Onan CCK Service Manual

CRANKSHAFT
Inspect the bearing journals. If they are scored and
cannot be smoothed out by dressing down, the
bearing journals should be refinished to use nearest
available undersize bearings or a new crankshaft
shouid be installed. If a worn main bearing journal
cannot be fitted with an available precision type
undersize bearing, then refinish it to the next under¬
size. if a worn rod journal cannot be fitted by installing
new bearing inserts (forged rod), then refintsh it to
take the corresponding undersize bearing insert
available.
Whenever making major repairs on die engine,
always inspect the drilled passages of the crankshaft.
Clean them to remove any foreign material and to
assure proper lubrication of the connecting rods.
bearing in flush with the outside end of the bearing
bore. Press the rear bearing in until past the ignition
plunger hole.
Crankshaft New crankshaft main bearings are preci¬
sion type which do not require line reaming or line
boring after installation. See Parts Catalog 927-0264
for standard size and undersizes available.
Before putting in the main bearings, expand the
bearing bore by placing the casting in hot water or in
an oven heated to 200° F (93° C). If practical, cool the
precision bearing to shrink it.
|^Caution^1 M 3 t° rc h is used to heat bearing
^ bore, apply only a little heat evenly
to prevent warpage and loss of temper in the steel.
BEARINGS
Removal of the camshaft or crankshaft bearings
requires complete disassembly of the engine. Use a
press or a suitable drive plug to remove the bearings.
Support the casting to avoid distortion and avoid
damaging the bearing bore during removal and
installation. Use oil on the bearings to reduce friction
when installing and again lubricate with oil after
installing. See Figure 77. Use combination bearing
driver 420-0324 to install the camshaft bearings.
PRECISION TYPE
Do not line ream
or bore.
ALIGN HOLE IN BEARING
WITH HOLE IN BEARING BORE
7/32"
(5.6 mm)
PROM
OUTSIDE
CAMSHAFT BEARING
.LOCK PIN
fr- ALIGN BEARING OIL HOLES WITH
OIL HOLES IN BEARING BORE
PRECISION TYPE
Do not I ine ream
or bore.
LOCK PIN
BEARING
CRANKSHAFT BEARING
FIGURE 77. INSTALLATION OF CAM AND
CRANKSHAFT BEARINGS
Camshaft Replacement.camshaft bearings are preci¬
sion type which do not require line reaming or line
boring after installation. Coat the bearing with
lubricating oii to reduce friction. Place thebearing on
the crankcase over the bearing bore with the
lubricating hole {front only) in proper position. Be
sure to start the bearing straight. Press the front
For putting in either the front or mar main bearing,
using instructions following, always align the oil
hoie(s) in the bearing with the oil hole(s) in the
bearing bore. The oil passage must be at least 1/2
open. The cold oiled precision bearing should require
only light taps to position it. Install the bearing flush
with the inside end of the bore. If the head of a lock pin
is damaged, use side cutters or “Easy-Out” tool to
remove pin. Then install a new lock pin. Apply oil to
the thrust washers to hold in place when the
crankshaft is installed. The oil grooves in the thrust
washer bearings must face the crankshaft. Be sure
two notches fit over lock pins.
OIL SEALS
The bearing plate must be removed to replace its oil
seal. Drive the oil seal out from the inside using
bearing plate driver 420-0181 and gear cover driver
420-0313.
Before installing the seals, fill the space between
seals with a fibrous grease or stiff cup grease. This will
improve sealing. See Figure 78.
When installing the gear cover oil seal, tap the seal
inward until rear (spring side) of casing is 1-1/32inch
(26.2 mm) from the mounting face of the gear cover.
When installing the bearing plate oii seaf, tap the seal
into the bearing plate bore to bottom against the
shoulder in the plate bore. Use a seal expander, or
place a piece of shim stock around the end of the
crankshaft, when replacing thebearing plate to avoid
damaging the seal. Remove the shim stock as soon as
the plate is in place.
Engines equipped with some types of reduction gear
assemblies do not use the rear oil seal. The reduction
gear assembly is oiled directly from the engine
crankcase. Refer to the instructions screened on the
case of the reduction gear assembly.
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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)