McCulloch Model MC-49, MC-490, MC-49E MC-90, MCA, MCB, MCaIC MC-100 Mc-101, MC-1014, MC.101C ECE C TET mall Fi aE FFE if ive a seesaeeneue payee ore HE i & SMALL AIR-COOLED ENGINES 2.125 in, 1.315 in, (64 mm) 5 mm) 2.1685 in 1,635 in, (65mm) (41.5 mm) 2.250 in, 1.835 in, (67.2 mm) (46.6 mm) 2.280 in, 1.835 in, (67.9 mm) (46.6 mm) MAINTENANCE SPARK PLUG. For normal operating conditions, Models MC-49, MC-49C and MC-49E are equipped with Champion 389 spark plug, Models MC-91B and MC- 101A are equipped with Champion L78 spark plug and all other models use Champion J4J. spark plug. Electrode ‘gap for all models should be 0.025 inch (0.64 mm), Spark plug heat range may have to be changed for certain operating, conditions. CARBURETOR. McCulloch dia phragm of pressure pulse type car buretors are used on these models. Refer to Figs. MC25, C26, MCZ7 and MC2B for exploded view of carburetors. For initial carburetor adjustment on ‘MC-100, turn fuel adju: clockwise until they are lightly seated Open ile mixture needle (7=Fig. MC25) 1% turns and main fuel needle (8) 12 turns. "With ‘engine ato temperature and running, sus Fig. MC26—Exploded view Of McCulloch diaphragm McCULLOCH _ 4.9.cu. in (80 ce) 6.1 en. in (09 ec) 73 cu. in (220 ee) 7.5.cu. in, (123 ee) speed screw (25) until engine idles at a peed of 1500-1700 rpm. Check engine {or acceleration and open main fuel nee die a slight it if engine misfires, or ‘turn needle in a slight amount if engine smokes and is sluggish on acceleration On Model MC-49E, lightly seat idle mixture needle (19~Fig. MC26), then Open the needle 1% turns, Main fuel jet jis nonadjustable, Standard jet (17) has an orifice diameter of 0.031 inch (0.79 mm). Optional. jets with orifice diameters of 0.028 inch (0.71 mm) ean), 0.029 inch (0.73 mm) and 0.033 inch (0.84 mm) (rich) are available. With engine at operating. temperature and Dianne ie Spend of 1001700 rpm, Place & load on engine and check engine for acceleration. If engine falters or misfires on acceleration, open idle mixture needle a small amount. If fengine runs rough and smokes heavily fon. acceleration, turn needle in (Clockwise) slightly On Models MC-9i, MC9IA, MC-91C, ‘MC-101 and MC-101C, turn both fuel ad-SERVICE MANUAL justing needles until they are lightly seated, then open both fuel needles (16 and 20-Fig. MC27) 1 turn. With engine ‘warm and running, adjust idle speed serew (8) to obtain an engine idle speed cof 1500-1700 rpm. Check engine oF ac celeration and if engine falters or misfires, open main fuel needle slightly. If engine smokes and is sluggish on ac: celeration, turn main fuel needle in slightly. On Models MC-91B and MC-101A, turn idle mixture needle (23-Fig 'MC28) and main fuel needle (24) clockwise until they are lightly seated. ‘Tur idle mixture needle counterclock- wise 1% turns, then turn main fuel nee- dle counterclockwise 1% to 2 turn. ith engine at operating temperature and running, adjust idle speed screw (14) Lntil engine idle speed is 1500-1700 rpm. Pace alo on engine and check engine Acceleration. If engine runs rough or smokes heavily on acceleration, close main fuel needle a slight amount. If McCulloch engine falters or misfires on accelera- tion, open main fuel needle a slight amount. CAUTION: On all models, avoid car buretor settings that wil run the engine ‘00 lean. If setting s too lean, overheating ‘and lack of lubrication will seriously ‘damage the engine. MAGNETO AND TIMING. To get proper ignition timing, adjust breaker point gap. If degree wheel and static timing light are available, adjust break er points so they start to open at 25 de- sees BTDC on Models MC-49, MC-49C. ‘and MC-00; 26 degrees BTDC on Models MC-49E, MC-91, MC-91A, MC-OIB and MC-O1C, or 22 degrees BTDC on Models MC-100, MC-101, MC-1O1A and. MC- 1016, Another method to set timing is to adjust breaker point opening to 0.018 inch (0.46 mm) for 25 degrees BTDC, 0.019 inch (0.48 mm) for 26 degrees BIDC or 0.016 inch (0.38 mm) for 22 de- srees BTDC. Refer to Fig. MC30 for magneto used ‘on Models MC-49, MC-49C, MC-49E, MC-90, MC-91, MC-91A, MC-91B and MC-SIC. Model MC-100, MC-101, MC- OLA and MC-101C use magneto shown in Fig. MC31. Adjust armature air gap to 0.010 inch (0.25 mm) on all models. LUBRICATION. Mix one part SAE 40 two-stroke engine ol with 20 part of regular grade automotive gasoline or 100 octane white marine gasoline. CARBON. Lack of power may dicate exhaust ports need cleaning, Clean ports with a wooden scraper.McCulloch SMALL AIR-COOLED ENGINES REPAIRS TIGHTENING TORQUES. Recom- mended tightening torques are as Breaker point serews .... 30-35 in-Ths (3-4N-m) Carburetor to adapter .. 90-100 in-lbs. (10-11 Nem) Adapter to manifold as. ‘Manifold to cylinder (687.3 Nem) Coil and lamination serews .. 