McCulloch SMALL AIR-COOLED ENGINES McCULLOCH Model Mce, MCT, MCS MC-30, MC-40, MC-45 wes MC, MC10 Mc20 Mc-70 Me75 MAINTENANCE ‘SPARK PLUG. Recommended spark plug for average conditions is a Cham- pion J6J. Spark plug heat range may have to be changed for certain operat- ing conditions. Set electrode gap to (0.026 inch (0.63 mm) on all models, shown in Fig. MC2 or Fig. MCS. All buretors are diaphragm type with in- tegral fuel pump. Thitial carburetor adjustment. for Models MC-40 and MC-10 is. 2 turns open on both ide and main fuel mixture needles on both carburetors. On remain: ing. models, initial adjustment is. 1% turns open on idle fuel mixture needle and 1¥ turns open on main fuel mixture needle, Make final adjustments with engine at operating temperature and running. Adjust idle speed regulating Screw so engine ides at 1500-1700 rpm. Tum idle fuel needle slowly in clock wise direction until engine idles smoothly. If engine starts to accelerate ‘while turning needle in clockwise direc- tion, tum needle back counterclock- ‘Wise until engine slows down. Ifengine Iisfires during acceleration, enrich fuel mixture by turning idle fuel needle counterclockwise a fraction ofa turn at 4 time until engine accelerates smooth- 320 McCULLOCH CORP. P.O. Box 11990 ‘Tucson, Arizona 85734-1990 Bore Stroke 2.165 in. 1.635 in (65 mm) (41.5 mm) 2.125 in, 1.376 in, G4 mm) (65 mm} 2.128 in, 1.500 in, (4mm) @&.1mm) 2.125 in 1.636 in, (64 mm) (41.5 mm) 2.217 in 1.835 in (66.3 mm) (46.6 mm) 2.250 in 1,836 in, (612 mm) (46.6 mm) HPTERLTT He EER a Py i ith tt f SORESS WARMEBRYSORNRREO RED: ian ri Displacement 6.1.cu. in (99 cc) 49 cu. in, (80 ce) 53.u. in, (Tec) 58 cu. in (95 ce) 7.1eu. in (116 cx) 73.cu. in (120 ee) ent ay Mca CrpSERVICE MANUAL McCulloch ‘Models MC2, MCS and MCTS nr simi : ee re ; i hea a eee : ie i. E Sana Pee, ay 2s. =" eo cea. ly and rapidly. If engine appears slug- fish on acceleration, aleaner fuel mix- ttre may be required. Turn idle needle a fraction of a turn at a time in clock- ‘wise direction until engine acceleration {sat maximum. Because main fuel nee- dle has not had final adjustment at this time, acceleration may not be at maxi- ‘mum peak "Test engine at high speed under load If engine four strokes (fires every other stroke), Jean the fuel mixture by turning ‘the main fuel needle in small increments in clockwise direction until engine fires | ters ey Mea Comp 321McCulloch Fig, MCB On MC-10 engines, crantshat can be locked in fring position by inertng ® Vlneh 16.38 mm) pn nto bored hoe In Nywheel. ‘on every stroke at peak rpm. Never at tempt to adjust the main fuel mixture needle unless engine is under load. ‘After adjusting the main fuel needle, it may be necessary to readjust the idle fuel needle as previously outlined. MAGNETO AND TIMING. ‘The magnet in cat into the fywheel on all models, The breaker points and con- denser onthe Model MC10 are mounted ‘n'a breaker box outside the engine trankcase. The iywhee! must be remo fetonall other models to gain acces to the ‘breaker points and condenser. Breaker point gap on all models is 0.018 inch (0.46 mm) “To adjust breaker point gup on Model MC-10, insert a Neneh (6.35 mm) pin the hole in the crankease cover (Fig. MC8) and turn engine until pin foes into. timing hole in. flywheel. Disconnect primary lead from breaker point terminal. Connect timing Tight in eres between breaker point terminal land engine ground as shown in Fig 322 SMALL AIR-COOLED ENGINES MC9, Adjust breaker points so light is on, then slowiy adjust breaker points 50 light just goes out. Tighten breaker point mounting screws. ‘To adjust breaker points on all other models, remove flywheel and_ install degree’ wheel on engine crankshaft. ‘Tum engine to 25 degrees BTDC. Hook up timing light and adjust_breaker points as previously outlined. If degree ‘wheel is not available, set breaker point gap to 0.018 inch (0.46 mm) using feel- er gage. Clearance between coil laminations and flywheel is 0.007-0.012 inch (0.18.0.31 mm) on all models. Desired clearance of 0.010 inch (0.25 mm) is set as shown in Fig. MC10. LUBRICATION. The engine is lubri- cated by mixing oil with the fuel. Rec- ‘ommended oil is McCulloch two-stroke engine oil mixed at a 40:1 ratio. If McCulloch oil is not available, a good quality oll designed for use’ in air- cooled, two-stroke engines may be used ‘when mixed at a 20:1 ratio. Use a sep- arate container to mix oil and gasoline. CARBON. Lack of power may_in- dicate exhaust ports need cleaning. Clean ports with wooden seraper. REPAIRS TIGHTENING TORQUES. Recom- mended tightening torques are as Brsker point cms Capping. Adapter to manifold - 60-65 in, in eons hem Manifold tocylindr ‘a Condenser screw 30-85 in-tbs. G4 Nem) Connecting rod~ MC-0& MC-75 90-95 inIbs. (010.7 Nem) Allother models 5-70 in-Ibs. (7.8.8 Nem) Crankease bottom screws, 95-100 in-Ibs. (20,7-11.8 Nm) Cylinder head serews ... .55-60 in-lbs. (6.26.8 Nem) Exhaust stack. 55-60 inclbs. Fan housing Flywheel nut . Reed valve clamp (B-4N-m) Spark plug. 216-264 inclbs, (24-30 Nem) Cluteh or sprocket nut . 