Professional Documents
Culture Documents
K-Series Torques & Specs
K-Series Torques & Specs
K-Series Torques & Specs
Table of Contents
Standard Application Torque Recommendations ..................................................................................................3
KSeries Single Cylinder Engine Specifications & Tolerances ........................................................................ 4-5
KSeries Twin Cylinder Engine Specification & Tolerances ............................................................................. 6-7
KSeries Single Cylinder Torque Values & Sequences for Fasteners .................................................................8
KSeries 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
Metric Fastener
Tightening Torque: Nm (in. lb.) + or 10%
Property Class
4.8
Size
M4
M5
M6
M8
1.2 (11)
2.5 (22)
4.3 (38)
10.5 (93)
5.8
1.7
3.2
5.7
13.6
(15)
(28)
(50)
(120)
8.8
2.9
5.8
9.9
24.4
(26)
(51)
(88)
(216)
10.9
4.1
8.1
14.0
33.9
(36)
(72)
(124)
(300)
12.9
5.0
9.7
16.5
40.7
(44)
(86)
(146)
(360)
Noncritical
Fasteners
Into
Aluminum
2.0
4.0
6.8
17.0
(18)
(35)
(60)
(150)
M10
M12
M14
4.8
5.8
8.8
21.7 (16)
36.6 (27)
58.3 (43)
27.1 (20)
47.5 (35)
76.4 (55)
47.5 (35)
82.7 (61)
131.5 (97)
10.9
66.4 (49)
81.4 (60)
116.6 (86) 139.7 (103)
184.4 (136) 219.7 (162)
1/8" NPT
4.5 (40 in. lb.)
17.0 (150 in. lb.)
1/4"
11.3 (100 in. lb.)
20.3 (180 in. lb.)
3/8"
13.6 (120 in. lb.)
27.1 (20 ft. lb.)
1/2"
17.6 (13 ft. lb.)
33.9 (25 ft. lb.)
3/4"
21.7 (16 ft. lb.)
X-708-11 27.1/33.9 (20/25 ft. lb.) 27.1/33.9 (20/25 ft. lb.)
12.9
Noncritical
Fasteners
Into
Aluminum
33.9 (25)
61.0 (45)
94.9 (70)
Torque
Conversions
Nm = in. lb. x 0.113
Nm = ft. lb. x 1.356
in. lb. = Nm x 8.85
ft. lb. = Nm x 0.737
Grade 2
Size
8-32
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
2.3
3.6
3.6
7.9
9.6
17.0
18.7
29.4
33.9
(20)
(32)
(32)
(70)
(85)
(150)
(165)
(260)
(300)
Grade 5
2.8 (25)
4.5 (40)
4.5 (40)
13.0 (115)
15.8 (140)
28.3 (250)
30.5 (270)
-----------------
Grade 2 or 5
Fasteners Into
Aluminum
Grade 8
------------------------18.7 (165)
22.6 (200)
39.6 (350)
-------------------------
2.3 (20)
3.6 (32)
--------7.9 (70)
--------17.0 (150)
-------------------------
40.7 (30)
67.8 (50)
81.4 (60)
108.5 (80)
142.4 (105)
155.9 (115)
223.7 (165)
237.3 (175)
311.9 (230)
352.6 (260)
447.5 (330)
474.6 (350)
637.3 (470)
---------------------------------------------------------------------------------------------------------
------------------------47.5 (35)
61.0 (45)
67.8 (50)
94.9 (70)
101.7 (75)
135.6 (100)
149.2 (110)
189.8 (140)
199.3 (150)
271.2 (200)
---------47.5 (35)
54.2 (40)
74.6 (55)
101.7 (75)
108.5 (80)
142.4 (105)
169.5 (125)
223.7 (165)
244.1 (180)
311.9 (230)
332.2 (245)
440.7 (325)
General
Balance
Gear
Shaft O.D.
