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SPECS & TORQUES
SPECIFICATIONS & TOLERANCES TORQUE VALUE & SEQUENCES
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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
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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
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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
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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
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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
Small End I.D. (New)
Max. Wear Limit
Max. Out of Round
Max. Taper
Max.Out of Round
Displacement Cu. In.
Bore x Stroke
Max. Out of Flatness
Max. Taper
End Play
Max. Taper (Sleeve)
Diameter
TP-2469-A 12/07 6
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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
Nominal Angle Valve Seat
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
Service Replacement Sizes
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
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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
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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.
(Engines with 3/8-16 studs)
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
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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
Small End I.D. (New)
Bore x Stroke
Shaft O.D.
General
Running Clearance
End Play
Model (Horsepower)
Max. Operating RPM
Displacement Cu. In.
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.)
Max. Out of Flatness
Ignition
Module Air Gap
Type (Champion® or Equivalent)Spark Plug
TP-2469-A 12/07 10
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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)
Nominal Angle Valve Seat
Thrust Face to Bore Clearance (New)1
Thrust Face to Bore Clearance (New)1
Thrust Face to Bore Clearance (New)1
Thrust Face O.D.3
Max. Ring Side Clearance
Max. Ring Side Clearance
Guide Reamer Size
Ring End Gap
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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
Max. Out of Flatness
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
Small End I.D. (New)
Displacement Cu. In.
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
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Magnum — Twin Cylinder Engine Specifications and Tolerances (cont'd)All dimensions in inches.
New Bore3
Max. Ring Side Clearance
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)
Service Replacement Sizes
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
Thrust Face to Bore Clearance (New)1
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
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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
Non Metallic Fuel Pump
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
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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
(Engines with 5/16-18 studs)
Final Torque - 360 in. lbs.
(Engines with 3/8-16 studs)
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
Non Metallic Fuel Pump
Mounting Screws
125 in. lbs.
TP-2469-A 12/07 15
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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
O.D. Max. Wear Limit
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
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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. - Max. Wear Limit
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
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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
Camshaft Bearing Surface Crankcase End
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
Bearing Journal Max. Taper
Max. Out of Round
O.D. - New
PTO End Main O.D.- Max. Wear Limit
Bearing Journal Max. Taper
Max. Out of Round
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
Connecting Rod Journal
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
Bore 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
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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. - Max. Wear Limit
I.D. - Std.
I.D. - Max. Wear Limit
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
Top Compression Ring to Groove Side Clearance
Middle Compression Ring to Groove Side Clearance
Oil Control Ring to Groove Side Clearance
Model (Horsepower)
Max. Out of Flatness
Governor Cross Shaft O.D. - Max. Wear Limit
Governor Gear Shaft O.D. - Max. Wear LimitGovernor
Cylinder Bore Cylinder Bore I.D.
Exhaust Valve Minimum Lift
Intake Valve Minimum Lift
Exhaust Valve Stem to Valve Guide Running Clearance
Intake Valve Stem to Valve Guide Running Clearance
Hydraulic Lifter to Crankcase Running Clearance
Nominal Valve Seat Angle
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
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Command — Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).
Balance
Shaft
Bearing
In CrankcaseCamshaft In Oil Pan
Camshaft Bearing Surface Crankcase End
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 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
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
End Play (Free)
Flywheel End Main Bearing
Connecting Rod Journal
Crankshaft PTO Bearing
Bore I.D. Max. Wear Limit
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
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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. - Max. Wear Limit
I.D. - Std.
I.D. - Max. Wear Limit
Valves and
Valve Lifters
Intake Valve Guide
Exhaust Valve Guide
Cylinder Bore I.D.
CH & CV15 (15)
Middle Compression Ring to Groove Side Clearance
Oil Control Ring to Groove Side Clearance
Governor Cross Shaft O.D. - Max. Wear Limit
Governor Gear Shaft O.D. - Max. Wear Limit
Governor Cross Shaft Bore (In Crankcase)
I.D. - Max. Wear Limit
1Measure 6 mm above bottom of piston skirt at right angles to piston pin.
