CHAPTER 1 GENERAL INFORMATION 1
ENGINE IDENTIFICATION 1
INTERPRETATION OF MODEL NUMBER 1
SHORT BLOCKS 2
FUELS 2
ENGINE OIL 2
CAPACITIES 2
OIL CHANGE INTERVALS 3
OIL CHECK 3
OIL CHANGE PROCEDURE 3
TUNE-UP PROCEDURE 3
STORAGE 4
DRAINING THE FUEL SYSTEM 4
OIL CYLINDER BORE 4
CHAPTER 2 AIR CLEANERS 5
GENERAL INFORMATION 5
OPERATION 5
COMPONENTS 5
TROUBLESHOOTING OR TESTING 6
SERVICE 6
DISASSEMBLY PROCEDURE 6
POLYURETHANE-TYPE FILTER ELEMENT OR PRE-CLEANER 7
PAPER -TYPE FILTER ELEMENT 7
FLOCKED SCREEN 7
CHAPTER 3 CARBURETORS AND FUEL SYSTEMS 8
GENERAL INFORMATION 8
OPERATION 8
FUEL PRIMERS 9
IMPULSE FUEL PUMPS 9
FLOAT STYLE CARBURETORS 9
CARBURETOR VISUAL IDENTIFICATION 10
SERIES I CARBURETORS 10
SERIES III & SERIES IV CARBURETORS 10
SERIES VI CARBURETORS 10
SERIES VII 10
SERIES VIII 11
SERIES IX 11
WALBRO MODEL LMK 11
TESTING 12
SERVICE 12
CARBURETOR PRE-SETS AND ADJUSTMENTS 12
PRE-SETS AND ADJUSTMENTS (TECUMSEH AND WALBRO CARBURETORS) 13
FINAL ADJUSTMENTS 13
TECUMSEH CARBURETORS 13
WALBRO CARBURETOR 13
CARBURETOR DISASSEMBLY PROCEDURE 14
IMPULSE FUEL PUMP 15
FLOAT ADJUSTING PROCEDURE 16
INSPECTION 16
THROTTLE AND CHOKE 16
IDLE AND HIGH SPEED MIXTURE ADJUSTING SCREW 16
FUEL BOWL RETAINING NUT 16
FUEL BOWL, FLOAT, NEEDLE AND SEAT 17
ASSEMBLY PROCEDURE 18
WELCH PLUGS 18
THROTTLE SHAFT AND PLATE 18
CHOKE SHAFT AND PLATE 19
FUEL INLET FITTING 19
HIGH AND LOW SPEED ADJUSTING SCREW, MAIN NOZZLE 19
INLET NEEDLE AND SEAT 20
FLOAT INSTALLATION 20
FUEL BOWL AND BOWL NUT 21
IMPULSE FUEL PUMP 21
PRIMER BULB 21
FINAL CHECKS 21
CHAPTER 4 GOVERNORS AND LINKAGE 22
GENERAL INFORMATION 22
OPERATION 22
TROUBLESHOOTING 22
ENGINE OVERSPEEDING 22
ENGINE SURGING 22
SERVICE 23
GOVERNOR ADJUSTMENT 23
GOVERNOR GEAR AND SHAFT SERVICE 23
GOVERNOR GEAR OR SHAFT REPLACEMENT, UPSET STYLE GOVERNOR SHAFT 23
GOVERNOR SHAFT REPLACEMENT, RETAINING RING STYLE 24
SPEED CONTROLS AND LINKAGE 25
CONVERSION TO REMOTE CONTROL 27
OVM, OVXL, OHV VERTICAL SPEED CONTROL 28
OHV 11-17 HORIZONTAL SPEED CONTROL 28
CHAPTER 5 RECOIL STARTERS 29
GENERAL INFORMATION 29
OPERATION 29
COMPONENTS 29
SERVICE 29
ROPE SERVICE 29
ROPE RETAINER REPLACEMENT 30
STYLIZED REWIND STARTER (OHH, OVRM, OHM, OHSK, OVM, OVXL, OHV 11-13), AND STAMPED STEEL STARTER 30
DISASSEMBLY PROCEDURE 30
ASSEMBLY PROCEDURE 31
STYLIZED REWIND STARTER WITH PLASTIC RETAINER 31
DISASSEMBLY PROCEDURE 31
ASSEMBLY 32
KEEPER SPRING STYLE STARTERS 32
DISASSEMBLY PROCEDURE 32
ASSEMBLY PROCEDURE 33
STYLIZED STARTER (OHV 13.5 -17) 34
ASSEMBLY 34
CHAPTER 6 ELECTRICAL SYSTEMS 35
GENERAL INFORMATION 35
OPERATION 35
STARTING CIRCUIT AND ELECTRIC STARTERS 35
CHARGING CIRCUIT 35
CONVERTING ALTERNATING CURRENT TO DIRECT CURRENT 36
HALF WAVE RECTIFIER SINGLE DIODE 36
FULL WAVE RECTIFIER BRIDGE RECTIFIER 36
COMPONENTS 36
BATTERY 36
WIRING 36
ELECTRICAL TERMS 37
BASIC CHECKS 37
TROUBLESHOOTING ELECTRICAL STARTER CIRCUIT FLOW CHART 38
TROUBLESHOOTING ELECTRICAL CHARGING CIRCUIT FLOW CHART 39