Camshaft
New
Max. Wear Limit
End Play
End Play
K301 (12)
K321 (14)
K341 (16)
2.375 x 2.000
2.938 x 2.500
2.938 x 2.750
3.251 x 2.875
3.375 x 3.250
3.500 x 3.250
3.750 x 3.250
8.86
4000
16.94
3600
18.64
3600
23.85
3600
0.4998/0.5001
29.07
3600
0.4998/0.5001
31.27
3600
0.4998/0.5001
35.90
3600
0.4998/0.5001
0.4996
0.4996
0.4996
0.4996
0.002/0.010
0.002/0.010
0.002/0.010
0.002/0.010
0.005/0.010
0.005/0.010
0.005/0.010
0.005/0.010
0.005/0.010
0.001/0.0025
0.001/0.002
0.001/0.002
0.001/0.002
0.001/0.002
0.001/0.002
0.001/0.002
Rod to Crankpin
Wear Limit
0.003
0.0025
0.0025
0.0025
0.0025
0.0025
0.0025
0.0007/0.0008
0.0006/0.0011
0.0006/0.0011
0.0003/0.0008
0.0003/0.0008
0.0003/0.0008
0.0003/0.0008
0.5630/0.5633
0.6255/0.6258
0.6255/0.6258
0.8596/0.8599
0.8757/0.8760
0.8757/0.8760
0.8757/0.8760
0.9841/0.9844
1.1811/1.1814
1.1811/1.1814
1.5745/1.5749
1.5745/1.5749
1.5745/1.5749
1.5745/1.5749
0.9841
1.1811
1.1811
1.5745
1.5745
1.5745
1.5745
0.9360/0.9355
1.1860/1.1855
1.1860/1.1855
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
0.9350
1.1850
1.1850
1.4990
1.4990
1.4990
1.4990
0.0005
0.0005
0.0005
0.0005
0.0005
0.0005
0.0005
0.001
0.004/0.023
0.001
0.002/0.023
0.001
0.002/0.023
0.001
0.003/0.020
0.001
0.003/0.020
0.001
0.003/0.020
0.001
0.003/0.020
2.3755/2.3745
2.378
0.003
2.9380/2.9370
2.941
0.003
2.9380/2.9370
2.941
0.003
3.2515/3.2505
3.254
0.003
3.3755/3.3745
3.378
0.003
3.5005/3.4995
3.503
0.003
3.7505/3.7495
3.753
0.003
Max. Taper
0.003
0.003
0.003
0.002
0.002
0.002
0.002
0.003
0.003
0.003
0.003
0.003
0.003
0.003
RCJ-8
RCJ-8
RCJ-8
RH-10
RH-10
RH-10
RH-10
Spark Plug
Battery
Type & Gap
Magneto
Gaseous Fuels
0.025
0.025
0.018
0.025
0.025
0.018
0.025
0.025
0.018
0.035
0.025
0.018
0.035
0.025
0.018
0.035
0.025
0.018
0.035
0.025
0.018
0.020
0.020
0.020
0.020
0.020
0.020
0.020
Crankshaft
New
Max. Wear Limit
Max. Out of Round
Inside
Diameter
Type (Champion or
equivalent)
K241 (10)
0.005/0.010
Ignition
K181 (8)
0.005/0.020
Connecting
Rod
Cylinder
Head
K161 (7)
Rod to Crankpin
(New)
Running
Clearance
Cylinder
Bore
K91 (4)
Model (Horsepower)
All Pistons
1/2"
Piston
Piston
K321 (14)
K341 (16)
2.9297/2.9281
2.925
2.9297/2.9281
2.925
3.2432/3.2413
3.238
3.368/3.365
3.363
3.4941/3.4925
3.491
3.7425/3.7410
3.738
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
0.007/0.017
0.007/0.017
0.007/0.017
0.010/0.020
0.010/0.020
0.010/0.020
0.010/0.020
0.027
0.006
0.027
0.006
0.027
0.006
0.030
0.006
0.030
0.006
0.030
0.006
0.030
0.006
3.7465/3.7455
3.744
0.0030/0.0050
0.010/0.020
0.030
New Bore
2.9329/2.9336
3.3700/3.3693
3.4945/3.4938
0.004
3.7433/3.7426
O.D.4
2.931
3.367
3.492
3.7406
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
0.006
0.006
0.006
0.004
0.5623/0.5625
0.250
0.6247/0.6249
0.3125
0.6247/0.6249
0.3125
0.8591/0.8593
0.3125
0.8752/0.8754
0.3125
0.8752/0.8754
0.3125
0.8752/0.8754
0.3125
Intake
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
Exhaust
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
Minimum
Intake
Lift
(Zero Lash) Exhaust
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
Minimum
Valve Stem
O.D.
Intake
0.2478
0.3103
0.3103
0.3103
0.3103
0.3103
0.3103
Exhaust
0.2458
0.3088
0.3088
0.3074
0.3074
0.3074
0.3074
45
45
45
45
45
45
45
Intake
0.005
0.005
0.005
0.006
0.006
0.006
0.006
Exhaust
0.007
0.007
0.007
0.008
0.008
0.008
0.008
Ring End
Gap
New Bore5
Used Bore (Max.)
