Magnum Single Cylinder Torque Values & Sequences for Fasteners…………………..14

Magnum Twin Cylinder Torque Values & Sequences for Fasteners…………………….15

Command Single Cylinder Engine Specifications & Tolerances……………………..16-21

Command Twin Cylinder Engine Specification & Tolerances………………………...22-25

Command Single Cylinder Torque Values & Sequences for Fasteners……………..26-27

Command Twin Cylinder Torque Values & Sequences for Fasteners……………….28-29

Conversion Factors……………………………………………………………………………30

TP-2469-A 12/07 2



Standard Application Torque RecommendationsTorque values are in N·m. Values in parenthesis ( ) are English equivalents.

English Fastener

Bolts, Screws, Nuts and FastenersGrade 2 or 5

Non-critical Fasteners into

Fasteners Aluminum

into

Aluminum

Size Size Grade 2 Grade 5 Grade 8

M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) 8-32 2.3 (20) 2.8 (25) — 2.3 (20)

M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35) 10-24 3.6 (32) 4.5 (40) — 3.6 (32)

M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60) 10-32 3.6 (32) 4.5 (40) — —

M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150) 1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)

1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —

Tightening Torque N·m (in. lb.) + or -10% 5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)

5/16-24 18.7 (165) 30.5 (270) — —

3/8-16 29.4 (260) — — —

3/8-24 33.9 (300) — — —

Non-critical

Fasteners

into Size

Aluminum 5/16-24 — — 40.7 (30) —3/8-16 — 47.5 (35) 67.8 (50) —

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25) 3/8-24 — 54.2 (40) 81.4 (60) —

M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45) 7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —

M14 58.3 (43) 76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70) 7/16-20 61.0 (45) 101.7 (75) 142.4 (105) —

1/2-13 67.8 (50) 108.5 (80) 155.9 (115) — 1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —

9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —

Size 9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —

1/8" NPT 5/8-11 149.2 (110) 244.1 (180) 352.6 (260) —

1/4" 5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —

3/8" 3/4-10 199.3 (150) 332.2 (245) 474.6 (350) —

1/2" 3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

3/4"

X-708-11

N•m = ft. lb. x 1.356

27.1 (20 ft. lb.)

33.9 (25 ft. lb.)

Tightening Torque N·m (in. lb.) + or- 20%

Assembled Into Cast Iron or Steel

Tightening Torque N·m (ft. lb.) + or- 20%

in. lb. = N•m x 8.85

ft. lb. = N•m x 0.737

TorqueConversions

N•m = in. lb. x 0.113

4.5 (40 in. lb.)—

27.1/33.9 (20/25 ft. lb.)

11.3 (100 in. lb.)

13.6 (120 in. lb.)

17.6 (13 ft. lb.)

21.7 (16 ft. lb.)

27.1/33.9 (20/25 ft. lb.)

17.0 (150 in. lb.)

13/8" thread with hex head nut and fiber gasket.

Metric Fastener

Property Class

Tightening Torque N·m (in. lb.) + or -10%

Property Class

20.3 (180 in. lb.)

Into Cast Iron Into Aluminum

Oil Drain Plugs (All Models)

TP-2469-A 12/07 3



K-Series — Single Cylinder Engine Specifications TolerancesAll dimensions in inches.

K91 (4) K161 (7) K181 (8) K241 (10) K301 (12) K321 (14) K341 (16)2.375 x 2.000 2.938 x 2.500 2.938 x 2.750 3.251 x 2.875 3.375 x 3.250 3.500 x 3.250 3.750 x 3.250

General 8.86 16.94 18.64 23.85 29.07 31.27 35.94000 3600 3600 3600 3600 3600 3600

New — — — 0.4998/0.5001 0.4998/0.5001 0.4998/0.5001 0.4998/0.5001

Balance Gear Max. Wear Limit — — — 0.4996 0.4996 0.4996 0.4996

End Play — — — 0.002/0.010 0.002/0.010 0.002/0.010 0.002/0.010

Camshaft 0.005/0.020 0.005/0.010 0.005/0.010 0.005/0.010 0.005/0.010 0.005/0.010 0.005/0.010

Rod to Crankpin (New) 0.001/0.0025 0.001/0.002 0.001/0.002 0.001/0.002 0.001/0.002 0.001/0.002 0.001/0.002

Rod to Crankpin

Connecting Wear Limit

Rod Rod to Piston Pin (New) 0.0007/0.0008 0.0006/0.0011 0.0006/0.0011 0.0003/0.0008 0.0003/0.0008 0.0003/0.0008 0.0003/0.0008

0.5630/0.5633 0.6255/0.6258 0.6255/0.6258 0.8596/0.8599 0.8757/0.8760 0.8757/0.8760 0.8757/0.8760

New 0.9841/0.9844 1.1811/1.1814 1.1811/1.1814 1.5745/1.5749 1.5745/1.5749 1.5745/1.5749 1.5745/1.5749

Flywheel End O.D. Max. Wear Limit 0.9841 1.1811 1.1811 1.5745 1.5745 1.5745 1.5745

C

Crankshaft R

A

N

K

P

I

N

0.004/0.023 0.002/0.023 0.002/0.023 0.003/0.020 0.003/0.020 0.003/0.020 0.003/0.020

Inside New 2.3755/2.3745 2.9380/2.9370 2.9380/2.9370 3.2515/3.2505 3.3755/3.3745 3.5005/3.4995 3.7505/3.7495

Cylinder Diameter Max. Wear Limit 2.378 2.941 2.941 3.254 3.378 3.503 3.753

Bore Max. Out of Round 0.003 0.003 0.003 0.003 0.003 0.003 0.003

0.003 0.003 0.003 0.002 0.002 0.002 0.002

Cylinder

Head Type (Champion®

or Equivalent)

Battery 0.025 0.025 0.025 0.035 0.035 0.035 0.035

Ignition Magneto 0.025 0.025 0.025 0.025 0.025 0.025 0.025

Gaseous Fuels 0.018 0.018 0.018 0.018 0.018 0.018 0.018

0.02 0.02 0.02 0.02 0.02 0.02 0.02

New

Max. Taper

0.003 0.003

0.001 0.001 0.0010.001 0.001 0.001

0.003

Max. Wear Limit

Max. Out of Round

0.003 0.003 0.003 0.003

0.0005 0.0005 0.0005

0.001

0.0005 0.0005 0.0005 0.0005

1.5000/1.4995 1.5000/1.4995 1.5000/1.4995

0.935 1.185 1.185 1.499 1.499 1.499 1.499

0.9360/0.9355 1.1860/1.1855 1.1860/1.1855 1.5000/1.4995

Main PTO &

Running

Clearance

End Play

Displacement Cu. In.

Small End I.D. (New)

Bore x Stroke

Shaft O.D.

Model (Horsepower)

Max. Operating RPM

Max. Taper

Max. Out of Flatness

End Play

Nominal Point Gap

Spark Plug

Type & Gap

RCJ-8 RCJ-8 RCJ-8 RH-10 RH-10 RH-10 RH-10

0.003 0.0025 0.0025 0.0025 0.0025 0.0025 0.0025

TP-2469-A 12/07 4



K-Series — Single Cylinder Engine Specifications Tolerances (cont'd)All dimensions in inches.

K91 (4) K161 (7) K181 (8) K241 (10) K301 (12) K321 (14) K341 (16)

All Pistons Service Replacement Sizes

Thrust New 2.371/2.369 2.9297/2.9281 2.9297/2.9281 3.2432/3.2413 3.368/3.365 3.4941/3.4925 3.7425/3.7410Face O.D.

2Max. Wear Limits 2.366 2.925 2.925 3.238 3.363 3.491 3.738

Thrust Face to

New Bore 0.007/0.017 0.007/0.017 0.007/0.017 0.010/0.020 0.010/0.020 0.010/0.020 0.010/0.020

Used Bore (Max.) 0.027 0.027 0.027 0.03 0.03 0.03 0.03

Max. Ring Side Clearance 0.006 0.006 0.006 0.006 0.006 0.006 0.006

Thrust New — — — — — — 3.7465/3.7455

Face O.D.4

Max. Wear Limits — — — — — — 3.744

Thrust Face to — — — — — —— — — — — — 0.0030/0.0050

New Bore5

— — — — — — 0.010/0.020

Used Bore (Max.)5

— — — — — — 0.03

Max. Ring Side Clearance — — — — — — 0.004

Thrust Face New — — 2.9329/2.9336 — 3.3700/3.3693 3.4945/3.4938 3.7433/3.7426

O.D.4

Max. Wear Limits — — 2.931 — 3.367 3.492 3.7406

— — — — — — —

— — 0.0034/0.0051 — 0.0045/0.0062 0.0050/0.0067 0.0062/0.0079

New Bore5 — — 0.010/0.023 — 0.010/0.020 0.010/0.020 0.013/0.025

Used Bore (Max.)5

— — 0.032 — 0.03 0.03 0.033

Max. Ring Side Clearance — — 0.006 — 0.006 0.006 0.004

Piston Pin Outside Diameter 0.5623/0.5625 0.6247/0.6249 0.6247/0.6249 0.8591/0.8593 0.8752/0.8754 0.8752/0.8754 0.8752/0.8754

0.25 0.3125 0.3125 0.3125 0.3125 0.3125 0.3125

Tappet Intake 0.005/0.009 0.006/0.008 0.006/0.008 0.008/0.010 0.008/0.010 0.008/0.010 0.008/0.0103

Clearance (Cold) Exhaust 0.011/0.015 0.017/0.019 0.017/0.019 0.017/0.019 0.017/0.019 0.017/0.019 0.017/0.019

Minimum Lift Intake 0.2035 0.2718 0.2718 0.318 0.318 0.318 0.318

(Zero Lash) Exhaust 0.1768 0.2482 0.2482 0.318 0.318 0.318 0.318

Minimum Valve Intake 0.2478 0.3103 0.3103 0.3103 0.3103 0.3103 0.3103Stem O.D. Exhaust 0.2458 0.3088 0.3088 0.3088 0.3074 0.3074 0.3074

45° 45° 45° 45° 45° 45° 45°

Guide I.D. Max. Intake 0.005 0.005 0.005 0.006 0.006 0.006 0.006

Wear Limit1

Exhaust 0.007 0.007 0.007 0.008 0.008 0.008 0.0084Measure 1/2" above the bottom of the piston skirt.

5Top and center compression rings.

³1800 RPM generator sets .005/.007.

0.0035/0.006 0.007/0.010 0.007/0.010

²Measure just below oil ring groove at right angles to piston pin.

¹Subtract O.D. of inner part from I.D. of outer part.

0.007/0.010 0.007/0.010

Ring End Gap

Ring End Gap

Ring End Gap

Valves

0.007/0.010

Model (Horsepower)

Nominal Angle Valve Seat

Bore Clearance (New)1

Clearance (New)1

Bore Clearance (New)1

————————————— 0.003 – 0.010 – 0.020 – 0.030 —————————————

0.007/0.010

Thrust Face to Bore

Guide Reamer Size

TP-2469-A 12/07 5



K-Series — Twin Cylinder Engine Specifications Tolerances

All dimensions in inches.

KT17 (17) KT19 (19) K582 (23)3.125 x 2.750 3.125 x 3.063 3.500 x 3.000

General 42.18 47 57.73

3600 3600 3600

Rear 1.251/1.252

Camshaft Front 1.876/1.877

0.003/0.013 0.003/0.013 0.003/0.024

Rod to Crankpin (New) 0.0012/0.0024 0.0012/0.0024 0.001/0.002

Connecting Rod to Crankpin Wear Limit 0.0029 0.0029 0.0025

Rod Rod to Piston Pin (New) 0.0006/0.0011 0.0006/0.0011 0.0003/0.0008

0.6255/0.6258 0.7507/0.7510 0.8757/0.8760Sleeve Bearing New 1.7412/1.7422 1.7412/1.7422 1.7495/1.7500

Journal Wear Limit 1.7407 1.7407 1.749

Ball/Roller New — — 1.7716/1.7721

M Bearing Journal Wear Limit — — 1.7711

A 0.0005 0.0005 0.0005

I 0.001 0.001 0.001

N Running Clearance New Max. 0.0049 0.0049 0.004

(Sleeve) Wear Limit1

0.0059 0.0059 0.005

New Sleeve Bearing I.D.Installed 1.7439/1.7461 1.7439/1.7461 1.7515/1.7535

Crankshaft C

R

A

N

K

P

I

N0.002/0.014 0.002/0.014 0.004/0.010

New 3.1255/3.1245 3.1255/3.1245 3.5005/3.4995

Cylinder Max. Wear Limit 3.128 3.128 3.503

Bore 0.002 0.002 0.005

0.0015 0.0015 0.002

Cylinder

Head

1.6250/1.6245

0.0005 0.0005 0.0005

1.3728 1.49882 1.624

0.003 0.003 0.003

0.001 0.001 0.001

Running Clearance

——

New 1.3738/1.3733 1.4998/1.49932

Inside

Model (Horsepower)

Sleeve I.D. Installed

Max. Operating RPM

Max. Out of Round (Sleeve)

End Play


Max. Wear Limit

Max. Out of Round

Max. Taper

Max.Out of Round


Bore x Stroke


Max. Taper

End Play

Max. Taper (Sleeve)

Diameter

TP-2469-A 12/07 6



K-Series — Twin Cylinder Engine Specifications Tolerances (cont'd)All dimensions in inches.

KT17 (17) KT19 (19) K582 (23)

RY17YC RV17YC RH-10

Ignition 0.025 0.025 0.025Gaseous Fuels 0.018 0.018 0.018

0.02 0.02 0.02

Thrust Face New 3.118/3.117 3.121/3.120 3.4941/3.4925

O.D.3

Max. Wear Limits 3.113 3.113 3.491

0.0065/0.0085 0.0035/0.0055 0.007/0.010

New Bore 0.010/0.020 0.010/0.020 0.010/0.020

Used Bore (Max.) 0.03 0.03 0.030.004 0.004 0.006

Thrust Face New 3.1210/3.1203 3.1215/3.1208 —

O.D.4

Max. Wear Limits 3.118 3.119 —

0.0035/0.0052 0.0030/0.0047 —

New Bore5

0.010/0.020 0.010/0.023 —

0.032 0.032 —

0.006 0.006 —

Piston Pin 0.6247/0.6249 0.7499/0.7501 0.8752/0.8754

0.3125 0.3125 0.3125

Tappet Intake 0.003/0.006 0.003/0.006 0.008/0.010

Clearance (Cold) Exhaust 0.011/0.014 0.011/0.014 0.017/0.020

Minimum Lift Intake 0.28 0.28 0.318

(Zero Lash) Exhaust 0.28 0.28 0.318

Valves Minimum Valve Intake 0.3103 0.3103 0.3103

Stem O.D. Exhaust 0.3088 0.3088 0.307445° 45° 45°

Guide I.D. Max Intake 0.005 0.005 0.006

Wear Limit1

Exhaust 0.007 0.007 0.008

3, 4Measure just below oil ring groove and at right angles to piston pin.

1Subtract O.D. of inner part from I.D of outer part.

——— 0.003 – 0.010 – 0.020 – 0.030 ———

——— 0.003 – 0.010 – 0.020 – 0.030 ———

2Pre Series II 1.3733/1.3738, maximum wear 1.3728.

4Measure 1/2" above bottom of piston skirt.

5Top and center compression rings.

Guide Reamer Size


Thrust Face to Bore Clearance (new)1, 4

Type (Champion® or Equivalent)

Battery

Service Replacement Sizes

Model (Horsepower)

Nominal Point Gap

Spark Plug

Ring End Gap

Outside Diameter


Thrust Face to Bore Clearance (New)1

Max. Ring Side Clearance

Max. Ring Size Clearance

Used Bore (Max.)5

Ring End Gap

TP-2469-A 12/07 7



K-Series-Single Cylinder Torque Values and Sequences for Fasteners

K91 (4) K161 (7) K181 (8) K241 (10) K301 (12) K321 (14) K341 (16)

New 140 in. lbs.

Connecting Used 100 in. lbs.

Rods1

18-22 ft. lbs.

Flywheel Nut1 40-50 ft. lbs.

Retaining5

Screw1 250 in. lbs.

70-90 in. lbs.

Grass Metal —

Screen Plastic —

Oil Pan

Sheet Metal1 —

¹Lubricate fastener threads with engine oil.

USED - Component from a running engine.

Model (Horsepower)

Spark Plugs

Governor Bushing

Non Metallic Fuel Pump

Mounting Screws—

Cylinder Head1

Posi-Lock1, 2

Capscrew1, 3

²Do not over torque-Do not loosen and retorque hex. nuts on Posi-Lock connecting rods.4Prior to Serial No. 23209832 - 45-55 ft. lbs.

5Flywheel and crankshaft tapers must be clean and dry.

20-30 in. lbs.

37-45 in. lbs. 37-45 in. lbs.

200 in. lbs.

35 ft. lbs.Grade 5-250 in. lbs.

—

18-22 ft. lbs.

85-90 ft. lbs.4

—

130-150 in. lbs.

