DUROMAX XP20HP Service Manual
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DUROMAX XP20HP Service Manual

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XP20HP
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REV: XP20HP_servicemanual_rev01112023
5800 Ontario Mills Pkwy
This manual provides information regarding the
Ontario, CA 91764 USA
operation and maintenance of these products. We
www.duromaxpower.com
have made every effort to ensure the accuracy of the
Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri
information in this manual. We reserve the right to
844-DUROMAX
change this product at any time without prior notice.

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Summary of Contents for DUROMAX XP20HP

  • Page 1 XP20HP REV: XP20HP_servicemanual_rev01112023 5800 Ontario Mills Pkwy This manual provides information regarding the Ontario, CA 91764 USA operation and maintenance of these products. We www.duromaxpower.com have made every effort to ensure the accuracy of the Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri information in this manual.

  • Page 3: Table Of Contents

    CONTENTS Maintenance and Care Maintenance Schedule ....................4 Break-In Period ....................... 5 High Altitude Operation ....................5 Checking the Oil ......................6 Changing the Oil ......................7 Changing the Air Filter ....................8 Spark Plug Maintenance ....................10 Emptying the Gas Tank ....................12 Storing the Engine for Same Day Use ................

  • Page 4: Maintenance And Care

    MAINTENANCE AND CARE Proper routine maintenance of your engine is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. WARNING: Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously injured or killed. Always follow the inspection, maintenance recommendations, and schedules in this instruction manual.

  • Page 5: Break-In Period

    Operation at altitudes below 3,000 feet (900 meters) with a modified carburetor may cause the engine to overheat and result in serious engine damage. Note: Jet kits available for purchase upon request, please contact us at 844-DUROMAX to set up your parts order.

  • Page 6: Checking The Oil

    (see “Adding Oil” portion of the “Maintenance” section). The oil will be visible in the oil fill spout when full. Be sure to replace the cap when finished checking oil. Model Number XP20HP Engine Oil Capacity 40.5 fl. oz (1.2 L)

  • Page 7: Changing The Oil

    Changing the Oil CAUTION: Worn out or dirty oil does not cool the engine properly and can lead to catastrophic engine damage. In addition to regular oil changes, it is necessary to drain the oil from the crankcase if it has become contaminated with water or dirt.

  • Page 8: Changing The Air Filter

    Remove old filter element Remove the wing nut on top of the air filter element and slide filter element off center bolt. This filter is paper and is not reusable. Please call 1-844-DUROMAX to order a replacement filter for your engine.
  • Page 9 Replace new filter element Slide new filter element over center bolt, and replace wing nut. Tighten wing nut hand tight to keep filter in place. Replace filter cover Replace plastic air filter cover over the air filter base. Secure filter cover Fasten the air filter cover with the air filter cover wing nut and tighten about hand tight.

  • Page 10: Spark Plug Maintenance

    MAINTENANCE AND CARE (CONTINUED) Spark Plug Maintenance The spark plug is important for proper engine operation. SPARK PLUG A good spark plug should be intact, free of deposits, and CONSULT MANUAL properly gapped. BEFORE REMOVING CAUTION: Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads.
  • Page 11 Measure plug gap Measure the plug gap with a gauge. The gap should be 0.7-0.8 mm (0.028-0.031 in). Clean and re-gap If you are re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base and then re-gap the spark plug.

  • Page 12: Emptying The Gas Tank

    MAINTENANCE AND CARE (CONTINUED) Emptying the Gas Tank If you have been using gasoline in your engine, before storing your engine for extended periods of time you should drain your engine fuel tank of gasoline. CAUTION: Do not store fuel from one season to another.
  • Page 13 Turn fuel valve ON and drain Turn the fuel valve to “ON” and allow gasoline to drain into the container until the gas tank is empty. Shut fuel valve OFF Once the gasoline is fully drained, move the fuel valve back to the “OFF”...

  • Page 14: Storing The Engine For Same Day Use

    MAINTENANCE AND CARE (CONTINUED) Storing the Engine for Same Day Use Run the engine Allow the engine to run for 3-5 minutes. Turn engine switch to OFF Flip the switch down to the “OFF” position to shut the engine off. Store engine After the engine shuts off and cools, then you can store the engine.

  • Page 15: Storing The Engine For Use Within 30 Days

    Storing the Engine for Use Within 30 Days Run the engine Allow the engine to run for 3-5 minutes. Shut fuel valve OFF and run dry Shut the fuel valve “OFF” and allow engine to run until it stalls out. Turn the engine switch OFF Flip the switch down to the “OFF”...

  • Page 16: Storing The Engine For Longer Than 30 Days

    MAINTENANCE AND CARE (CONTINUED) Storing the Engine for Longer Than 30 Days Run the engine Allow the engine to run for 3-5 minutes. Shut fuel valve OFF and run dry Shut the fuel valve “OFF” and allow engine to run until it stalls out.
  • Page 17 Remove spark plug Remove spark plug as shown in “Spark Plug Maintenance” on page 10. Add oil to cylinder Add 2 tablespoons of 10W-30 motor oil directly into the spark plug hole, and pull the recoil to lubricate cylinder. After lubricating cylinder reinstall the spark plug as shown in “Spark Plug Maintenance”...

