Summary of Contents for Generac Power Systems GTH760
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® ENGINE SERVICE MANUAL OHVI® V-Twin Engine MODELS: GTH760/990/1000 GTV760/990/1000 A I R - C O O L E D E N G I N E S...
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FOREWORD This manual has been written and published by GENERAC ® POWER SYSTEMS, INC. to aid our dealers’ mechanics, company service personnel 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, manufactured and marketed by GEN- ERAC ®...
SECTION 14: SPECIFICATIONS 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. The use of this product in any other than it’s intended application will void the warranty! Use of these engines in such applications could result in...
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RULES FOR SAFE OPERATION If any portion of this manual is not understood, contact the nearest RULES FOR SAFE OPERATION Dealer for starting, operating and servicing procedures. Study these RULES FOR SAFE OPERATION carefully before operat- Throughout this publication, and on tags and decals affixed to the ing or servicing this equipment.
RULES FOR SAFE OPERATION WHILE OPERATING SERVICE INFORMATION • This engine was designed and manufactured for specific applica- tions. Do not attempt to modify the equipment or use it for any Service on this engine within and after the war- application for which it was not designed.
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 dead By the time the piston reaches TDC , combustion is already in progress.
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SECTION 1: GENERAL INFORMATION LUBRICATION: MAINTENANCE SCHEDULE Oil has four purposes. It cools, cleans, seals and lubricates. During Every Every normal operation, small particles of metal from the cylinder walls, Every 8 Every 50 pistons, bearings and combustion deposits will gradually contaminate Hours Hours or Hours or...
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).
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SECTION 1: GENERAL INFORMATION The air cleaner on every engine brought in for a check up or repair INTAKE should be examined and serviced. If the air cleaner shows signs of SCREEN neglect, show it to the customer before cleaning. Instruct the customer on proper care, to assure long engine life.
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SECTION 1: GENERAL INFORMATION Note: The air cleaner assemblies on some equipment may have CHECK IGNITION: been supplied by the equipment manufacturer. See the equipment If spark does not occur look for: manufacturer’s owner’s manual for service information specific to that product. • Shorted ignition/ground wire (see Page 2-1) • Two closed diodes in ground wire harness (see Page 2-1) TROUBLESHOOTING...
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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 application does not exceed the power produced by the one cylinder. INLET GUAGE PRESSURE SET COMPRESSED POINT AIR IN OUTLET GUAGE PRESSURE...
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SECTION 2: IGNITION GENERAL INFORMATION attached for remainder of test. Generac GTH/GTV-760/990 OHVI V-Twin engines use a magneto 5. Touch BLACK test lead probe to terminal "B." ignition: an ignition coil with a self-contained transistor module (no a. If meter "Beeps" once, diode is OK. moving parts).
SECTION 2: IGNITION DIODE (BUILT INTO COIL) IGNITION GROUND WIRE SPARK PLUG GROUND DIODE BUILT IN HARNESS WIRE ON OLDER MODELS HARNESS DIODE (BUILT INTO COIL) SPARK PLUG Figure 2-4. Engine Wiring Harness ground stud on engine and re-check. If ignition now has spark, 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. Loosen flywheel nut until it is flush with end of crankshaft threads (Figure 2-8.) 4. Install flywheel puller. 5.
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SECTION 2: IGNITION FLYWHEEL COIL WIRE ROUTED UNDER BREATHER Figure 2-11. Torquing Flywheel Nut Figure 2-9. Removing Flywheel INSPECT HERE Figure 2-10. Check Flywheel And Crankshaft Figure 2-12. Installing Flywheel Fan 3. Install washer and flywheel nut. INSTALL FLYWHEEL: a. Torque flywheel nut to 204.0 Nm (150 ft. lbs.), Figure 2-11. Note: CLEAN flywheel and crankshaft taper removing all oil, dirt 4.
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 gasoline powered OHVI V-Twin engines utilize a two-barrel type carburetor. Some LP engines use a single barrel 7.
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SECTION 3: CARBURETION AND FUEL SYSTEM MANIFOLD CHOKE LINK PLENUM 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 the idle 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 Fuel Pump Breakdown (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 valve and extends 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 ter minal. 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 counterclock- wise).