70-140 in. lbs.

—

Grade 8-350 in. lbs.

3Over torque 20%, loosen below torque value and retorque to final value.

NEW - Component directly from stock.

100-120 in. lbs.

70-140 in. lbs.

New 260 in. lbs.

Used 200 in. lbs.

18-22 ft. lbs.

285 in. lbs.

50-60 ft. lbs.

22-27 ft. lbs.

Cast Iron1

200 in. lbs.

—

140 in. lbs.

—

250 in. lbs.

TP-2469-A 12/07 8



K-Series — Twin Cylinder Torque Values and Sequences for Fasteners

K582 (23)

ConnectingRods1 5/16-200 in. lbs.

3/8-300 in. lbs.

18-22 ft. lbs.

Flywheel Nut 115 ft. lbs.

Retaining Screw1 —

Grass Metal 70-140 in. lbs.

Screen Plastic –

Aluminum1 30 ft. lbs.

Cast Iron1 35 ft. lbs.

210 in. lbs.

40 ft. lbs.

Gear Cover

Install two

shoulder

capscrews(1/2" thread

depth) in

Bolt No.

third holes as Bolt No. Torque 1-4

indicated. 1, 2, 3, 4, 5-6

(12, 14 Grade 8)

5-11,13, 15 150 in. lbs.

16 35 in. lbs.

Tighten to 150 in. lbs.,

then install other capscrews

Torque remaining bolts

in most expedient30 ft. lbs

Model (Horsepower)

200 in. lbs.

260 in. lbs.

Torque

KT17 & KT19

*When reinstalling a closure plate or

#2 Side Crankcase

Posi-Lock1, 2

Mounting ScrewsNon-Metallic Fuel Pump

20-30 in. lbs.

—Oil Pan

Capscrew1,3

Spark Plugs

Cylinder Head1

40 ft. lbs.

Camshaft Nut

Manifold Screw/Nut

second and

K582

Closure Plate

10-15 ft. lbs.

New 140 in. lbs.

Used 100 in. lbs.—

200 in. lbs.Half Exterior

Cylinder Barrel

Closure Plate 150 in. lbs.

Preliminary torque - 100 in. lbs.

Final torque - 200 in. lbs.

(Engines with 5/16-18 studs)

Final torque - 360 in. lbs.


Apply sealant to crankcase.*

installing a service replacement

KT17 & KT19

cylinder barrels with a gasket, use a

new gasket. When reinstalling one

with sealant, use new sealant. When

Crankcase

260 in. lbs.

#2 Side Crankcase

Half Interior

closure plate or cylinder barrels,

use new sealant.and torque to 150 in. lbs. sequence to 200 in. lbs.

70-140 in. lbs.

—

37-45 in. lbs. 37-45 in. lbs.

—

150 in. lbs.

—

TP-2469-A 12/07 9



Magnum — Single Cylinder Engine Specifications and TolerancesAll dimensions in inches.

M8 (8) M10 (10) M12 (12) M14 (14) M16 (16)2.94 x 2.75 3.25 x 2.88 3.38 x 3.25 3.500 x 3.25 3.750 x 3.25

18.64 29.07 29.07 31.27 35.9

3600 3600 3600 3600 3600

New — 0.4998/0.5001 0.4998/0.5001 0.4998/0.5001 0.4998/0.5001

Balance Max. Wear Limit — 0.4996 0.4996 0.4996 0.4996

Gear End Play — 0.002/0.010 0.002/0.010 0.002/0.010 0.002/0.010

Camshaft 0.005/0.010 0.005/0.010 0.005/0.010 0.005/0.010 0.005/0.010

Rod to Crankpin (New) 0.001/0.002 0.001/0.002 0.001/0.002 0.001/0.002 0.001/0.002

Connecting Rod to Crankpin Max. Wear Limit 0.0025 0.0025 0.0025 0.0025 0.0025

Rod Rod to Piston Pin (New) 0.0006/0.0011 0.0003/0.0008 0.0003/0.0008 0.0003/0.0008 0.0003/0.00080.6255/0.6258 0.8757/0.8760 0.8757/0.8760 0.8757/0.8760 0.8757/0.8760

New 1.1811/1.1814 1.5745/1.5749 1.5745/1.5749 1.5745/1.5749 1.5745/1.5749

End O.D. Max. Wear Limit 1.1811 1.5745 1.5745 1.5745 1.5745

C

R

A

N

K

PI

N

0.002/0.023 0.003/0.020 0.003/0.020 0.003/0.020 0.003/0.020

New 2.9380/2.9370 3.2515/3.2505 3.3755/3.3745 3.5005/3.4995 3.7505/3.7495

Cylinder Max. Wear Limit 2.941 3.254 3.378 3.503 3.753

Bore 0.005 0.005 0.005 0.005 0.005

0.003 0.002 0.002 0.002 0.002

Cylinder

Head

Gap 0.025 0.025 0.025 0.025 0.025

0.012/0.016 0.012/0.016 0.012/0.016 0.012/0.016 0.012/0.016

RH-10 RH-10 RH-10 RH-10

0.003 0.003 0.003 0.003

1.5000/1.4995

1.499

0.0005

0.001

1.5000/1.4995

1.499

0.0005

0.0010.001

0.0005

1.499

1.5000/1.49951.5000/1.4995

1.499

0.0005

0.001

Max. Wear Limit

Max. Out of Round

Max. Taper

1.1860/1.1855

1.185

0.0005

0.001


Bore x Stroke

Shaft O.D.

General

Running Clearance

End Play

Model (Horsepower)

Max. Operating RPM


0.003

Crankshaft

End Play

Max. Out of Round (I.D.)

Inside Diameter

Main PTO & Flywheel

New - O.D.

RCJ-8

Max. Taper (I.D.)


Ignition

Module Air Gap

Type (Champion® or Equivalent)Spark Plug

TP-2469-A 12/07 10



Magnum — Single Cylinder Engine Specifications and Tolerances (cont'd)All dimensions in inches.

M8 (8) M10 (10) M12 (12) M14 (14) M16 (16)All Pistons Service Replacement Sizes

Thrust New 2.9297/2.9281 3.2432/3.2413 3.368/3.365 3.4941/3.4925 —Face O.D.

2Max. Wear Limits 2.925 3.238 3.363 3.491 —

0.007/0.010 0.007/0.010 0.007/0.010 0.007/0.010 —

New Bore 0.007/0.017 0.010/0.020 0.010/0.020 0.010/0.020 —

Used Bore (Max.) 0.027 0.03 0.03 0.03 —

0.006 0.006 0.006 0.006 —

Thrust New — — — — 3.7465/3.7455

Face O.D.3

Max. Wear Limits — — — — 3.7435

— — — — 0.0030/0.0050New Bore

4— — — — 0.010/0.020

Used Bore (Max.)4

— — — — 0.03

Max. Ring Side Clearance — — — — 0.004

New 2.9329/2.9336 — 3.3700/3.3693 3.4945/3.4938 3.7433/3.7426

Max. Wear Limits 2.9312 — 3.3673 3.4918 3.7406

0.0034/0.0051 — 0.0045/0.0062 0.0050/0.0067 0.0062/0.0079

New Bore4

0.010/0.023 — 0.010/0.020 0.010/0.020 0.013/0.025

Used Bore (Max.)4

0.032 — 0.03 0.03 0.033

0.006 — 0.006 0.006 0.004

Piston Pin Outside Diameter 0.6247/0.6249 0.8591/0.8593 0.8752/0.8754 0.8752/0.8754 0.8752/0.8754

0.3125 0.3125 0.3125 0.3125 0.3125

Tappet Intake 0.006/0.008 0.0080/.010 0.008/0.010 0.008/0.010 0.008/0.010

Clearance (Cold) Exhaust 0.017/0.019 0.017/0.019 0.017/0.019 0.017/0.019 0.017/0.019

Minimum Lift Intake 0.2718 0.318 0.318 0.318 0.318

(Zero Lash) Exhaust 0.2482 0.318 0.318 0.318 0.318

Valves Minimum Valve Intake 0.3103 0.3103 0.3103 0.3103 0.3103Stem O.D. Exhaust 0.3074 0.3074 0.3074 0.3074 0.3074

45° 45° 45° 45° 45°

Guide I.D. Max. Intake 0.006 0.006 0.006 0.006 0.006

Wear Limit1

Exhaust 0.008 0.008 0.008 0.008 0.008

——————— 0.003 – 0.010 – 0.020 – 0.030 —————————

Ring End Gap

Ring End Gap

Model (Horsepower)





Thrust Face O.D.3



Guide Reamer Size

Ring End Gap

TP-2469-A 12/07 11



Magnum — Twin Cylinder Engine Specifications and TolerancesAll dimensions in inches.

General

Camshaft

Rod to Crankpin (New)

Connecting Rod to Crankpin Wear Limit

Rod Rod to Piston Pin (New)

PTO & Flywheel New

M End O.D. Max. Wear Limit

A

I

N Running Clearance Max. New

(Sleeve) Wear Limit1

C

R

A

N

K

P

I

N

New

Max. Wear Limit

Type (Champion®

or equivalent)

Ignition Gap

M20 & MV20 (20)

Max. Taper (Sleeve)

New Sleeve Bearing I.D. Installed


0.002/0.014

3.1255/3.1245

3.128

0.0049

0.0059

1.7439/1.7461

0.0005

0.0012/0.0024

0.0029

0.0006/0.0011

0.7507/0.7510

1.7412/1.7422

1.7407

0.0005

0.001

1.4988

1.7439/1.7461

3.125 x 3.062

46.98

3600

0.003/0.013

0.0005

0.001

0.0049

0.0059

0.0006/0.0011

0.6255/0.6258

1.7412/1.7422

1.7407

3600

0.003/0.013

0.0012/0.0024

0.0029

MV16 (16) M18 & MV18 (18)3.125 x 2.750

42.18

3.125 x 2.750

42.18

Model (Horsepower)

Max. Operating RPM

Max. Out of Round (Sleeve)

Running Clearance

End Play



Bore x Stroke

0.0012/0.0024

0.0029

0.0006/0.0011

0.6255/0.6258

3600

0.003/0.013

Spark Plug

Module Air Gap

1.7412/1.7422

1.7407

New

Max. Wear Limit

1.7439/1.7461

0.0005

0.001

0.0049

Max. Out of Round

Max. Taper

0.0059

0.0005 0.0005

3.1255/3.1245

0.001

0.002/0.014

Max. Taper

End Play

Max. Out of Round

0.00150.0015

0.003

0.035 0.035 0.035

0.003 0.003

0.008/0.012 0.008/0.012 0.008/0.012

RV17C RV17C RV17C

0.001

0.0015

3.128

0.002

3.1255/3.1245

0.002/0.014

0.002

3.128

0.002

1.4998/1.4993

Cylinder Head

Cylinder Bore

Crankshaft

Inside Diameter

1.37281.3728

1.3738/1.3733 1.3738/1.3733

0.001

TP-2469-A 12/07 12



Magnum — Twin Cylinder Engine Specifications and Tolerances (cont'd)All dimensions in inches.

New Bore3


Piston Pin Outside Diameter

Guide Reamer Size

IntakeBefore Serial No.

Tappet 181600646

Clearance Serial No. 18100656

(Cold) to 191780296

After Serial No.

1917809296

Minimum Lift Intake

(Zero Lash) Exhaust

Minimum Valve Intake

Stem O.D. Exhaust

Nominal Angle - Serial No. 1816500646 & Earlier

Valve Seat Serial No. 181650056 & Later

Guide I.D. Max. Intake

Wear Limit1

Exhaust1Subtract O.D. of inner part from I.D. of outer part.

2Measure 1/2" above the bottom of the piston skirt.3Top and center compression rings.

Model (Horsepower)


Thrust Face O.D.2 NewMax. Wear Limits

Ring End Gap

Exhaust

Valves

0.010/0.023

0.032

0.006

0.6247/0.6249

MV16 (16)

3.1210/3.12033.1181

0.0035/0.0052

0.3125

0.003/0.006

0.016/0.019

0.011/0.014

0.013/0.016

0.274

0.274

0.3103

0.3088

45°

30°

0.005

0.007

——— 0.003 – 0.010 – 0.020 – 0.030 ———

M18 & MV18 (18) M20 & MV20 (20)

3.1210/3.12033.1181

0.0035/0.0052

0.010/0.023

0.032

0.006

0.6247/0.6249

0.3125

0.003/0.006

0.016/0.019

45°

30°

0.011/0.014

0.013/0.016

0.274

0.274

0.005

0.007

3.1215/3.12083.1186

0.0030/0.0047

0.010/0.023

0.032

0.006

0.7499/0.7501

0.3125

0.005

0.007

0.274

0.274

0.3103

0.3088


Used Bore (Max.)3

45°

30°

0.003/0.006

0.016/0.019

0.011/0.014

0.013/0.016

0.3103

0.3088

TP-2469-A 12/07 13



Magnum — Single Cylinder Torque Values and Sequences for Fasteners

M8 (8) M10 (10) M12 (12) M14 (14) M16 (16)

Connecting New 140 in. lbs.

Rods1, 2

Used 100 in. lbs.18-22 ft. lbs.

Screw1 —

Flywheel5 Nut1 85-90 ft. lbs.

Fan 115 in. lbs.

Anti-Lock 15 in. lbs.

Bushing 100-120 in. lbs.

32 in. lbs.

——

Isolation Mount Hand Tighten (2-12 in. lbs.)

Bracket3 150 in. lbs.

Mounting 90 in. lbs.

Speed Control Remote4 10-15 in. lbs.

Wing/Hex. Nut Local 15-25 in. lbs.

USED – Component that was in a running engine.

2DO NOT overtorque – DO NOT loosen and retorque the hex nuts on Posi-Lock connecting rods.

Cylinder Head1

Model (Horsepower)

Spark Plugs


Governor

37-45 in. lbs.

—

115 in. lbs.

—

Mounting Screws

Ignition Module

Cam Gear Cover

37-45 in. lbs.

100-120 in. lbs.

32 in. lbs.

115 in. lbs.Key Switch Nut

—

—

¹Lubricate fastener threads with engine oil.

Fuel Tank

90-100 in. lbs.

Hand Tighten (2-12 in. lbs.)

3To cylinder head, electric start side.

NEW – Component directly from stock.

10-15 in. lbs.

15-25 in. lbs.

5Flywheel and crankshaft tapers must be clean and dry.

4Torque, then loosen 1/2 turn.

260 in. lbs.

200 in. lbs.18-22 ft. lbs.

35-40 ft. lbs.

TP-2469-A 12/07 14



Magnum — Twin Cylinder Torque Values and Sequences for Fasteners

Connecting New

Rods1,2 Used

Screw1

Fan

Bolt No. Torque

Lines 1-4 260 in. lbs.

Oil Line 5-6 200 in. lbs.Remote Flared Nuts

Oil Filter Adapter

Adapter Fittings

Cover Plate

*When reinstalling a closure

plate or cylinder barrels

sealant. When installing a

service replacement

barrels, use new sealant.

#2 Side Crankcase Half Exterior

150 in. lbs.

37-45 in. lbs.

32 in. lbs.

closure plate or cylinder

Apply sealant to crankcase*

Preliminary Torque - 100 in. lbs.

Final Torque - 200 in. lbs. with a gasket, use a new

gasket. When reinstalling

one with sealant, use new

Oil Filter


Final Torque - 360 in. lbs.


Snug Plus 1/2 Turn (50/80 in. lbs.)

Oil Pan (MV16, MV18, Cylinder Barrel (All)

65-80 in. lbs.

100-120 in. lbs.

125 in. lbs.

90-130 in. lbs. to 200 in. lbs.

Twin Cylinder Engines

most expedient sequence

Torque remaining bolts in

Closure Plate (M18 & M20) 150 in. lbs.

#2 Side Crankcase Half Interior Crankcase (All)

Model (Horsepower)

Manifold Screw/Nut

Spark Plugs 10-15 ft. lbs.

MV16, M18 & MV18, M20 &MV20

40 ft. lbs.

115 in. lbs.

Cylinder Head1

Flywheel5

oil pans.

MV20) 150 in. lbs

NOTE: Do not use gasket on MV

140 in. lbs.

100 in. lbs.

Ignition Module


Mounting Screws

125 in. lbs.

TP-2469-A 12/07 15



Command – Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

General Bore

Stroke

Displacement

End Play (With Shims)

In Crankcase

Camshaft In Closure Plate

Camshaft Bearing Surface Crankcase End

O.D. - Max. Wear Limit Closure Plate End

Connecting Connecting Rod to Crankpin Running Clearance - NewRod Connecting Rod to Crankpin Running Clearance - Max. Wear Limit

End Play (Free)

O.D - New

O.D. Max. Wear Limit

Max. Taper

Max. Out of Round

Crankshaft O.D - NewPTO End Main O.D. Max. Wear Limit

Bearing Journal Max. Taper

Max. Out of Round

O.D - New


Max. Taper

Max. Out of Round

New

Max. Wear Limit

Max. Out of Round

Max. Taper

Cylinder Head

Governor

Cylinder Bore

Connecting Rod Journal

Cylinder Bore I.D.

