Engine Removal - Cushman HAULER 800X Technician's Repair And Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Fig. 21 Valve Clearance Adjustment
Valve Clearance (when cold): Inlet, Exhaust 0.10 - 0.15
mm (0.004 - 0.006 in.)
Loosen the lock screw (10) using the 3 mm Allen bit and
the adjusting nut (11). Insert the feeler gauge (7)
between the rocker arm and the valve stem end and
move the adjusting nut (11) until the feeler gauge begins
to bind between the rocker arm and the valve stem end.
Hold the adjusting nut (11) in place using a wrench and
tighten the lock screw (10) to the specified torque.
ITEM TORQUE SPECIFICATION
10 61 in. lbs (6.9 Nm)
Do NOT overtighten.
Remeasure any clearance that was adjusted. Readjust if
necessary.
Replace the Rocker Cover (6), gasket and the four bolts
(5). Tighten the bolts to secure the cover in place.

ENGINE REMOVAL

Tool List
Torque Wrench, ft. lbs ................................................. 1
Socket, 10 mm ............................................................ 1
Socket, 12 mm ............................................................ 1
Socket, 14 mm ............................................................ 1
Socket, 1/2" ................................................................. 1
Socket, 5/8" ................................................................. 1
Impact Socket, 19 mm................................................. 1
Wrench, 8 mm ............................................................. 1
Wrench, 10 mm ........................................................... 1
Wrench, 12 mm ........................................................... 1
Wrench, 13 mm ........................................................... 1
Wrench, 14 mm ...........................................................2
Wrench, 15 mm ...........................................................1
Wrench, 19 mm ...........................................................1
7
Combo Wrench, 19 mm...............................................1
Pliers............................................................................1
Extension 6".................................................................1
Ratchet ........................................................................1
Flat Ratchet .................................................................1
10
Impact Tool ..................................................................1
Straight Blade Screwdriver ..........................................1
11
Drip Pan.......................................................................1
This section covers the removal and installation of the
engine, for information on rebuilding the engine please
see the Engine Shop Rebuild Manual for this vehicle.
In the following text, there are references to removing/installing
bolts etc. Additional hardware (nuts, washers etc.) that are
removed must always be installed in their original positions
unless otherwise specified. Non specified torque specifications
are as shown in the table contained in Section "A".
This operation will remove the engine through the top of the
engine compartment. The weight of the engine exceeds nor-
mal OSHA limits for one person; therefore, a second person or
an engine hoist will be needed to remove the engine. If a hoist
is employed, it will be necessary to remove the sun top.
1. Disconnect Battery ground wire.
2. Disconnect air hose at carburetor.
3. Jack up rear of vehicle as directed in Section B of this
manual. Use jack stands for stability.
4. Remove the drive belt by rotating clutch toward rear of
vehicle when the belt is slipped off the top of the
clutch. Remove belt from vehicle.
5. Disconnect the 'DF' wire from starter using 8mm
wrench, lay harness out of the way
6. Remove the ground strap from the Starter/Generator
Qty.
using a 10 mm socket.
7. Remove the Starter/Generator (See Starter/Generator
Replacement in this section).
8. Remove the two bolts between muffler and Starter/
Generator bracket using a flat ratchet.
9. Remove the ground strap at the crankcase using the
10 mm socket. Route ground strap through bracket
and under the throttle rod and cover.
10. Remove the bracket holding the pulse line with a 6"
extension and a 10 mm socket. Remove bracket and
unsnap the ignition wire from the harness.
Repair and Service Manual
ENGINE
NOTICE
Page G-9
B
B