Onan CCK Service Manual

Engine Disassembly
If engine disassembly is necessary, first remove all
the complete assemblies (e.g., manifold with car¬
buretor and cartridge air cleaner}. Individual
assemblies, as the carburetor, can be removed and
serviced later, if necessary. Any special assembly
instructions for a particular group are included in the
applicable section. When reassembling, check each
section for these special assembly instructions or
procedures.
Keep all parts in their respective order... valve assemblies, rod
caps for respective rod and piston assemblies, etc.. Analyze
reasons for parts failures. Use new gaskets for assembly.
FLYWHEEL
To remove the flywheel, turn the flywheel mounting
screw outward about two turns and use Onan puller
420-0100 to pull the flywheel. Figure 59.
FIGURE 59. ONAN FLYWHEEL PULLER
Do not use 3 screwdriver or similar
tool or pry behind the flywheel
against the gearcase. The gearcase cover is die-cast
material and will break if undue pressure is applied in
this manner.
Do nol drop the flywheel. A broken fin will destroy the
balance. Always use a steel key for mounting the
flywheel.
A magneto flywheel which has lost its magnetism can
be remagnetized. The spark should jump a 3/16-inch
gap with ease, as tested by holding the spark plug
wire away from a clean metal part of the engine while
cranking.
GEAR COVER
After removing the flywheel key and mounting
screws, tap the gear cover gently with a soft-faced
hammer to loosen it.
When installing the gear cover, make
sure that the pin in the gear cover
engages the governor cup correctly, Figure 60.
Turn the governor cup so that the metal lined hole is at
the three o'clock position. The smooth side of the
governor yoke must ride against the governor cup.
Tum the governor arm and shaft clockwise as far as
possible and hold in this position until the gear cover
is installed flush against the crankcase. Be careful not
to damage the gear cover oil seal. Adjust the roll
(stop) pin to protrude to a point 3/4 inch from the
cover mounting surface. See Figure 60.
GOVERNOR CUP
ROLL PIN
ROTATE
GOVERNOR CUP
SO THAT ROLL PIN
FITS INTO THE
METAL LINED
HOLE IN THE CUP
-GOVERNOR ARM
GOVERNOR SHAFT
GOVERNOR
SHAFT YOKE
(Smooth Side
Toward Cup)
OIL SEAL
IF FEELER WILL
ENTER HOLE 1/2’
BALL HAS
FALLEN OUT
FIGURE 60. GEAR COVER ASSEMBLY
53

Onan CCK Specifications

General

Cylinders	2
Ignition System	Battery ignition
Fuel Type	Gasoline
Cooling System	Air-cooled
Fuel System	Carburetor
Starter	Electric
Governor	Mechanical
Max RPM	1800 RPM
Engine Type	4-cycle
Bore and Stroke	3.25 x 3.625 inches (82.55 x 92.08 mm)