Outside Diameter
Guide Reamer Size
Tappet
Clearance
(Cold)
Valves
K301 (12)
Piston Pin
K241 (10)
2.371/2.369
2.366
Ring End
Gap
1/2"
K181 (8)
New
Max. Wear Limits
Ring End
Gap
Piston
K161 (7)
K91 (4)
KT17 (17)
KT19 (19)
K582 (23)
3.125 x 2.750
3.125 x 3.063
3.500 x 3.000
42.18
3600
47.0
3600
57.73
3600
Rear 1.251/1.252
0.003/0.013
0.003/0.013
0.003/0.024
0.0012/0.0024
0.0012/0.0024
0.001/0.002
0.0029
0.0029
0.0025
0.0006/0.0011
0.6255/0.6258
0.0006/0.0011
0.7507/0.7510
0.0003/0.0008
0.8757/0.8760
1.7412/1.7422
1.7412/1.7422
1.7495/1.7500
1.7407
1.7407
1.7490
1.7716/1.7721
0.0005
0.001
0.0005
0.001
1.7711
0.0005
0.001
0.0049
0.0049
0.004
0.0059
1.7439/1.7461
0.0059
1.7439/1.7461
0.005
1.7515/1.7535
Bore x Stroke
General
Camshaft
End Play
Connecting
Rod
Crankshaft
Cylinder
Bore
Cylinder
Head
Running
Clearance
New
Max. Wear Limit
Front 1.876/1.877
1.3738/1.3733
1.4998/1.4993
1.3728
1.4988
0.0005
0.0005
1.6250/1.6245
1.6240
0.0005
0.001
0.001
0.001
0.002/0.014
3.1255/3.1245
0.002/0.014
3.1255/3.1245
0.004/0.010
3.5005/3.4995
3.128
3.128
3.503
0.002
0.0015
0.002
0.0015
0.005
0.002
0.003
0.003
0.003
Model (Horsepower)
Spark Plug
Type & Gap
Ignition
Gaseous Fuels
Nominal Point Gap
Service Replacement Sizes
New
Thrust Face O.D.3
Max. Wear Limits
Piston
New Bore
Piston
New
Max. Wear Limits
New Bore5
Used Bore (Max.)5
Piston Pin
RH-10
0.025
0.018
0.025
0.018
0.025
0.018
0.020
0.020
0.020
3.118/3.117
3.113
3.4941/3.4925
3.491
0.0065/0.0085
0.0035/0.0055
0.007/0.010
0.010/0.020
0.010/0.020
0.010/0.020
0.030
0.004
0.030
0.004
0.003 0.010 0.020 0.030
0.030
0.006
3.1210/3.1203
3.1215/3.1208
3.118
3.119
0.0035/0.0052
0.010/0.020
0.0030/0.0047
0.010/0.023
0.032
0.032
0.006
0.7499/0.7501
0.3125
0.8752/0.8754
0.3125
Intake
0.003/0.006
0.003/0.006
0.008/0.010
Exhaust
0.011/0.014
0.011/0.014
0.017/0.020
Minimum
Intake
Lift
(Zero Lash) Exhaust
0.280
0.280
0.318
0.280
0.280
0.318
Minimum
Valve Stem
O.D.
Intake
0.3103
0.3103
0.3103
Exhaust
0.3088
0.3088
0.3074
45
45
45
0.005
0.005
0.006
0.007
0.007
0.008
Intake
Exhaust
K582 (23)
RV17YC
0.006
Valves
KT19 (19)
RY17YC
0.6247/0.6249
0.3125
Outside Diameter
Tappet
Clearance
(Cold)
KT17 (17)
K91 (4)
K161 (7)
K181 (8)
Posi-Lock1,2
Capscrew1,3
Spark Plugs
Cast Iron1
Sheet Metal
K241,
K301, K321
25-30 ft. lbs.
7
9
3
4
10
35 ft. lbs.
Overtorque 20%, loosen below torque value and retorque to final torque value.
Prior to Serial No. 23209832 45-55 ft. lbs.
5
Flywheel and crankshaft tapers must be clean and dry.
3
K341
25-30 ft. lbs.
K341 (16)
Oil Pan
K321 (14)
K91
200 in. lbs. 5
Nut1
Flywheel
5
Retaining
Screw1
Governor Bushing
Metal
Grass
Screen
Plastic
K301 (12)
Cylinder Head1
K241 (10)
9
6
Posi-Lock1,2
Capscrew
1,3
Spark Plugs
K582 (23)
Crankcase
5/16-200 in. lbs.