6.425 (0.2530)Governor Cross Shaft Bore (In Crankcase) I.D. - Max. Wear Limit

Governor Cross Shaft O.D. - Max. Wear Limit

Governor Gear Shaft O.D. - Max. Wear Limit

6.296 (0.2479)

9.960 (0.3921)

67.00/67.03 (2.6378/2.6390)

Crankshaft Bore to Crankshaft Running Clearance - Max. Wear Limit

Flywheel End Main

Bearing Journal

0.076 (0.003)Max. Out of Flatness

30.934 (1.2179)

0.025 (0.0010)

0.013 (0.0005)

0.150 (0.0059)

0.100 (0.0039)

Model (Horsepower)

Horsepower (@3600 RPM - net rating per SAE J1349)

Kilowatt (kW) Output (@3600 RPM - net rating per SAE J1349)

Crankshaft Bore to Crankshaft Running Clearance - New (Sleeve Bearing)

Bore I.D. Max. Wear Limit

67.049 (2.6397)

— 0.02/0.09 (0.0008/0.0036)

— 0.115 (0.0046)

— 30.000/30.008 (1.20/1.2003)

—

30.947/30.960 (1.2184/1.2189)

29.95 (1.198)

— 0.020 (0.0008)

— 0.025 (0.0010)

—— 29.93 (1.1972)

— 0.020 (0.0008)

0.15/0.55 (0.005/0.0217)

— 0.025 (0.0010)

25.430 (1.001)

15.954 (0.6281)

25.350 (0.9980)

0.030/0.056 (0.0012/0.0022)0.0635 (0.0025)

0.000/0.056 (0.000/0.0022)

29.971/29.980 (1.988/1.992)

5 6*

16.030 (0.6311)

CH5 (5) CH6 (6)3.73 4.47*

67 (2.64)

51 (2.01)

180 cm³ (10.98 in.³)

TP-2469-A 12/07 16



CH5 (5) CH6 (6)

Ignition

Pistons,

Piston Rings, Piston Thrust Face1(@D1)

and Piston Pin to Cylinder Bore

Valves and

Valve Lifters

1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.

45°

66.941/66.959 (2.635/2.636)

66.816 (2.630)

0.016/0.059 (0.0006/0.0023)

5.4 (0.213)

0.000/0.0508 (0.000/0.0020)0.000/0.508 (0.000/0.0020)

5.080 (0.2000)

5.4 (0.213)

Exhaust Valve Guide

I.D. - Max. Wear Limit

4.990/5.010 (0.1965/0.1972)

O.D. - New

Exhaust Valve to Tappet Cold ClearanceIntake Valve to Tappet Cold Clearance

5.085 (0.2002)

4.990/5.010 (0.1965/0.1972)

0.040/0.072 (0.0016/0.0028)

0.140/0.275 (0.0055/0.0108)

0.25/0.45 (0.010/0.018)

Used Bore (Max.) 0.75 (0.030)

Middle Compression Ring to Groove Side Clearance

New BorePiston Ring End Gap

*@ 4000 RPM (Gross rating per SAE J1995).

O.D. - Max. Wear Limit

New - Running Clearance

Nominal Valve Seat Angle

I.D. - Std.

Intake Valve Minimum Lift

Exhaust Valve Minimum Lift


I.D. - Std.Intake Valve Guide

RC12YC

1.02 (0.040)

Model (Horsepower)

Oil Control Ring to Groove Side Clearance

Top Compression Ring to Groove Side Clearance

Ignition Module Air Gap

Spark Plug Gap

Spark Plug Type (Champion®

or equivalent)

0.203/0.305 (0.008/0.012)

0.040/0.085 (0.0016/0.033)

TP-2469-A 12/07 17



Command — Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

CH & CV11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV14 (14)

8.2 9.33 9.75 10.5

11 12.5 13 14General

Balance

Shaft

Bearing

In Crankcase

Camshaft In Oil Pan


O.D. - Max. Wear Limit Oil Pan End

Connecting Connecting Rod to Crankpin New

Rod Running Clearance Max. Wear Limit

I.D. - New Installed

Max. Wear LimitCrankshaft Bore to Crankshaft New

Running Clearance Max. Wear Limit

O.D. New

Crankshaft Flywheel End Main O.D. - Max. Wear Limit


Max. Out of Round

O.D. - New

PTO End Main O.D.- Max. Wear Limit


Max. Out of Round

O.D. New


Max. Taper

Max. Out of Round


Crankshaft PTO Bearing

Balance Shaft Bearing Surface O.D. Max. Wear Limit

End Play

End Play (Free)

Crankshaft Sleeve Bearing I.D. - Max. Wear Limit


Stroke

Displacement

End Play (Free)

Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)

Model (Horsepower)

Kilowatt (kW) Output (@3600 RPM-SAE J1995)

Horsepower (@ 3600 RPM-SAE J1995)Bore 87 (3.43)

67 (2.64)

398 cm³ (24.3 in.³)

0.0575/0.3625 (0.0023/0.0143)

20.038 (0.7889)

19.959 (0.7858)

With Shims – 0.076/0.127 (0.003/0.005) Without Shims – 0.10/0.39 (0.004/0.015)

20.038 (0.7889)

20.038 (0.7889)

19.959 (0.7858)

19.959 (0.7858)

0.030/0.055 (0.0012/0.0022)

0.07 (0.0025)

0.0575/0.4925 (0.0023/0.0194)

45.016 (1.7723)

44.965/45.003 (1.7703/1.7718)

45.016 (1.7723)0.03/0.09 (0.0012/0.0035)

0.115 (0.0045)

44.913/44.935 (1.7582/1.7691)

45.016 (1.7723)

0.022 (0.0009)

0.025 (0.0010)

41.915/41.935 (1.6502/1.6510)

38.94 (1.5328)

0.012 (0.0005)

0.025 (0.0010)

41.86 (1.648)

0.020 (0.0008)

0.025 (0.0010)

38.958/38.970 (1.5338/1.5343)

TP-2469-A 12/07 18



CH & CH11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV14 (14)

New

Max. Wear LimitMax. Out of Round

Max. Taper

Cylinder Head

Ignition

New Bore

Used Bore (Max.)

Pistons, O.D. - New

Piston Rings, Piston Thrust Face1

(@D1) O.D. - Max. Wear Limit

and Piston Pin to Cylinder Bore New - Running Clearance

I.D. - Std.


I.D. - Std.


Valves and

Valve Lifters

Piston Ring End Gap

Governor Cross Shaft Bore (In Crankcase) I.D. -

Max. Wear Limit

Spark Plug Type (Champion® or equivalent)

Spark Plug GapIgnition Module Air Gap




Model (Horsepower)



Governor Gear Shaft O.D. - Max. Wear LimitGovernor

Cylinder Bore Cylinder Bore I.D.



Exhaust Valve Stem to Valve Guide Running Clearance

Intake Valve Stem to Valve Guide Running Clearance

Hydraulic Lifter to Crankcase Running Clearance


1Measure 6 mm above bottom of piston skirt at right angles to piston pin.

87.000/87.025 (3.4252/3.4262)

87.063 (3.4277)0.12 (0.0047)

0.05 (0.0020)

0.076 (0.003)

5.962 (0.2347)

5.977 (0.2353)

6.063 (0.2387)

RC12YC

1.02 (0.040)0.203/0.305 (0.008/0.012)

0.040/0.105 (0.0016/0.0041)

0.040/0.072 (0.0016/0.0028)

0.55/0.675 (0.0217/0.0266)

0.3/0.5 (0.012/0.020)

0.77 (0.030)

86.941/86.959 (3.4229/3.4236)

86.814 (3.4179)

0.041/0.044 (0.0016/0.0017)

0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)

8.96 (0.353)

9.14 (0.360)

16.13 (0.640)

15.727 (0.619)

Intake Valve Guide

Exhaust Valve Guide

45°

0.0124/0.0501 (0.0005/0.0020)

7.038/7.058 (0.2771/0.2778)

7.134 (0.2809)

7.038/7.058 (0.2771/0.2779)

7.159 (0.2819)

Rocker Shaft O.D. - Max. Wear Limit

Rocker Arm I.D. - Max. Wear Limit

TP-2469-A 12/07 19



Command — Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

Balance

Shaft

Bearing

In CrankcaseCamshaft In Oil Pan


O.D. - Max. Wear Limit Oil Pan End


Rod Running Clearance Max. Wear Limit

I.D. - New Installed

Max. Wear Limit

Crankshaft Bore to Crankshaft New

Running Clearance Max. Wear Limit

O.D. New

Crankshaft O.D. - Max. Wear Limit

Max. Taper

Max. Out of Round

O.D. - NewClosure Plate or Oil Pan O.D.- Max. Wear Limit

End Main Bearing Max. Taper

Max. Out of Round

O.D. New


Max. Taper

Max. Out of Round

End Play (Free)

Flywheel End Main Bearing


Crankshaft PTO Bearing


End Play (Free)

Crankshaft Sleeve Bearing I.D. - Max. Wear Limit

Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)

Balance Shaft Bearing Surface O.D. Max. Wear Limit

End Play

CH & CV15 (15)

11.2

1590 (3.60)

With Shims – 0.076/0.127 (0.003/0.005) Without Shims – 0.10/0.39 (0.004/0.015)

19.959 (0.7858)

67 (2.64)

426 cc (26.0 cu. in.)

0.0575/0.3625 (0.0023/0.0143)

20.038 (0.7889)

Model (Horsepower)

Kilowatt (kW) Output (@3600 RPM-SAE J1995)

Horsepower (@ 3600 RPM-SAE J1995)BoreGeneral

Stroke

Displacement

0.0575/0.4925 (0.0023/0.0194)

19.959 (0.7858)

20.038 (0.7889)

0.030/0.055 (0.0012/0.0022)

19.959 (0.7858)

0.07 (0.0025)

20.038 (0.7889)

45.016 (1.7723)

44.965/45.003 (1.7703/1.7718)

45.016 (1.7723)

0.03/0.09 (0.0012/0.0035)

0.115 (0.0045)

44.913/44.935 (1.7582/1.7691)

44.84 (1.765)

0.022 (0.0009)

0.025 (0.0010)

41.915/41.935 (1.6502/1.6510)41.86 (1.648)

0.020 (0.0008)

0.025 (0.0010)

0.025 (0.0010)

38.958/38.970 (1.5338/1.5343)

38.94 (1.5328)

0.012 (0.0005)

TP-2469-A 12/07 20



Command — Single Cylinder Engine Specifications and Tolerances (cont'd)All dimensions in millimeters (inches).

New

Cylinder Max. Wear LimitBore Max. Out of Round

Max. Taper

Cylinder Head

Governor

Ignition

New Bore

Used Bore (Max.)

Pistons, O.D. - New

Piston Rings, Piston Thrust Face

1

(@D1) O.D. - Max. Wear Limitand Piston Pin to Cylinder Bore New - Running Clearance

I.D. - Std.


I.D. - Std.


Valves and

Valve Lifters

Intake Valve Guide

Exhaust Valve Guide

Cylinder Bore I.D.

CH & CV15 (15)





Governor Cross Shaft Bore (In Crankcase)


1Measure 6 mm above bottom of piston skirt at right angles to piston pin.


Spark Plug Gap



RC12YC

1.02 (0.040)

0.203/0.305 (0.008/0.012)

0.060/0.105 (0.0023/0.0041)

0.040/0.085 (0.0015/0.0002)

Model (Horsepower)





Rocker Shaft O.D. - Max. Wear LimitRocker Arm I.D. - Max. Wear Limit




90.000/90.025 (3.5433/3.5443)

90.063 (3.5457)

0.076 (0.003)

6.063 (0.2387)

5.977 (0.2353)

5.962 (0.2347)

0.05 (0.0020)

0.12 (0.0047)

0.176/0.026 (0.0069/0.0010)

0.27/0.51 (0.010/0.020)

0.77 (0.030)

89.951/89.969 (3.5413/3.5420)

0.0124/0.0501 (0.0005/0.0020)

89.824 (3.5363)0.031/0.043 (0.0012/0.0016)

7.038/7.058 (0.2771/0.2778)

7.134 (0.2809)

Piston Ring End Gap

0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)

9.14 (0.360)

16.13 (0.640)15.727 (0.619)

45°

7.038/7.058 (0.2771/0.2779)

7.159 (0.2819)

8.96 (0.353)

TP-2469-A 12/07 21



Command — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

CH & CV22 (22) 16.4

22General Bore

Stroke

Displacement


In Crankcase

Camshaft

Connecting New

Rod Max. Wear Limit

End Play (Free)

O.D - New

Crankshaft O.D. Max. Wear Limit

Max. Taper Max. Out of Round

O.D - New


Max. Taper

Max. Out of Round

New

Cylinder Max. Wear Limit

Bore Max. Out of Round

Max. Taper

Cylinder Head

Governor

0.12 (0.0047)

0.05 (0.0020)

6.063 (0.2387)

0.076 (0.003)

5.962 (0.2347)

5.977 (0.2353)

0.018 (0.0007)

0.025 (0.0010)

77.000/77.015 (3.0315/3.0325)

77.063 (3.0340)

0.022 (0.0009)0.025 (0.0010)

35.955/35.973 (1.4156/1.4163)

35.94 (1.415)

0.03/0.09 (0.0012/0.0035)

0.039/0.074 (0.0015/0.0029)

40.913/40.935 (1.6107/1.6116)

40.84 (1.608)

0.030/0.055 (0.0012/0.0022)

0.07 (0.0025)

0.070/0.480 (0.0028/0.0189)

41.016 (1.6148)

18 20


Running Clearance

77 (3.03)

67 (2.64)

624 cm³ (38.1 in.³)

0.076/0.127 (0.003/0.005)

20.038 (0.7889)

19.959 (0.7858)

CH & CV18 (18) CH & CV20 (20)13.4 14.9

Model (Horsepower)

Horsepower (@3600 RPM - SAE J1995)

Kilowatt (kW) Output (@3600 RPM - SAE J1995)

Crankshaft Main Bearing I.D. - Max. Wear Limit

Camshaft Bearing Surface


Connecting Rod to Crankpin

Governor Cross Shaft Bore (In Crankcase) I.D. - Max. Wear Limit




Main Bearing Journals

Oil Pan End


Cylinder Bore I.D.

Crankshaft to Sleeve Bearing Running Clearance -

New (Early CH models only)

Crankshaft Bore to Crankshaft Running Clearance - New

TP-2469-A 12/07 22



Command — Twin Cylinder Engine Specifications and Tolerances (cont'd)All dimensions in millimeters (inches).

CH & CV18 (18) CH & CV20 (20) CH & CV22 (22)

Ignition

Pistons,

Piston Rings,

and Piston Pin Piston Thrust Face1

(@D1

)

to Cylinder Bore

Valves and

Valve Lifters

Model (Horsepower)




Spark Plug Gap


or equivalent)



I.D. - Std.


I.D. - Std.




Hydraulic Lifter to Crankcase Running ClearanceIntake Valve Stem to Valve Guide Running Clearance

Exhaust Valve Guide

8.07 (0.3177)

8.07 (0.3177)

RC12YC

0.015/0.058 (0.0006/0.0023)

7.038/7.058 (0.2771/0.2779)

7.134 (0.2809)

76.967/76.985 (3.0302/3.0309)

76.840 (3.0252)

7.038/7.058 (0.2771/0.2779)

7.159 (0.2819)I.D. - Max. Wear Limit

0.76 (0.030)

0.28/0.33 (0.011/0.013)

0.040/0.080 (0.0016/0.0031)

0.040/0.072 (0.0016/0.0028)

New Bore

Used Bore (Max.)


New - Running Clearance


45°

0.0124/0.0501 (0.0005/0.0020)0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)

Intake Valve Guide

Piston Ring End Gap

0.060/0.202 (0.0024/0.0080)

0.25/0.45 (0.0098/0.0177)

0.77 (0.030)

O.D. - New

TP-2469-A 12/07 23



Command — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

General Bore

Stroke

Displacement


In Crankcase

Camshaft Camshaft Bearing Surface



Rod Running Clearance Max. Wear LimitEnd Play (Free)

O.D - New


Max. Taper Max. Out of Round

O.D - New


Max. Taper

Max. Out of Round

New

Max. Wear Limit

Cylinder Bore Max. Out of Round

Max. Taper

Cylinder Head

Governor

0.076 (0.003)Max. Out of Flatness

0.025 (0.0010)


40.913/40.935 (1.6107/1.6116)

40.84 (1.608)

0.022 (0.0009)

82.988/83.013 (3.2672/3.2682)

83.051 (3.2697)

0.12 (0.0047)


Cylinder Bore I.D.

0.018 (0.0007)

35.955/35.973 (1.4156/1.4163)

35.94 (1.415)

0.025 (0.0010)

0.05 (0.0020)


5.962 (0.2347)

5.977 (0.2353)

Model (Horsepower)

Horsepower (@3600 RPM - SAE J1995)

Kilowatt (kW) Output (@3600 RPM - SAE J1995)

End Play (With Thrust Bearing Components).