TESTING PROCEDURE 40
STARTING CIRCUIT 40
CHARGING CIRCUIT 40
350 MILLIAMP CHARGING SYSTEM 40
18 WATT A.C. LIGHTING ALTERNATOR 41
35 WATT A.C. 41
2.5 AMP D.C., 35 WATT LIGHTING 41
3 AMP DC ALTERNATOR SYSTEM - DIODE IN HARNESS SLEEVE 42
5 AMP D.C. ALTERNATOR SYSTEM REGULATOR-RECTIFIER UNDER BLOWER HOUSING 43
3 AMP D.C. 5 AMP A.C. ALTERNATOR 43
MODELS OVM/OVXL/OHV12.5 44
MODELS OHV 13.5 - 17 (3/5 AMP SPLIT). 44
MODELS OVM/OVXL/OHV12.5 (RED BETWEEN ENGINE AND DIODE) 44
MODELS OHV 13.5 - 17 (RED BETWEEN ENGINE AND DIODE) 45
7 AMP D.C. ALTERNATOR SYSTEM REGULATOR-RECTIFIER UNDER ENGINE HOUSING 45
10 AMP A.C. ALTERNATOR 46
16 AMP ALTERNATOR SYSTEM WITH EXTERNAL REGULATOR 46
VOLTAGE REGULATORS 46
FUEL SHUT-DOWN SOLENOIDS 46
LOW OIL SHUTDOWN SWITCHES 47
LOW OIL PRESSURE SENSOR 47
LOW OIL SENSOR 47
ELECTRIC STARTER SERVICE 48
12 VOLT OR 120 VOLT ELECTRIC STARTERS 48
INSPECTION AND REPAIR 49
BRUSH CARD REPLACEMENT 49
CHAPTER 7 FLYWHEEL BRAKE SYSTEMS 50
GENERAL INFORMATION 50
OPERATION 50
COMPONENTS 51
SERVICE 51
BRAKE BRACKET ASSEMBLY 52
IGNITION GROUNDOUT TERMINAL 52
STARTER INTERLOCK SWITCH 52
CONTROL CABLE 52
BRAKE BRACKET REPLACEMENT 52
CHAPTER 8 IGNITION 53
GENERAL INFORMATION 53
OPERATION 53
SOLID STATE IGNITION SYSTEM (CDI) 53
COMPONENTS 53
TESTING PROCEDURE 54
FOUR CYCLE IGNITION TROUBLESHOOTING 55
SERVICE 56
SPARK PLUG SERVICE 56
CONDITIONS CAUSING FREQUENT SPARK PLUG FOULING 56
IGNITION TIMING CHECK 57
SERVICE TIPS 57
CHAPTER 9 INTERNAL ENGINE AND CYLINDER 58
GENERAL INFORMATION 58
OPERATION 58
4-CYCLE ENGINE THEORY 58
LUBRICATION SYSTEMS 59
COUNTERBALANCE SYSTEMS 59
COMPONENTS 60
ENGINE OPERATION PROBLEMS 61
ENGINE OPERATION PROBLEMS 62
TESTING 63
ENGINE KNOCKS 63
ENGINE OVERHEATS 63
SURGES OR RUNS UNEVENLY 63
ENGINE MISFIRES 63
ENGINE VIBRATES EXCESSIVELY 64
BREATHER PASSING OIL 64
EXCESSIVE OIL CONSUMPTION 64
LACKS POWER 65
SERVICE 65
DISASSEMBLY PROCEDURE 65
CYLINDERS 68
CYLINDER HEAD AND VALVE TRAIN SERVICE 69
VALVES, SPRINGS, AND PUSH RODS 69
PISTONS, RINGS, AND CONNECTING RODS 70
PISTON 70
PISTON RINGS .70
PISTON RING ORIENTATION 70
CONNECTING RODS 71
CRANKSHAFTS AND CAMSHAFTS 71
CAMSHAFTS 71
VALVE SEATS 72
VALVE LIFTERS 73
VALVE GUIDES 73
VALVE GUIDE REMOVAL (OVM, OHM, OHSK110 & 120, OVXL ONLY) 73
VALVE GUIDE INSTALLATION (OVM, OHM, OHSK110 & 120, OVXL ONLY) 73
CRANKCASE BREATHERS 74
TOP MOUNTED BREATHER 74
SIDE MOUNTED BREATHER 74
CYLINDER COVER, OIL SEAL, AND BEARING SERVICE 75
CYLINDER COVER 75
OIL SEAL SERVICE 75
CRANKSHAFT BEARING SERVICE 75
BALL BEARING SERVICE 75
SERVICE BUSHING 76
BUSHING SIZE CHART 76
ENGINE ASSEMBLY 76
CHAPTER 10 83
ENGINE SPECIFICATIONS AND SEARS CRAFTSMAN CROSS-REFERENCE 83
OVERHEAD VALVE SEARS CRAFTSMAN CROSS REFERENCE 83
ENGINE SPECIFICATIONS 85
OVERHEAD VALVE TORQUE SPECIFICATIONS 86
OVERHEAD VALVE TORQUE SPECIFICATIONS 87
CHAPTER 11 EDUCATIONAL MATERIALS AND TOOLS 88
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