260-800 in.-Ibs. (29-84 Nem) CONNECTING ROD. On Models MC-2 and MC-70, the cylinder head is ‘nonremovable and the piston and con- necting rod assembly must be removed from the bottom. Remove engine bottom cover, detach rod from crankshaft and remove crankshaft and engine cover ‘assembly, Withdraw rod and piston through bottom opening. On all other models, rod and piston assembly are removed from above. Fig, MCTO— Recommended magneto sir gap 1 ‘OBtined by shifting coll on mounting Screws. Desc creny MiCc CoSERVICE MANUAL ‘The erankpin bearing on Model MC-2 is a tworpiece floating bushing. On all ‘other models, 24 uncaged needle roller bearing are used. Renew rod, bushings, or crankshaft on Model MC-2 if scored ‘or worn excessively. On all other models, erankpin nominal diameter is 0.6298 inch (15.997 mm). Clearance be- tween end of rollers and side of erankpin journal (needle end clearanee) should be 0.008-0.018 inch (0.20-0.46 mm). Ac- cumulative clearance between rollers should be 0.008-0.010 inch (0.20-0.025 mm), Side clearance between rod and crankshaft should be 0.100-0.110 inch (2,542.79 mm). Renew rod and/or crankshaft if scored or if any wear spots are visible. Install crankpin needle rollers by sticking 12 rollers in the rod and 12 in the rod cap with grease. Align “pips” (Fig. MC12) on rod and eap when install- ing on crankpin. Parting faces of con- necting rod and cap are fractured to pro- vide the dowel effect on the meshing, of sent ory Mauch Cop Cinder at Bo Ope mele earing Md Comnetegrad Baber i cledeaieccae™® i ete’ Seater ine Sate Sn the consequent uneven surface. It is ad- visable to wiggle the rod cap back and forth while tightening to make sure the surfaces of the fractured joint are in perfect mesh. When properly meshed, no “eatch points” will be felt when fingernail is rubbed along parting line of rod and cap (Fig. MCI3). PISTON, PIN AND RINGS. Piston in early MC.5 and MC-10 model engines was fitted with two thick eompression 323McCulloch SMALL AIR-COOLED ENGINES Fig, MC16—Exploded vew of MCS engl; MCS, MCT and MC ar smile except that MC and ‘MC- use an "0" rng In place of crontcase core” gasket shown adjacent fo Ball Dearing 21kSERVICE MANUAL rings. Ring end gap should be 0,007-0.010 inch (0.18-0.25 mm). If piston, skirt-to-eylinder wall clearance ‘exceeds 0.005 inch (0.13 mm) or ring end ‘gap exceeds 0.010 inch (0.25 mm) with new piston ring, hone oF rebore cylinder to next oversize or renew cylinder. If ring side clearance in top ring groove ex ceeds 0,004 inch (0.10 mm), renew the piston. Piston rings should always be renewed whenever engine is disassem- bled for service. Piston and rings are available in oversizes, Install the chrome ted ring in top ring, groove and install ‘cast iron ring in second ring groove. ‘On late production MC-5 and MC-10 model engines and all other models, a ew Mea Ca piston is fitted with two thin chrome Compression rings. Ring end gap should be 0.051-0.001 inch (127-231 mm) on Models MC-40, "MC-45, -MC-70" and MC-TS which have ring retaining pins in the ring grooves. Ring end gap on all other thimring pistons is 0.0040.050 inch (0.10-1.27 ram). If piston skiet-to- cjlinder wall clearance ‘exceeds 0.007 {ch (0.18 mm) or new rings cannot be fitted within end gap tolerance, hone or rete liner, next overs for Which piston and rings are avalable or renew eylinder. If ring side clearance in top ring groove exceeds 0.004 inch (0.10 ram) with new piston ring, renew piston, Piston rings should always be renewed McCullochMcCulloch Fig, MC21— Reed inet ale instalation used on ‘Mode! MC-30. Two sets of rood valves are used ler to Fig. MC22 24 Coorteraae are Eh a SMALL AIR-COOLED ENGINES whenever engine is disassembled for serviee. Piston and rings are available in variety of oversizes as well as standard site, Piston pin is a press fit in connecting ‘Model MC-5 piston has ite bushings in piston ‘models use one open ind one elosed end nee- de bearing. in piston. Piston must be supported "in special support block available from MeCulloch Corporation when pressing pin in or out of piston and rod, The closed end needle bearing used in the piston of all models exeept MC-5 ‘must be installed in the side of the piston towards the exbaust port in ylinder (CRANKSHAFT. The crankshaft is sup- ported by a ball bearing at the flywheelSERVICE MANUAL ‘end and a caged needile roller bearing at the pto end on Models MC-2, MC-5, MC-6, MC-7 and MCB. On Models ‘MC-10, MC-20, MC-40 and MC-70, the crankshaft is spportd by bal earings teach end Th bal pe ain bearings ings are a press fit in the crankease or cover. Inspect pto end journal where eee nein eae Fey rach ies condos re Crankease and crankease cover must be heated to 200° F (93° C) in an oven McCulloch ‘when installing ball or needle type bear- ings to prevent damage to bearing bore. VALVE SYSTEM. A combination of reed and third port (piston, porting) the plate. fs used, The smooth side of reed should face the valve 927