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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 3-23. Figure 3-21. Install Secondary Valve Spring, Figure 3-19. Rotate The Diaphragm To Align the Lever and Pivot Pin Cover Screw Holes Figure 3-20. Install Primary Spring, Primary Cover and Screws 9. Place secondary valve spring (5/16” dia. x 5/8’ long) in spring Figure 3-22.
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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 pres- ent, go back to Step 20a.
SECTION 4: GOVERNOR CONTROLS AND GOVERNOR MECHANICAL GOVERNOR DISASSEMBLE: 1. Drain the oil from the engine. 2. Remove any rust, nicks, or burrs from the crankshaft. GOVERNOR SPOOL 3. Remove the four (4) oil cooler screws. PASSAGE 4. Disconnect the wiring from the oil pressure switch. O-RING 5.
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SECTION 4: GOVERNOR CONTROLS AND GOVERNOR GOVERNOR ARM 2. Slide the arm down and out of the bushings. If the governor arm does not move freely, or if the arm feels loose in the 3. Replace any parts that appear worn. bushings, it may need replacing.
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SECTION 4: GOVERNOR CONTROLS AND GOVERNOR 3. Put a new gasket on the crankcase. GOVERNOR LEVER Note: On vertical shaft engines, align the camshaft drive and oil pump gerotor. 4. Slide the crankcase cover back on the crankcase. Note: Hold the governor arm in the counter-clockwise position GOVERNOR 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 in Sec- Remove exhaust system from engine. Disconnect choke and throttle tion 1, under “Troubleshooting”. control cables. Remove spark plugs. Cylinders are numbered as shown in Figure 5-1. 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 is 1. Valve seats may be reconditioned using a valve seat cutter. removed from surfaces before checking. If valve seat is wider than dimension shown in Figure 5-9, a narrowing cutter should be used to ensure that contact area a.
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SECTION 5: CYLINDER HEAD AND VALVES 1.600” [40 mm] Figure 5-13. Install Valve Stem Seals Figure 5-11. Measure Valve Stem Diameter 2. Install valves (Figure 5-14). 4. Check valve springs for free length (Figure 5-12). Note: Lightly coat valve stems with oil before installing valves. Be sure lubricant is not on valve face and seat.
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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). Valve Clearance (cold) Intake and Exhaust 0.076 mm (.003“). b. Torque jam nut to 19 Nm (168 in. lbs.). Figure 5-15.
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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 outlined on Page 4-3. 7. Install finger guard. a. If engine is equipped with hex head screws, torque screws to 4.5 Nm (40 in.
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SECTION 6: ELECTRIC STARTER GENERAL INFORMATION ENGINE WILL NOT CRANK: The starter motor utilizes a solenoid, similar to an automobile starter, to a. Faulty safety interlocks. assist in pinion gear engagement. When the starter motor is activated, b. Discharged or defective battery. the pinion gear engages a ring gear attached to the engine flywheel c.
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SECTION 6: ELECTRIC STARTER TEST STARTER MOTOR is being used. Check the engine manufacturer's Operator's Manual for battery size recommendations. TESTING STARTER SOLENOID: With the engine and all other accessories turned off, measure the The solenoid is a normally open, electrically activated switch. With battery voltage across the battery posts using a VOM set to the 20 the keyswitch in the “START”...
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SECTION 6: ELECTRIC STARTER 5. Check the (-) negative side of the system. Place the VOM (+) • Some equipment manufacturers may use a constant drive pump, positive lead on the starter case and the other lead on the (-) which may have too heavy of oil or too tight of belt tension.
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SECTION 6: ELECTRIC STARTER 2. Place battery in holder with flat base. Tighten hold down evenly TESTING BATTERY: until snug. DO NOT overtighten. Set a digital multimeter to read DC Volts. 3. Connect positive terminal to positive post FIRST to prevent 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 regulator-rectifier con- 26 Volts AC verts the AC current to DC, and regulates the current to the battery.
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SECTION 7: ALTERNATORS 2. With the charging system properly connected (all wires re- Note: With the engine running, the battery voltage should be at least 13 Volts DC. attached to the regulator), start the engine. 3. Bring the engine up to normal operating speed and test the battery BATTERIES voltage again.
