specs & torques
TRANSCRIPT
SPECS & TORQUES
SPECIFICATIONS & TOLERANCESTORQUE VALUE & SEQUENCES
2
Table of Contents
Standard 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
3
Standard Application Torque RecommendationsTorque values are in N·m. Values in parenthesis ( ) are English equivalents.
Metric Fastener
SizeM4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
Tightening Torque: N•m (ft. lb.) + or – 10%
M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)M14 58.3 (43) 76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
Tightening Torque: N•m (in. lb.) + or – 10%
Oil Drain Plugs (All Models)Size1/8" NPT1/4"3/8"1/2"3/4"X-708-11
NoncriticalFasteners
IntoAluminum
Property Class
Property Class
10.9 12.9
NoncriticalFasteners
IntoAluminum
Into Cast Iron–
17.0 (150 in. lb.)20.3 (180 in. lb.)27.1 (20 ft. lb.)33.9 (25 ft. lb.)
27.1/33.9 (20/25 ft. lb.)
Into Aluminum4.5 (40 in. 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.)
N•m = in. lb. x 0.113N•m = ft. lb. x 1.356in. lb. = N•m x 8.85ft. lb. = N•m x 0.737
TorqueConversions
English FastenerTightening Torque: N•m (in. lb.) + or – 20%Bolts, Screws, Nuts and FastenersAssembled Into Cast Iron or Steel
Grade 2 Grade 5 Grade 8
Grade 2 or 5Fasteners Into
Aluminum
Size8-32 2.3 (20) 2.8 (25) --------- 2.3 (20)10-24 3.6 (32) 4.5 (40) --------- 3.6 (32)10-32 3.6 (32) 4.5 (40) --------- ---------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) ---------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) --------- --------- ---------
Size5/16-24 --------- ---------- 40.7 (30) ---------3/8-16 --------- 47.5 (35) 67.8 (50) ---------3/8-24 --------- 54.2 (40) 81.4 (60) ---------7/16-14 47.5 (35) 74.6 (55) 108.5 (80) ---------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) ---------9/16-18 135.6 (100) 223.7 (165) 311.9 (230) ---------5/8-11 149.2 (110) 244.1 (180) 352.6 (260) ---------5/8-18 189.8 (140) 311.9 (230) 447.5 (330) ---------3/4-10 199.3 (150) 332.2 (245) 474.6 (350) ---------3/4-16 271.2 (200) 440.7 (325) 637.3 (470) ---------
Tightening Torque: N•m (ft. lb.) + or – 20%
13/8-16 thread with hex. head nut and fiber gasket.
5.8 8.84.8
4.8 5.8 8.8 10.9 12.9
4
K-Series–Single Cylinder Engine Specifications & TolerancesAll dimensions in inches.
Model (Horsepower) K91 (4) K161 (7) K181 (8) K241 (10) K301 (12) K321 (14) K341 (16)Bore x StrokeDisplacement Cu. In.Max. Operating RPM
General
NewMax. Wear Limit
Shaft O.D.
End PlayCamshaft End Play
Rod to Crankpin(New)Rod to CrankpinWear LimitRod to Piston Pin(New)
RunningClearance
Small End I.D. (New)
ConnectingRod
Crankshaft
Main PTO &FlywheelEnd O.D.CRANKPIN
2.375 x 2.0008.864000
–––
0.001/0.0025
0.003
0.005/0.020
0.5630/0.56330.0007/0.0008
Max. Wear Limit 0.9841
New 0.9841/0.9844
Max. Taper 0.001
0.9350Max. Wear Limit
0.9360/0.9355New
Max. Out of Round
0.004/0.023End PlayNewMax. Wear Limit
InsideDiameterMax. Out of RoundMax. Taper
CylinderBore
CylinderHead Max. Out of Flatness
Type (Champion® orequivalent)
2.3755/2.37452.3780.0030.003
0.003
RCJ-8
2.938 x 2.50016.943600
–––
0.001/0.002
0.0025
0.005/0.010
0.6255/0.62580.0006/0.0011
1.1811
1.1811/1.1814
0.001
1.1850
1.1860/1.1855
0.002/0.0232.9380/2.9370
2.9410.0030.003
0.003
RCJ-8
0.00050.0005
2.938 x 2.75018.643600
–––
0.001/0.002
0.0025
0.005/0.010
0.6255/0.62580.0006/0.0011
1.1811
1.1811/1.1814
0.001
1.1850
1.1860/1.1855
0.002/0.0232.9380/2.9370
2.9410.0030.003
0.003
RCJ-8
3.251 x 2.87523.853600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8596/0.85990.0003/0.0008
1.5745
1.5745/1.5749
0.001
1.4990
1.5000/1.4995
0.003/0.0203.2515/3.2505
3.2540.0030.002
0.003
RH-10
0.00050.0005
3.375 x 3.25029.073600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8757/0.87600.0003/0.0008
1.5745
1.5745/1.5749
0.001
1.4990
1.5000/1.4995
0.003/0.0203.3755/3.3745
3.3780.0030.002
0.003
RH-10
3.500 x 3.25031.273600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8757/0.87600.0003/0.0008
1.5745
1.5745/1.5749
0.001
1.4990
1.5000/1.4995
0.003/0.0203.5005/3.4995
3.5030.0030.002
0.003
RH-10
0.00050.0005
3.750 x 3.25035.903600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8757/0.87600.0003/0.0008
0.001
1.4990
0.003/0.0203.7505/3.7495
3.7530.0030.002
0.003
RH-10
0.0005
1.5745/1.5749
1.5745
1.5000/1.4995
BalanceGear
MagnetoGaseous Fuels
Battery
Nominal Point Gap
Ignition Spark PlugType & Gap 0.025
0.0250.0180.020
0.0250.0250.0180.020
0.0250.0250.0180.020
0.0350.0250.0180.020
0.0350.0250.0180.020
0.0350.0250.0180.020
0.0350.0250.0180.020
5
Model (Horsepower) K91 (4) K161 (7) K181 (8) K241 (10) K301 (12) K321 (14) K341 (16)Service Replacement Sizes
2.371/2.3692.366
2.9297/2.92812.925
2.9297/2.92812.925
0.003 – 0.010 – 0.020 – 0.0303.2432/3.2413
3.2383.368/3.365
3.3633.4941/3.4925
3.4913.7425/3.7410
3.738ThrustFace O.D.2 Max. Wear Limits
New
Thrust Face to Bore Clearance(New)1
0.007/0.0170.027
0.007/0.0170.027
0.007/0.0170.027
0.010/0.0200.030
0.010/0.0200.030
0.010/0.0200.030
0.010/0.0200.030
Ring EndGap
New BoreUsed Bore (Max.)
