9-3
REMOVING AND INSTALLING ENGINE
Removal
1. Unless it has already been performed, discon-
nect all wiring from the engine, remove the gen-
erator/engine bracket and loosen or remove
the cylinder shroud screws shown in Fig-
ure 9-1.
2. Remove the ignition coils, flywheel and ex-
haust manifold (Section 7. Fan, Drive Belt, Fly-
wheel, Ignition, Exhaust).
3. Remove the five screws securing the engine to
the generator/engine base and lift off the base.
Installation
Installation is the reverse of removal. Torque the en-
gine mounting screws to 20 lb-ft (27 N-m). Torque
the cylinder shroud screws to 8 lb-ft (11 N-m).
STARTER MOTOR
Replacing Starter Motor
To remove the starter motor (Figure 9-1), discon-
nect all wiring and remove the two mounting screws.
Follow instructions in the starter motor kit if the start-
er is to be repaired. When installing a starter motor,
torque the mounting screws to 20 lb-ft (27 N-m) and
the terminal nut to 6.5 lb ft (8 N-m).
Replacing Starter Motor Solenoid
The starter solenoid is separately replaceable. To
determine whether the problem is in the solenoid or
in the motor:
WARNING
This test involves high electrical
currents, strong arcing and moving parts that
can cause severe personal injury. Do not con-
duct this test near fuel tanks or when flammable
vapors are present. Wear safety glasses. Keep
fingers away from the pinion gear.
1. Secure the motor assembly in a vice after it has
been removed from the genset.
2. Using a heavy jumper cable, because of the
large currents involved, connect the motor ter-
minal on the solenoid (the one closest to the
motor) to the positive (+) terminal on a 12 volt
battery.
3. Using a heavy cable from the negative (–) ter-
minal on the battery, briefly touch the mounting
flange on the motor.
A. If the motor does not spin up quickly and
smoothly, replace the motor/solenoid as-
sembly.
B. If the motor does spin up quickly and
smoothly, the motor is probably okay: re-
place the solenoid.
C. The solenoid is removeable by discon-
necting the motor lead from the solenoid
terminal and removing the two solenoid
mounting nuts. When installing a new sole-
noid, make sure the solenoid plunger en-
gages the shift fork.
D. The solenoid is removeable by discon-
necting the motor lead from the solenoid
terminal and removing the two solenoid
mounting nuts. When installing a new sole-
noid, make sure the solenoid plunger en-
gages the shift fork.
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