Summary of Contents for Generac Power Systems GTH760
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Foreword This manual has been written and published by GeNerAC ® Power SYSTeMS, INC. to aid our dealers’ mechanics, company service person- nel and general consumers when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufac- tured and marketed by GeNerAC ®...
Generac parts and are listed as such in this manual. ATTeNTIoN! Generac Power Systems does not approve or authorize the use of these engines on All Terrain vehicles (ATv’s), go-carts, motorbikes, aircraft products, personal watercraft, or vehicles intended for use in competitive events.
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ruleS For SAFe oPerATIoN ruleS For SAFe oPerATIoN If you do not understand any portion of this manual, con- tact Generac or your nearest Generac Authorized Service Study these RULES FOR SAFE OPERATION carefully before Dealer for starting, operating and servicing procedures. operating or servicing this equipment.
Service on this engine within and after the warranty • Generac Power Systems does not approve or authorize the period can be performed by any authorized service use of these engines on All Terrain Vehicles (ATV’s), go- dealer.
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4-CYCle eNGINe THeorY If the engine is to run properly, four (4) events must occur in the proper sequence and at the correct time. These events are (A) intake, (B) compression, (C) ignition and power, and (D) exhaust. INTAke IGNITIoN ANd Power The piston is travelling from top dead center (TDC) to bottom By the time the piston reaches TDC , combustion is already in dead center (BDC).
SeCTIoN 1: GeNerAl INForMATIoN MAINTeNANCe SCHedule LUBRICATION: Oil has four purposes. It cools, cleans, seals and lubricates. Every Every Every Every During normal operation, small particles of metal from the 8 Hours or 25 Hours 50 Hours 100 Hours Daily Season Season Season...
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SeCTIoN 1: GeNerAl INForMATIoN CHANGE OIL FILTER: Replace oil filter every 100 hours. Before installing new filter, lightly oil filter gasket with fresh clean engine oil. Screw filter on by hand until gasket contacts filter adapter. Tighten 3/4 to one full turn farther, Figure 1-5. Start and run engine at idle for 30 seconds and stop engine.
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SeCTIoN 1: GeNerAl INForMATIoN The air cleaner on every engine brought in for a check up INTAKE or repair should be examined and serviced. If the air cleaner SCREEN shows signs of neglect, show it to the customer before clean- ing.
SeCTIoN 1: GeNerAl INForMATIoN Note: The air cleaner assemblies on some equipment CHECK IGNITION: may have been supplied by the equipment manufacturer. If spark does not occur look for: See the equipment manufacturer’s owner’s manual for service information specific to that product. •...
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SeCTIoN 1: GeNerAl INForMATIoN CHECK COMPRESSION: It has been determined through testing that a simple and accurate indication of compression can be made as follows: Remove both spark plugs and insert a compression gauge into either cylinder (one cylinder at a time). Open the throttle to Wide Open Throttle (WOT) position.
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SeCTIoN 1: GeNerAl INForMATIoN NOTE: A twin cylinder engine will run well on one cylinder as long as the power required for the applica- tion does not exceed the power produced by the one INLET GUAGE PRESSURE SET COMPRESSED POINT cylinder.
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SeCTIoN 2: IGNITIoN GeNerAl INForMATIoN 3. Rotate selector to (Diode Test) position. Generac GTH/GTV-760/990 OHVI V-Twin engines use a mag- 4. Insert RED test lead clip into connector "A" (Figure 2-2). neto ignition: an ignition coil with a self-contained transistor Leave attached for remainder of test.
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SeCTIoN 2: IGNITIoN DIODE (BUILT INTO COIL) IGNITION GROUND WIRE SPARK PLUG DIODE BUILT IN HARNESS GROUND WIRE ON OLDER MODELS HARNESS DIODE (BUILT INTO COIL) SPARK PLUG Figure 2-4. Engine Wiring Harness wIre HArNeSS CHeCk Note: The flywheel does not need to be removed to service ignition except to check the flywheel key.
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SeCTIoN 2: IGNITIoN FlYwHeel REMOVE FLYWHEEL: 1. Remove two screws that attach fan and fan retainer to flywheel. 2. Remove fan retainer and fan. 3. Remove flywheel nut and washer, Figure 2-8. 4. Reinstall flywheel nut. Turn nut down flush with top of threads.