0.006 0.006 0.006 0.006 0.006 0.006 0.006Max. Ring Side Clearance
0.0035/0.006 0.007/0.010 0.007/0.010 0.007/0.010 0.007/0.010 0.007/0.010 0.007/0.010
Piston
All Pistons
NewMax. Wear Limits
Thrust FaceO.D.4
Thrust Face to Bore Clearance(New)1
– – – – – –3.744
3.7465/3.7455
– – – – – – 0.0030/0.0050
2
– – – – – –
– – – 0.010/0.020– – – 0.030– – – 0.004
New Bore5Ring EndGap Used Bore (Max.)5
Max. Ring Side ClearanceNewMax. Wear Limits
Thrust FaceO.D.4
Thrust Face to Bore Clearance(New)1
––
––
2.9312.9329/2.9336
3.3673.3700/3.3693
3.4923.4945/3.4938
3.74063.7433/3.7426
– – 0.0034/0.0051 0.0045/0.0062 0.0050/0.0067 0.0062/0.0079
– – 0.010/0.023 – 0.010/0.020 0.010/0.020 0.013/0.025– – 0.032 – 0.030 0.030 0.033
0.6247/0.62490.5623/0.5625 0.8591/0.85930.6247/0.6249 0.8752/0.87540.8752/0.8754 0.8752/0.87540.250 0.3125 0.3125 0.3125 0.3125 0.3125 0.3125
0.005/0.009 0.006/0.008 0.006/0.008 0.008/0.010 0.008/0.010 0.008/0.010 0.008/0.010 3
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
0.2035 0.2718 0.2718 0.318 0.318 0.318 0.318
0.1768 0.2482 0.2482 0.318 0.318 0.318 0.318
0.2478 0.3103 0.3103 0.3103 0.3103 0.3103 0.3103
0.2458 0.3088 0.3088 0.3074 0.3074 0.3074 0.307445° 45° 45° 45° 45° 45° 45°
0.005 0.005 0.005 0.006 0.006 0.006 0.006
0.008 0.008 0.008 0.008
– – 0.006 – 0.006 0.006 0.004
New Bore5Ring EndGap Used Bore (Max.)5
Guide Reamer SizeTappetClearance(Cold)
Intake
ExhaustMinimumLift(Zero Lash)
Intake
ExhaustMinimumValve StemO.D.
Intake
ExhaustNominal Angle Valve SeatGuide I.D.Max. WearLimit1
Intake
Exhaust
Outside Diameter
0.007 0.007 0.007
Max. Ring Side ClearancePiston Pin
Valves
1Subtract O.D. of inner part from I.D. of outer part.2Measure just below oil ring groove and at right angles to piston pin.31800 RPM generator sets .005/.007.
4Measure 1/2" above the bottom of the piston skirt.5Top and center compression rings.
Piston
4 1/2"
4 1/2"
Piston
–––
––
–
––
–
–––
6
K-Series–Twin Cylinder Engine Specifications & TolerancesAll dimensions in inches.
Model (Horsepower) KT17 (17) KT19 (19) K582 (23)Bore x StrokeDisplacement Cu. In.Max. Operating RPM
General
End Play
3.125 x 2.75042.183600
0.003/0.0130.0012/0.0024
3.125 x 3.06347.03600
0.003/0.0130.0012/0.0024
3.500 x 3.00057.733600
Rear 1.251/1.252Front 1.876/1.877
0.003/0.0240.001/0.002
CamshaftSleeve I.D. Installed – –
Rod to Crankpin (New)Rod to Crankpin Wear LimitRod to Piston Pin (New)
RunningClearanceConnecting
Rod
SleeveBearingJournal
0.00290.0006/0.0011
0.00290.0006/0.0011
0.00250.0003/0.0008
Small End I.D. (New) 0.6255/0.6258 0.7507/0.7510 0.8757/0.8760
1.7412/1.7422
1.7407
1.7412/1.7422
1.7407
1.7495/1.7500
1.7490
Max. Out of Round (Sleeve)Max. Taper (Sleeve)RunningClearance(Sleeve) Wear Limit¹
New (Max.)
New Sleeve Bearing I.D. InstalledCRANKPIN Max. Taper
Max. Wear Limit
New
Max. Out of Round
End PlayNewMax. Wear Limit
InsideDiameterMax. Out of RoundMax. Taper
CylinderBore
CylinderHead Max. Out of Flatness
0.0005 0.0005 0.00050.001 0.001 0.001
0.0049 0.0049 0.004
0.0059 0.0059 0.0051.7439/1.7461 1.7439/1.7461 1.7515/1.7535
1.3738/1.3733 1.4998/1.4993 2 1.6250/1.6245
1.3728 1.4988 2 1.6240
0.0005 0.0005 0.0005
0.001 0.001 0.0010.002/0.014 0.002/0.014 0.004/0.010
3.1255/3.12453.1280.002
0.0015
0.003
3.1255/3.1245 3.5005/3.49953.1280.002
0.0015
3.5030.0050.002
0.003 0.003
Ball/RollerBearingJournal
–
–
–
–
1.7716/1.7721
1.7711
Wear Limit
New
New
Wear Limit
Crankshaft
MAIN
7
Model (Horsepower) KT17 (17) KT19 (19) K582 (23)Type (Champion® or equivalent)Battery
RY17YC RV17YC RH-10
Gaseous FuelsNominal Point Gap
0.025 0.025 0.025
0.020 0.020 0.0200.018 0.018 0.018
Spark PlugType & Gap
Service Replacement Sizes3.118/3.117
3.113
0.003 – 0.010 – 0.020 – 0.0303.121/3.120
3.1133.4941/3.4925
3.491Thrust Face to Bore Clearance (New)1
Max. Wear LimitsNewThrust Face O.D.3
0.010/0.0200.030
0.010/0.0200.030
0.010/0.0200.030
0.004 0.004 0.006Max. Ring Side ClearanceService Replacement Sizes
Thrust Face to Bore Clearance (New)1,4
3.1183.1210/3.1203
3.1193.1215/3.1208
––
0.0065/0.0085 0.0035/0.0055 0.007/0.010
0.003 – 0.010 – 0.020 – 0.030
0.010/0.020 0.010/0.023 –0.032 0.032 –
Guide Reamer SizeTappetClearance(Cold)
Intake
ExhaustMinimumLift(Zero Lash)
Intake
ExhaustMinimumValve StemO.D.
Intake
ExhaustNominal Angle Valve SeatGuide I.D.Max. WearLimit1
Intake
Exhaust
Outside Diameter 0.6247/0.6249 0.7499/0.7501 0.8752/0.87540.3125 0.3125 0.3125
0.003/0.006 0.003/0.006 0.008/0.010
0.011/0.014 0.011/0.014 0.017/0.020
0.280 0.280 0.318
0.280 0.280 0.318
0.3103 0.3103 0.3103
0.3088 0.3088 0.307445° 45° 45°
0.005 0.005 0.006
0.007 0.007 0.008
Max. Ring Side Clearance 0.006 0.006 –
0.0035/0.0052 0.0030/0.0047 –
New BoreUsed Bore (Max.)
NewMax. Wear Limits
New Bore5
Used Bore (Max.)5Ring End Gap
Thrust Face O.D.4
Ring End GapPiston
3
Piston Pin
Valves
Ignition
Piston
4 1/2"
1Subtract O.D. of inner part from I.D. of outer part.2Pre Series II 1.3733/1.3738, Maximum Wear 1.3728.3Measure just below oil ring groove and at right angles to piston pin.
4Measure 1/2" above the bottom of the piston skirt.5Top and center compression rings.
8
K-Series–Single Cylinder Torque Values & Sequences for FastenersModel (Horsepower)
FlywheelRetaining5
Nut1
Screw1
GrassScreen
MetalPlastic
K91 (4)
18-22 ft. lbs.
40-50 ft. lbs.250 in. lbs.
70-90 in. lbs.––
K161 (7) K181 (8) K241 (10)New 140 in. lbs.Used 100 in. lbs.
18-22 ft. lbs.
85-90 ft. lbs. 4
–130-150 in. lbs.70-140 in. lbs.
–
New 260 in. lbs.Used 200 in. lbs.
285 in. lbs.18-22 ft. lbs.
50-60 ft. lbs.22-27 ft. lbs.
100-120 in. lbs.70-140 in. lbs.20-30 in. lbs.
K301 (12) K321 (14) K341 (16)
Cylinder Head1 K91200 in. lbs.
1 3
524
6 17
53
4
62
K161 & K18115-20 ft. lbs.
187
35 2
69
4
10K34125-30 ft. lbs.