Oil Pan End

Crankshaft


83 (3.27)

67 (2.64)

725 cm³ (44 in.³)

0.076/0.127 (0.003/0.005)

CH & CV25 (25)

Governor Cross Shaft Bore (In Crankcase) I.D. - Max. Wear Limit

18.6

25

0.050/0.5 (0.0020/0.0197)

0.050/0.75 (0.0020/0.0295)

41.016 (1.6148)

0.03/0.09 (0.0012/0.0035)

6.063 (0.2387)


0.039/0.074 (0.0015/0.0029)Crankshaft Bore to Crankshaft Running Clearance - New

20.038 (0.7889)

0.070/0.480 (0.0028/0.0189)

19.959 (0.7858)

Crankshaft Main Bearing I.D. - Max. Wear Limit

Crankshaft to Main Bearing Running Clearance - New

0.030/0.055 (0.0012/0.0022)

0.07 (0.0025)

End Play (CH25 below Serial No. 2403500008)

TP-2469-A 12/07 24



Command — Twin Cylinder Engine Specifications and Tolerances (cont'd)All dimensions in millimeters (inches).

Ignition

Pistons,

Piston Rings,

and Piston Pin Piston Thrust Face1

to Cylinder Bore

Valves andValve Lifters

Model (Horsepower)




Spark Plug Gap


or equivalent)

0.015/0.037 (0.0006/0.0015)

0.026/0.176 (0.0010/0.0070)

0.25/0.56 (0.0100/0.0224)

O.D. - Max. Wear Limit1

Used Bore (Max.) 0.94 (0.037)

82.986 (3.2672)

82.841 (3.2615)

RC12YC

0.76 (0.030)

0.28/0.33 (0.011/0.013)

0.025/0.048 (0.0010/0.0019)

0.002/0.045 (0.001/0.0018)New - Running Clearance

8.07 (0.3177)

7.038/7.058 (0.2771/0.2779)

7.134 (0.2809)

7.038/7.058 (0.2771/0.2779)

7.159 (0.2819)

8.07 (0.3177)

CH & CV25 (25)




O.D. - New1


New Bore

I.D. - Std.


I.D. - Std.


45°

0.0124/0.0501 (0.0005/0.0020)

0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)




Exhaust Valve Guide

Intake Valve Guide

Piston Ring End Gap


TP-2469-A 12/07 25



Command — Single Cylinder Torque Values and Sequences for Fasteners

CH5 (5) CH6 (6)

Valve Cover Closure Plate

Fuel Bowl Screw

Mounting Nuts

Fastener

Cylinder Head

Valve Cover Closure Plate (CH)/Oil Pan (CV)

Rocker Studs

Fasteners - M6

Fasteners - M8Spark Plug (14 mm w/gasket)

Ignition Module

1

For self-tapping (thread forming) fasteners: The higher torque value is for initialinstallation into a new cored hole. *The lower torque value is for subsequent

installation into tapped holes and weld nuts.

Charging Stator Mounting Screw

Closure Plate

Electric Starter Mounting

Oil Sentry™ SwitchThrottle Control Lever

Valve Cover

CH5 & CH6

CH11-15 & CV11-15

Model (Horsepower)Air Cleaner Base Nuts - M6 6.8 N·m (58 in. lb.)

9.8 N·m (87 in. lb.)

6.8 N·m (58 in. lb.)

4.0 N·m (35 in. lb.)

9.0 N·m (80 in. lb.)

Flywheel Retainer Screw

Muffler Retaining Nuts

Carburetor

Fuel Tank

Ignition

Connecting Rod Cap Fastener Torque

—

22.6 N·m (200 in. lb.)

22.6 N·m (200 in. lb.)

13.6 N·m (120 in. lb.)

17/19 N·m (150/170 in. lb.)

67.8 N·m (50 ft. lb.)6.8 N·m (60 in. lb.)

17.0 N·m (150 in. lb.)24.4/29.8 N·m (18/22 ft. lb.)

3.4 N·m (30 in. lb.)

4.0*/6.2 N·m (35*/55 in. lb.)1

22.6 N·m (200 in. lb.)13.6 N·m (120 in. lb.)4.3 N·m (38 in. lb.)

TP-2469-A 12/07 26



Command — Single Cylinder Torque Values and Sequences for Fasteners

CH & CV11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV 14 (14) CH & CV15 (15)

Fastener

Rocker Pedestal (Pivot)

Fan Fasteners

Retaining Screws

Spark Plug

Ignition Module

Oil Filter

Oil Drain Plug (1/8" NPT)

Oil Sentry™ Switch

Throttle/Choke Governor Control Lever

Controls Speed Control Assembly

Flywheel

7.3*/10.7 N·m (65*/95 in. lb.)

7.3/9.0 N·m (65/80 in. lb.)

7.9 N·m (70 in. lb.)

4.0*/6.2 N·m (35*/55 in. lb.)1

9.9 N·m (88 in. lb.)

4.0*/6.2 N·m (35*/55 in. lb.)

24.4 N·m (216 in. lb.)

5.7/9.0 N·m (50/80 in. lb.)

7.3*/10.7 N·m (65*/95 in. lb.)1

1For self-tapping fasteners, the higher torque value is for initial installation into a new cored hole. *The lower torque value is for subsequent installation, and installation into tapped holes and weld nuts.

2Tighten in two stages. First torque to 15 ft. lb., following the sequence. Then tighten to final torque value of 30 ft. lb.

5.1/6.2 N·m (45/55 in. lb.)

4.0 N·m (35 in. lb.)8mm straight 22.7 N·m (200 in. lb.), 8mm step-down 14.7 N·m (130 in. lb.), 6mm straight 11.3 N·m (100 in. lb.)

24.4 N·m (216 in. lb.)

40.7 N·m (30 ft. lb.)2

Rocker bridge type 9.9 N·m (88 in. lb.), Guide plate type 11.3 N·m (100 in. lb.)

15.3 N·m (135 in. lb.)

Oil Filter

Model (Horsepower)Air Cleaner Base Nuts - M6 9.9 N·m (88 in. lb.)

Carburetor Fuel Bowl Screw

Charging Stator Mounting Screw

9.9 N·m (88 in. lb.)

66.4 N·m (49 ft. lb.)

7.3*/9.0 N·m (65*/80 in. lb.)1

38.0/43.4 N·m (28/32 ft. lb.)

Cylinder Head

Oil Pump Cover Fasteners

Valve Cover


Closure Plate (CH)/Oil Pan (CV)


Electronic Starter Mounting

Fuel Pump Fasteners

Ignition

TP-2469-A 12/07 27



Command-Twin Cylinder Torque Values and Sequences for Fasteners

CH & CV18 (18) CH & CV20 (20) CH & CV22 (22) CH & CV25 (25)

Fastener

Cylinder

Head

Rocker Pedestal (Pivot)

Fan Fasteners

Flywheel Retaining Screw

Spark Plug

Ignition Ignition Module

Oil Filter

Oil Drain Plug (1/8" NPT)Oil Sentry™ Switch

Throttle/Choke Governor Control Lever Controls Speed Control Assembly

Gasket/Sealant Type

O-Ring Type

Oil Filter

Valve Cover


Closure Plate (CH)/Oil Pan (CV)


Rectifier Fasteners

Manifold (Intake)

Electronic Starter Mounting

Model (Horsepower)

Breather Plate

Carburetor Mounting NutsCharging Stator Mounting Screw

7.3 N·m (65 in. lb.)

9.9 N·m (88 in. lb.)4.0 N·m (35 in. lb.)

8mm straight 22.7 N·m (200 in. lb.), 8mm step-down 14.7 N·m (130 in. lb.), 6mm straight 11.3 N·m (100 in. lb.)

24.4 N·m (216 in. lb.)

Two step process: First torque to 22.6 N·m (200 in. lb.), Second torque to 41.8 N·m (370 in. lb.)

11.3 N·m (100 in. lb.)

15.3 N·m (135 in. lb.)

9.9 N·m (88 in. lb.)

66.4 N·m (49 ft. lb.)

24.4/29.8 N·m (18/22 ft. lb.)

4.0*/6.2 N·m (35*/55 in. lb.)

9.9 N·m (88 in. lb.)

24.4 N·m (216 in. lb.)

4.0 N·m (35 in. lb.)

5.7/9.0 N·m (50/80 in. lb.)

3.4 N·m (30 in. lb.)

7.9 N·m (70 in. lb.)

13.6 N·m (10 ft. lb.)7.9 N·m (70 in. lb.)

9.9 N·m (88 in. lb.)7.3*/10.7 N·m (65*/95 in. lb.)1

TP-2469-A 12/07 28



Command-Twin Cylinder Torque Values and Sequences for Fasteners

Valve Cover Closure Plate (CH)/Oil Pan (CV) Breather Plate

TP-2469-A 12/07 29



Ounce (Weight) x 28.350 = Grams (g)

Pound x 0.4536 = Kilograms (kg)

Conversion Factors

Inches x 25.4 = Millimeters (mm)

Inches x 2.54 = Centimeters (cm)

Horsepower x 0.746 = Kilowatt (kW)

Cubic Inches x 16.387 = Cubic Centimeters (cu cm3)

Inch Pounds x 0.113 = Newton-meter (N·m)

Foot Pounds x 1.356 = Newton-meter (N·m)

TP-2469-A 12/07 30



LH630 (22) LH640 (24) LH685 (25) LH690 (26)

Cylinder 77.063 (3.0340) 77.063 (3.0340) 80.065 (3.1522) 80.065 (3.1522)

Bore 0.05 (0.0020) 0.05 (0.0020) 0.05 (0.0020) 0.05 (0.0020)

0.12 (0.0047) 0.12 (0.0047) 0.12 (0.0047) 0.12 (0.0047)

Cylinder Head 0.076 (0.003) 0.076 (0.003) 0.076 (0.003) 0.076 (0.003)

New

Max. Wear Limit 7.936 (0.3124) 7.936 (0.3124) 7.936 (0.3124) 7.936 (0.3124)

New

Max. Wear Limit 5.977 (0.2353) 5.977 (0.2353) 5.977 (0.2353) 5.977 (0.2353)

RC14YC RC14YC RC14YC RC14YC

Ignition 0.76 (0.030) 0.76 (0.030) 0.76 (0.030) 0.76 (0.030)

New

Max. Wear Limit 17.025 (0.6703) 17.025 (0.6703) 17.025 (0.6703) 17.025 (0.6703)Piston, Piston New

Rings, and Max. Wear Limit 16.994 (0.6691) 16.994 (0.6691) 16.994 (0.6691) 16.994 (0.6691)

Piston Pin

Top and Middle Compression Top Ring

Ring End Gap - New Bore Middle Ring

Used Bore (Max.) 0.77 (0.030) 0.77 (0.030) 0.80 (0.0315) 0.80 (0.0315)

NewMax. Wear Limit 76.840 (3.0252) 76.840 (3.0252) 79.831 (3.1430) 79.831 (3.1430)

0.019/0.062 (0.0007/0.0024)

16.995/17.000 (0.6691/0.6693)

0.046/0.196 (0.0018/0.0077)

0.180/0.430 (0.0071/0.0169)

0.250/0.450 (0.0098/0.0177) 0.250/0.460 (0.0098/0.0181)

76.968/76.986 (3.0302/3.0309) 79.963/79.981 (3.1481/3.1488)

0.040/0.086 (0.0016/0.0034) 0.050/0.096 (0.0020/0.0038)

7.949/8.000 (0.3129/0.3149)

0.025/0.126 (0.0009/0.0049)

5.990/6.000 (0.2358/0.2362)

0.090/0.160 (0.0035/0.0063)

Model (Horsepower)

Governor Cross Shaft O.D.

Gear Shaft-to-Governor Gear Running Clearance


Governor Cross Shaft to

80.000/80.025 (3.1496/3.1506)

Bore1

Running Clearance

Piston Thrust Face-to-Cylinder

0.040/0.086 (0.0016/0.0034)

Spark Plug Gap

0.014/0.057 (0.0005/0.0022)

17.006/17.013 (0.6695/0.6698)

0.006/0.018 (0.0002/0.0007)

0.203/0.305 (0.008/0.012)

0.030/0.076 (0.0012/0.0030)

1Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.


Piston-to-Piston Pin

Oil Control Ring-to-Groove Side Clearance

Piston Pin Bore I.D.

Piston Pin O.D.

Top Compression Ring-to-Groove Side Clearance

Middle Compression Ring-to-Groove Side Clearance

0.180/0.380 (0.0071/0.0150)

Piston Thrust Face O.D.1

Cylinder Bore I.D.

New

Max. Wear Limit

Max. Taper

Max. Out-of-Round

Governor

Governor Gear Shaft O.D.

Max. Out-of-Flatness

Crankcase Running Clearance

TP-2469-A 12/07 32



LH630 (22) LH640 (24) LH685 (25) LH690 (26)

NewMax. Wear Limit

Valves and New

Valve Lifters Max. Wear Limit

Standard

0.25 mm O.S.

45°

7.048 (0.2775)

8.88 (0.3496)

8.88 (0.3496)

7.298 (0.2873)

Intake Valve Stem Diameter - New

Exhaust Valve Guide I.D.

Exhaust Valve Stem Diameter - New

Valve Guide Reamer Size

Intake Valve Lift

Exhaust Valve Lift


6.982/7.000 (0.2749/0.2756)

7.038/7.058 (0.2771/0.2779)

Exhaust Valve Stem-to-Valve Guide Running Clearance

Intake Valve Guide I.D.

Hydraulic Valve Lifter to Crankcase Running Clearance

Model (Horsepower)

Intake Valve Stem-to-Valve Guide Running Clearance

6.970/6.988 (0.2744/0.2751)

0.0124/0.0501 (0.0005/0.0020)

0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)

7.038/7.058 (0.2771/0.2779)7.134 (0.2809)

7.159 (0.2819)

TP-2469-A 12/07 33

A i T i C li d E i S ifi ti d T l



Aegis — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

LH750 (27) LH755 (28) LH760 (29) LH775 (31)

20.1 kW (27 HP) 20.9 kW (28 HP) 21.6 kW (29 HP) 23.1 kW (31 HP)

Camshaft

New

Max. Wear Limit

New

Max Wear Limit

Connecting

Rod New

Max. Wear Limit

New

Max. Wear Limit

New

Max. Wear Limit

O.D. - New


41.038 (1.6156)

40.84 (1.608)

0.022 (0.0009)

8.025/8.075 (0.3159/0.3179)

0.070/0.590 (0.0028/0.0230)

40.974/40.987 (1.6131/1.6136)

40.974/41.000 (1.6131/1.6141)

41.000 (1.6141)

0.043/0.068 (0.0016/0.0026)

0.26/0.63 (0.0102/0.0248)

0.015/0.028 (0.0006/0.0011)

17.015/17.023 (0.6699/0.6702)

0.076/0.127 (0.0030/0.0050)

0.025/0.063 (0.0010/0.0025)

20.000/20.025 (0.7874/0.7884)

19.962/19.975 (0.7859/0.7864)

Running Clearance - New

Crankshaft Bore (in closure plate)-to-Crankshaft


Crankshaft Bore (in closure plate)

Max. Taper Max. Out-of-Round

O.D. - New

Crankshaft to Sleeve Bearing (crankcase)

PTO End, Crank in Engine


Max. Taper

Max. Out-of-Round

Running Clearance

New

Max. Wear LimitBore I.D.

Camshaft Bearing Surface O.D.

Crankcase

Entire Crank, in V-BlocksCrankshaft T.I.R.


Model (Horsepower)

Rod-to-Crankpin Side Clearance

Governor Cross Shaft Bore I.D

Piston Pin End I.D.

Rod-to-Piston Pin Running Clearance

Bore x StrokeDisplacement Cu. In.

End Play (With Shim)

Horsepower (@3600 RPM) - Maximum kW (HP)

General

Rod-to-Crankpin Running

Clearance

New

Max. Wear Limit

Crankshaft Sleeve Bearing I.D.