Spark Plug Type (Champion® or equivalent)
Spark Plug Gap
Ignition Module Air Gap
Top Compression Ring to Groove Side Clearance
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)
Exhaust Valve Stem to Valve Guide Running Clearance
Intake Valve Stem to Valve Guide Running Clearance
Hydraulic Lifter to Crankcase Running Clearance
Nominal Valve Seat Angle
Rocker Shaft O.D. - Max. Wear LimitRocker Arm I.D. - Max. Wear Limit
Exhaust Valve Minimum Lift
Intake Valve Minimum Lift
Max. Out of Flatness
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
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Command — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).
CH & CV22 (22) 16.4
22General Bore
Stroke
Displacement
End Play (With Shims)
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
O.D. Max. Wear Limit
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
Bore I.D. Max. Wear Limit
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
O.D. - Max. Wear Limit
Connecting Rod to Crankpin
Governor Cross Shaft Bore (In Crankcase) I.D. - Max. Wear Limit
Max. Out of Flatness
Governor Cross Shaft O.D. - Max. Wear Limit
Governor Gear Shaft O.D. - Max. Wear Limit
Main Bearing Journals
Oil Pan End
Connecting Rod Journal
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
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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)
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)
Middle Compression Ring to Groove Side Clearance
1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
I.D. - Std.
I.D. - Max. Wear Limit
I.D. - Std.
Nominal Valve Seat Angle
Intake Valve Minimum Lift
Exhaust Valve Minimum Lift
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.)
O.D. - Max. Wear Limit
New - Running Clearance
Exhaust Valve Stem to Valve Guide 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
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Command — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).
General Bore
Stroke
Displacement
End Play (With Shims)
In Crankcase
Camshaft Camshaft Bearing Surface
O.D. - Max. Wear Limit
Connecting Connecting Rod to Crankpin New
Rod Running Clearance Max. Wear LimitEnd Play (Free)
O.D - New
O.D. Max. Wear Limit
Max. Taper Max. Out of Round
O.D - New
O.D. Max. Wear Limit
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)
Main Bearing Journals
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)
Connecting Rod Journal
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)
Governor Gear Shaft O.D. - Max. Wear Limit
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
Governor Cross Shaft O.D. - Max. Wear Limit
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)
Bore I.D. Max. Wear Limit
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
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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)
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)
0.015/0.037 (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)
Middle Compression Ring to Groove Side Clearance
Intake Valve Minimum Lift
Exhaust Valve Minimum Lift
O.D. - New1
I.D. - Max. Wear Limit
New Bore
I.D. - Std.
I.D. - Max. Wear Limit
I.D. - Std.
1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
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)
Nominal Valve Seat Angle
Hydraulic Lifter to Crankcase Running Clearance
Intake Valve Stem to Valve Guide Running Clearance
Exhaust Valve Guide
Intake Valve Guide
Piston Ring End Gap
Exhaust Valve Stem to Valve Guide Running Clearance
TP-2469-A 12/07 25
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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
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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
Connecting Rod Cap Fastener Torque
Closure Plate (CH)/Oil Pan (CV)
Muffler Retaining Nuts
Electronic Starter Mounting
Fuel Pump Fasteners
Ignition
TP-2469-A 12/07 27
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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
Connecting Rod Cap Fastener Torque
Closure Plate (CH)/Oil Pan (CV)
Muffler Retaining Nuts
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
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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
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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
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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
Spark Plug Type (Champion® or equivalent)
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.
Ignition Module Air Gap
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
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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
Nominal Valve Seat Angle
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
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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
O.D. - Max. Wear Limit
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
Connecting Rod Journal
Crankshaft Bore (in closure plate)
Max. Taper Max. Out-of-Round
O.D. - New
Crankshaft to Sleeve Bearing (crankcase)
PTO End, Crank in Engine
O.D. - Max. Wear Limit
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.