ConnectingRods1
Spark Plugs
Governor Bushing
Sheet Metal1
250 in. lbs.– –
Grade 5-250 in. lbs.Grade 8-350 in. lbs. 35 ft. lbs.
200 in. lbs.Non Metallic Fuel Pump
Mounting Screws – 37-45 in. lbs. 37-45 in. lbs.1Lubricate fastener threads with engine oil.2DO NOT overtorque – DO NOT loosen and retorque the hex. nuts on Posi-Lock connecting rods.
NEW – Component directly from stock.USED – Component that was in a running engine.
Oil Pan
Posi-Lock1,2
Capscrew1,3
–
140 in. lbs.
–
200 in. lbs.
87
K241,K301, K32125-30 ft. lbs.
14
9
6253
Cast Iron1
3Overtorque 20%, loosen below torque value and retorque to final torque value.4Prior to Serial No. 23209832 – 45-55 ft. lbs.5Flywheel and crankshaft tapers must be clean and dry.
9
K-Series–Twin Cylinder Torque Values & Sequences for FastenersModel (Horsepower)
FlywheelRetaining
NutScrew1
KT17 (17)
10-15 ft. lbs.
–40 ft. lbs.
GrassScreen
MetalPlasticAluminum1
Cast Iron1
70-140 in. lbs.20-30 in. lbs.
–
Manifold Screw/NutCamshaft Nut
Non Metallic Fuel PumpMounting Screws
150 in. lbs.–
–
K582 (23)KT19 (19)New 140 in. lbs.Used 100 in. lbs. –
5/16-200 in. lbs.3/8-300 in. lbs.18-22 ft. lbs.
37-45 in. lbs.
115 ft. lbs.–
70-140 in. lbs.–
30 ft. lbs.35 ft. lbs.
210 in. lbs.40 ft. lbs.
37-45 in. lbs.
K582
KT17 & KT19
Gear Cover
Install two shoulder capscrews (1/2"thread depth) in second and thirdholes as indicated. Tighten to 150 in.lbs. – then install other capscrews andtorque to 150 in. lbs.
Closure Plate
30 ft. lbs.
23
3
2
1
4
17
3
8
94
625
KT17 & KT1915-20 ft. lbs.
9
83
4 1 57
62
K58235 ft. lbs.
*Use a gasket or sealant asnecessary: When reinstalling aclosure plate or cylinder barrelsoriginally installed with a gasket,use a new gasket. When reinstallinga closure plate or cylinder barrelsoriginally installed with sealant, usenew sealant. When installing aservice replacement closure plateor cylinder barrels, use newsealant.
Sealant*Sealant*
5 6
1 2
3 4
Apply sealant to crankcase.*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)
Cylinder Barrel
Oil Gallery Plug65-80 in. lbs.
Sealant*
53
1
6
89
4
2
7
ConnectingRods1
200 in. lbs.Spark Plugs
Cylinder Head1
Oil Pan
Posi-Lock1,2
Capscrew1,3
Crankcase
Closure Plate150 in. lbs.
#2 Side CrankcaseHalf Interior#2 Side Crankcase
Half Exterior
Oil Passage(In #1Half)
Sealant
SealantSealant
Sealant
TorqueBolt No.1-45-6 200 in. lbs.
Torque remainingbolts in most
expedient sequence to
260 in. lbs.TorqueBolt No.
1, 2, 3, 4,(12, 14 Grade 8)
5-11, 13, 15 150 in. lbs.35 in. lbs.16
260 in. lbs.
1
2564
3
KT17 SerialNo. 9755085& later –and KT19
200 in. lbs.
145
10 1216
1 3
8
2 413 156
7 9 11
KT17 Priorto Serial No.9755085
10
Magnum–Single Cylinder Engine Specifications & TolerancesAll dimensions in inches.
Model (Horsepower) M10 (10) M12 (12) M16 (16)Bore x StrokeDisplacement Cu. In.Max. Operating RPM
General
NewMax. Wear Limit
Shaft O.D.
End PlayCamshaft End Play
Rod to Crankpin(New)Rod to Crankpin –Max. Wear LimitRod to Piston Pin(New)
RunningClearance
Small End I.D. (New)
Crankshaft
Main PTO &FlywheelEnd O.D.CRANKPIN
Max. Wear Limit
New
Max. Taper
Max. Wear Limit
New – O.D.
Max. Out of Round
End PlayNewMax. Wear Limit
InsideDiameterMax. Out of Round (I.D.)Max. Taper (I.D.)
CylinderBore
CylinderHead Max. Out of Flatness
Type (Champion® orequivalent)
3.25 x 2.8823.853600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8596/0.85990.0003/0.0008
1.5745
1.5745/1.5749
0.001
1.4990
1.5000/1.4995
0.003/0.0203.2515/3.2505
3.2540.0050.002
0.003
RH-10
3.38 x 3.2529.073600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8757/0.87600.0003/0.0008
1.5745
1.5745/1.5749
0.001
1.4990
1.5000/1.4995
0.003/0.0203.3755/3.3745
3.3780.0050.002
0.003
RH-10
0.00050.0005
3.750 x 3.2535.903600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8757/0.87600.0003/0.0008
0.001
1.4990
0.003/0.0203.7505/3.7495
3.7530.0050.002
0.003
RH-10
0.0005
1.5745/1.5749
1.5745
1.5000/1.4995
BalanceGear
M8 (8)2.94 x 2.75
18.643600
–––
0.001/0.002
0.0025
0.005/0.010
0.6255/0.62580.0006/0.0011
1.1811
1.1811/1.1814
0.001
1.1850
1.1860/1.1855
0.002/0.0232.9380/2.9370
2.9410.0050.003
0.003
RCJ-8
0.0005
M14 (14)3.500 x 3.25
31.273600
0.4998/0.50010.4996
0.002/0.010
0.001/0.002
0.0025
0.005/0.010
0.8757/0.87600.0003/0.0008
1.5745
1.5745/1.5749
0.001
1.4990
1.5000/1.4995
0.003/0.0203.5005/3.4995
3.5030.0050.002
0.003
RH-10
0.0005
ConnectingRod
Gap 0.0250.012/0.016
0.0250.012/0.016
0.0250.012/0.016
0.0250.012/0.016
0.0250.012/0.016
Spark Plug
Module Air GapIgnition
11
Model (Horsepower) M10 (10) M12 (12) M16 (16)Service Replacement Sizes
3.2432/3.24133.238
0.003 – 0.010 – 0.020 – 0.0303.368/3.365
3.363––
ThrustFace O.D.2 Max. Wear Limits
New
Thrust Face to Bore Clearance(New)1
0.010/0.0200.030
0.010/0.0200.030
––
Ring EndGap
New BoreUsed Bore (Max.)
0.006 0.006 –Max. Ring Side Clearance
0.007/0.010 0.007/0.010 –
2.9297/2.92812.925
0.007/0.0170.0270.006
0.007/0.010
M8 (8)
3.4941/3.49253.491
0.010/0.0200.0300.006
0.007/0.010
M14 (14)All Pistons
NewMax. Wear Limits
Thrust FaceO.D.3
Thrust Face to Bore Clearance(New)1
––
––
3.74353.7465/3.7455
– – 0.0030/0.0050
––
–
––
–
Piston
NewMax. Wear Limits
Thrust FaceO.D.3
Thrust Face to Bore Clearance(New)1
––
3.36733.3700/3.3693
3.74063.7433/3.7426
– 0.0045/0.0062 0.0062/0.0079
2.93122.9329/2.9336
0.0034/0.0051
3.49183.4945/3.4938
0.0050/0.0067
Ring EndGap
New Bore4
Used Bore (Max.)4
– 0.010/0.020 0.013/0.025– 0.030 0.033
Guide Reamer SizeTappetClearance(Cold)
Intake
ExhaustMinimumLift(Zero Lash)
Intake
ExhaustMinimumValve StemO.D.