End Play (Free)

(Crankcase)

Crankshaft


20.038 (0.7889)

83 (3.3) x 69 (2.7)747 cc (45.6)

19.959 (0.7858)

0.083 (0.0032)

17.036 (0.6707)

8.088 (0.3184)

0.025 (0.0010)

0.039/0.087 (0.0015/0.0034)

40.913/40.935 (1.6107/1.6116)

35.94 (1.415)

0.039/0.074 (0.0015/0.0029)

35.955/35.973 (1.4156/1.4163)

0.10 (0.0039)0.15 (0.0059)

0.025 (0.0010)

0.018 (0.0007)

TP-2469-A 12/07 34

A i T i C li d E i S ifi ti d T l



Aegis — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

LH750 (27) LH755 (28) LH760 (29) LH775 (31)

20.1 kW (27 HP) 20.9 kW (28 HP) 21.6 kW (29 HP) 23.1 kW (31 HP)

Camshaft

New

Max. Wear Limit

New

Max Wear Limit

Connecting

Rod New

Max. Wear Limit

New

Max. Wear Limit

New

Max. Wear Limit

O.D. - New


41.038 (1.6156)

40.84 (1.608)

0.022 (0.0009)

8.025/8.075 (0.3159/0.3179)

0.070/0.590 (0.0028/0.0230)

40.974/40.987 (1.6131/1.6136)

40.974/41.000 (1.6131/1.6141)

41.000 (1.6141)

0.043/0.068 (0.0016/0.0026)

0.26/0.63 (0.0102/0.0248)

0.015/0.028 (0.0006/0.0011)

17.015/17.023 (0.6699/0.6702)

0.076/0.127 (0.0030/0.0050)

0.025/0.063 (0.0010/0.0025)

20.000/20.025 (0.7874/0.7884)

19.962/19.975 (0.7859/0.7864)


Crankshaft Bore (in closure plate)-to-Crankshaft


Crankshaft Bore (in closure plate)

Max. Taper Max. Out-of-Round

O.D. - New

Crankshaft to Sleeve Bearing (crankcase)



Max. Taper

Max. Out-of-Round

Running Clearance

New

Max. Wear LimitBore I.D.


Crankcase

Entire Crank, in V-BlocksCrankshaft T.I.R.


Model (Horsepower)


Governor Cross Shaft Bore I.D

Piston Pin End I.D.


Bore x StrokeDisplacement Cu. In.



General

Rod-to-Crankpin Running

Clearance

New

Max. Wear Limit


End Play (Free)

(Crankcase)

Crankshaft


20.038 (0.7889)

83 (3.3) x 69 (2.7)747 cc (45.6)

19.959 (0.7858)

0.083 (0.0032)

17.036 (0.6707)

8.088 (0.3184)

0.025 (0.0010)

0.039/0.087 (0.0015/0.0034)

40.913/40.935 (1.6107/1.6116)

35.94 (1.415)

0.039/0.074 (0.0015/0.0029)

35.955/35.973 (1.4156/1.4163)

0.10 (0.0039)0.15 (0.0059)

0.025 (0.0010)

0.018 (0.0007)

TP-2469-A 12/07 35



LH750 (27) LH755 (28) LH760 (29) LH775 (31)

Cylinder Bore

Cylinder Head

Governor Cross Shaft to

Crankcase Running Clearance

New

Max. Wear Limit

NewMax. Wear Limit

Ignition

New

Max. Wear Limit

Piston, Piston NewRings, and Max. Wear Limit

Piston Pin

New Bore

Used Bore

New

Max. Wear Limit

82.973/82.991 (3.2666/3.2673)

0.015/0.058 (0.005/0.0022)

0.014/0.041 (0.0005/0.0016)

0.012/0.039 (0.0004/0.0015)

0.026/0.176 (0.0010/0.0070)

0.250/0.56 (0.0098/0.022)

0.203/0.305 (0.008/0.012)

0.006/0.018 (0.0002/0.0007)

17.006/17.013 (0.6695/0.6698)

16.995/17.000 (0.6691/0.6693)

0.025/0.126 (0.0009/0.0049)

7.949/8.000 (0.3129/0.3149)

5.990/6.000 (0.2358/0.2362)

0.090/0.160 (0.0035/0.0063)

1Measure 6 mm (0.236 in.) above the bottom of the piston skirt, at right angles to the piston pin.

Model (Horsepower)

Cylinder Bore I.D.

New

Max. Wear LimitMax. Taper

Max. Out-of-Round


Governor

83.006/83.031 (3.2679/3.2689)


Piston Pin O.D.



Spark Plug Gap


Bore1

Running Clearance






Ring End Gap - New Bore

Top and Middle Compression



82.841 (3.3136)

0.94 (0.037)

16.994 (0.6691)

17.025 (0.6703)

0.76 (0.030)

RC14YC

5.977 (0.2353)

7.936 (0.3124)


83.069 (3.2704)

0.05 (0.0020)

0.12 (0.0047)

0.076 (0.003)

TP-2469-A 12/07 36



LH750 (27) LH755 (28) LH760 (29) LH775 (31)

New

Max. Wear Limit

Valves and

Valve Lifters New

Max. Wear Limit

Standard0.25 mm O.S.



Model (Horsepower)

Intake Valve Lift



Exhaust Valve Lift






6.982/7.000 (0.2749/0.2756)

7.038/7.058 (0.2771/0.2779)

6.970/6.988 (0.2744/0.2751)

0.0124/0.0501 (0.0005/0.0020)

0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)

7.038/7.058 (0.2771/0.2779)

7.134 (0.2809)

7.159 (0.2819)

45°

7.048 (0.2775)7.298 (0.2873)

8.88 (0.3496)

8.88 (0.3496)

TP-2469-A 12/07 37



LH750 (27) LH755 (28) LH760 (29) LH775 (31)

New

Max. Wear Limit

Valves and

Valve Lifters New

Max. Wear Limit

Standard0.25 mm O.S.



Model (Horsepower)

Intake Valve Lift



Exhaust Valve Lift






6.982/7.000 (0.2749/0.2756)

7.038/7.058 (0.2771/0.2779)

6.970/6.988 (0.2744/0.2751)

0.0124/0.0501 (0.0005/0.0020)

0.038/0.076 (0.0015/0.0030)0.050/0.088 (0.0020/0.0035)

7.038/7.058 (0.2771/0.2779)

7.134 (0.2809)

7.159 (0.2819)

45°

7.048 (0.2775)7.298 (0.2873)

8.88 (0.3496)

8.88 (0.3496)

TP-2469-A 12/07 38

A i T i C li d T V l d S f F t



Aegis — Twin Cylinder Torque Values and Sequences for Fasteners

LH630 (22) LH640 (24) LH685 (25) LH690 (26)

Step 1

Carburetor and Step 2

Intake Manifold

Connecting Rod

Closure Plate

Step 1

Step 2

Starter Mounting ScrewStarter Brush Holder Fastener

Model (Horsepower)

Breather Cover Fastener

Rocker Pivot Fastener

Cylinder Head (torque in two increments)

Closure Plate Fastener

Cylinder Head Fastener

Crankcase

(torque in two increments)

Intake Manifold Fastener

24.4 N·m (216 in. lb.)

16.9 N·m (150 in. lb.)

33.9 N·m (300 in. lb.)

11.3 N·m (100 in. lb.)

Thermostat Housing Mount Fastener

Carburetor Mounting Fastener

Cap Fastener - Incrementally torque to:

Into new hole

Into used hole

Electric Starter

Closure Plate

Starter Thru Bolt

Starter Solenoid Fastener

Brush Lead Retaining Nut

Starter Solenoid Positive (+)

Oil Drain Plug

7.4 N·m (66 in. lb.)

9.9 N·m (88 in. lb.)

6.2-7.3 N·m (55-65 in. lb.)

9.9 N·m (88 in. lb.)

11.3 N·m (100 in. lb.)

10.7 N·m (95 in. lb.)

7.3 N·m (65 in. lb.)

13.6 N·m (10 ft. lb.)

Intake Manifold

5.6-9.0 N·m (49-79 in. lb.)

15.3 N·m (135 in. lb.)2.5-3.3 N·m (22-29 in. lb.)

4.0-6.0 N·m (35-53 in. lb.)

Cylinder Head #2 Cylinder Head #1

8.0-11.0 N·m (71-97 in. lb.)

TP-2469-A 12/07 39



LH630 (22) LH640 (24) LH685 (25) LH690 (26)

Lower Flywheel Cover

Mounting Screw

Governor

Muffler

Speed Control Bracket

Assembly Fastener

Stator

Valve Cover/

Rocker Arms

Breather Cover Valve Cover Water Pump

Model (Horsepower)

Fan/Flywheel

Rear Fan Shaft to Mounting Bracket Nut

Front Fan Assembly to Fan Shaft Nut

Fan/Pulley/Hub Assembly Fastener Flywheel Retaining Screw

Into hex or weld nuts

Into Timmerman clips/nuts

Lower Pulley Mounting Screw

Governor Lever Nut Torque

Ignition

Spark Plug

Ignition Module Fastener Into new hole

Into used hole

Rectifier-Regulator Fastener

Stator Mounting Screw

Valve Cover Fastener


Oil Filter Oil Filter Instructions:

Speed ControlInto new hole

Into used hole

Water PumpMounting Screw

Pulley Mounting Screw

9.9 N·m (88 in. lb.)

9.9 N·m (88 in. lb.)

15.8 N·m (140 in. lb.)

15.8 N·m (140 in. lb.)

6.8 N·m (60 in. lb.)66.4 N·m (49 ft. lb.)

9.9 N·m (88 in. lb.)

24.3 N·m (215 in. lb.)

6.8 N·m (60 in. lb.)

6.2 N·m (55 in. lb.)

2.2-2.8 N·m (20-25 in. lb.)

24.4-29.8 N·m (18-22 ft. lb.)

4.0 N·m (35 in. lb.)

4.0 N·m (35 in. lb.)

24.4 N·m (216 in. lb.)

Rotate filter 3/4-1 turn after gasket contact

10.7 N·m (95 in. lb.)

7.3 N·m (65 in. lb.)

6.2 N·m (55 in. lb.)

6.2 N·m (55 in. lb.)

TP-2469-A 12/07 40

Aegis — Twin Cylinder Torque Values and Sequences for Fasteners



LH750 (27) LH755 (28) LH760 (29) LH775 (31)

Step 1

Carburetor and Step 2

Intake Manifold

Connecting Rod

Closure Plate

Step 1

Step 2

Starter Mounting Screw

Starter Brush Holder Fastener

Starter Solenoid Fastener

Lead Retaining Nut

Closure Plate Cylinder Head #2 Cylinder Head #1

Crankcase Into used hole

Electric Starter

Thermostat Housing Mount Fastener

Carburetor Mounting Fastener

Cap Fastener - Torque in Increments to:

Into new hole

Intake Manifold

Model (Horsepower)

Breather Cover Fastener

Rocker Pivot Fastener

Cylinder Head (torque in two increments)



Oil Drain Plug

(torque in two increments)

Starter Solenoid Positive (+) Brush

Intake Manifold Fastener

15.3 N·m (135 in. lb.)

5.6-9.0 N·m (49-79 in. lb.)

11.3 N·m (100 in. lb.)

33.9 N·m (300 in. lb.)

16.9 N·m (150 in. lb.)

24.4 N·m (216 in. lb.)

Starter Thru Bolt

7.4 N·m (66 in. lb.)

9.9 N·m (88 in. lb.)

6.2-7.3 N·m (55-65 in. lb.)

9.9 N·m (88 in. lb.)

8.0-11.0 N·m (71-97 in. lb.)

4.0-6.0 N·m (35-53 in. lb.)

2.5-3.3 N·m (22-29 in. lb.)

7.3 N·m (65 in. lb.)

10.7 N·m (95 in. lb.)

11.3 N·m (100 in. lb.)

13.6 N·m (10 ft. lb.)

TP-2469-A 12/07 41

LH750 (27) LH755 (28) LH760 (29) LH775 (31)Model (Horsepower)



( ) ( ) ( ) ( )

Lower Flywheel Cover

Mounting Screw

Governor

Ignition Module

Fastener

Muffler

Speed Control Bracket

Assembly Fastener

Stator

Valve Cover/Rocker Arms

Breather Cover Valve Cover Water Pump

6.2 N·m (55 in. lb.)

6.2 N·m (55 in. lb.)

9.9 N·m (88 in. lb.)

9.9 N·m (88 in. lb.)

24.4 N·m (216 in. lb.)

Rotate filter 3/4-1 turn after gasket contact

10.7 N·m (95 in. lb.)

7.3 N·m (65 in. lb.)

24.4-29.8 N·m (18-22 ft. lb.)

6.2 N·m (55 in. lb.)

4.0 N·m (35 in. lb.)

4.0 N·m (35 in. lb.)

9.9 N·m (88 in. lb.)

2.2-2.8 N·m (20-25 in. lb.)

24.3 N·m (215 in. lb.)

6.8 N·m (60 in. lb.)

15.8 N·m (140 in. lb.)

15.8 N·m (140 in. lb.)

6.8 N·m (60 in. lb.)

66.4 N·m (49 ft. lb.)

( p )

Fan/Flywheel

Rear Fan Shaft to Mounting Bracket Nut

Front Fan Assembly to Fan Shaft Nut

Fan/Pulley/Hub Assembly Fastener

Flywheel Retaining ScrewInto hex or weld nuts

Into Timmerman clips/nuts

Lower Pulley Mounting Screw

Governor Lever Nut Torque

Ignition

Spark Plug

Into new hole

Into used hole



Oil Filter Oil Filter Instructions:

Speed ControlInto new hole

Into used hole


Water PumpMounting Screw

Pulley Mounting Screw


TP-2469-A 12/07 42

Aegis — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches)



All dimensions in millimeters (inches).LV560 LV625 LV675

12.7 kW (17 HP) 14.9 kW (20 HP) 17.1 kW (23 HP)

73 (2.87) x 67 (2.64) 77 (3.03) x 67 (2.64) 80 (3.14) x 67 (2.64)

561 cc (34.2 cu. in.) 624 cc (38.1 cu. in.) 674 cc (41.1 cu. in.)

Camshaft

New

Max. Wear Limit

New

Max Wear Limit

Connecting

Rod New

Max. Wear Limit

New

Max. Wear Limit

New

Max. Wear LimitNew

Max. Wear Limit

Crankshaft O.D. - New


Max. Taper

Max. Out-of-Round

O.D. - New


Max. Taper

Max. Out-of-Round


Entire Crank, in V-Blocks



Crankshaft T.I.R.

35.955/35.973 (1.4156/1.4163)

35.94 (1.415)

0.018 (0.0007)

0.15 (0.0059)

0.10 (0.0039)

Crankshaft Bore (in oil pan)-to-Crankshaft


Crankshaft Bore (in crankcase)-to-Crankshaft

End Play (Free)

Crankshaft Bore (in crankcase)

Crankshaft Bore (in oil pan)




Piston Pin End I.D.

Crankcase Governor Cross Shaft Bore I.D

New

Max. Wear Limit


Rod-to-Crankpin Running Clearance

17.015/17.023 (0.6699/0.6702)

8.025/8.075 (0.3159/0.3179)

Model (Horsepower)

General


Bore x Stroke

DisplacementEnd Play (With Shim)

Running Clearance

Bore I.D.

0.076/0.127 (0.0030/0.0050)

0.025/0.063 (0.0010/0.0025)

20.000/20.025 (0.7874/0.7884)

19.962/19.975 (0.7859/0.7864)

20.038 (0.7889)

0.039/0.087 (0.0015/0.0034)

41.000 (1.6141)

41.038 (1.6156)

0.025 (0.0010)

0.039/0.074 (0.0015/0.0029)

40.84 (1.608)

0.022 (0.0009)

0.025 (0.0010)

40.913/40.935 (1.6107/1.6116)

0.070/0.590 (0.0028/0.0232)

40.974/40.987 (1.6131/1.6136)

40.974/41.000 (1.6131/1.6141)

19.959 (0.7858)

0.083 (0.0032)

17.036 (0.6707)

8.088 (0.3184)

0.043/0.068 (0.0016/0.0026)

0.26/0.63 (0.0102/0.0248)

0.015/0.028 (0.0006/0.0011)

TP-2469-A 12/07 43



LV560 LV625 LV675New 73.006/73.03 (2.8742/2.8752) 77.000/77.025 (3.0315/3.0325) 80.000/80.025 (3.1496/3.1506)

Cylinder Max. Wear Limit 73.070 (2.8767) 77.063 (3.0340) 80.065 (3.1522)

Bore Max. Out-of-RoundMax. Taper

Cylinder Head

Governor

New

Max. Wear Limit

New

Max. Wear Limit

Ignition

New

Max. Wear Limit

New

Piston, Piston Max. Wear LimitRings, and 0.040/0.096 (0.0016/0.0037) 0.040/0.086 (0.0016/0.0034) 0.050/0.096 (0.0012/0.0030)

Piston Pin 0.030/0.080 (0.0012/0.0031) 0.040/0.086 (0.0016/0.0034) 0.030/0.076 (0.0012/0.0030)

0.046/0.201 (0.0018/0.0079) 0.046/0.196 (0.0018/0.0077) 0.046/0.196 (0.0018/0.0077)

Top Ring 0.180/0.380 (0.0071/0.0150) 0.180/0.380 (0.0071/0.0150) 0.180/0.430 (0.0071/0.0169)

Middle Ring 0.180/0.440 (0.0071/0.0173) 0.250/0.450 (0.0098/0.0177) 0.250/0.460 (0.0098/0.0181)

Used Bore (Max.) 0.76 (0.029) 0.77 (0.030) 0.80 (0.0315)

New 72.966/72.984 (2.8727/2.8734) 76.967/76.985 (3.0302/3.0309) 79.963/79.981 (3.1481/3.1488)

Max. Wear Limit 72.839 (2.8677) 76.840 (3.0252) 79.831 (3.1430)


17.025 (0.6703)

16.995/17.000 (0.6691/0.6693)

16.994 (0.6691)

0.76 (0.030)

0.2/0.3 (0.008/0.012)

0.006/0.018 (0.0002/0.0007)

17.006/17.013 (0.6695/0.6698)

0.12 (0.0047)0.05 (0.0020)

0.076 (0.003)

0.025/0.126 (0.0009/0.0049)

Model (Horsepower)

Top and Middle Compression

Ring End Gap - New Bore

0.014/0.057 (0.0005/0.0022)

Piston Pin O.D.