3/8-300 in. lbs.
Cylinder Head1
3
Nut
Screw1
40 ft. lbs.
Grass
Screen
Metal
Plastic
Oil Pan
Aluminum
Cast Iron1
Manifold Screw/Nut
Camshaft Nut
Non Metallic Fuel Pump
Mounting Screws
Sealant
Oil Passage
(In #1
Half)
Sealant
Sealant
30 ft. lbs.
35 ft. lbs.
40 ft. lbs.
12
16
14
Closure Plate
30 ft. lbs.
Bolt No.
KT17 Serial
No. 9755085
& later
1
and KT19
Sealant*
35 in. lbs.
3
Sealant*
5
7
Torque
11
1, 2, 3, 4,
(12, 14 Grade 8) 260 in. lbs.
5-11, 13, 15 150 in. lbs.
16
15
6
7
KT17 Prior
to Serial No.
9755085
13
Closure Plate
150 in. lbs.
10
Sealant
Sealant*
K582
#2 Side Crankcase
Half Interior
#2 Side Crankcase
Half Exterior
Gear Cover
Cylinder Barrel
K582
35 ft. lbs.
Flywheel
Retaining
Bolt No.
Torque
1-4
5-6
Torque remaining
bolts in most
200 in. lbs.
expedient
sequence to
8
9
*Use a gasket or sealant as
necessary: When reinstalling a
closure plate or cylinder barrels
originally installed with a gasket,
use a new gasket. When reinstalling
a closure plate or cylinder barrels
originally installed with sealant, use
new sealant. When installing a
service replacement closure plate
or cylinder barrels, use new
sealant.
M8 (8)
M10 (10)
M12 (12)
M14 (14)
M16 (16)
Bore x Stroke
Displacement Cu. In.
2.94 x 2.75
18.64
3600
3.25 x 2.88
23.85
3600
3.38 x 3.25
29.07
3600
3.500 x 3.25
31.27
3600
3.750 x 3.25
35.90
3600
0.4998/0.5001
0.4998/0.5001
0.4998/0.5001
0.4998/0.5001
0.4996
0.002/0.010
0.4996
0.002/0.010
0.4996
0.002/0.010
0.4996
0.002/0.010
0.005/0.010
0.005/0.010
0.005/0.010
0.005/0.010
0.005/0.010
0.001/0.002
0.001/0.002
0.001/0.002
0.001/0.002
0.001/0.002
0.0025
0.0025
0.0025
0.0025
0.0025
General
Balance
Gear
Camshaft
Connecting
Rod
Crankshaft
Cylinder
Bore
Cylinder
Head
Ignition
Running
Clearance
Rod to Crankpin
Max. Wear Limit
Rod to Piston Pin
(New)
0.0006/0.0011
0.0003/0.0008
0.0003/0.0008
0.0003/0.0008
0.0003/0.0008
0.6255/0.6258
0.8596/0.8599
0.8757/0.8760
0.8757/0.8760
0.8757/0.8760
1.1811/1.1814
1.5745/1.5749
1.5745/1.5749
1.5745/1.5749
1.5745/1.5749
1.1811
1.5745
1.5745
1.5745
1.5745
1.1860/1.1855
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
1.1850
1.4990
1.4990
1.4990
1.4990
0.0005
0.0005
0.0005
0.0005
0.0005
0.001
0.002/0.023
0.001
0.003/0.020
0.001
0.003/0.020
0.001
0.003/0.020
0.001
0.003/0.020
New
Max. Wear Limit
2.9380/2.9370
2.941
0.005
3.2515/3.2505
3.254
0.005
3.3755/3.3745
3.378
0.005
3.5005/3.4995
3.503
0.005
3.7505/3.7495
3.753
0.005
0.003
0.002
0.002
0.002
0.002
0.003
0.003
0.003
0.003
0.003
RCJ-8
RH-10
RH-10
RH-10
RH-10
0.025
0.012/0.016
0.025
0.012/0.016
0.025
0.012/0.016
0.025
0.012/0.016
0.025
0.012/0.016
Inside
Diameter
Spark Plug
Type (Champion or
equivalent)
Gap
10
Model (Horsepower)
All Pistons
1/2"
Piston
0.007/0.010
0.007/0.010
0.010/0.020
0.010/0.020
0.010/0.020
0.027
0.006
0.030
0.006
0.030
0.006
0.030
0.006
3.7465/3.7455
3.7435
0.0030/0.0050
0.010/0.020
0.004
2.9329/2.9336
3.3700/3.3693
3.4945/3.4938
3.7433/3.7426
2.9312
3.3673
3.4918
3.7406
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
New Bore4
Used Bore (Max.)