Intake
ExhaustNominal Angle Valve SeatGuide I.D.Max. WearLimit1
Intake
Outside Diameter 0.8752/0.87540.8591/0.8593 0.8752/0.87540.3125 0.3125 0.3125
0.0080/.010 0.008/0.010 0.008/0.010
0.017/0.019 0.017/0.019 0.017/0.019
0.318 0.318 0.318
0.318 0.318 0.318
0.3103 0.3103 0.3103
0.3074 0.3074 0.307445° 45° 45°
0.006 0.006 0.006
Max. Ring Side Clearance – 0.006 0.004
0.010/0.0230.032
0.6247/0.62490.3125
0.006/0.008
0.017/0.019
0.2718
0.2482
0.3103
0.307445°
0.006
0.006
0.008Exhaust 0.008 0.008 0.008
0.010/0.0200.030
0.8752/0.87540.3125
0.008/0.010
0.017/0.019
0.318
0.318
0.3103
0.307445°
0.006
0.006
0.008
Valves
Piston Pin
1Subtract O.D. of inner part from I.D. of outer part.2Measure just below oil ring and at right angles to piston pin.
Ring EndGap
New Bore4
Used Bore (Max.)4
– 0.010/0.020– 0.030
Max. Ring Side Clearance – 0.004
Piston
Piston
3Measure 1/2" above the bottom of the piston skirt.4Top and center compression rings.
3 1/2"
3 1/2"
2
–––
––
––
– –
12
Magnum–Twin Cylinder Engine Specifications & TolerancesAll dimensions in inches.
Model (Horsepower) MV16 (16) M18 & MV18 (18) M20 & MV20 (20)Bore x StrokeDisplacement Cu. In.Max. Operating RPM
General3.125 x 2.750
42.183600
3.125 x 2.75042.183600
3.125 x 3.06246.983600
End Play 0.003/0.0130.0012/0.0024
0.003/0.0130.0012/0.0024
0.003/0.0130.0012/0.0024Rod to Crankpin (New)
Rod to Crankpin Wear LimitRod to Piston Pin (New)
RunningClearanceConnecting
Rod
PTO &FlywheelEnd O.D.
0.00290.0006/0.0011
0.00290.0006/0.0011
0.00290.0006/0.0011
Small End I.D. (New) 0.6255/0.6258 0.6255/0.6258 0.7507/0.7510
Max. Wear Limit
New
Max. Out of Round (Sleeve)Max. Taper (Sleeve)RunningClearance(Sleeve) Wear Limit¹
Max. New
New Sleeve Bearing I.D. InstalledCRANKPIN Max. Taper
Max. Wear Limit
New
Max. Out of Round
End PlayNewMax. Wear Limit
InsideDiameterMax. Out of RoundMax. Taper
CylinderBore
CylinderHead Max. Out of Flatness
Type (Champion® or equivalent)Gap
1.7412/1.7422
1.74070.0005
1.7412/1.7422
1.74070.0005
1.7412/1.7422
1.74070.0005
0.001 0.001 0.001
0.0049 0.0049 0.0049
0.0059 0.0059 0.00591.7439/1.7461 1.7439/1.7461 1.7439/1.7461
1.3738/1.3733 1.3738/1.3733 1.4998/1.4993
1.3728 1.3728 1.4988
0.0005 0.0005 0.0005
0.001 0.001 0.0010.002/0.014 0.002/0.014 0.002/0.014
Crankshaft
3.1255/3.12453.1280.0020.0015
RV17C
0.003
3.1255/3.1245 3.1255/3.12453.1280.0020.0015
3.1280.0020.0015
0.003 0.003
RV17C RV17C0.035 0.035 0.035
0.008/0.012 0.008/0.012 0.008/0.012
Camshaft
Spark Plug
Module Air Gap
Ignition
MAIN
13
Model (Horsepower) MV16 (16) M18 & MV18 (18) M20 & MV20 (20)Service Replacement Sizes
3.1210/3.12033.1181
0.003 – 0.010 – 0.020 – 0.0303.1210/3.1203
3.11813.1215/3.1208
3.1186Thrust Face to Bore Clearance (New)1
Max. Wear LimitsNewThrust Face O.D.2
0.010/0.0230.032
0.010/0.0230.032
0.010/0.0230.032
0.006 0.006 0.006Max. Ring Side Clearance
0.0035/0.0052 0.0035/0.0052 0.0030/0.0047New Bore3
Used Bore (Max.)3Ring End Gap
Guide Reamer Size
Intake
Outside Diameter 0.6247/0.6249 0.6247/0.6249 0.7499/0.75010.3125 0.3125 0.3125
0.003/0.006 0.003/0.006 0.003/0.006
Piston Pin
Before SerialNo. 181600646Serial No. 18100656 to1917809296After SerialNo. 1917809296
MinimumLift(Zero Lash)
Intake
ExhaustMinimumValve StemO.D.
Intake
ExhaustNominalAngle –Valve Seat
0.274 0.274 0.274
0.274 0.274 0.274
0.3103 0.3103 0.3103
0.3088 0.3088 0.3088
Exhaust
TappetClearance(Cold)
0.016/0.019
0.011/0.014
0.013/0.016
0.016/0.019
0.011/0.014
0.013/0.016
0.016/0.019
0.011/0.014
0.013/0.016
Guide I.D.Max. WearLimit1
Intake
Exhaust
0.005 0.005 0.005
0.007 0.007 0.0071Subtract 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.
Serial No. 1816500646 & earlier
Serial No. 181650056 & later
Valves
45° 45° 45°
30° 30° 30°
Piston
2 1/2"
14
Magnum–Single Cylinder Torque Values & Sequences for FastenersModel (Horsepower)
ConnectingRods1,2
Nut1
Fan
M8 (8) M10 (10)260 in. lbs.
M12 (12) M14 (14) M16 (16)NewUsed
Spark Plugs
Cylinder Head1
Screw1
Anti-LockBushing
Governor
Non Metallic Fuel PumpMounting ScrewsIgnition ModuleCam Gear CoverKey Switch Nut
Bracket3
Mounting
Isolation MountFuel Tank
Remote4
LocalSpeed ControlWing/Hex. Nut
1Lubricate fastener threads with engine oil.2DO NOT overtorque – DO NOT loosen and retorque the hex. nuts on Posi-Lock connecting rods.
NEW – Component directly from stock.USED – Component that was in a running engine.
140 in. lbs.100 in. lbs.
18-22 ft. lbs.200 in. lbs.
18-22 ft. lbs.
–85-90 ft. lbs.115 in. lbs.15 in. lbs.
100-120 in. lbs.
37-45 in. lbs.32 in. lbs.
––
Hand Tight (2-12 in. lbs.)150 in. lbs.90 in. lbs.
10-15 in. lbs.15-25 in. lbs.
35-40 ft. lbs.–
––
10-15 in. lbs.15-25 in. lbs.
115 in. lbs.–
100-120 in. lbs.
37-45 in. lbs.32 in. lbs.115 in. lbs.
90-100 in. lbs.Hand Tight (2-12 in. lbs.)
7 1 4
35 2 6
M815-20 ft. lbs.
78
14
9
6253
M10,M12,M1425-30 ft. lbs.
78 1 4
9
6253
10M1625-30 ft. lbs.
Flywheel5
3To cylinder head, electric start side.4Torque, then loosen 1/2 turn.5Flywheel and crankshaft tapers must be clean and dry.