Running Clearance - New
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
Main Bearing Journals
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
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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
O.D. - Max. Wear Limit
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
Connecting Rod Journal
Crankshaft Bore (in closure plate)
Max. Taper Max. Out-of-Round
O.D. - New
Crankshaft to Sleeve Bearing (crankcase)
PTO End, Crank in Engine
O.D. - Max. Wear Limit
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.
Running Clearance - New
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
Main Bearing Journals
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
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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
Max. Out-of-Flatness
Governor
83.006/83.031 (3.2679/3.2689)
Piston Pin Bore I.D.
Piston Pin O.D.
Gear Shaft-to-Governor Gear Running Clearance
Spark Plug Type (Champion® or equivalent)
Spark Plug Gap
Piston Thrust Face-to-Cylinder
Bore1
Running Clearance
Piston Thrust Face O.D.1
Ignition Module Air Gap
Top Compression Ring-to-Groove Side Clearance
Middle Compression Ring-to-Groove Side Clearance
Oil Control Ring-to-Groove Side Clearance
Ring End Gap - New Bore
Top and Middle Compression
Piston-to-Piston Pin
Governor Cross Shaft O.D.
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)
Governor Gear Shaft O.D.
83.069 (3.2704)
0.05 (0.0020)
0.12 (0.0047)
0.076 (0.003)
TP-2469-A 12/07 36
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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.
Exhaust Valve Stem-to-Valve Guide Running Clearance
Intake Valve Guide I.D.
Model (Horsepower)
Intake Valve Lift
Hydraulic Valve Lifter to Crankcase Running Clearance
Intake Valve Stem-to-Valve Guide Running Clearance
Exhaust Valve Lift
Nominal Valve Seat Angle
Intake Valve Stem Diameter - New
Exhaust Valve Guide I.D.
Exhaust Valve Stem Diameter - New
Valve Guide Reamer Size
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
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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.
Exhaust Valve Stem-to-Valve Guide Running Clearance
Intake Valve Guide I.D.
Model (Horsepower)
Intake Valve Lift
Hydraulic Valve Lifter to Crankcase Running Clearance
Intake Valve Stem-to-Valve Guide Running Clearance
Exhaust Valve Lift
Nominal Valve Seat Angle
Intake Valve Stem Diameter - New
Exhaust Valve Guide I.D.
Exhaust Valve Stem Diameter - New
Valve Guide Reamer Size
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
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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
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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
Muffler Retaining Nuts
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
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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)
Closure Plate Fastener
Cylinder Head Fastener
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)
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( ) ( ) ( ) ( )
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
Rectifier-Regulator Fastener
Muffler Retaining Nuts
Oil Filter Oil Filter Instructions:
Speed ControlInto new hole
Into used hole
Stator Mounting Screw
Water PumpMounting Screw
Pulley Mounting Screw
Valve Cover Fastener
TP-2469-A 12/07 42
Aegis — Twin Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches)
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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
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
PTO End, Crank in Engine
Entire Crank, in V-Blocks
Running Clearance - New
Connecting Rod Journal
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
Running Clearance - New
Crankshaft Bore (in crankcase)-to-Crankshaft
End Play (Free)
Crankshaft Bore (in crankcase)
Crankshaft Bore (in oil pan)
Main Bearing Journals
Rod-to-Crankpin Side Clearance
Rod-to-Piston Pin Running Clearance
Piston Pin End I.D.
Crankcase Governor Cross Shaft Bore I.D
New
Max. Wear Limit
Camshaft Bearing Surface O.D.
Rod-to-Crankpin Running Clearance
17.015/17.023 (0.6699/0.6702)
8.025/8.075 (0.3159/0.3179)
Model (Horsepower)
General
Horsepower (@3600 RPM) - Maximum kW (HP)
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
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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)
Piston Thrust Face-to-Cylinder
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.