0.006
0.006
0.006
0.004
0.8591/0.8593
0.8752/0.8754
0.3125
0.8752/0.8754
0.3125
0.8752/0.8754
0.3125
Intake
0.006/0.008
0.0080/.010
0.008/0.010
0.008/0.010
0.008/0.010
Exhaust
0.3125
0.017/0.019
0.017/0.019
0.017/0.019
0.017/0.019
0.017/0.019
Minimum
Intake
Lift
(Zero Lash) Exhaust
0.2718
0.318
0.318
0.318
0.318
0.2482
0.318
0.318
0.318
0.318
Minimum
Valve Stem
O.D.
Intake
0.3103
0.3103
0.3103
0.3103
0.3103
Exhaust
0.3074
0.3074
0.3074
0.3074
0.3074
45
45
45
45
45
0.006
0.006
0.006
0.006
0.006
0.008
0.008
0.008
0.008
0.008
0.030
0.6247/0.6249
0.3125
Outside Diameter
Tappet
Clearance
(Cold)
0.007/0.017
Valves
New Bore
Piston Pin
M16 (16)
0.007/0.010
Piston
M14 (14)
0.007/0.010
Ring End
Gap
1/2"
M12 (12)
M10 (10)
2.9297/2.9281
2.925
Ring End
Gap
Piston
M8 (8)
Intake
Exhaust
3
4
11
Bore x Stroke
Displacement Cu. In.
Camshaft
Connecting
Rod
Crankshaft
Cylinder
Bore
Cylinder
Head
Ignition
Running
Clearance
3.125 x 2.750
42.18
3600
3.125 x 2.750
42.18
3600
3.125 x 3.062
46.98
3600
0.003/0.013
0.003/0.013
0.003/0.013
0.0012/0.0024
0.0012/0.0024
0.0012/0.0024
0.0029
0.0029
0.0029
0.0006/0.0011
0.6255/0.6258
0.0006/0.0011
0.6255/0.6258
0.0006/0.0011
0.7507/0.7510
1.7412/1.7422
1.7412/1.7422
1.7412/1.7422
1.7407
0.0005
0.001
1.7407
0.0005
0.001
1.7407
0.0005
0.001
0.0049
0.0049
0.0049
0.0059
1.7439/1.7461
0.0059
1.7439/1.7461
0.0059
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
0.001
0.002/0.014
0.002/0.014
0.002/0.014
3.1255/3.1245
3.128
3.1255/3.1245
3.128
3.1255/3.1245
3.128
0.002
0.0015
0.002
0.0015
0.002
0.0015
0.003
0.003
0.003
RV17C
RV17C
RV17C
0.035
0.008/0.012
0.035
0.008/0.012
0.035
0.008/0.012
Inside
Diameter
Spark Plug
New
Max. Wear Limit
12
MV16 (16)
Model (Horsepower)
1/2"
Piston
Piston Pin
MV16 (16)
3.1210/3.1203
3.1181
3.1215/3.1208
3.1186
0.0035/0.0052
0.0035/0.0052
0.0030/0.0047
0.010/0.023
0.010/0.023
0.010/0.023
0.032
0.006
0.032
0.006
0.032
0.006
0.6247/0.6249
0.3125
0.6247/0.6249
0.3125
0.7499/0.7501
0.3125
0.003/0.006
0.003/0.006
0.003/0.006
0.016/0.019
0.016/0.019
0.016/0.019
0.011/0.014
0.011/0.014
0.011/0.014
0.013/0.016
0.013/0.016
0.013/0.016
Minimum
Intake
Lift
(Zero Lash) Exhaust
0.274
0.274
0.274
0.274
0.274
0.274
Minimum
Valve Stem
O.D.
Intake
0.3103
0.3103
0.3103
Exhaust
0.3088
0.3088
0.3088
Nominal
Angle
Valve Seat
45
45
45
30
30
30
Intake
0.005
0.005
0.005
Exhaust
0.007
0.007
0.007
New Bore
Outside Diameter
Guide Reamer Size
Intake
Tappet
Clearance
(Cold)
Before Serial
No. 181600646
Exhaust Serial No. 18100656 to
1917809296
After Serial
No. 1917809296
Valves
Guide I.D.