15
Magnum–Twin Cylinder Torque Values & Sequences for FastenersModel (Horsepower)Connecting
Rods1,2
MV16 (16) M18 & MV18 (18) Twin Cylinder EnginesM20 & MV20 (20)NewUsed
Spark Plugs
Screw1
140 in. lbs.100 in. lbs.
10-15 ft. lbs.
40 ft. lbs.
17
3
8
94
625
All Models15-20 ft. lbs.
Crankcase (All)
Cylinder Head1
FanManifold Screw/Nut
Non Metallic Fuel PumpMounting ScrewsIgnition Module
Oil FilterLinesOil LineFlared Nuts
Adapter Fittings
115 in. lbs.150 in. lbs.
37-45 in. lbs.32 in. lbs.
Snug Plus 1/2 Turn (50/80 in. lbs.)65-80 in. lbs.
90-130 in. lbs.125 in. lbs.
100-120 in. lbs.Adapter
125 in. lbs.
Flywheel5
Cover Plate
RemoteOil Filter
5 6
Oil Gallery Plug65-80 in. lbs.
Sealant*
53
1
6
89
4
2
7
*Use a gasket or sealant asnecessary: When reinstalling aclosure plate or cylinder barrelsoriginally installed with a gasket,use a new gasket. When reinstallinga closure plate or cylinder barrelsoriginally installed with sealant, usenew sealant. When installing aservice replacement closure plateor cylinder barrels, use newsealant.
Closure Plate (M18 & M20)150 in. lbs.
#2 Side CrankcaseHalf Interior#2 Side Crankcase
Half Exterior
Oil Passage(In #1Half)
Sealant
SealantSealant
Sealant
1
256
4
3 5-6 200 in. lbs.
TorqueBolt No.1-4
Torque remainingbolts in most
expedient sequence to
260 in. lbs.
200 in. lbs.
Cylinder Barrel (All)Oil Pan (MV16, MV18, MV20)150 in. lbs.
Sealant*Sealant*1 2
3 4
Apply sealant to crankcase.*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)
5 3Oil Pan
1Sealant*
6
89
7
2
4
NOTE: Do not use gasket on MV oilpans.
16
Command–Single Cylinder Engine Specifications & TolerancesAll dimensions in millimeters (inches).
Model (Horsepower) CH5 (5) CH6 (6)Kilowatt (kW) Output (@ 3600 RPM – net rating per SAE J1349)Horsepower (@ 3600 RPM – net rating per SAE J1349)Bore
3.735.0
67 (2.64)
4.47*6.0*
180 cm³ (10.98 in.³)DisplacementStroke
General51 (2.01)
Camshaft
End Play (With Shims)
In Closure Plate
0.15/0.55 (0.005/0.0217)16.030 (0.6311)25.430 (1.001)
Bore I.D. Max. Wear Limit
Crankcase EndClosure Plate End
15.954 (0.6281)25.350 (0.9980)
Camshaft Bearing SurfaceO.D. – Max. Wear LimitConnecting Rod to Crankpin Running Clearance – NewConnecting Rod to Crankpin Running Clearance – Max. Wear Limit
ConnectingRod
End Play (Free)
0.030/0.056 (0.0012/0.0022)0.0635 (0.0025)
0.000/0.056 (0.000/0.0022)
In Crankcase
Crankshaft Bore to Crankshaft Running Clearance – New (Sleeve Bearing)Crankshaft Bore to Crankshaft Running Clearance – Max. Wear Limit
O.D. – Max. Wear LimitMax. Taper
Flywheel End Main BearingJournal
Max. Out of RoundO.D. – NewO.D. – Max. Wear LimitMax. Taper
PTO End MainBearing Journal
Max. Out of RoundO.D. – NewO.D. – Max. Wear LimitMax. Taper
––––––
0.02/0.09 (0.0008/0.0036)0.115 (0.0046)
30.000/30.008 (1.20/1.2003)29.95 (1.198)0.020 (0.0008)0.025 (0.0010)
– 29.971/29.980 (1.988/1.992)29.93 (1.1972)–
–0.025 (0.0010)–
30.947/30.960 (1.2184/1.2189)30.934 (1.2179)0.025 (0.0010)0.013 (0.0005)
0.020 (0.0008)
O.D. – New
Max. Wear LimitMax. Out of RoundMax. Taper
Max. Out of Flatness
Cylinder Bore I.D.
67.00/67.03 (2.6378/2.6390)67.049 (2.6397)0.150 (0.0059)0.100 (0.0039)
0.076 (0.003)
Max. Out of RoundNew
Cylinder HeadGovernor Cross Shaft O.D. – Max. Wear LimitGovernor Gear Shaft O.D. – Max. Wear LimitGovernor Cross Shaft Bore (In Crankcase) I.D. – Max. Wear Limit
6.296 (0.2479)
6.425 (0.2530)
Governor 9.960 (0.3921)
Crankshaft
Cylinder Bore
Connecting Rod Journal
17
Model (Horsepower) CH5 (5) CH6 (6)Spark Plug Type (Champion® or equivalent)Spark Plug GapIgnition Module Air GapTop Compression Ring to Groove Side ClearanceMiddle Compression Ring to Groove Side ClearanceOil Control Ring to Groove Side Clearance
New BoreUsed Bore (Max.)
Piston Ring End Gap
RC12YC1.02 (0.040)
0.203/0.305 (0.008/0.012)0.040/0.085 (0.0016/0.033)
0.040/0.072 (0.0016/0.0028)0.140/0.275 (0.0055/0.0108)
0.25/0.45 (0.010/0.018)0.75 (0.030)
Ignition
O.D. – NewO.D. – Max. Wear LimitNew – Running Clearance
66.941/66.959 (2.635/2.636)66.816 (2.630)
0.016/0.059 (0.0006/0.0023)Intake Valve to Tappet Cold ClearanceExhaust Valve to Tappet Cold Clearance
I.D. – Std.I.D. – Max. Wear Limit
Intake Valve Guide
I.D. – Std.I.D. – Max. Wear Limit
Exhaust Valve Guide
Intake Valve Minimum LiftExhaust Valve Minimum Lift
0.000/0.0508 (0.000/0.0020)0.000/0.508 (0.000/0.0020)
4.990/5.010 (0.1965/0.1972)5.085 (0.2002)
4.990/5.010 (0.1965/0.1972)5.080 (0.2000)
5.4 (0.213)5.4 (0.213)
45°Nominal Valve Seat Angle* @ 4000 RPM (Gross rating per SAE J1995).1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
Valves andValve Lifters
Piston Thrust Face¹ (@D1)to Cylinder Bore
Pistons,Piston Rings,
andPiston Pin
1 D1
6 mm
18
Command–Single Cylinder Engine Specifications & TolerancesAll dimensions in millimeters (inches).