Top Compression Ring-to-Groove Side Clearance
Middle Compression Ring-to-Groove Side Clearance
Oil Control Ring-to-Groove Side Clearance
Spark Plug Gap
Ignition Module Air Gap
1Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.
0.019/0.062 (0.0007/0.0024)
Piston Thrust Face O.D.1
0.022/0.065 (0.0009/0.0026)Bore
1Running Clearance
Governor Cross Shaft to Crankcase
Piston-to-Piston Pin
Cylinder Bore I.D.
Max. Out-of-Flatness
Running Clearance
Governor Cross Shaft O.D.
Governor Gear Shaft O.D.
Piston Pin Bore I.D.
7.949/8.000 (0.3129/0.3149)
Governor
Gear Shaft-to-Governor Gear Running Clearance
Spark Plug Type (Champion® or equivalent)
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
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LV560 LV625 LV675
Intake Valve Stem Diameter - New
Max. Wear LimitExhaust Valve Guide I.D.
Standard
Intake Valve Minimum Lift
Exhaust Valve Minimum Lift
Nominal Valve Seat Angle
0.25 mm O.S.
Valve Guide Reamer Size
Valves and
Valve Lifters
Model (Horsepower)Hydraulic Valve Lifter to Crankcase Running Clearance
Intake Valve Stem-to-Valve Guide Running Clearance
Exhaust Valve Stem-to-Valve Guide Running Clearance
New
Max. Wear LimitIntake Valve Guide I.D.
New
Exhaust Valve Stem Diameter - 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
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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 new as-cast hole
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.)
Flywheel Retaining Screw
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
Cylinder Head Fastener
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)
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LV560 LV625 LV675
Muffler
Oil Pan
Into new as-cast hole
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)
Muffler Retaining Nuts
Speed Control Bracket Assembly Fastener
Stator Mounting Screw
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).
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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
Ignition Module Air Gap
Model (Horsepower)
Camshaft Bearing Surface O.D. — Max. Wear Limit
Crankshaft
Camshaft
Rod-to-Piston Pin Running Clearance
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
Rod-to-Crankpin Running Clearance
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®
Max. Out-of-Flatness
NGK
Champion®
Max. Out-of-Round
Cylinder Bore I.D.
Rod-to-Crankpin Side Clearance
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
Command PRO CS — Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).
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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
Rod-to-Piston Pin Running Clearance
Rod-to-Crankpin Side Clearance
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
Ignition Module Air Gap
Spark Plug Gap
Kilowatt (kW) Output (@3600 RPM)
Horsepower (@3600 RPM)
Rod-to-Crankpin Running Clearance
End Play (Free)
Runout (Either End)
Limit (Either End)
Flywheel End Main Bearing Journal O.D.
Max. Out-of-Flatness
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
Command PRO CS — Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).
CS4 CS6 CS8 5 (spec 95xxxx)Model (Horsepower)
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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.
2Measure 10 mm (0.394 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)
Exhaust Valve Guide I.D.
Guide Running Clearance
Exhaust Valve Stem-to-Valve
Valve-to-Tappet Clearance (Cold)
Valve Guide Reamer Size - STD
Intake Valve Minimum Lift
Exhaust Valve Minimum Lift
Nominal Valve Seat Angle
Guide Running Clearance
Bore Running Clearance1, 2
Intake Valve Stem-to-Valve
Intake Valve Guide I.D.
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
Piston Thrust Face-to-Cylinder
Top Compression Ring End Gap
Middle Compression Ring End Gap
Piston Pin O.D.
Model (Horsepower)Piston-to-Piston Pin Clearance
Piston Pin Bore I.D.
TP-2469-A 12/07 50
Command PRO CS — Single Cylinder Engine Specifications and TolerancesAll dimensions in millimeters (inches).
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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
Middle Compression Ring End Gap
Oil Control Ring End Gap
Side Clearance
Model (Horsepower)
Piston-to-Piston Pin Clearance
Piston Pin Bore I.D.