Max. Wear
Limit1
13
Model (Horsepower)
M10 (10)
Spark Plugs
Cylinder Head1
3
Screw1
Flywheel
Governor
Nut1
Fan
Anti-Lock
Bushing
Fuel Tank
Bracket3
Mounting
M8
15-20 ft. lbs.
M10,
M12,M14
25-30 ft. lbs.
8
7
32 in. lbs.
32 in. lbs.
90 in. lbs.
10-15 in. lbs.
15-25 in. lbs.
10
M16
25-30 ft. lbs.
5
M16 (16)
14
M14 (14)
New
Used
Connecting
Rods1,2
M12 (12)
Connecting New
Rods1,2
Used
Spark Plugs
Screw1
9
Sealant
6
Sealant
40 ft. lbs.
115 in. lbs.
Fan
Manifold Screw/Nut
Non Metallic Fuel Pump
Mounting Screws
Ignition Module
Oil Filter
32 in. lbs.
Bolt No.
Torque
1-4
5-6
Adapter Fittings
Torque remaining
bolts in most
200 in. lbs.
expedient
sequence to
4
6
Cover Plate
3
Oil Pan
Sealant*
Sealant*
Sealant
Remote
Oil Filter Adapter
Oil Passage
(In #1
Half)
Sealant
Lines
Oil Line
Flared Nuts
#2 Side Crankcase
Half Interior
#2 Side Crankcase
Half Exterior
All Models
15-20 ft. lbs.
Flywheel5
Crankcase (All)
Cylinder Head
5
3
Sealant*
1
6
7
9
15
General
CH5 (5)
CH6 (6)
3.73
5.0
4.47*
6.0*
67 (2.64)
Bore
Stroke
51 (2.01)
180 cm (10.98 in.)
Displacement
End Play (With Shims)
Camshaft
0.15/0.55 (0.005/0.0217)
In Crankcase
In Closure Plate
16.030 (0.6311)
25.430 (1.001)
Connecting
Rod
Crankshaft
PTO End Main
Bearing Journal
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
New
0.0635 (0.0025)
0.000/0.056 (0.000/0.0022)
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)
0.020 (0.0008)
0.025 (0.0010)
30.947/30.960 (1.2184/1.2189)
30.934 (1.2179)
0.025 (0.0010)
0.013 (0.0005)
67.00/67.03 (2.6378/2.6390)
67.049 (2.6397)
0.150 (0.0059)
Max. Taper
0.100 (0.0039)
16
0.030/0.056 (0.0012/0.0022)
Governor
15.954 (0.6281)
25.350 (0.9980)
0.076 (0.003)
6.296 (0.2479)
9.960 (0.3921)
Governor Cross Shaft Bore (In Crankcase) I.D. Max. Wear Limit
6.425 (0.2530)
Model (Horsepower)
Spark Plug Type (Champion or equivalent)
Ignition
D1
CH6 (6)
RC12YC
1.02 (0.040)
0.203/0.305 (0.008/0.012)
6 mm
CH5 (5)
0.040/0.085 (0.0016/0.033)
0.040/0.072 (0.0016/0.0028)
0.140/0.275 (0.0055/0.0108)
Pistons,
Piston Rings,
Piston Thrust Face (@D1)
and
to Cylinder Bore
Piston Pin
New Bore
Used Bore (Max.)
O.D. New
O.D. Max. Wear Limit
New Running Clearance
0.25/0.45 (0.010/0.018)
0.75 (0.030)
66.941/66.959 (2.635/2.636)
66.816 (2.630)
0.016/0.059 (0.0006/0.0023)
0.000/0.0508 (0.000/0.0020)
0.000/0.508 (0.000/0.0020)
Valves and
Valve Lifters Exhaust Valve Guide
I.D. Std.
I.D. Max. Wear Limit
I.D. Std.
I.D. Max. Wear Limit
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
17
Balance
Shaft
Bearing
Camshaft
Displacement
End Play (Free)
9.75
13
12.5
10.50
14
87 (3.43)
0.0575/0.3625 (0.0023/0.0143)
20.038 (0.7889)
In Crankcase
In Oil Pan
New
Max. Wear Limit
O.D. New
Flywheel End Main Bearing O.D. Max. Wear Limit
Journal
Max. Taper
Max. Out of Round
PTO End Main
Bearing Journal
19.959 (0.7858)
20.038 (0.7889)
20.038 (0.7889)
19.959 (0.7858)
19.959 (0.7858)
0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
0.0575/0.4925 (0.0023/0.0194)
18
9.33
Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)
Crankshaft
8.20
11
67 (2.64)
398 cm (24.3 in.)