Kilowatt (kW) Output (@ 3600 RPM – SAE J1995)Horsepower (@ 3600 RPM – SAE J1995)
Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)Balance Shaft Bearing Surface O.D. Max. Wear Limit
0.0575/0.3625 (0.0023/0.0143)20.038 (0.7889)19.959 (0.7858)
DisplacementEnd Play (Free)Balance
ShaftBearing
End PlayIn Crankcase
With Shims – 0.076/0.127 (0.003/0.005) Without Shims – 0.10/0.39 (0.004/0.015)20.038 (0.7889)
Bore
Crankcase End20.038 (0.7889)19.959 (0.7858)Camshaft Bearing Surface
O.D. – Max. Wear Limit Oil Pan End
Max. Wear LimitConnecting
RodEnd Play (Free)Crankshaft Sleeve Bearing I.D. – Max. Wear Limit
Max. Wear Limit
O.D. – Max. Wear LimitMax. Taper
Flywheel End Main BearingJournal
Max. Out of RoundO.D. – NewO.D. – Max. Wear LimitMax. Taper
PTO End MainBearing Journal
Max. Out of RoundO.D. – NewO.D. – Max. Wear LimitMax. TaperMax. Out of Round
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)
45.016 (1.7723)
CrankshaftO.D. – New
Max. Wear LimitNewCrankshaft Bore to Crankshaft
Running Clearance
I.D. – New Installed
NewConnecting Rod to CrankpinRunning Clearance
44.965/45.003 (1.7703/1.7718)
45.016 (1.7723)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)
38.958/38.970 (1.5338/1.5343)38.94 (1.5328)0.012 (0.0005)0.025 (0.0010)
44.913/44.935 (1.7582/1.7691)0.115 (0.0045)
0.03/0.09 (0.0012/0.0035)
Camshaft In Oil Pan
Stroke87 (3.43)
398 cm³ (24.3 in.³)
Model (Horsepower)
67 (2.64)General
Bore I.D. Max. Wear Limit
Connecting Rod Journal
10.5014
Crankshaft PTO Bearing
9.3312.5
8.2011
CH & CV12.5 (12.5)CH & CV11 (11) CH & CV13 (13) CH & CV14 (14)
139.75
19
Model (Horsepower)NewMax. Wear LimitMax. Out of RoundMax. Taper
Max. Out of FlatnessCylinder HeadGovernor Cross Shaft O.D. – Max. Wear Limit
Governor Cross Shaft Bore (In Crankcase)I.D. – Max. Wear Limit
0.12 (0.0047)0.05 (0.0020)
0.076 (0.003)5.962 (0.2347)
Spark Plug Type (Champion® or equivalent)Spark Plug GapIgnition Module Air GapTop Compression Ring to Groove Side ClearanceMiddle Compression Ring to Groove Side ClearanceOil Control Ring to Groove Side Clearance
New BoreUsed Bore (Max.)
Piston Ring End Gap
RC12YC1.02 (0.040)
0.040/0.072 (0.0016/0.0028)
0.3/0.5 (0.012/0.020)0.77 (0.030)
Governor
Ignition
CylinderBore
Cylinder Bore I.D.
Governor Gear Shaft O.D. – Max. Wear Limit 5.977 (0.2353)
87.000/87.025 (3.4252/3.4262)87.063 (3.4277)
6.063 (0.2387)
0.203/0.305 (0.008/0.012)0.040/0.105 (0.0016/0.0041)
0.55/0.675 (0.0217/0.0266)
86.814 (3.4179)86.941/86.959 (3.4229/3.4236)
0.041/0.044 (0.0016/0.0017)
Intake Valve Minimum Lift
Intake Valve Guide
Exhaust Valve Guide
Exhaust Valve Minimum LiftRocker Arm I.D. – Max. Wear LimitRocker Shaft O.D. – Max. Wear Limit
Hydraulic Lifter to Crankcase Running ClearanceIntake Valve Stem to Valve Guide Running ClearanceExhaust Valve Stem to Valve Guide Running Clearance
7.038/7.058 (0.2771/0.2778)
7.159 (0.2819)
9.14 (0.360)
15.727 (0.619)
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
7.134 (0.2809)7.038/7.058 (0.2771/0.2779)
8.96 (0.353)
16.13 (0.640)
45°
Valves andValve Lifters
I.D. – Max. Wear Limit
I.D. – Max. Wear Limit
I.D. – Std.
I.D. – Std.
O.D. – NewO.D. – Max. Wear LimitNew – Running Clearance
Piston Thrust Face1 (@D1)to Cylinder Bore
Pistons,Piston Rings,and Piston Pin
1 D1
6 mm
1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
CH & CV14 (14)CH & CV13 (13)CH & CV12.5 (12.5)CH & CV11 (11)
20
Command–Single Cylinder Engine Specifications & TolerancesAll dimensions in millimeters (inches).
Kilowatt (kW) Output (@ 3600 RPM – SAE J1995)Horsepower (@ 3600 RPM – SAE J1995)
Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)Balance Shaft Bearing Surface O.D. Max. Wear Limit
0.0575/0.3625 (0.0023/0.0143)20.038 (0.7889)19.959 (0.7858)
DisplacementEnd Play (Free)Balance
ShaftBearing
End PlayIn Crankcase
With Shims – 0.076/0.127 (0.003/0.005) Without Shims – 0.10/0.39 (0.004/0.015)20.038 (0.7889)
Bore
Crankcase End20.038 (0.7889)19.959 (0.7858)Camshaft Bearing Surface
O.D. – Max. Wear Limit Oil Pan End
Max. Wear LimitConnecting
RodEnd Play (Free)Crankshaft Sleeve Bearing I.D. – Max. Wear Limit
Max. Wear Limit
O.D. – Max. Wear LimitMax. Taper
Flywheel End Main Bearing
Max. Out of RoundO.D. – NewO.D. – Max. Wear LimitMax. Taper
Closure Plate or Oil PanEnd Main Bearing
Max. Out of RoundO.D. – NewO.D. – Max. Wear LimitMax. TaperMax. Out of Round
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)
45.016 (1.7723)
CrankshaftO.D. – New
Max. Wear LimitNewCrankshaft Bore to Crankshaft
Running Clearance
I.D. – New Installed
NewConnecting Rod to CrankpinRunning Clearance
44.965/45.003 (1.7703/1.7718)
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)
38.958/38.970 (1.5338/1.5343)38.94 (1.5328)0.012 (0.0005)0.025 (0.0010)
44.913/44.935 (1.7582/1.7691)0.115 (0.0045)
0.03/0.09 (0.0012/0.0035)
Camshaft In Oil Pan
Stroke90 (3.60)
426 cc (26.0 cu. in.)
Model (Horsepower)
67 (2.64)General
Bore I.D. Max. Wear Limit
Connecting Rod Journal
CH & CV15 (15)11.215
Crankshaft PTO Bearing
21
Model (Horsepower) CH & CV15 (15)NewMax. Wear LimitMax. Out of RoundMax. Taper
Max. Out of FlatnessCylinder HeadGovernor Cross Shaft O.D. – Max. Wear Limit
Governor Cross Shaft Bore (In Crankcase)I.D. – Max. Wear Limit
0.12 (0.0047)0.05 (0.0020)
0.076 (0.003)5.962 (0.2347)
Spark Plug Type (Champion® or equivalent)Spark Plug GapIgnition Module Air GapTop Compression Ring to Groove Side ClearanceMiddle Compression Ring to Groove Side ClearanceOil Control Ring to Groove Side Clearance
New BoreUsed Bore (Max.)
Piston Ring End Gap
RC12YC1.02 (0.040)
0.040/0.085 (0.0015/0.0002)
0.27/0.51 (0.010/0.020)0.77 (0.030)
Cylinder Bore I.D.
Governor Gear Shaft O.D. – Max. Wear Limit 5.977 (0.2353)
90.000/90.025 (3.5433/3.5443)90.063 (3.5457)
6.063 (0.2387)
0.203/0.305 (0.008/0.012)
0.176/0.026 (0.0069/0.0010)
0.060/0.105 (0.0023/0.0041)
O.D. – NewO.D. – Max. Wear LimitNew – Running Clearance
89.824 (3.5363)
Intake Valve Minimum Lift
Intake Valve Guide
Exhaust Valve Guide
Exhaust Valve Minimum LiftRocker Arm I.D. – Max. Wear LimitRocker Shaft O.D. – Max. Wear Limit
Hydraulic Lifter to Crankcase Running ClearanceIntake Valve Stem to Valve Guide Running ClearanceExhaust Valve Stem to Valve Guide Running Clearance
7.038/7.058 (0.2771/0.2778)
7.159 (0.2819)
15.727 (0.619)
0.038/0.076 (0.0015/0.0030)
Nominal Valve Seat Angle
16.13 (0.640)
45°
I.D. – Max. Wear Limit
I.D. – Max. Wear Limit
I.D. – Std.