Spark Plug Gap



0.019/0.062 (0.0007/0.0024)


0.022/0.065 (0.0009/0.0026)Bore

1Running Clearance

Governor Cross Shaft to Crankcase


Cylinder Bore I.D.


Running Clearance




7.949/8.000 (0.3129/0.3149)

Governor



7.936 (0.3124)

5.990/6.000 (0.2358/0.2362)

5.977 (0.2353)

0.090/0.160 (0.0035/0.0063)

RC14YC

TP-2469-A 12/07 44



LV560 LV625 LV675


Max. Wear LimitExhaust Valve Guide I.D.

Standard




0.25 mm O.S.


Valves and

Valve Lifters

Model (Horsepower)Hydraulic Valve Lifter to Crankcase Running Clearance



New

Max. Wear LimitIntake Valve Guide I.D.

New


0.0124/0.0501 (0.0004/0.0020)

0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)

7.038/7.058 (0.2771/0.2779)

7.134 (0.2809)

6.982/7.000 (0.2749/0.2756)

7.038/7.058 (0.2771/0.2779)

7.159 (0.2819)

8.88 (0.3496)

45°

6.970/6.988 (0.2744/0.2751)

7.048 (0.2775)

7.298 (0.2873)8.88 (0.3496)

TP-2469-A 12/07 45

Aegis LV17-23 — Twin Cylinder Torque Values and Sequences for Fasteners



LV560 LV625 LV675Blower Housing

(Lower)

Carburetor and

Intake Manifold

Connecting Rod

Into new as-cast hole

Into used hole

Cylinder Head #2 Valve Cover #1

Step 1

Step 2

Electric Starter


Into used hole

6.2 N·m (55 in. lb.)

6.2 N·m (55 in. lb.)

11.3 N·m (100 in. lb.)

Model (Horsepower)4.0 N·m (35 in. lb.)

6.8 N·m (60 in. lb.)

4.0 N·m (35 in. lb.)

Crankcase

Valve Cover #2

Oil Drain Plugs

10.7 N·m (95 in. lb.)

7.3 N·m (65 in. lb.)

13.6 N·m (120 in. lb.)

16.9 N·m (150 in. lb.)


M5 Fasteners

M6 Fasteners

Rectifier Fastener

Breather Cover Fasteners

Cap Fastener - Incrementally torque to:

Starter Mounting Fastener

Intake Manifold Mounting Fasteners

Carburetor Mounting Fasteners

Ignition


Fan/Flywheel

Rocker Pivot Fastener Torque (screw)

Rocker Pivot Fastener Torque (nut)

Ignition Module Fastener

Cylinder Head

Cylinder Head #1

Spark Plug

Fan Fastener

33.9 N·m (300 in. lb.)

11.3 N·m (100 in. lb.)

15.8 N·m (140 in. lb.)

15.3 N·m (135 in. lb.)

3.9 N·m (35 in. lb.)

13.6 N·m (120 in. lb.)

66.4 N·m (49 ft. lb.)

24.4-29.8 N·m (18-22 ft. lb.)

6.2 N·m (55 in. lb.)

TP-2469-A 12/07 46

LV560 LV625 LV675Model (Horsepower)



LV560 LV625 LV675

Muffler

Oil Pan


Into used hole

Stator

Throttle/Choke Controls Governor Control Lever Fastener

Valve Cover/Rocker Arms Valve Cover Fastener

Breather Cover Water PumpIntake Manifold

Model (Horsepower)


Speed Control Bracket Assembly Fastener


Oil Pan/Filter

Oil Filter

Oil Pan Fastener

24.4 N·m (216 in. lb.)

8.1-9.4 N·m (72-84 in. lb.)

24.4 N·m (216 in. lb.)

10.7 N·m (95 in. lb.)

7.3 N·m (65 in. lb.)

6.2 N·m (55 in. lb.)

9.9 N·m (88 in. lb.)

6.2 N·m (55 in. lb.)

TP-2469-A 12/07 47

Command PRO CS — Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).



CS4 CS6 CS8.5 (spec. 95xxxx)

2.9 4.47 5.4

4 6 8.5

56.0 (2.20) x 50.0 (1.97) 66.0 (2.60) x 50.0 (1.97) 75.0 (2.95) x 57.0 (2.44)123 cc (7.50 cu. in.) 171 cc (10.43 cu. in.) 251 cc (15.30 cu. in.)

0.05 (0.0020) 0.05 (0.0020) 0.05 (0.0020)

14.95 (0.583) 14.95 (0.583) 15.95 (0.627)

New

Max Wear Limit

Connecting

Rod New 16.006/16.020 (0.6301/0.6307) 16.006/16.020 (0.6301/0.6307) 18.006/18.020 (0.7089/0.7094)

Max. Wear Limit 16.10 (0.634) 16.10 (0.634) 18.10 (0.713)

New 28.000/28.015 (1.1023/1.1029) 28.000/28.015 (1.1023/1.1029) 32.000/32.015 (1.2598/1.2604)

Max. Wear Limit 28.115 (1.1069) 28.115 (1.1069) 32.115 (1.2644)

NewMax. Wear Limit

New

Max. Wear Limit

New 27.969/27.984 (1.011/1.017) 27.969/27.984 (1.011/1.017) 31.969/31.984 (1.2586/1.2592)

Max. Wear Limit 27.9 (1.098) 27.9 (1.098) 31.9 (1.2559)

New 56.005/56.015 (2.2049/2.2053) 66.005/66.015 (2.5986/2.5990) 75.005/75.015 (2.9530/2.9533)

Cylinder Max. Wear Limit 56.15 (2.211) 66.15 (2.604) 75.15 (2.959)

Bore

Cylinder Head


Model (Horsepower)

Camshaft Bearing Surface O.D. — Max. Wear Limit

Crankshaft

Camshaft


Runout (Either End)

Limit (Either End)

Connecting Rod Journal O.D.

PTO End Main Bearing Journal O.D.

Kilowatt (kW) Output (@3600 RPM)

0.016/0.046 (0.0006/0.0018)

0.1 (0.004)

Spark Plug Gap

15.05 (0.592)

Journal End I.D.

Piston Pin End I.D.

End Play (Threaded Pump Shaft Models Only)

End Play (Free)

Flywheel End Main Bearing Journal O.

Spark Plug Type

15.05 (0.592) 16.05 (0.649)

Displacement

End Play

Horsepower (@3600 RPM)General


Bore x Stroke

Bore I.D. — Max. Wear Limit

0.2/0.6 (0.008/0.024)

0.006/0.025 (0.0002/0.0001)

Ignition Champion®


NGK

Champion®

Max. Out-of-Round

Cylinder Bore I.D.


52 (2.047)

52.05 (2.0492)

0.02 (0.0008)

0.04 (0.0015)

0.0/0.2 (0.0/0.007)

52 (2.047)

52.05 (2.0492)

0.04 (0.0016)

0.05 (0.002)

0.1 (0.004)

BPR4ES (13/16 hex)

RN14YC (13/16 hex)

RC14YC (5/8) hex)

0.76 (0.030)

0.4/0.6 (0.015/0.023)

TP-2469-A 12/07 48




CS8.5 (spec. 92xxxx) CS10 CS12

6.33 7.45 8.95

8.5 10 12

78.0 (3.07) x 63.0 (2.48) 78.0 (3.07) x 63.0 (2.48) 85.0 (3.35) x 63.0 (2.48)

301 cc (18.37 cu. in.) 301 cc (18.37 cu. in.) 357 cc (21.79 cu. in.)

New

Max Wear Limit

Connecting

Rod New

Max. Wear Limit

New

Max. Wear Limit

New

Max. Wear Limit

New

Max. Wear Limit

New

Max. Wear Limit

Cylinder

Bore New 78.00/78.02 (3.0709/3.0717) 78.00/78.02 (3.0709/3.0717) 85.00/85.02 (3.3465/3.3472)

Max. Wear Limit 78.65 (3.096) 78.65 (3.096) 85.65 (3.372)

Cylinder Head

Crankshaft

Camshaft

End Play (Threaded Pump Shaft Models Only)

General

Model (Horsepower)

Camshaft Bearing Surface O.D. – Max. Wear Limit

Displacement

Bore I.D. – Max. Wear Limit

End Play

Ignition



Journal End I.D.

Piston Pin End I.D.

Champion®

PTO End Main Bearing Journal O.D.

Max. Out-of-Round

Cylinder Bore I.D.

0.016/0.046 (0.0006/0.0018)

0.1 (0.004)

Bore x Stroke

15.95 (0.627)

0.05 (0.0020)

NGK

Champion®

Connecting Rod Journal O.D.

Spark Plug Type


Spark Plug Gap


Horsepower (@3600 RPM)


End Play (Free)

Runout (Either End)

Limit (Either End)

Flywheel End Main Bearing Journal O.D.


0.2/0.65 (0.0079/0.0256)

0.006/0.025 (0.0002/0.0001)

20.006/20.020 (0.7876/0.7882)

20.10 (0.791)

36.000/36.015 (1.4173/1.4179)

36.115 (1.4219)

0.04 (0.0015)

0.0/0.2 (0.0/0.007)

0.02 (0.0008)

0.04 (0.0016)

80 (3.149)

80.05 (3.1515)

72 (2.834)

72.05 (2.836)

0.76 (0.030)

0.1 (0.004)

0.4/0.6 (0.015/0.023)

16.05 (0.649)

0.05 (0.002)

BPR4ES (13/16 hex)

RN14YC (13/16 hex)

RC14YC (5/8) hex)

35.969/35.984 (1.4161/1.4167)

35.9 (1.4134)

TP-2469-A 12/07 49


CS4 CS6 CS8 5 (spec 95xxxx)Model (Horsepower)



CS4 CS6 CS8.5 (spec. 95xxxx)0.004/0.020 (0.0002/0.0008)

New 18.004/18.015 (0.7088/0.7093)

Piston, Piston Max Wear Limit 18.03 (0.7098)

Rings, and New 17.995/18.000 (0.7084/0.7086)

Piston Pin Max Wear Limit 17.98 (0.7079)

Middle Compression Ring to

0.25/0.4 (0.010/0.016)

0.25/0.4 (0.010/0.016)

0.2/0.7 (0.0079/0.028)New 55.975/55.990 (2.2037/2.2043)

165.975/65.990 (2.597/2.598)

174.954/74.998 (2.9509/2.9527)

2

Max Wear Limit 55.900 (2.20) 65.900 (2.60) 74.898 (2.9487)

New 6.0/6.012 (0.2362/0.2367)Max Wear Limit 6.10 (0.240)

Valves and New 6.0/6.012 (0.2362/0.2367)

Valve Lifters Max Wear Limit 6.0 (0.236)

6.0 (0.236)

2.7 (0.106)

2.9 (0.114)

45°

0.1 (0.004)1Measure 5 mm (0.197 in.) above the bottom of the piston skirt at right angles to the piston pin.


Top Compression Ring to

Groove Side Clearance

Groove Side Clearance

2.7 (0.106)

45°

0.1 (0.004)

5.5 (0.22)

0.04/0.08 (0.0016/0.003)

0.03/0.07 (0.0012/0.0028)

0.002/0.066 (0.0001/0.0026)2

0.045/0.072 (0.0018/0.0028)

0.037/0.064 (0.0015/0.0025)

2.4 (0.094)

0.2/0.4 (0.008/0.016)

0.2/0.4 (0.0079/0.0157)

0.015/0.040 (0.0006/0.0016)1

0.04/0.06 (0.0016/0.0024)

5.60 (0.220)

5.5 (0.216)

15.98 (0.6291)

0.04/0.08 (0.0016/0.003)

0.02/0.06 (0.0008/0.0024)

0.2/0.4 (0.008/0.016)

0.002/0.018 (0.0001/0.0007)

16.002/16.013 (0.6300/0.6304)

16.03 (0.6311)

15.995/16.000 (0.6297/0.6299)


Guide Running Clearance

Exhaust Valve Stem-to-Valve

Valve-to-Tappet Clearance (Cold)

Valve Guide Reamer Size - STD




Guide Running Clearance

Bore Running Clearance1, 2

Intake Valve Stem-to-Valve


0.06/0.08 (0.002/0.003)

5.5 (0.22)5.60 (0.220)

Oil Control Ring End Gap

Piston Thrust Face O.D.1, 2


Top Compression Ring End Gap

Middle Compression Ring End Gap

Piston Pin O.D.

Model (Horsepower)Piston-to-Piston Pin Clearance


TP-2469-A 12/07 50




CS8.5 (spec. 92xxxx) CS10 CS12

New

Max Wear Limit

Piston, Piston New

Rings, and Max Wear Limit

Piston Pin

0.2/0.4 (0.008/0.016) 0.2/0.4 (0.008/0.016) 0.25/0.4 (0.010/0.016)

0.2/0.4 (0.008/0.016) 0.2/0.4 (0.008/0.016) 0.25/0.4 (0.010/0.016)

New 77.954/77.998 (3.0691/3.0708)2

77.954/77.998 (3.0691/3.0708)2

84.954/84.998 (3.3446/3.3464)2

Max Wear Limit 77.898 (3.0669) 77.898 (3.0669) 84.898 (3.3424)

New

Valves and Max Wear Limit

Valve Lifters New

Max Wear Limit

2.9 (0.114)

45°

0.1 (0.004)

6.0/6.012 (0.2362/0.2367)

6.0 (0.236)

6.0 (0.236)

2.7 (0.106)

0.037/0.064 (0.0015/0.0025)

0.045/0.072 (0.0018/0.0028)

20.004/20.015 (0.7876/0.7880)

20.03 (0.7886)

19.995/20.000 (0.7872/0.7874)

19.98 (0.7866)

0.2/0.7 (0.0079/0.028)

6.0/6.012 (0.2362/0.2367)

6.10 (0.240)

Middle Compression Ring to Groove

Top Compression Ring to Groove

Running Clearance2

0.004/0.020 (0.0002/0.0008)

0.04/0.08 (0.0016/0.003)

0.03/0.07 (0.0012/0.0028)

0.002/0.066 (0.0001/0.0026)2


Oil Control Ring End Gap

Side Clearance

Model (Horsepower)

Piston-to-Piston Pin Clearance


Piston Pin O.D.

Running Clearance


Piston Thrust Face-to-Cylinder Bore

Exhaust Valve Stem-to-Valve Guide

Running Clearance

Intake Valve Stem-to-Valve Guide

Side Clearance

Valve-to-Tappet Clearance (Cold)

Valve Guide Reamer Size - STD






Top Compression Ring End Gap

TP-2469-A 12/07 51

Command PRO CS — Single Cylinder Torque Values and Sequences for Fasteners

CS4 CS6 CS8 5 ( 95 ) Cl Pl tM d l (H )



CS4 CS6 CS8.5 (spec. 95xxxx) Closure Plate

CS4 & CS6

7 N·m (62 in. lb.) 7 N·m (62 in. lb.) 9 N·m (79 in. lb.)

Connecting Rod

22 N·m (195 in. lb.) 22 N·m (195 in. lb.) 30 N·m (265 in. lb.) CS8.5

17 N·m (150 in. lb.) 17 N·m (150 in. lb.) 20 N·m (177 in. lb.)

Cylinder Head 20 N·m (177 in. lb.) 20 N·m (177 in. lb.) 50 N·m (36 ft. lb.)

— — 5.3 N·m (47.7 in. lb.)

— — 16 N·m (141 in. lb.)

Flywheel

Fuel Tank Stator

Muffler 8-12 N·m (71-106 in. lb.) 8-12 N·m (71-106 in. lb.) 18-22 N·m (159-195 in. lb.)

Cylinder Head

10 N·m (88 in. lb.) 10 N·m (88 in. lb.) 30 N·m (22 ft. lb.)

Retractable Starter 6.5 N·m (57 in. lb.) 6.5 N·m (57 in. lb.) 7 N·m (62 in. lb.)

10 N·m (88 in. lb.) 10 N·m (88 in. lb.) —

Throttle Control 7-9 N·m (62-80 in. lb.) 7-9 N·m (62-80 in. lb.) 9-11 N·m (80-97 in. lb.)

Valve Cover 10 N·m (88 in. lb.) 10 N·m (88 in. lb.) 11 N·m (97 in. lb.)

Model (Horsepower)

Air Cleaner

Fuel Bowl Retaining Screw

Throttle/Choke Plate Screws

Carburetor

Fastener Screws

Ignition Module Mounting Screws

Spark Plug

Crankcase

Head Bolt

Electric Starter Thru Bolt (Case)

Mounting Bolts (to block)

Ignition

Flange Nuts and Bracket Bolts

Oil Sentry™Float Switch

Indicator Light Retaining Nut

Rocker ArmStud into Cylinder Head

Adjusting Jam Nut

Reduction System Case Mounting Bolts

Crankshaft Gear Bolt

Control Lever Fastener

Valve Cover

Base Bolt

Base Nut

Blower Housing Screws

Rod Fastener


Oil Drain Plug


Retaining Screw

5-8 N·m (44-71 in. lb.)