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SeCTIoN 2: IGNITIoN FLYWHEEL COIL WIRE ROUTED UNDER BREATHER Figure 2-11. Torquing Flywheel Nut Figure 2-9. Removing Flywheel Figure 2-10. Check Flywheel And Crankshaft Figure 2-12. Installing Flywheel And Fan 3. Install washer and flywheel nut. INSTALL FLYWHEEL: a. Torque flywheel nut to 204.0 Nm (150 ft. lbs.), Figure Note: CLEAN flywheel and crankshaft taper removing 2-11.
SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM CArbureTor TYPeS 6. Remove the four nuts holding the carburetor and plenum to the intake manifold (see Figure 3-6). All Generac OHVI V-Twin engines utilize a two-barrel type carburetor. 7. Remove the plenum, carburetor and gaskets from the manifold and discard the gaskets.
SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM MANIFOLD CHOKE PLENUM LINK CARBURETOR PLENUM GASKET GASKET Figure 3-5. Figure 3-6. 6. Remove choke link (Figure 3-5), throttle link (Figure 3-4) and fuel shut-off solenoid wire from carburetor. 8. Reinstall choke link on carburetor and clip the link into the bellcrank.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM 10. Move speed control lever to slow speed position and hold throttle lever against idle stop screw. 11. Adjust stop screw to maintain ~ 1800 RPM idle. 12. Slowly move speed control lever to high-speed position. 13.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM HARDWARE SPRING LOWER FUEL FUEL UPPER VENT: UPPER RETURN DIAPHRAGM CHECK- CHECK- DIAPHRAGM VENT ASSEMBLY VALVE 1 VALVE 2 Figure 3-10. Fuel Pump Assembly The pump consists of (see Figure 3-10): This is accomplished with a special valve that is installed on a normal propane cylinder with a tube that is attached to the 1.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM TeSTING THe Fuel SHuT-oFF SoleNoId COIL BOLT 1. Remove the spark plug wires from each spark plug to prevent accidental starting of the engine. 2. Check for 12 volts DC at the solenoid terminal. See Figure 3-11.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM NOTE: TEST REGULATOR ON ENGINE FIRST OR, FOR SCHEDULED MAINTENANCE, PROCEED TO "REMOVE REGULATOR AND DISMANTLE AS FOLLOWS". 1. Make sure the fuel tank(s) have an adequate supply of fuel. 2. Make sure the valve on the tank is fully open (turned counterclockwise).
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM Figure 3-15. Remove Secondary Lever and Spring Figure 3-18. Remove/Replace Two Screws 8-32 x 0.375” long REASSEMBLY OF REGULATOR: 1. Carefully clean and inspect all metal parts-springs, levers, pivot pins and screws. Replace all parts that are included in the repair and rebuilding kits.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM but are crimped at the factory with proper tension to allow movement but still hold their position. See Figure 3-23. Figure 3-19. Rotate The Diaphragm To Align the Cover Screw Holes Figure 3-21. Install Secondary Valve Spring, Lever and Pivot Pin Figure 3-20.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM Figure 3-23. Positioning Secondary Lever Valve Figure 3-26. Check Primary Pressure Reading 15. Check around the secondary seat for leaks using a liquid leak detector solution. If a leak is detected, repeat Step 11 to insure no leakage at the secondary seat.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM b. Connect LP line(s), reconnect battery and turn on fuel supply at the tank(s). c. Turn ignition switch to the "ON" position to verify that the solenoid is opening. d. Check all fuel connections with a leak detector. If leaks are present, go back to Step 20a.
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SeCTIoN 3: CArbureTIoN ANd Fuel SYSTeM MANUAL TANK SHUT OFF VALVE ITEMS INSIDE DASHED LINE ARE OEM SUPPLIED LP TANKS ITEMS OUTSIDE DASHED LINE ARE GENERAC SUPPLIED MANUAL TANK SHUT OFF VALVE ENGINE CARBURETOR PRESSURE RELIEF VALVE SOLENOID SHUT OFF VAPORIZOR / ON DEMAND REGULATOR NOTE: ALL FUEL LINES ARE REQUIRED TO BE...
SeCTIoN 4: GoverNor CoNTrolS ANd GoverNor MeCHANICAl GoverNor DISASSEMBLE: 1. Drain the oil from the engine. GOVERNOR 2. Remove any rust, nicks, or burrs from the crankshaft. SPOOL 3. Remove the four (4) oil cooler screws. PASSAGE 4. Disconnect the wiring from the oil pressure switch. O-RING 5.