  • Page 18: Common Engine Parts

    COMMON ENGINE PARTS Common Engine Parts 1. Crankcase 11310-Z0D0510-0BA0 2. Oil Drain Bolt 11007-Z080110-00A0 3. Oil Protector 37050-Z010210-0000 4. Oil Seal 90682-Z0J0110-00A0 5. Crankcase Cover 11411-Z0D0510-0BA0 6. Crankshaft Bearing 90547-0208-CLAE 7. Bearing 90548-0202-CLA0 8. Oil Fill Cap/Dipstick 15010-Z080130-Q500 9. Crankcase Cover Gasket 11001-Z0D0110-00A0...
  • Page 19 10. Valve Cover 12410-Z0D0210-0BA0 11. Breather Tube 17004-Z0D0410-00A0 12. Valve Cover Gasket 12004-Z0D0211-00A0 13. Muffler/Cylinder Head Gasket 18101-Z0D0110-00A0 14. Spark Plug 30010-Z010210-00A0 15. Cylinder Head Gasket 12131-Z0D0310-00A0 16. Crankshaft Assembly 13300-Z0D0210-CLTM 17. Piston Rings 13200-Z0D0110-00A9 18. Pin Clip 13122-Z100110-00A0 19. Piston 13111-Z0D0211-00A0 20.
  • Page 20 COMMON ENGINE PARTS (CONTINUED) 22. Ignition Coil Assembly 30400-Z190210-0000 23. Charging Coil Assembly 30140-Z160230-0000 24. Camshaft Assembly 14200-Z0D0410-00A0 25. Recoil Assembly 28200-Z710110-BG00 26. Spacer/Cylinder Gasket 17002-Z0D0210-00A0 27. Carburetor Spacer 16003-Z0D0210-00A0 28. Spacer/Carburetor Gasket 16001-Z100110-00A0 29. Carburetor Assembly 16100-Z0D1210-00M0 30. Carburetor/Air Filter Gasket 17001-Z0D0110-00A0 31.
  • Page 21 32. Muffler Gasket 18101-Z0D0210-00A0 33. Manifold 18150-Z0D0610-00A0 34. Muffler/Cylinder Head Gasket 18101-Z0D0110-00A0 35. Governor Spring 16063-Z0D0510-00A0 36. Throttle Return Spring 16012-Z0D0110-00A0 37. Muffler Assembly 18100-Z0D0110-00A0 38. Engine Switch 35540-Z010110-0001 39. Fuel Tank Assembly 16620-Z0D0210-BGA0 40. Fuel Filter 16652-Z010910-00A0 41. Fuel Cap 16730-Z310310-00A0...
  • Page 22 COMMON ENGINE PARTS (CONTINUED) 42. Air Filter Element 17150-Z710110-00A0 43. Air Filter Assembly 17100-Z0D0510-00A0...

  • Page 23: Specifications

    SPECIFICATIONS Displacement 500cc Fuel Type ≥87 octane, ≤10% ethanol, unleaded gasoline Dry Weight 77 lbs Maximum Torque 22.87 ft. lb @ 2500 rpm Compression Ratio 8.5:1 Bore X Stroke 94 mm x 72 mm Engine Oil Capacity 40.5 oz. (1.2 L) Fuel Tank Capacity 1.35 gal.

  • Page 24: Adjustment And Torque Value Specifications

    SPECIFICATIONS (CONTINUED) Adjustment and Torque Value Specifications Adjustment Specification Spark Plug Clearance .027-.031 in. (0.7-0.8 mm) Spark Plug Type F6TC (Torch), BP6ES (NGK), RN9YC (Champion), W7DC (Bosch), W20EP-U (Denso) Valve Clearance (Cold) Intake: .00295 in ± .00098 in (0.075 mm ± 0.025 mm) Exhaust: .00295 in ±...

  • Page 25: Engine Diagrams

    Engine Diagrams 4×3/8-16UNC-2B 6×5/16-24UNF-2B 71.5 71.5 44.8 44.8 Ø146 -0.0063 (Ø165.2) (Ø126.5) 44.6 44.6 2×C2.5 Ø18 58.4 58.4 25° R8.7...
  • Page 26 SPECIFICATIONS (CONTINUED) 89.8 mm R12.7 +0.05 R0.16~R.25 60° 1.5 mm Ø25.4- 6 mm 0.025 28 mm 32 mm 56 mm 72.2 mm 125° 4×R13.5 4×R7 18.5 110° 70° 98.2 2×R6 2×M6-6H 2×Ø7 2×Ø12 15° 136.5 144.5 149.5 2×Ø23...

  • Page 27: Wiring Diagram

    Wiring Diagram...

  • Page 28: Troubleshooting

    TROUBLESHOOTING Mode Description Solution Engine switch is “OFF” Set engine switch to “ON” Fuel valve is “OFF” Turn fuel valve to “ON” Choke is open Close the choke Engine is out of fuel Add fuel Engine will not start Fuel is old or contaminated Change fuel Spark plug is dirty Clean spark plug...

  • Page 29: Maintenance Log

    MAINTENANCE LOG Maintenance Log As a best practice it’s recommended to keep a log of the engine hours and maintenance to ensure your engine is always operating to its full potential. Date Engine Hours Maintenance Performed...
  • Page 30 MAINTENANCE LOG (CONTINUED) Date Engine Hours Maintenance Performed...
  • Page 31 Date Engine Hours Maintenance Performed...
  • Page 32 MAINTENANCE LOG (CONTINUED) Date Engine Hours Maintenance Performed...
  • Page 33 Date Engine Hours Maintenance Performed...
  • Page 34 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX REV: XP20HPE_rev12012022...

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