5-8 N·m (44-71 in. lb.)

1.5-2.5 N·m (13-22 in. lb.)

12 N·m (106 in. lb.)

65 N·m (48 ft. lb.)

8-12 N·m (71-106 in. lb.)

20 N·m (14.7 ft. lb./177 in. lb.)

10 N·m (88 in. lb.)

7 N·m (62 in. lb.)

5-8 N·m (44-70 in. lb.)

10 N·m (88 in. lb.)

0.6-0.8 N·m (5-7 in. lb.)

22 N·m (195 in. lb.)

TP-2469-A 12/07 52

Command PRO CS — Single Cylinder Torque Values and Sequences for Fasteners

CS8 5 (spec 92xxxx) CS10 CS12 Closure PlateModel (Horsepower)



CS8.5 (spec. 92xxxx) CS10 CS12 Closure Plate

CS8.5-12

Connecting Rod

Cylinder Head

Stator

Flywheel

Fuel Tank

Muffler

Cylinder Head

Retractable Starter

Throttle Control

Valve Cover

Control Lever Fastener

Valve Cover

Base Bolt

Base Nut

Blower Housing Screws

Rod Fastener


Oil Drain Plug


Retaining Screw

Rocker ArmStud into Cylinder Head

Adjusting Jam Nut

Reduction SystemCase Mounting Bolts

Crankshaft Gear Bolt

Flange Nuts and Bracket Bolts

Oil Sentry™Float Switch

Indicator Light Retaining Nut

Fastener Screws

Ignition Module Mounting Screws

Spark Plug

Crankcase

Head Bolt

Electric Starter Thru Bolt (Case)

Mounting Bolts (to block)

Ignition

Model (Horsepower)

Air Cleaner

Fuel Bowl Retaining Screw

Throttle/Choke Plate Screws

Carburetor

11 N·m (97 in. lb.)

9-11 N·m (80-97 in. lb.)

7 N·m (62 in. lb.)

7 N·m (62 in. lb.)

—

65 N·m (48 ft. lb.)

30 N·m (22 ft. lb.)

0.6-0.8 N·m (5-7 in. lb.)

10 N·m (88 in. lb.)

18-22 N·m (159-195 in. lb.)

5-8 N·m (44-70 in. lb.)

10 N·m (88 in. lb.)

20 N·m (14.7 ft. lb./177 in. lb.)

8-12 N·m (71-106 in. lb.)

120 N·m (85 ft. lb.)

16 N·m (141 in. lb.)

5.3 N·m (47.7 in. lb.)

50 N·m (36 ft. lb.)

20 N·m (177 in. lb.)

30 N·m (265 in. lb.)

20 N·m (177 in. lb.)

1.5-2.5 N·m (13-22 in. lb.)

9 N·m (79 in. lb.)

10-12 N·m (88-106 in. lb.)

5-8 N·m (44-71 in. lb.)

TP-2469-A 12/07 53

Courage SV — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).



SV710, SV810 SV715 SV720, SV820 SV72514.9 16.4 17.2 17.9

20 22 23 24

New

Max Wear Limit

Connecting

Rod

O.D. - New


Max. Taper

Max. Out-of-Round

O.D. - New


Max. Taper

Max. Out-of-Round

O.D. - New


Max. Taper

Max. Out-of-Round

Crankshaft

Oil Pan End Main Bearing Journal0.022 (0.0009)

0.025 (0.0010)

35.955/35.973 (1.4156/1.4163)

Crankshaft T.I.R. PTO End, Crank in EngineEntire Crank, in V-Blocks


Crankshaft Bore (In Oil Pan)-to-Crankshaft Running Clearance - New

Flywheel End Main Bearing Journal

0.039/0.074 (0.0015/0.0029)

40.913/40.935 (1.6107/1.6116)

40.84 (1.608)

0.022 (0.0009)

0.025 (0.0010)

End Play (Free)New

Crankshaft Bore (In Oil Pan) - New

0.070/0.590 (0.0028/0.0230)40.965/41.003 (1.6128/1.6143)

41.016 (1.6148)

40.987/40.974 (1.6136/1.6131)

Max Wear LimitCrankshaft Bore (In Crankcase)

Piston Pin End I.D.17.036 (0.6707)

Connecting Rod-to-Piston Pin Running Clearance

New

Max Wear Limit

0.26/0.63 (0.0102/0.0248)

0.015/0.028 (0.0006/0.0011)

17.015/17.023 (0.6699/0.6702)

Max Wear Limit

8.025/8.075 (0.3159/0.3179)

8.088 (0.3184)

19.959 (0.7858 )

Connecting Rod-to-Crankpin Running Clearance

Connecting Rod-to-Crankpin Side Clearance

0.030/0.055 (0.0012/0.0022)

0.070 (0.0028)

20.000/20.025 (0.7874/0.7884)

20.038 (0.7889)

19.962/19.975 (0.7859/0.7864)New


Running Clearance

Max Wear LimitCamshaft


NewBore I.D.

Max Wear Limit

Model (Horsepower)

General



Bore x Stroke

Displacement

83 (3.27) x 67 (2.64 )

725 cc (44 cu. in.)

0.076/0.127 (0.0030/0.0050)

0.025/0.063 (0.0010/0.0025)

Crankcase

40.913/40.935 (1.6107/1.6116)

40.84 (1.608)

0.10 (0.0039)

35.94 (1.415)

0.018 (0.0007)

0.025 (0.0010)

0.279 (0.0110)

Governor Cross Shaft Bore I.D.New

TP-2469-A 12/07 54

SV710, SV810 SV715 SV720, SV820 SV725New


Bore Max.Out-of-Round

83.031/83.006 (3.2689/3.2679)

83.069 (3.2704)

0.12 (0.0047)

Model (Horsepower)

Cylinder Bore I.D.



Max. Taper

Cylinder Head

NewMax. Wear Limit

New

Max. Wear Limit

New

Max. Wear Limit

New

Piston, Piston Max. Wear Limit

Rings, and

Piston Pin

Top and Center Compression New Bore

Used Bore (Max.)New

Max. Wear Limit

Valves and

Valve Tappets

0.05 (0.0020)

0.076 (0.003)

0.025/0.126 (0.0009/0.0049)Governor Cross Shaft-to-Crankcase Running Clearance

7.949/8.000 (0.3129/0.3149)7.936 (0.3124)


0.015/0.140 (0.0006/0.0055)

5.990/6.000 (0.2358/0.2362)

5.977 (0.2353)

Governor Gear Shaft-to-Governor Gear Running Clearance


Top Compression Ring-to-Groove Side Clearance 0.025/0.048 (0.0010/0.0019)

17.025 (0.6703)

0.06/0.100 (0.0023/0.0039)

82.802 (3.2599)

Piston Thrust Face-to-Cylinder Bore1


Ring End Gap82.947 (3.2656)

Oil Control Ring-to-Groove Side Clearance 0.026/0.176 (0.0010/0.0070)

0.25/0.56 (0.0100/0.0224)

0.94 (0.037)



0.101/0.152 (0.004/0.006)

0.013/0.073 (0.0005/0.0029)

0.038/0.076 (0.0015/0.0030)

0.050/0.088 (0.0020/0.0035)

Valve Clearance

Middle Compression Ring-to-Groove Side Clearance 0.015/0.037 (0.0006/0.0015)


Ignition Spark Plug Gap


RC12YC, XC12YC, or Platinum 3071

0.76 (0.030)

Piston Pin Bore O.D.16.994 (0.6691)

0.006/0.017 (0.0002/0.0007)

17.006/17.012 (0.6695/0.6698)

0.28/0.33 (0.011/0.013)

Valve Tappet to Crankcase Running Clearance


16.995/17.000 (0.6691/0.6693)

Piston-to-Piston Pin Running Clearance

Governor

Spark Plug Type (Champion® or Equivalent)



TP-2469-A 12/07 55

SV710, SV810 SV715 SV720, SV820 SV725Model (Horsepower)



New

Max. Wear Limit

Valves and New

Valve Tappets Max. Wear Limit

Standard

0.25 mm O.S.

7.038/7.058 (0.2771/0.2779)






Intake Valve Minimum Lift 8.07 (0.3177)

8.07 (0.3177)

45°

7.134 (0.2809)

7.038/7.058 (0.2771/0.2779)

7.159 (0.2819)

7.298 (0.2873)

7.048 (0.2775)

TP-2469-A 12/07 56

Courage SV — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

SV730 SV830 SV735 SV740 SV840Model (Horsepower)



SV730, SV830 SV735 SV740, SV84018.6 19.4 20.1

25 26 27

New

Connecting Max Wear Limit

Rod

O.D. - New


Max. Taper

Max. Out-of-Round

O.D. - New


Max. Taper

Max. Out-of-Round

O.D. - New


Max. Taper

Max. Out-of-Round 0.025 (0.0010)

0.279 (0.0110)

0.10 (0.0039)

Crankcase

40.913/40.935 (1.6107/1.6116)

40.84 (1.608)

0.022 (0.0009)

0.018 (0.0007)

40.987/40.974 (1.6136/1.6131)

0.070/0.590 (0.0028/0.0230)

19.959 (0.7858 )

0.030/0.055 (0.0012/0.0022)

8.025/8.075 (0.3159/0.3179)

8.088 (0.3184)

0.015/0.028 (0.0006/0.0011)

17.015/17.023 (0.6699/0.6702)

Model (Horsepower)

General



Bore x Stroke

Displacement

Camshaft


Running Clearance

Max Wear Limit


NewBore I.D.

0.076/0.127 (0.0030/0.0050)

0.025/0.063 (0.0010/0.0025)

20.000/20.025 (0.7874/0.7884)

New

Max Wear Limit

20.038 (0.7889)

19.962/19.975 (0.7859/0.7864)

Connecting Rod-to-Crankpin Running Clearance


0.070 (0.0028)

0.26/0.63 (0.0102/0.0248)

Piston Pin End I.D.17.036 (0.6707)

Max Wear Limit

Connecting Rod-to-Piston Pin Running Clearance

New

Governor Cross Shaft Bore I.D.New

Max Wear Limit

0.039/0.074 (0.0015/0.0029)

End Play (Free)

New

Crankshaft Bore (In Oil Pan) - New

Max Wear LimitCrankshaft Bore (In Crankcase)

Crankshaft Bore (In Oil Pan)-to-Crankshaft Running Clearance - New

41.016 (1.6148)40.965/41.003 (1.6128/1.6143)

35.94 (1.415)


40.913/40.935 (1.6107/1.6116)

40.84 (1.608)

0.022 (0.0009)

0.025 (0.0010)

Crankshaft

83 (3.27) x 67 (2.64 )

725 cc (44 cu. in.)

Crankshaft T.I.R.PTO End, Crank in Engine

Entire Crank, in V-Blocks


Oil Pan End Main Bearing Journal

0.025 (0.0010)

35.955/35.973 (1.4156/1.4163)

TP-2469-A 12/07 57

SV730, SV830 SV735 SV740, SV840N 83 031/83 006 (3 2689/3 2679)

Model (Horsepower)



New


Bore Max.Out-of-Round

Max. Taper

Cylinder Head

New

Max. Wear Limit

New

Max. Wear Limit

New

Max. Wear Limit

New

Piston, Piston Max. Wear Limit

Rings, and

Piston Pin

Top and Center Compression New Bore

Used Bore (Max.)

New

Max. Wear Limit

Valves and

Valve Tappets

16.995/17.000 (0.6691/0.6693)

16.994 (0.6691)

0.025/0.048 (0.0010/0.0019)

0.015/0.037 (0.0006/0.0015)

0.76 (0.030)

0.28/0.33 (0.011/0.013)

0.006/0.017 (0.0002/0.0007)

17.006/17.012 (0.6695/0.6698)

0.015/0.140 (0.0006/0.0055)

5.990/6.000 (0.2358/0.2362)

5.977 (0.2353)

RC12YC, XC12YC, or Platinum 3071

0.076 (0.003)

0.025/0.126 (0.0009/0.0049)

7.949/8.000 (0.3129/0.3149)

7.936 (0.3124)

Cylinder Bore I.D.

83.031/83.006 (3.2689/3.2679)

83.069 (3.2704)

0.12 (0.0047)

0.05 (0.0020)


Governor Cross Shaft-to-Crankcase Running Clearance

Shaft O.D.

Governor Cross

Governor Gear Shaft-to-Governor Gear Running Clearance



Governor Gear

Shaft O.D.

Spark Plug Type (Champion® or Equivalent)



0.06/0.100 (0.0023/0.0039)


Ring End Gap

0.026/0.176 (0.0010/0.0070)

0.25/0.56 (0.0100/0.0224)

0.94 (0.037)

82.947 (3.2656)

82.802 (3.2599)


0.050/0.088 (0.0020/0.0035)

Governor

Ignition

Bore I.D. 17.025 (0.6703)



0.101/0.152 (0.004/0.006)

0.013/0.073 (0.0005/0.0029)

0.038/0.076 (0.0015/0.0030)



Spark Plug Gap

Piston Pin

Bore O.D.

Piston-to-Piston Pin Running Clearance

Piston Pin

Valve Clearance

Valve Tappet to Crankcase Running Clearance

TP-2469-A 12/07 58

SV730, SV830 SV735 SV740, SV840New

Max. Wear Limit

New

Model (Horsepower)

Intake Valve Guide I.D.7.038/7.058 (0.2771/0.2779)

7.134 (0.2809)

7 038/7 058 (0 2771/0 2779)



New

Valves and Max. Wear Limit

Valve Tappets Standard

0.25 mm O.S.






45°

7.038/7.058 (0.2771/0.2779)

7.159 (0.2819)

7.048 (0.2775)

7.298 (0.2873)

8.07 (0.3177)

8.07 (0.3177)

TP-2469-A 12/07 59

Courage SV — Twin Cylinder Torque Values and Sequences for Fasteners

SV710, SV810 SV715 SV720, SV820 SV725Blower 2 8 N·m (25 in lb )

Model (Horsepower)M4 HI-LO Screws



Blower

Housing

and Sheet

MetalCarburetor Step 1

and Intake Step 2

Manifold

Connecting

Rod

Into new hole

Into used hole

Into new hole

Into used hole

Oil Pan

Step 1

Step 2

Fan/Flywheel

Governor

M8 Hex Nuts

5/16-18 Capscrews

Speed Control Into new hole

Bracket Into used hole

2.8 N m (25 in. lb.)

4.0 N·m (35 in. lb.)

Intake Manifold Mounting Fastener - Torque in Two Stages

Carburetor Mounting Nut

6.8 N·m (60 in. lb.)

4.0 N·m (35 in. lb.)

7.4 N·m (66 in. lb.)

9.9 N·m (88 in. lb.)


7.3 N·m (65 in. lb.)

M4 HI LO Screws

M5 Fasteners

M6 Fasteners

6.2-7.3 N·m (55-65 in. lb.)

10.7 N·m (95 in. lb.)

Cap Fastener - Torque Incrementally to: 11.3 N·m (100 in. lb.)

4.0 N·m (35 in. lb.)

1.3 N·m (11.5 in. lb.)

13.6 N·m (120 in. lb.)

Breather Assembly

7.3 N·m (65 in. lb.)Inner Cover Fastener

Outer Cover Stud6.2 N·m (55 in. lb.)

Hex Nut

24.4 N·m (216 in. lb.)

22.6 N·m (200 in. lb.)

41.8 N·m (370 in. lb.)

Oil Filter

24.4 N·m (216 in. lb.)

16.9 N·m (150 in. lb.)

Rocker Arm/Valve Adjustment Setscrew

11.3 N·m (100 in. lb.)

Ignition

Muffler FastenersMuffler

11.3 N·m (100 in. lb.)

7.3 N·m (65 in. lb.)7.9 N·m (70 in. lb.)

Rocker Arm/Valve Adjustment Jam Nut

74.5 N·m (55 ft. lb.)

6.8 N·m (60 in. lb.)

24.4-29.8 N·m (18-22 ft. lb.)

4.0-6.2 N·m (35-55 in. lb.)

Rotate Filter 3/4-1 Turn After Gasket Contact

33.9 N·m (300 in. lb.)10.7 N·m (95 in. lb.)


Governor Lever Nut

Spark Plug


Oil Filter Installation

Nipple Torque (Oil Filter/Oil Cooler Adapter)

Fastener

Crankcase

Cylinder Head Fastener - Head Bolt: Torque in Two Stages

Rocker Arm Screw

Rocker Arm StudCylinder Head

Oil Pan Fastener

Oil Drain Plug

TP-2469-A 12/07 60


SV710, SV810 SV715 SV720, SV820 SV725Blower 2.8 N·m (25 in. lb.)