I.D. – Std.7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
8.96 (0.353)9.14 (0.360)
0.0124/0.0501 (0.0005/0.0020)
0.050/0.088 (0.0020/0.0035)
89.951/89.969 (3.5413/3.5420)
0.031/0.043 (0.0012/0.0016)
Piston Thrust Face1 (@D1)to Cylinder Bore
Pistons,Piston Rings,and Piston Pin
Valves andValve Lifters
Ignition
Governor
CylinderBore
1 D1
6 mm
1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
22
Command–Twin Cylinder Engine Specifications & TolerancesAll dimensions in millimeters (inches).
Kilowatt (kW) Output (@ 3600 RPM – SAE J1995)Horsepower (@ 3600 RPM – SAE J1995)
Displacement
BoreStroke
77 (3.03)
624 cm³ (38.1 in.³)
CH & CV18 (18)Model (Horsepower)13.418
67 (2.64)
End Play (With Shims)In Crankcase
0.076/0.127 (0.003/0.005)20.038 (0.7889)Bore I.D. Max. Wear Limit
Camshaft Bearing SurfaceO.D. – Max. Wear Limit
Max. Wear LimitConnecting
RodEnd Play (Free)Crankshaft Main Bearing I.D. – Max. Wear Limit
19.959 (0.7858)0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)0.070/0.480 (0.0028/0.0189)
NewConnecting Rod to CrankpinRunning Clearance
Oil Pan End
General
Camshaft
CH & CV20 (20)14.920
16.422
CH & CV22 (22)
41.016 (1.6148)
0.03/0.09 (0.0012/0.0035)Crankshaft to Sleeve Bearing RunningClearance – New (Early CH models only.)
O.D. – Max. Wear LimitMax. TaperMax. Out of Round
O.D. – New40.84 (1.608)
0.022 (0.0009)0.025 (0.0010)
40.913/40.935 (1.6107/1.6116)
Crankshaft
0.039/0.074 (0.0015/0.0029)Crankshaft Bore to Crankshaft RunningClearance – New
Main Bearing Journals
O.D. – NewO.D. – Max. Wear LimitMax. TaperMax. Out of Round
35.955/35.973 (1.4156/1.4163)35.94 (1.415)
0.018 (0.0007)0.025 (0.0010)
Cylinder Bore Cylinder Bore I.D. 77.063 (3.0340)0.12 (0.0047)0.05 (0.0020)
77.000/77.015 (3.0315/3.0325)NewMax. Wear LimitMax. Out of RoundMax. Taper
Max. Out of FlatnessCylinder Head 0.076 (0.003)
Connecting Rod Journal
Governor Cross Shaft O.D. – Max. Wear LimitGovernor Gear Shaft O.D. – Max. Wear LimitGovernor Cross Shaft Bore (In Crankcase)I.D. – Max. Wear Limit
5.962 (0.2347)5.977 (0.2353)Governor
6.063 (0.2387)
23
Model (Horsepower) CH & CV18 (18) CH & CV20 (20) CH & CV22 (22)Spark Plug Type (Champion® or equivalent)Spark Plug GapIgnition Module Air GapTop Compression Ring to Groove Side ClearanceMiddle Compression Ring to Groove Side ClearanceOil Control Ring to Groove Side Clearance
New BoreUsed Bore (Max.)
Piston Ring End Gap
RC12YC0.76 (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)0.060/0.202 (0.0024/0.0080)
0.25/0.45 (0.0098/0.0177)0.77 (0.030)
Ignition
O.D. – NewO.D. – Max. Wear LimitNew – Running Clearance
76.967/76.985 (3.0302/3.0309)76.840 (3.0252)
0.015/0.058 (0.0006/0.0023)
I.D. – Max. Wear LimitIntake Valve Guide
I.D. – Max. Wear LimitExhaust Valve Guide
Intake Valve Minimum LiftExhaust Valve Minimum Lift
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.07 (0.3177)
7.134 (0.2809)7.038/7.058 (0.2771/0.2779)
8.07 (0.3177)
Hydraulic Lifter to Crankcase Running ClearanceIntake Valve Stem to Valve Guide Running ClearanceExhaust Valve Stem to Valve Guide Running Clearance
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 45°
Piston Thrust Face1 (@D1)to Cylinder Bore
I.D. – Std.
I.D. – Std.
Valves andValve Lifters
Pistons,Piston Rings,and Piston Pin
1 D1
6 mm
1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
24
Command–Twin Cylinder Engine Specifications & TolerancesAll dimensions in millimeters (inches).
Kilowatt (kW) Output (@ 3600 RPM – SAE J1995)Horsepower (@ 3600 RPM – SAE J1995)
Displacement
BoreStroke
83 (3.27)
725 cm³ (44 in.³)
Model (Horsepower)
67 (2.64)
End Play (With Shims)In Crankcase
0.076/0.127 (0.003/0.005)20.038 (0.7889)Bore I.D. Max. Wear Limit
Camshaft Bearing SurfaceO.D. – Max. Wear Limit
Max. Wear LimitConnecting
RodEnd Play (Free)
19.959 (0.7858)0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)0.070/0.480 (0.0028/0.0189)
NewConnecting Rod to CrankpinRunning Clearance
Oil Pan End
General
Camshaft
18.625
CH & CV25 (25)
End Play (With Thrust Bearing Components) 0.050/0.5 (0.0020/0.0197)End Play (CH25 below Serial No. 2403500008) 0.050/0.75 (0.0020/0.0295)
O.D. – NewO.D. – Max. Wear LimitMax. TaperMax. Out of Round
35.955/35.973 (1.4156/1.4163)35.94 (1.415)
0.018 (0.0007)0.025 (0.0010)
Cylinder Bore I.D. 83.051 (3.2697)0.12 (0.0047)0.05 (0.0020)
82.988/83.013 (3.2672/3.2682)NewMax. Wear LimitMax. Out of RoundMax. Taper
Max. Out of FlatnessCylinder Head 0.076 (0.003)
Connecting Rod Journal
41.016 (1.6148)Crankshaft to Main Bearing Running Clearance – New 0.03/0.09 (0.0012/0.0035)Crankshaft Bore to Crankshaft Running Clearance – New 0.039/0.074 (0.0015/0.0029)
O.D. – Max. Wear LimitMax. TaperMax. Out of Round
O.D. – New40.84 (1.608)
0.022 (0.0009)0.025 (0.0010)
40.913/40.935 (1.6107/1.6116)
Main Bearing Journals
Crankshaft Main Bearing I.D. – Max. Wear Limit
Crankshaft
Governor Cross Shaft O.D. – Max. Wear LimitGovernor Gear Shaft O.D. – Max. Wear LimitGovernor Cross Shaft Bore (In Crankcase)I.D. – Max. Wear Limit
5.962 (0.2347)5.977 (0.2353)
6.063 (0.2387)
Governor
Cylinder Bore
25
Model (Horsepower) CH & CV25 (25)Spark Plug Type (Champion® or equivalent)Spark Plug GapIgnition Module Air GapTop Compression Ring to Groove Side ClearanceMiddle Compression Ring to Groove Side ClearanceOil Control Ring to Groove Side Clearance
New BoreUsed Bore (Max.)