SECTION 8: LUBRICATION SYSTEM DESCRIPTION The Generac GTH/GTV-760/990 OHVI V-twins use a full pressure lubri- cation system with an oil filter. The gerotor type oil pump draws oil from a screened oil pickup in the sump and pumps oil through the oil filter. The filtered oil flows through an oil gallery in the sump and is distributed to the main bearings, connecting rod bearings and camshaft bearings.
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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.
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SECTION 8: LUBRICATION SYSTEM OIL COOLER All GTH/GTV-760/990 V-Twin engines are equipped with an oil cooler, PUMP BODY which is mounted on the blower housing. Forced air from the flywheel fan flows through the oil cooler fins dissipating heat from the engine oil (see Figure 8-5) .
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SECTION 8: LUBRICATION SYSTEM The components of both pressure relief valves are identical. The difference in pressure is determined by the depth of the hole in which the assembly is installed. CAMSHAFT BOSS RELIEF SPRING OIL PUMP DRIVE RELIEF BALL OIL PUMP COVER COLD START...
SECTION 9: ENGINE DISASSEMBLY ENGINE DISASSEMBLY 3. Rotate crankshaft and camshaft until timing marks align and remove camshaft (Figure 9-2). Drain oil, disconnect the wire harness,connector, cables and fuel hose. Remove engine from equipment. Remove intake and exhaust systems. Note: If necessary, place the engine flywheel side down to prevent Remove engine shroud and all cylinder wrappers.
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SECTION 9: ENGINE DISASSEMBLY Note: Clean all surfaces of gasket material. Remove oil seals and thoroughly clean components in solvent. Organize components, keeping parts which are assemblies together. Figure 9-2. Remove Camshaft Figure 9-5. Remove Oil Pump (Vertical Shaft Engine) Figure 9-3.
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 Cut a wood block and place inside crankcase to prevent hone from Honing grit is highly abrasive and will cause rapid wear to all of the extending further than 3/4" to 1" (19 mm to 25 mm) below cylinder internal components of the engine unless it is completely removed.
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SECTION 10: CYLINDER & CRANKCASE COVER CHECK CAMSHAFT BEARINGS Use a telescoping gauge and caliper to check camshaft bearings. If camshaft bearings are worn, crankcase or crankcase cover must be replaced. (For vertical shaft engines, the oil pump cover must be replaced).
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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...
SECTION 11: CRANKSHAFT & CAMSHAFT CHECK CRANKSHAFT: CHECK CAMSHAFT: Inspect crankshaft threads, keyways and timing gear for damage or Inspect gear teeth, lobes and journals for wear and nicks (see Figure wear. If threads, keyways or timing gear are damaged or worn, replace 11-2).
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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 whenever the a. Remove piston pin locks. engine is disassembled for major servicing or overhaul, providing that 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 connect- ing rod, Figure 12-8.
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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 and top TOP COMPRESSION RING...
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SECTION 13: ENGINE ASSEMBLY INSTALL CRANKSHAFT Lubricate magneto bearing and inside edge of oil seal with engine oil RING 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.
SECTION 13: ENGINE ASSEMBLY Note: The number on #1 connecting rod and the number 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. Assemble ignition coils to engine, Figure 13-11. a. Mounting holes in coil are slotted. Push coil as far back as pos- sible and tighten one screw to hold coil in place. 4. Repeat for second coil. Note: The spark plug lead must be at the top.
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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 1.
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SECTION 13: ENGINE ASSEMBLY ADJUST VALVE CLEARANCE 1. Set No. 1 cylinder at TDC (Top Dead Center), compression stroke. VALVE COVER a. Adjust rocker arms to specified clearance, Figure 13-16. Valve Clearance (cold) INTAKE and EXHAUST: 0.076mm, +/- 0.02mm (.003" +/- .001") 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 in a. Torque screws to 21.7 Nm (192 in. lbs.). backing plate (see Figure 13-19). 6.
SECTION 14: SPECIFICATIONS GENERAL SPECIFICATIONS MODEL GTH & GTV 760 GTH & GTV 990 GTH & GTV 1000 Bore 90 mm (3.54”) 90.00 mm (3.54”) 90.00 mm (3.54”) Stroke 60 mm (2.36”) 78 mm (3.07”) 78.58 mm (3.09”) Displacement 763cc 992cc 999cc OIL CAPACITY...
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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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