SeCTIoN 4: GoverNor CoNTrolS ANd GoverNor GoverNor ArM 1. Remove the e-clips. If the governor arm does not move freely, or if the arm feels 2. Slide the arm down and out of the bushings. loose in the bushings, it may need replacing. If wear is noticed, 3.
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SeCTIoN 4: GoverNor CoNTrolS ANd GoverNor 2. Be sure that the new oil passage o-ring is in place (see Figure 4-1). GOVERNOR LEVER 3. Put a new gasket on the crankcase. 4. Slide the crankcase cover back on the crankcase. Note: Hold the governor arm in the counter-clockwise GOVERNOR position while installing.
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SeCTIoN 4: GoverNor CoNTrolS ANd GoverNor HIGH SPEED SCREW Figure 4-8. Dynamic Governor Adjustment Figure 4-10. Dynamic Governor Adjustment (Vertical Shaft) (Horizontal Shaft) SPEED CONTROL LEVER ALLEN WRENCH Figure 4-9. Dynamic Governor Adjustment (Horizontal Shaft)
SeCTIoN 5: CYlINder HeAd ANd vAlveS GeNerAl INForMATIoN reMove CYlINder HeAdS Compression testing information and procedures is described Disconnect exhaust system from exhaust manifold. Remove in Section 1, under “Troubleshooting”. exhaust manifold from engine. Disconnect choke and throttle control cables. Remove spark plugs. Cylinders are numbered as shown in Figure 5-1.
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SeCTIoN 5: CYlINder HeAd ANd vAlveS BALL STUD ROCKER ARM JAM NUT PUSH ROD GUIDE (TABS MUST FACE UPWARD) Figure 5-4. Remove Cylinder Head Figure 5-3. 3. Remove push rod guide plate. 4. Remove head bolts and cylinder head (Figure 5-4). a.
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SeCTIoN 5: CYlINder HeAd ANd vAlveS INSPeCT ANd rePAIr REFACE VALVES AND SEATS: 1. Check cylinder head (Figure 5-7). Be sure all gasket material 1. Valve seats may be reconditioned using a valve seat is removed from surfaces before checking. Use a gasket cutter.
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SeCTIoN 5: CYlINder HeAd ANd vAlveS 4. Measure valve stem diameter at specified distance from end of valve, as shown in Figure 5-11. Replace if less than 6.9 mm (0.272 inches), or if total clearance between valve stem and valve guide exceeds 0.12 mm (0.0047 in).
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SeCTIoN 5: CYlINder HeAd ANd vAlveS AdjuST vAlve CleArANCe 1. Set No. 1 cylinder at TDC, compression stroke. a. Adjust rocker arms and check clearance (Figure 5-17). Figure 5-15. Compress valve spring and install keepers 6. Repeat procedure for other valve(s). 7.
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SeCTIoN 5: CYlINder HeAd ANd vAlveS 6. Install rotating screen. 8. Assemble air cleaner. a. Torque screws to 1.9 Nm (17 in. lbs). 9. Make Static and Dynamic Governor adjustments as out- lined on Page 4-3. 7. Install finger guard. a.
SeCTIoN 6: eleCTrIC STArTer GeNerAl INForMATIoN ENGINE WILL NOT CRANK: The starter motor utilizes a solenoid, similar to an automo- a. Faulty safety interlocks. bile starter, to assist in pinion gear engagement. When the b. Discharged or defective battery. starter motor is activated, the pinion gear engages a ring gear c.
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SeCTIoN 6: eleCTrIC STArTer TeST STArTer MoTor CHeCkING STArTer volTAGe droP Before starting this test, make sure the battery is at least 70 TESTING STARTER SOLENOID: percent charged (12.5 volts or higher). Also make sure the The solenoid is a normally open, electrically activated correct sized battery is being used.
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SeCTIoN 6: eleCTrIC STArTer 0.2 volt drop. If greater, a check of each wire and terminal • Engine oil viscosity too heavy (see engine manufacturer’s connection should be made. At each connection, no more Operators Manual). than 0.2 volts should be seen. •...
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SeCTIoN 6: eleCTrIC STArTer 2. Place battery in holder with flat base. Tighten hold down TESTING BATTERY: evenly until snug. do NoT overtighten. Set a digital multimeter to read DC Volts. 3. Connect positive terminal to positive post FIrST to Attach RED meter test lead to positive(+) battery terminal.