Piston Pin O.D.
Running Clearance
Intake Valve Guide I.D.
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
Intake Valve Minimum Lift
Exhaust Valve Minimum Lift
Nominal Valve Seat Angle
Exhaust Valve Guide I.D.
Piston Thrust Face O.D.2
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 )
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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
Closure Plate Fastener
Oil Drain Plug
Stator Mounting Screw
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)
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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
Closure Plate Fastener
Oil Drain Plug
Stator Mounting Screw
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).
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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
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
O.D. - New
O.D. - Max. Wear Limit
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
Connecting Rod Journal
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
End Play (With Shim)
Running Clearance
Max Wear LimitCamshaft
Camshaft Bearing Surface O.D.
NewBore I.D.
Max Wear Limit
Model (Horsepower)
General
Kilowatt (kW) Output (@3600 RPM)
Horsepower (@3600 RPM)
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
Cylinder Max. Wear Limit
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.
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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)
Governor Cross Shaft O.D.
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
Governor Gear Shaft O.D.
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
Running Clearance - New
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)
1Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.
Ignition Module Air Gap
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)
Exhaust Valve Stem-to-Valve Guide Running Clearance
Ignition Spark Plug Gap
Piston Thrust Face O.D.1
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
Intake Valve Stem-to-Valve Guide Running Clearance
16.995/17.000 (0.6691/0.6693)
Piston-to-Piston Pin Running Clearance
Governor
Spark Plug Type (Champion® or Equivalent)
Max. Out-of-Flatness
Piston Pin Bore I.D.
TP-2469-A 12/07 55
SV710, SV810 SV715 SV720, SV820 SV725Model (Horsepower)
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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)
Nominal Valve Seat Angle
Intake Valve Guide I.D.
Exhaust Valve Guide I.D.
Valve Guide Reamer Size
Exhaust Valve Minimum Lift
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)
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SV730, SV830 SV735 SV740, SV84018.6 19.4 20.1
25 26 27
New
Connecting Max Wear Limit
Rod
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
O.D. - New
O.D. - Max. Wear Limit
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
Kilowatt (kW) Output (@3600 RPM)
Horsepower (@3600 RPM)
Bore x Stroke
Displacement
Camshaft
End Play (With Shim)
Running Clearance
Max Wear Limit
Camshaft Bearing Surface O.D.
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
Connecting Rod-to-Crankpin Side 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)
Flywheel End Main Bearing Journal
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
Connecting Rod Journal
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)
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New
Cylinder Max. Wear Limit
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)
Max. Out-of-Flatness
Governor Cross Shaft-to-Crankcase Running Clearance
Shaft O.D.
Governor Cross
Governor Gear Shaft-to-Governor Gear Running Clearance
Piston Thrust Face-to-Cylinder Bore1
Running Clearance - New
Governor Gear
Shaft O.D.
Spark Plug Type (Champion® or Equivalent)
Top Compression Ring-to-Groove Side Clearance
Middle Compression Ring-to-Groove Side Clearance
0.06/0.100 (0.0023/0.0039)
Piston Thrust Face O.D.1
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)
Oil Control Ring-to-Groove Side Clearance
0.050/0.088 (0.0020/0.0035)
Governor
Ignition
Bore I.D. 17.025 (0.6703)
Intake Valve Stem-to-Valve Guide Running Clearance
Exhaust Valve Stem-to-Valve Guide Running Clearance
0.101/0.152 (0.004/0.006)
0.013/0.073 (0.0005/0.0029)
0.038/0.076 (0.0015/0.0030)
1Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.
Ignition Module Air Gap
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)
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New
Valves and Max. Wear Limit
Valve Tappets Standard
0.25 mm O.S.
Nominal Valve Seat Angle
Exhaust Valve Guide I.D.
Valve Guide Reamer Size
Exhaust Valve Minimum Lift
Intake Valve Minimum Lift
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
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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.)
Rectifier-Regulator Fastener
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.)