60 in bs. (6.2.6.8 N-m) Condenser screw 80-99 in-lbs. G4 Nem) Connecting: rod — ‘MC-100, MC-101, MC-101A, MC-101C ... 90-95 in tbs. (10.0-10.5 N-m) MC-91, MC-LA MC-91B, MC-IC .....105-110in-tbs. (1213 Nem) Allother models ...... 65-70 in.tbs. (738N-m) Crankease bottom serews 95-100 in-bs. (20.5-11.0 Nem) Cylinder head screws ......55-60 in-bs. (6.2.6.8 Nem) Exhaust stack .. 55-60 inthe, (6.2.6.8 N-m) Fanhousing ......2.+.+3 55-60 in. Tbs, Flywheel nut . Reed valvectamp ... Spark plug Cluteh or sprocket ‘nut _SERVICE MANUAL McCulloch CONNECTING ROD. On Models faces are scored or rough. When 12 needle rollers in cap. Fit connecting MC-49, MC49C and MC-49E, the reassembling, use light grease to stick cylinder head is not removable and the piston and connecting rod_assembly must be removed from bottom of ‘erankease after removing bottom cover, ‘erankease cover and the crankshaft. On all other models, piston and connecting rod assembly can be removed after removing bottom cover and eylinder head. On all models, 24 uncaged needle rollers are used for erankpin bearing. Renew the node rors a8. complete setif anyroller has a fat spot, or Huei Ges men iecer senses and/or connecting rod if bearing: sur- teas ee D. - \ cross By Se 8- ceeeeee gears Soros cece eames sa rod to cranky with “pips” align PISTON, PIN AND RINGS. Piston is fitted with two thin steel rings. Ring fend gap. should be 0,004-0.050 inch (0.10-127 mm) on pistons that do not have ring locating pin, or 0.051-0.091 ‘neh (1802.21 mm) on pistons with pin red rings. If ring ide clearance in groove ‘exceeds 0,004 inch (0.10 mmm) with new ing, the piston should he renewed Also, renew piston. if scored or if cylinder to piston skirt clearance ex- ceeds 0.007 inch (0.18 mm). Piston and ings are available in standard size for all models as well as a variety of over: ‘Piston pin is retained by snap rings at tach end of pin bore in piston on Model MC-49 (Fig. MC33), and by being a press fit in connecting rod on all other models. ‘On Model MC-49, piston pin rides in onrenewable bushings in piston; ms an all other models are fitted in, then install ea as shown in Fig. With caged needle roller bearings a8 3 110McCulloch shown in Fig. MC34. To remove or in- stall piston pin and needle roller bear- ings in pistons used in Models MC-91, MC9IA, MC9IB, MC9IC, MC-101, MC:01A and MC-101C, refer to Figs. Of too it for pan pad Peeig it for piston pin i removal and installation, ‘On pistons with one closed end bear- ing, press pin out towards closed end bearing, forcing the bearing out with pin, Then, press open end bearing from fison. Install new earings in piston 90 ner ends of bearing cages are Mush rth piston pin boss. Insert piston in ough open bearing and press through connecting rod until end of pin is fush with outer end of open end needle bear- SMALL AIR-COOLED ENGINES ing cage. Always support piston in fbx ture when pressing pin in or out Heating the connecting rod to approx: imately 180°F (82°C) will permit easier piston pin installation. CRANKCASE. Where cylinder is worn so piston skirt to cylinder clearance is 0.007 inch (0.18 mm) or more with new piston or if ring end gap is excessive with new piston rings, the eylinder must be rebored to nearest oversize for which piston and rings are available or new erankease and cylinder assembly must be installed, CRANKSHAFT. On Models MC-100, MC-101, MC-10IA and MC-1010, crankshaft is supported in ball bearings at each end. On all other mocels Shel end of crankshat is supported in ball bearing. and output end is sup- rted in a needle roller bearing. The Fail bearings are a press fit on crankshaft and both the needle and ball bearings are a press fit in crankcase and erankease ‘cover. Ingpect output end ‘ain journal for scoring or wear spots ‘on models with needle bearing. (Grankease and erankease cover must be heated to 180°F (82°C) prior to in- Fig. MC40—Exploded vow of V block reed valve ‘Sseembiy vaed on Medals MCT, MCOTA, MC- ‘918, MCO1C, MEOH, MCTOIA and MC-101C. ot oe stalling crankshaft and ball bearing assembly, ot installing: needle bearing in crankcase on models s0 equipped. REED VALVES. Flat valve reeds as shown in Fig. MC38 are used on Models MC-49, MC49C and MC-9E. Models MC-90' and MC-100 are equipped with pyramid reeds as shown in Fig. MC39. Models MC91, MC-SIA, MC-3IB, MC- $1¢, MC-101, MC-101A’ and MC-i01C, which use MeCulloch “pressure pulse type carburetor, are equipped ‘with Viype reed block as shown in Fig. cio. Correct seating of reed valves is essential to. maintain crankease pressure, Be sure reeds and seats are clean and reeds lay flat against seat. Renew any broken or chipped reeds. Renev reed plate, pyramid seat or reed bck if worn in seat area.