Connecting
Rod
CH & CV11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV14 (14)
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
45.016 (1.7723)
44.965/45.003 (1.7703/1.7718)
45.016 (1.7723)
0.03/0.09 (0.0012/0.0035)
0.115 (0.0045)
44.913/44.935 (1.7582/1.7691)
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)
Model (Horsepower)
New
Cylinder
Bore
Ignition
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)
6.063 (0.2387)
D1
Pistons,
Piston Rings,
1
and Piston Pin Piston Thrust Face (@D1)
to Cylinder Bore
New Bore
Used Bore (Max.)
O.D. New
O.D. Max. Wear Limit
0.203/0.305 (0.008/0.012)
0.040/0.105 (0.0016/0.0041)
0.040/0.072 (0.0016/0.0028)
0.55/0.675 (0.0217/0.0266)
0.3/0.5 (0.012/0.020)
0.77 (0.030)
86.941/86.959 (3.4229/3.4236)
86.814 (3.4179)
0.041/0.044 (0.0016/0.0017)
I.D. Std.
7.038/7.058 (0.2771/0.2778)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.96 (0.353)
16.13 (0.640)
15.727 (0.619)
45
RC12YC
1.02 (0.040)
87.063 (3.4277)
Max. Taper
6 mm
87.000/87.025 (3.4252/3.4262)
CH & CV11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV14 (14)
9.14 (0.360)
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
19
Balance
Shaft
Bearing
Camshaft
Displacement
End Play (Free)
0.0575/0.3625 (0.0023/0.0143)
Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)
20.038 (0.7889)
In Crankcase
In Oil Pan
New
Max. Wear Limit
O.D. New
Flywheel End Main Bearing O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
Closure Plate or Oil Pan
End Main Bearing
20
19.959 (0.7858)
20.038 (0.7889)
20.038 (0.7889)
19.959 (0.7858)
19.959 (0.7858)
0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
0.0575/0.4925 (0.0023/0.0194)
Crankshaft
11.2
15
90 (3.60)
67 (2.64)
426 cc (26.0 cu. in.)
Connecting
Rod
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
45.016 (1.7723)
44.965/45.003 (1.7703/1.7718)
45.016 (1.7723)
0.03/0.09 (0.0012/0.0035)
0.115 (0.0045)
44.913/44.935 (1.7582/1.7691)
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)
Model (Horsepower)
New
Cylinder
Bore
Ignition
0.12 (0.0047)
Max. Taper
0.05 (0.0020)
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)
6.063 (0.2387)
D1
Pistons,
Piston Rings,
Piston Thrust Face1 (@D1)
and Piston Pin
to Cylinder Bore
New Bore
Used Bore (Max.)
O.D. New
O.D. Max. Wear Limit
0.203/0.305 (0.008/0.012)
0.060/0.105 (0.0023/0.0041)
0.040/0.085 (0.0015/0.0002)
0.176/0.026 (0.0069/0.0010)
0.27/0.51 (0.010/0.020)
0.77 (0.030)
89.951/89.969 (3.5413/3.5420)
89.824 (3.5363)
0.031/0.043 (0.0012/0.0016)
I.D. Std.
7.038/7.058 (0.2771/0.2778)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.96 (0.353)
16.13 (0.640)
15.727 (0.619)
45
RC12YC
1.02 (0.040)
6 mm
90.063 (3.5457)
9.14 (0.360)
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
21
Camshaft
Connecting
Rod
Displacement
End Play (With Shims)
Bore I.D. Max. Wear Limit
New
Max. Wear Limit
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
New
22
18
20.038 (0.7889)
19.959 (0.7858)
0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
41.016 (1.6148)
0.03/0.09 (0.0012/0.0035)
0.039/0.074 (0.0015/0.0029)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
77.000/77.015 (3.0315/3.0325)
77.063 (3.0340)
0.12 (0.0047)
Max. Taper
0.05 (0.0020)
16.4
0.070/0.480 (0.0028/0.0189)
14.9
20
77 (3.03)
0.076/0.127 (0.003/0.005)
In Crankcase
13.4
67 (2.64)
624 cm (38.1 in.)
Crankshaft
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)
6.063 (0.2387)
22
Model (Horsepower)
Spark Plug Type (Champion or equivalent)
Ignition
D1
0.040/0.080 (0.0016/0.0031)
0.040/0.072 (0.0016/0.0028)
0.060/0.202 (0.0024/0.0080)
New Bore
RC12YC
0.25/0.45 (0.0098/0.0177)
0.77 (0.030)
76.967/76.985 (3.0302/3.0309)
76.840 (3.0252)
0.015/0.058 (0.0006/0.0023)
I.D. Std.