Piston Ring End Gap
IgnitionRC12YC
0.76 (0.030)0.28/0.33 (0.011/0.013)
0.025/0.048 (0.0010/0.0019)0.015/0.037 (0.0006/0.0015)0.026/0.176 (0.0010/0.0070)
0.25/0.56 (0.0100/0.0224)0.94 (0.037)
O.D. – New1
O.D. – Max. Wear Limit1
New – Running Clearance
82.986 (3.2672)82.841 (3.2615)
0.002/0.045 (0.001/0.0018)I.D. – Std.I.D. – Max. Wear Limit
Intake Valve Guide
I.D. – Std.I.D. – Max. Wear Limit
Exhaust Valve Guide
Intake Valve Minimum LiftExhaust Valve Minimum Lift
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.07 (0.3177)
7.134 (0.2809)7.038/7.058 (0.2771/0.2779)
8.07 (0.3177)
Hydraulic Lifter to Crankcase Running ClearanceIntake Valve Stem to Valve Guide Running ClearanceExhaust Valve Stem to Valve Guide Running Clearance
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 45°
Piston Thrust Face¹ (@D1)to Cylinder Bore
Valves andValve Lifters
Pistons,Piston Rings,and Piston Pin
1Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
1 D1
6 mm
26
Command–Single Cylinder Torque Values & Sequences for FastenersModel (Horsepower)
6.8 N·m (58 in. lb.)4.0 N·m (35 in. lb.)
Air Cleaner Base Nuts – M6
Carburetor
9.0 N·m (80 in. lb.)22.6 N·m (200 in. lb.)22.6 N·m (200 in. lb.)Fastener
Fuel Bowl ScrewMounting Nuts
Charging Stator Mounting ScrewConnecting Rod Cap Fastener Torque
CylinderHead
Rocker Studs
9.8 N·m (87 in. lb.)
CH5 (5) CH6 (6)
13.6 N·m (120 in. lb.)
6.8 N·m (58 in. lb.)
Electric Starter Mounting 17/19 N·m (150/170 in. lb.)Flywheel Retainer Screw 67.8 N·m (50 ft. lb.)
Fuel TankFasteners – M8Fasteners – M6
Ignition Spark Plug (14 mm w/gasket)Ignition Module
Muffler Retaining Nuts
6.8 N·m (60 in. lb.)17.0 N·m (150 in. lb.)
24.4/29.8 N·m (18/22 ft. lb.)4.0*/6.2 N·m (35*/55 in. lb.)1
22.6 N·m (200 in. lb.)Oil Sentry™ Switch 13.6 N·m (120 in. lb.)
4.3 N·m (38 in. lb.)Throttle Control LeverValve Cover 3.4 N·m (30 in. lb.)
CH5 & CH6
CH11-15 & CV11-15
Closure Plate
Valve Cover Closure Plate (CH)/Oil Pan (CV)
Valve Cover Closure Plate
41
3 2
1 4
3 2
5 3
21
64
42
53
1
6 810
12
1
3
4
2
119 7
5
1For self-tapping (thread forming) fasteners: The higher torque value is for initial installation into anew cored hole * the lower torque value is for subsequent installation, and installation into tappedholes and weld nuts.
27
Command–Single Cylinder Torque Values & Sequences for Fasteners
Air Cleaner Base Nuts – M6Model (Horsepower)
9.9 N·m (88 in. lb.)Carburetor Fuel Bowl Screw
40.7 N·m (30 ft. lb.)2Fastener
Charging Stator Mounting ScrewConnecting Rod Cap Fastener Torque
CylinderHead
24.4 N·m (216 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.)
4.0 N·m (35 in. lb.)
5.1/6.2 N·m (45/55 in. lb.)
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
Rocker Pedestal (Pivot)Electric Starter Mounting
Fan FastenersRetainer Screw
Fuel Pump Fasteners
Flywheel
15.3 N·m (135 in. lb.)Rocker bridge type 9.9 N·m (88 in. lb.), Guide plate type 11.3 N·m (100 in. lb.)
38.0/43.4 N·m (28/32 ft. lb.)4.0*/6.2 N·m (35*/55 in. lb.)
Ignition Spark PlugIgnition Module
Oil FilterOil FilterOil Drain Plug (1/8" NPT)Oil Sentry™ Switch
Oil Pump Cover FastenersThrottle/Choke
Controls
5.7/9.0 N·m (50/80 in. lb.)24.4 N·m (216 in. lb.)
Speed Control Assembly
Governor Control Lever
Valve Cover 7.3*/10.7 N·m (65*/95 in. lb.)
9.9 N·m (88 in. lb.)
7.3*/10.7 N·m (65*/95 in. lb.)1
Closure Plate (CH)/Oil Pan (CV)
Muffler Retaining Nuts
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
1For self-tapping (thread forming) fasteners: The higher torque value is for initial installation into anew cored hole * the lower torque value is for subsequent installation, and installation into tappedholes and weld nuts.2Tighten in two stages. Torque first to 15 ft. lb. following sequence. Then tighten to final torque value(30 ft. lb.).
CH & CV11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV14 (14) CH & CV15 (15)
42
1
35
28
Command–Twin Cylinder Torque Values & Sequences for Fasteners
Breather PlateModel (Horsepower) CH & CV18 (18)
7.3 N·m (65 in. lb.)
CH & CV20 (20) CH & CV22 (22) CH & CV25 (25)
Carburetor Mounting Nuts 9.9 N·m (88 in. lb.)
Two Step Process; First torque 22.6 N·m (200 in. lb.), Second torque 41.8 N·m (370 in. lb.)Fastener
Charging Stator Mounting ScrewConnecting Rod Cap Fastener Torque
CylinderHead
24.4 N·m (216 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.)
4.0 N·m (35 in. lb.)
9.9 N·m (88 in. lb.)66.4 N·m (49 ft. lb.)
Rocker Pedestal (Pivot)Electric Starter Mounting
Fan FastenersRetainer Screw
Flywheel
15.3 N·m (135 in. lb.)11.3 N·m (100 in. lb.)
24.4/29.8 N·m (18/22 ft. lb.)4.0*/6.2 N·m (35*/55 in. lb.)
Ignition Spark PlugIgnition ModuleManifold (Intake) 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.)Oil Filter
Oil FilterOil Drain Plug (1/8" NPT)Oil Sentry™ Switch
Rectifier FastenersMuffler Retaining Nuts
7.3*/10.7 N·m (65*/95 in. lb.)1
Throttle/Choke
Controls Speed Control Assembly
Governor Control Lever 9.9 N·m (88 in. lb.)
Closure Plate (CH)/Oil Pan (CV)
13.6 N·m (10 ft. lb.)7.9 N·m (70 in. lb.)
Gasket/Sealant TypeO-Ring Type
Valve Cover 3.4 N·m (30 in. lb.)7.9 N·m (70 in. lb.)
1For self-tapping (thread forming) fasteners: The higher torque value is for initial installation into anew cored hole * the lower torque value is for subsequent installation, and installation into tappedholes and weld nuts.
Exha
ust P
orts
Exha
ust P
orts
2
1 3
1
3 1
4 2 2 4
29
Command–Twin Cylinder Torque Values & Sequences for FastenersClosure Plate (CH)/Oil Pan (CV)Valve Cover Breather Plate
3
5
7
9
2 4
6
8
10
1
1
3
24
1 3
4 2
30
Conversion FactorsInches x 25.4 = Millimeters (mm)
Inches x 2.54 = Centimeters (cm)
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)
Ounce (Weight) x 28.350 = Grams (g)
Pound x 0.4536 = Kilograms (kg)
Horsepower x 0.746 = Kilowatt (kW)
FOR SALES AND SERVICE INFORMATIONIN U.S. AND CANADA, CALL
1-800-544-2444
LITHO IN U.S.A.
FORM NO.: TP-2469ISSUED: 5/95REVISED: 7/99MAILED:
KOHLER CO. KOHLER, WISCONSIN 53044