SPECS & TORQUES

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


– – – – – –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


––

––

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


CylinderBore


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 –


Intake


Intake


Intake


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 –


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.


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)


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


InsideDiameterMax. Out of Round (I.D.)Max. Taper (I.D.)

CylinderBore


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


0.010/0.0200.030

0.010/0.0200.030

––

Ring EndGap


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


––

––

3.74353.7465/3.7455

– – 0.0030/0.0050

––

–

––

–

Piston

NewMax. Wear Limits

Thrust FaceO.D.3


––

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


Intake


Intake


Intake


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


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



CylinderBore


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


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


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


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.



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


––––––

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


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


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


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


Flywheel End Main BearingJournal


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



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


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°


I.D. – Max. Wear Limit


I.D. – Std.

I.D. – Std.


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



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


RodEnd Play (Free)Crankshaft Sleeve Bearing I.D. – Max. Wear Limit

Max. Wear Limit


Flywheel End Main Bearing


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


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



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


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)


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


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. – 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)




Ignition

Governor

CylinderBore

1 D1

6 mm


22

Command–Twin Cylinder Engine Specifications & TolerancesAll dimensions in millimeters (inches).


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


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)


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)


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


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


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


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)


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°


I.D. – Std.

I.D. – Std.



1 D1

6 mm


24

Command–Twin Cylinder Engine Specifications & TolerancesAll dimensions in millimeters (inches).


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


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)


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)


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


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


Exhaust Valve Guide


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)


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




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


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


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

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