SeCTIoN 7: AlTerNATorS 20 AMP reGulATed AlTerNATor 5. With the engine running at 3600 RPM, output should be no less than: The 20 amp regulated alternator system provides AC current through two output leads to the regulator-rectifier. The regula- 26 volts - 20 Amp System tor-rectifier converts the AC current to DC, and regulates the 6.
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SeCTIoN 7: AlTerNATorS 2. With the charging system properly connected, start the Note: With the engine running, the battery voltage should be at least 13 Volts. engine. 3. Bring the engine up to normal operating speed and test bATTerIeS the battery voltage again. Note: See Section 6 for battery size and cable selection 4.
SeCTIoN 8: lubrICATIoN SYSTeM deSCrIPTIoN HIGH TEMPERATURE The Generac GTH/GTV-760/990 OHVI V-twins use a full pres- SWITCH PAD sure lubrication system with an oil filter. The gerotor type oil (SWITCH IS pump draws oil from a screened oil pickup in the sump and OPTIONAL) pumps oil through the oil filter.
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SeCTIoN 8: lubrICATIoN SYSTeM CHANGING THe eNGINe oIl ANd FIlTer RECOMMENDED OIL TYPE: Using the proper type and weight of oil in the crankcase is extremely important. Check the oil before each use and change the oil regularly (see Figures 1-1 through 1-5). Failure to use the correct oil, or using dirty oil, can cause premature engine wear and failure.
SeCTIoN 8: lubrICATIoN SYSTeM oIl Cooler All GTH/GTV-760/990 V-Twin engines are equipped with an PUMP BODY oil cooler, which is mounted on the blower housing. Forced air from the flywheel fan flows through the oil cooler fins dis- sipating heat from the engine oil (see Figure 8-5) . The oil cooler fins should be cleaned every 100 hours (or more often under dusty conditions) and checked periodically for debris.
SeCTIoN 9: eNGINe dISASSeMblY eNGINe dISASSeMblY 3. Rotate crankshaft and camshaft until timing marks align and remove camshaft (Figure 9-2). Drain oil, remove oil filter and remove engine from equip- ment. Remove intake and exhaust systems. Remove engine Note: If necessary, place the engine flywheel side down shroud and all cylinder wrappers.
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SeCTIoN 9: eNGINe dISASSeMblY 7. Remove oil pump from crankcase cover. Note: Clean all surfaces of gasket material. Remove oil seals and thoroughly clean components in solvent. Organize components, keeping parts which are assem- blies together. Figure 9-2. Remove Camshaft Figure 9-5.
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SeCTIoN 10: CYlINder & CrANkCASe Cover CHeCk CrANkCASe Check crankcase for cracks, stripped threads or broken fins. Check cylinder bores for damage or scoring. 1. Check cylinder head mounting surface for distortion with a straight edge, Figure 10-1. If mounting surfaces are distorted more than 0.1 mm (.004"), the crankcase must be replaced.
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SeCTIoN 10: CYlINder & CrANkCASe Cover Clamp honing fixture and crankcase securely in a vise at a Honing grit is highly abrasive and will cause rapid wear to convenient work height. all of the internal components of the engine unless it is com- pletely removed.
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SeCTIoN 10: CYlINder & CrANkCASe Cover CHECK CAMSHAFT BEARINGS Use a telescoping gauge and caliper to check camshaft bear- ings. If camshaft bearings are worn, crankcase or crankcase cover must be replaced. (For vertical shaft engines, the gerotor cover must be replaced). See Figure 10-8. TELESCOPING GAUGE Figure 10-6.
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SeCTIoN 10: CYlINder & CrANkCASe Cover 216mm [8.504"] 16.5mm [0.65"] 183.5mm [7.224"] 10.5mm [0.413"] 17mm [0.67"] Ø12mm [0.473"] TYP 254mm [10.0"] MATERIAL: WOOD 25.4mm [1"] x 216mm [8.5"] x 254mm [10.0"] CLAMP THIS END IN VISE Figure 10-10. Honing Fixture 10-4...
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SeCTIoN 11: CrANkSHAFT & CAMSHAFT CHECK CRANKSHAFT: CHECK CAMSHAFT: Inspect crankshaft threads, keyways and timing gear for Inspect gear teeth, lobes and journals for wear and nicks (see damage or wear. If threads, keyways or timing gear are dam- Figure 11-2). Check journals and lobes for scoring and wear. aged or worn, replace crankshaft.