Flywheel Retaining Screw
Governor Lever Nut
Spark Plug
Ignition Module Fastener
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
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
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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.)
Rectifier-Regulator Fastener
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.)
Flywheel Retaining Screw
Governor Lever Nut
Spark Plug
Ignition Module Fastener
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 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)
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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
Courage SV — Twin Cylinder Torque Values and Sequences for Fasteners
SV730, SV830 SV735 SV740, SV840Blower
Model (Horsepower)M4 HI-LO Screws 2.8 N·m (25 in. lb.)
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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 holeFastener
Crankcase
Cylinder Head Fastener - Head Bolt: Torque in Two Stages
Rocker Arm Screw
Rocker Arm StudCylinder Head
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.)
Rocker Arm/Valve Adjustment Jam Nut
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.)
Rocker Arm/Valve Adjustment Setscrew
41.8 N·m (370 in. lb.)
11.3 N·m (100 in. lb.)
Ignition
Muffler FastenersMuffler
Flywheel Retaining Screw
Spark Plug
Ignition Module Fastener
Oil Filter Installation
Nipple Torque (Oil Filter/Oil Cooler Adapter)
Cap Fastener - Torque Incrementally to:
Breather Assembly
Inner Cover Fastener
Outer Cover Stud
Hex Nut
Carburetor Mounting Nut
Rectifier-Regulator Fastener
6.2-7.3 N·m (55-65 in. lb.)
M5 Fasteners
M6 Fasteners
Intake Manifold Mounting Fastener - Torque in Two Stages
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.)
Rotate Filter 3/4-1 Turn After Gasket Contact
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
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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
Valve Cover Fastener
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)
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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
Flywheel End Main Bearing Journal
O.D. - New
O.D. - Max. Wear Limit
Max. Taper
Max. Out-of-Round
Crankshaft Sleeve Bearing I.D.
New
Max Wear Limit
End Play
General
Displacement
Bore x Stroke
Connecting Rod-to-Crankpin
End Play
Bore I.D. Max. Wear Limit
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
Connecting Rod-to-Crankpin Side 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)
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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 Bore I.D.
Piston Pin O.D.
Middle Compression Ring-to-Groove Side Clearance
Crankshaft T.I.R.
Max. Taper
Connecting Rod Journal
Governor Bushing to Camshaft Running Clearance
Governor Bushing I.D.
Spark Plug Type (Champion® or equivalent)
Governor Cross Shaft to Crankcase Running Clearance
Governor Cross Shaft O.D.
Cylinder Bore
Governor
Max. Out-of-Round
Cylinder Bore I.D.
Top Compression Ring-to-Groove Side Clearance
Oil Control Ring-to-Groove Side Clearance
Ignition Spark Plug Gap
Ignition Module Air 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
Middle Compression Ring End Gap
Piston Thrust Face O.D.1
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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 Guide Reamer Size
Intake Valve Minimum Lift
Valve Lash
Valves
Exhaust Valve Minimum Lift
Intake Valve Stem-to-Valve Guide Running ClearanceExhaust Valve Stem-to-Valve Guide Running Clearance
Intake Valve Guide I.D.
Nominal Valve Seat Angle
1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
Exhaust Valve Guide
Piston Thrust Face-to-Cylinder Bore1
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
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Blower Housing
and Sheet Metal
Carburetor
Connecting Rod
Electric Starter
Muffler
Speed Control
Stator
Throttle/Choke
Controls
Valve Cover
IgnitionSpark Plug
Ignition Module Fastener
Timing Belt
24.4 N·m (216 in. lb.)
Fan/FlywheelFan Fastener
Flywheel Retaining Screw
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
Stator Mounting Screw
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.)
Muffler Retaining Nuts
Oil Filter
TP-2469-A 12/07 68
OHC — Twin Cylinder Torque Values and Sequences for Fasteners
Oil Filter Adapter Breather Cover GasketCrankcase
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TP-2469-A 12/07 69
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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