Onan CCKA User Manual

The overrunning clutch is packed in a special high
melting point grease and after its initial assembly,
needs no further lubrication. This ciutch prevents the
engine from turning the starter motor at too high a
speed once it is started. Do not subject the overrun¬
ning clutch to grease dissolving or high temperature
cleaning methods. This may cause the clutch to lose
some or all of its grease.
If the pinion does not turn freely in the clutch in the
overrunning direction, or the ciutch tends to slip in
the opposite direction, replace the assembly. A worn
clutch indicated by excessive looseness of the pinion
requires replacement
Never attempt to repair or relubricate a defective clutch.
The clearance between the pinion and the housing
should be approximately 1/16- to 1/8-inch (1.6 -
3.2 mm) when the pinion is in the operating position.
Figure 43.
Drive Pinion: The teeth of the drive pinion are
chamfered on only one side and specially rounded
and polished to make the automatic meshing with the
flywheel ring gear more efficient. The drive is design¬
ed so if the ends of the pinion teeth meet end to end
with the ringgearteeth {keeping in mind thatthedrive
is freely mounted on the drive shaft), the drive
assembly can move back slightly against the pressure
of the driving spring. The longitudinal movement
permits the pinion to turn slightly farther and enter the
flywheel ring gear.
It is important the correct length of drive spring be used when
making replacements. The length of the. drive spring controls the
longitudinal movement of the pinion (meshing and unmeshing of
the pinion and flywheel ring gear).
Keep the drive shaft free of rust, burrs or bends so the
drive can move freely along it. A damaged pinion
necessitates the replacement of the assembly.
Onan recommends replacement of faulty gear drive assemblies
and provides no further service information concerning their
repair. For further repair information, contact the manufacturer of
your starter motor.
Disassembly:
1. Remove all wires to the starting unit. Tag each
wire so it can be reconnected as originally.
2. Remove the solenoid (where applicable).
3. Remove the starter motor thru-bolts and divide
the starter into three main assemblies—the front
bracket, the housing and the rear bracket. On
some model starters, short screws are used to
hold the three starter sections together {Figure
44). The spacers on the solenoid starters are used
for adjustment of the thrust gap of the armature
shaft and are located between the rear bracket
and the commutator shaft.
On the solenoid shill models, the steel spacing washer is on
the commutator side.
(0.07'‘—0.12” CLEARANCE.
SEE TEXT)
STARTING MOTOR NEED
NOT BE REMOVED FROM
ENSINE TO MAKE THIS
MEASUREMENT
FIGURE 43. PINION CLEARANCES (GEAR DRIVE)
46

Onan CCKA Specifications

General

Cylinders	2
Ignition System	Battery ignition
Engine Type	4-cycle
Bore	3.25 in (82.55 mm)
Power Output	Varies with model. e.g., 6.5 kW (CCK)
Horsepower	10 hp
Starter	Electric