Model (Horsepower)M4 HI-LO Screws



Blower

Housing

and Sheet


and Intake Step 2

Manifold

Connecting

Rod

Into new hole

Into used hole

Into new hole

Into used hole

Oil Pan

Step 1

Step 2

Fan/Flywheel

Governor

M8 Hex Nuts

5/16-18 Capscrews


Bracket Into used hole

2.8 N m (25 in. lb.)

4.0 N·m (35 in. lb.)



6.8 N·m (60 in. lb.)

4.0 N·m (35 in. lb.)

7.4 N·m (66 in. lb.)

9.9 N·m (88 in. lb.)


7.3 N·m (65 in. lb.)

M4 HI LO Screws

M5 Fasteners

M6 Fasteners

6.2-7.3 N·m (55-65 in. lb.)

10.7 N·m (95 in. lb.)

Cap Fastener - Torque Incrementally to: 11.3 N·m (100 in. lb.)

4.0 N·m (35 in. lb.)

1.3 N·m (11.5 in. lb.)

13.6 N·m (120 in. lb.)

Breather Assembly

7.3 N·m (65 in. lb.)Inner Cover Fastener

Outer Cover Stud6.2 N·m (55 in. lb.)

Hex Nut

24.4 N·m (216 in. lb.)

22.6 N·m (200 in. lb.)

41.8 N·m (370 in. lb.)

Oil Filter

24.4 N·m (216 in. lb.)

16.9 N·m (150 in. lb.)


11.3 N·m (100 in. lb.)

Ignition


11.3 N·m (100 in. lb.)

7.3 N·m (65 in. lb.)7.9 N·m (70 in. lb.)


74.5 N·m (55 ft. lb.)

6.8 N·m (60 in. lb.)

24.4-29.8 N·m (18-22 ft. lb.)

4.0-6.2 N·m (35-55 in. lb.)


33.9 N·m (300 in. lb.)10.7 N·m (95 in. lb.)


Governor Lever Nut

Spark Plug




Fastener

Crankcase


Rocker Arm Screw


Oil Pan Fastener

Oil Drain Plug

TP-2469-A 12/07 61

SV710, SV810 SV715 SV720, SV820 SV725

Starter

Assembly

4.5-5.7 N·m (40-50 in. lb.)

5.6-9.0 N·m (49-79 in. lb.)

15.3 N·m (135 in. lb.)

Model (Horsepower)

Thru BoltFASCO (Inertia Drive)

Delco-Remy (Solenoid Shift)

Mounting Screws (All)



Solenoid

(Starter)Stator

Valve Cover

Oil Pan Breather Cover

#1 #2

2.5-3.3 N·m (22-29 in. lb.)

Nut, Positive (+) Brush Lead - Delco-Remy Starter Mounting Screw

Mounting Hardware - Delco-Remy Starter

Brush Holder Mounting Screw - Delco-Remy Starter

Cylinder HeadsOil Pan (Sealant)

4.0-6.0 N·m (35-53 in. lb.)

8.0-11.0 N·m (71-97 in. lb.)6.2 N·m (55 in. lb.)

6.2 N·m (55 in. lb.)Valve Cover Fastener

TP-2469-A 12/07 62


SV730, SV830 SV735 SV740, SV840Blower

Model (Horsepower)M4 HI-LO Screws 2.8 N·m (25 in. lb.)



Housing

and Sheet


and Intake Step 2

Manifold

Connecting

Rod

Into new hole

Into used hole

Into new hole

Into used hole

Oil Pan

Step 1

Step 2

Fan/Flywheel

Governor

M8 Hex Nuts

5/16-18 Capscrews


Bracket Into used holeFastener

Crankcase


Rocker Arm Screw


Oil Pan Fastener

Oil Drain Plug

Governor Lever Nut

Oil Filter

4.0 N·m (35 in. lb.)

1.3 N·m (11.5 in. lb.)


74.5 N·m (55 ft. lb.)

13.6 N·m (120 in. lb.)

24.4 N·m (216 in. lb.)

22.6 N·m (200 in. lb.)


41.8 N·m (370 in. lb.)

11.3 N·m (100 in. lb.)

Ignition



Spark Plug




Cap Fastener - Torque Incrementally to:

Breather Assembly

Inner Cover Fastener

Outer Cover Stud

Hex Nut



6.2-7.3 N·m (55-65 in. lb.)

M5 Fasteners

M6 Fasteners


4.0 N·m (35 in. lb.)

6.8 N·m (60 in. lb.)

4.0 N·m (35 in. lb.)7.4 N·m (66 in. lb.)

9.9 N·m (88 in. lb.)

11.3 N·m (100 in. lb.)

10.7 N·m (95 in. lb.)

7.3 N·m (65 in. lb.)

6.2 N·m (55 in. lb.)

11.3 N·m (100 in. lb.)

7.3 N·m (65 in. lb.)7.9 N·m (70 in. lb.)

6.8 N·m (60 in. lb.)

24.4-29.8 N·m (18-22 ft. lb.)

4.0-6.2 N·m (35-55 in. lb.)

24.4 N·m (216 in. lb.)

7.3 N·m (65 in. lb.)

16.9 N·m (150 in. lb.)


33.9 N·m (300 in. lb.)10.7 N·m (95 in. lb.)

TP-2469-A 12/07 63

SV730, SV830 SV735 SV740, SV840

Starter

Assembly

Model (Horsepower)

Thru BoltFASCO (Inertia Drive)

Delco-Remy (Solenoid Shift)

Mounting Screws (All)

4.5-5.7 N·m (40-50 in. lb.)

5.6-9.0 N·m (49-79 in. lb.)

15.3 N·m (135 in. lb.)

2 5 3 3 N (22 29 i lb )B h H ld M ti S D l R St t



Solenoid

(Starter)Stator

Valve Cover

Valve Cover

Nut, Positive (+) Brush Lead - Delco-Remy Starter

Mounting Hardware - Delco-Remy Starter 4.0-6.0 N·m (35-53 in. lb.)

2.5-3.3 N·m (22-29 in. lb.)Brush Holder Mounting Screw - Delco-Remy Starter

Mounting Screw


Intake Manifold

8.0-11.0 N·m (71-97 in. lb.)6.2 N·m (55 in. lb.)

6.2 N·m (55 in. lb.)

TP-2469-A 12/07 64

OHC - Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).

TH16 TH1811.9 13.4

Model (Horsepower)Kilowatt (kW) Output (@ 3600 RPM – SAE J1349)



16 18

73 (2.87) x 62 (2.44) 75 (2.95) x 65 (2.56)

519cc (31.7 cu. in.) 574cc (35.0 cu. in.)

#1 Side 0.000/0.700 (0.000/0.0275) 0.000/0.700 (0.000/0.0275)

#2 Side 0.000/1.300 (0.000/0.0512) 0.000/1.300 (0.000/0.0512)

0.025/0.105 (0.0010/0.0041) 0.025/0.105 (0.0010/0.0041)

Front 32.000/32.025 (1.2598/1.2608) 32.000/32.025 (1.2598/1.2608)

Rear 24.800/24.825 (0.9764/0.9774) 24.800/24.825 (0.9764/0.9774)

Front 32.04 (1.2614) 32.04 (1.2614)

Rear 24.84 (0.9779) 24.84 (0.9779)

Front 31.920/31.975 (1.2567/1.2589) 31.920/31.975 (1.2567/1.2589)Rear 24.720/24.775 (0.9732/0.9754) 24.720/24.775 (0.9732/0.9754)

Front 31.91 (1.2562) 31.91 (1.2562)

Rear 24.71 (0.9728) 24.71 (0.9728)

0.056/0.030 (0.0022/0.0012) 0.056/0.030 (0.0022/0.0012)

Connecting 0.07 (0.0028) 0.07 (0.0028)

Rod 0.250/0.740 (0.0098/0.0291) 0.250/0.740 (0.0098/0.0291)

17.015/17.023 (0.6699/0.6702) 17.015/17.023 (0.6699/0.6702)

17.04 (0.6708) 17.04 (0.6708)

8.025/8.050 (0.3159/0.3169) 8.025/8.050 (0.3159/0.3169)8.07 (0.3177) 8.07 (0.3177)

Not Adjustable Not Adjustable

45.071/45.111 (1.7744/1.7760) 45.071/45.111 (1.7744/1.7760)

45.12 (1.7764) 45.12 (1.7764)

0.030/0.090 (0.0012/0.0035) 0.030/0.090 (0.0012/0.0035)

45.021/45.041 (1.7725/1.7735) 45.021/45.041 (1.7725/1.7735)

44.95 (1.7696) 44.95 (1.7696)

0.02 (0.0008) 0.02 (0.0008)

0.02 (0.0008) 0.02 (0.0008)

Crankshaft

Camshaft

Crankshaft to Sleeve Bearing Running Clearance - New


O.D. - New


Max. Taper

Max. Out-of-Round


New

Max Wear Limit

End Play

General

Displacement

Bore x Stroke

Connecting Rod-to-Crankpin

End Play


Camshaft Bearing Surface O.D. – Max. Wear Limit

Running Clearance

Max Wear LimitCrankcase

Max Wear Limit

New

Max Wear Limit

NewGovernor Cross Shaft Bore I.D.

Horsepower (@3600 RPM — SAE

( ) p (@ )

Piston Pin End I.D.

New

Bore I.D. - New

Camshaft Bearing Surface O.D. – New

Running Clearance


TP-2469-A 12/07 65

TH16 TH18

O.D. - New 45.021/45.041 (1.6107/1.6116) 45.021/45.041 (1.6107/1.6116)

O.D. - Max. Wear Limit 44.95 (1.7696) 44.95 (1.7696)

Max. Taper 0.02 (0.0008) 0.02 (0.0008)

PTO End Main Bearing Journal

Model (Horsepower)



p ( ) ( )

Max. Out-of-Round 0.02 (0.0008) 0.02 (0.0008)

O.D. - New 31.948/31.966 (1.2578/1.2585) 31.948/31.966 (1.2578/1.2585)O.D. - Max. Wear Limit 31.93 (1.2571) 31.93 (1.2571)

Max. Taper 0.02 (0.0008) 0.02 (0.0008)

Max. Out-of-Round 0.02 (0.0008) 0.02 (0.0008)

PTO End, Crank in Engine 0.015 (0.0006) 0.015 (0.0006)

Entire Crank, in V-Blocks 0.010 (0.0004) 0.010 (0.0004)

New 73.006/73.031 (2.8742/2.8752) 75.025/75.050 (2.9537/2.9547)

Max. Wear Limit 73.07 (2.8767) 75.09 (2.9563)

0.13 (0.005) 0.13 (0.005)

0.13 (0.005) 0.13 (0.005)

0.013/0.075 (0.0005/0.0030) 0.013/0.075 (0.0005/0.0030)

New 7.975/8.012 (0.3140/0.3154) 7.975/8.012 (0.3140/0.3154)

Max. Wear Limit 7.96 (0.3134) 7.96 (0.3134)

0.045/0.160 (0.0018/0.0063) 0.045/0.160 (0.0018/0.0063)

New 32.020/32.080 (1.2606/1.2630) 32.020/32.080 (1.2606/1.2630)

Max. Wear Limit 32.09 (1.2634) 32.09 (1.2634)

RC12YC RC12YC

0.76 (0.030) 0.76 (0.030)

0.20/0.30 (0.008/0.012) 0.20/0.30 (0.008/0.012)

0.006/0.016 (0.0002.0.0007) 0.006/0.016 (0.0002.0.0007)

New 17.006/17.012 (0.6695/0.6698) 17.006/17.012 (0.6695/0.6698)

Piston, Piston Max. Wear Limit 17.025 (0.6703) 17.025 (0.6703)

Rings, and New 16.996/17.000 (0.6691/0.6693) 16.996/17.000 (0.6691/0.6693)

Piston Pin Max. Wear Limit 16.995 (0.6691) 16.995 (0.6691)

0.040/0.085 (0.0016/0.0033) 0.040/0.085 (0.0016/0.0033)

0.030/0.080 (0.0012/0.0031) 0.030/0.076 (0.0012/0.0030)

0.046/0.201 (0.0018/0.0079) Minimum: 0.070 (0.0028)

Crankshaft

Piston Pin Bore to Piston Pin (select fit)


Piston Pin O.D.


Crankshaft T.I.R.

Max. Taper


Governor Bushing to Camshaft Running Clearance

Governor Bushing I.D.


Governor Cross Shaft to Crankcase Running Clearance


Cylinder Bore

Governor

Max. Out-of-Round

Cylinder Bore I.D.



Ignition Spark Plug Gap


TP-2469-A 12/07 66

TH16 TH18Piston (continued) 0.180/0.380 (0.0071/0.0150) 0.180/0.380 (0.0071/0.0150)

0.180/0.440 (0.0071/0.0173) 0.180/0.450 (0.0071/0.0177)

New 72.966/72.984 (2.8727/2.8734) 74.966/74.984 (2.9514/2.9521)

Max Wear Limit 72.839 (2.8677) 74.839 (2.9464)

Model (Horsepower)Top Compression Ring End Gap





0.022/0.065 (0.0009/0.0026) 0.041/0.084 (0.0016/0.0033)

0.038/0.076 (0.0015/0.0030) 0.038/0.076 (0.0015/0.0030)0.050/0.088 (0.0020/0.0035) 0.050/0.088 (0.0020/0.0035)

New 6.038/6.058 (0.2377/0.2385) 6.038/6.058 (0.2377/0.2385)

Max Wear Limit 6.13 (0.2413) 6.13 (0.2413)

New 6.038/6.058 (0.2377/0.2385) 6.038/6.058 (0.2377/0.2385)

Max Wear Limit 6.19 (0.2437) 6.19 (0.2437)

Standard 6.048 (0.2381) 6.048 (0.2381)

0.25 mm O.S. 6.298 (0.2480) 6.298 (0.2480)

7.50 (0.295) 7.50 (0.295)

7.50 (0.295) 7.50 (0.295)45º 45º

Intake 0.013/0.064 (0.0005/0.0025) 0.013/0.064 (0.0005/0.0025)

Exhaust 0.076/0.127 (0.0030/0.0050) 0.076/0.127 (0.0030/0.0050)

Side 1 Side 2



Valve Lash

Valves


Intake Valve Stem-to-Valve Guide Running ClearanceExhaust Valve Stem-to-Valve Guide Running Clearance




Exhaust Valve Guide


Running Clearance

TP-2469-A 12/07 67

OHC — Twin Cylinder Torque Values and Sequences for Fasteners

TH16 TH18

4 0 N·m (35 in lb )

Model (Horsepower)

M5 Fasteners



Blower Housing

and Sheet Metal

Carburetor

Connecting Rod

Electric Starter

Muffler

Speed Control

Stator

Throttle/Choke

Controls

Valve Cover

IgnitionSpark Plug


Timing Belt

24.4 N·m (216 in. lb.)

Fan/FlywheelFan Fastener


Starter Mounting Fastener

Belt Tensioner Mounting Screw

3.4/4.5 N·m (30/40 in. lb.)Belt Tension

5.6 N·m (50 in. lb.)

13.6 N·m (10 ft. lb.)

9.9 N·m (88 in. lb.)Carburetor Mounting Fasteners

Cap Fastener Torque (torque in increments) - 6 mm Step-Down

Oil Drain Plugs

9.9 N·m (88 in. lb.)Speed Control Bracket Assembly Fastener


Valve Cover Fastener 5.6 N·m (50 in. lb.)

4.0 N m (35 in. lb.)

7.3 N·m (65 in. lb.)

4.0 N·m (35 in. lb.)

4.0 N·m (35 in. lb.)

24.4/29.8 N·m (18/22 ft. lb.)

40.7 N·m (30 ft. lb.)

3.4 N·m (30 in. lb.)

7.9 N·m (70 in. lb.)

7.3 N·m (65 in. lb.)

9.9 N·m (88 in. lb.)

66.4 N·m (49 ft. lb.)

Oil Filter Nipple

Oil SentryTM Pressure Switch

M5 Fasteners

M6 Fasteners (into crankcase)

M6 Fasteners (into sheet baffle)

Rectifier Fastener

Breather Cover Mounting Fasteners

Crankcase Halves Mounting Screw

Crankcase

Oil Filter

Governor Control Lever Fastener

11.3 N·m (100 in. lb.)

4.0/6.2 N·m (35/55 in. lb.)

24.4 N·m (216 in. lb.)

5.6/9.0 N·m (50/80 in. lb.)

4.0 N·m (35 in. lb.)

9.9 N·m (88 in. lb.)


Oil Filter

TP-2469-A 12/07 68

OHC — Twin Cylinder Torque Values and Sequences for Fasteners

Oil Filter Adapter Breather Cover GasketCrankcase



TP-2469-A 12/07 69



FOR SALES AND SERVICE INFORMATION

IN U.S. AND CANADA, CALL

1-800-544-2444

LITHO IN U.S.A.

FORM NO.: TP-2469-A

ISSUED: 5/95

REVISED: 12/07

MAILED:

KOHLER CO. KOHLER, WISCONSIN 53044

kohler tableau de réglages atelier

Documents