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.07 (0.3177)
8.07 (0.3177)
45
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
23
Camshaft
Connecting
Rod
Displacement
End Play (With Shims)
Bore I.D. Max. Wear Limit
25
83 (3.27)
0.076/0.127 (0.003/0.005)
In Crankcase
New
Max. Wear Limit
20.038 (0.7889)
19.959 (0.7858)
0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
0.070/0.480 (0.0028/0.0189)
0.050/0.5 (0.0020/0.0197)
0.050/0.75 (0.0020/0.0295)
Crankshaft
Main Bearing Journals
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
O.D. New
O.D. Max. Wear Limit
Max. Taper
Max. Out of Round
New
41.016 (1.6148)
0.03/0.09 (0.0012/0.0035)
0.039/0.074 (0.0015/0.0029)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
82.988/83.013 (3.2672/3.2682)
83.051 (3.2697)
0.12 (0.0047)
Max. Taper
0.05 (0.0020)
24
18.6
67 (2.64)
725 cm (44 in.)
Governor
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)
6.063 (0.2387)
Model (Horsepower)
Spark Plug Type (Champion or equivalent)
Ignition
D1
0.76 (0.030)
0.025/0.048 (0.0010/0.0019)
0.015/0.037 (0.0006/0.0015)
0.026/0.176 (0.0010/0.0070)
New Bore
0.25/0.56 (0.0100/0.0224)
0.94 (0.037)
82.986 (3.2672)
82.841 (3.2615)
0.002/0.045 (0.001/0.0018)
I.D. Std.
7.038/7.058 (0.2771/0.2779)
RC12YC
0.28/0.33 (0.011/0.013)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.07 (0.3177)
8.07 (0.3177)
45
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
25
CH6 (6)
CH5 (5)
Valve Cover
Closure Plate
Closure Plate
Fastener
1
3
Cylinder
Head
Fasteners M6
Fasteners M8
Spark Plug (14 mm w/gasket)
Ignition Module
26
Valve Cover
For self-tapping (thread forming) fasteners: The higher torque value is for initial installation into a
new cored hole * the lower torque value is for subsequent installation, and installation into tapped
holes and weld nuts.
1
Valve Cover
12
4
1
5
3
11
9
CH & CV11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV14 (14) CH & CV15 (15)
8mm straight 22.7 Nm (200 in. lb.), 8mm step-down 14.7 Nm (130 in. lb.), 6mm straight 11.3 Nm (100 in. lb.)
Fastener
4
2
Cylinder
Head
1
3
Rocker bridge type 9.9 Nm (88 in. lb.), Guide plate type 11.3 Nm (100 in. lb.)
Fan Fasteners
Retainer Screw
Spark Plug
Ignition Module
Oil Filter
Valve Cover
For self-tapping (thread forming) fasteners: The higher torque value is for initial installation into a
new cored hole * the lower torque value is for subsequent installation, and installation into tapped
holes and weld nuts.
2
Tighten in two stages. Torque first to 15 ft. lb. following sequence. Then tighten to final torque value
(30 ft. lb.).
1
27
Breather Plate
8mm straight 22.7 Nm (200 in. lb.), 8mm step-down 14.7 Nm (130 in. lb.), 6mm straight 11.3 Nm (100 in. lb.)
Two Step Process; First torque 22.6 Nm (200 in. lb.), Second torque 41.8 Nm (370 in. lb.)
Exhaust Ports
Cylinder
Head
Flywheel
Retainer Screw
Spark Plug
Ignition
Ignition Module
Manifold (Intake)
Rectifier Fasteners
Oil Filter
Throttle/
Choke
Controls
Valve Cover
Oil Filter
Gasket/Sealant Type
O-Ring Type
For self-tapping (thread forming) fasteners: The higher torque value is for initial installation into a
new cored hole * the lower torque value is for subsequent installation, and installation into tapped
holes and weld nuts.
28
Exhaust Ports
Fastener
Valve Cover
Breather Plate
1
3
10
1
5
8
7
4
6
9
4
2
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Conversion Factors
Inches 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 (Nm)
Foot Pounds x 1.356 = Newton-meter (Nm)
Ounce (Weight) x 28.350 = Grams (g)
Pound x 0.4536 = Kilograms (kg)
Horsepower x 0.746 = Kilowatt (kW)
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