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SeCTIoN 12: PISToN, rINGS & CoNNeCTING rod INSPeCTIoN & ASSeMblY GeNerAl INForMATIoN 2. Disassemble piston from connecting rod, Figure 12-2. It is recommended that new piston rings be installed when- a. Remove piston pin locks. ever the engine is disassembled for major servicing or overhaul, b.
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SeCTIoN 12: PISToN, rINGS & CoNNeCTING rod INSPeCTIoN & ASSeMblY Figure 12-6. Check Piston Pin Figure 12-4. Checking Ring End Gap CRANKPIN BEARING PISTON PIN BEARING Figure 12-7. Check Rod Bearings ASSeMble PISToN ANd CoNNeCTING rod Lubricate parts with engine oil and assemble #1 piston and Figure 12-5.
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SeCTIoN 12: PISToN, rINGS & CoNNeCTING rod INSPeCTIoN & ASSeMblY CASTING MARK MUST CASTING MARK MUST FACE FLYWHEEL SIDE FACE FLYWHEEL SIDE NUMBER MUST FACE PTO SIDE NUMBER MUST FACE PTO SIDE Figure 12-9. Assemble #2 Rod And Piston Figure 12-8. Assemble #1 Rod And Piston ASSeMble PISToN rINGS To PISToN Install piston rings using ring expander when installing center TOP COMPRESSION RING...
SeCTIoN 13: eNGINe ASSeMblY INSTAll CrANkSHAFT Lubricate magneto bearing and inside edge of oil seal with RING engine oil and install crankshaft. COMPRESSOR Figure 13-2. Compressing Rings HAMMER HANDLE Figure 13-1. Installing Crankshaft INSTAll PISToN ANd CoNNeCTING rod Note: Install #1 piston and connecting rod first. 1.
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SeCTIoN 13: eNGINe ASSeMblY Note: The number 1 on #1 connecting rod and the number 2 on #2 connecting rod must be facing PTO side. Important: Failure to use a torque wrench can result in loose connecting rod screws causing breakage or tight connecting rod screws causing scoring.
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SeCTIoN 13: eNGINe ASSeMblY 3. Install starter motor. a. Torque screws to 27 Nm (228 in. lbs.). 4. Assemble ignition coils to engine, Figure 13-11. a. Mounting holes in coil are slotted. Push coil as far back as possible and tighten one screw to hold coil in place. 5.
SeCTIoN 13: eNGINe ASSeMblY a. Torque head bolts in sequence shown (Figure 13-14) to 29.9 Nm (22 ft. lbs.). 3. Insert push rods into recess in tappets. Figure 13-12. Torque Flywheel Nut AdjuST IGNITIoN CoIl AIr GAP TORQUE SEQUENCE FOR HEADS: 1.
SeCTIoN 13: eNGINe ASSeMblY AdjuST vAlve CleArANCe 1. Set No. 1 cylinder at TDC (Top Dead Center), com- pression stroke. VALVE COVER a. Adjust rocker arms and check clearance, Figure 13-16. Val v e C l e a r ance ( col d ) I N TA K E a nd EX HAU ST 0.076mm (.003") GASKET b.
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SeCTIoN 13: eNGINe ASSeMblY b. Torque M6 screws to 4.5 Nm (40 in. lbs.). 5. Install fan and retaining ring. c. Connect ignition ground wire to ignition ground terminal a. Torque screws to 21.7 Nm (192 in. lbs.). in backing plate (see Figure 13-19). 6.
SeCTIoN 14: SPeCIFICATIoNS GeNerAl SPeCIFICATIoNS MODEL GTH & GTv 760 GTH & GTv 990 Bore 90 mm (3.54”) 90.00 mm (3.54”) Stroke 60 mm (2.36”) 78 mm (3.07”) Displacement 763cc 992cc GTv 760 & 990 GTH 990 & 760 OIL CAPACITY With Oil Filter* 2.3L (2.4 qt) 2.2L (2.3 qt)
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SeCTIoN 14: SPeCIFICATIoNS STANdArd ANd rejeCT dIMeNSIoNS deSCrIPTIoN STANdArd dIMeNSIoN rejeCT dIMeNSIoN CYLINDER: Bore 90.00 – 90.025 mm (3.543” – 3.544”) 90.10 mm (3.547”) Out of Round 0.035 mm (.0015”) Main Bearing (Mag End) 38.044 – 38.099 mm (1.498” – 1.5”) 38.25 mm (1.506”) Cam Bearing 20.00 –...
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