Kohler Tableau de Réglages Atelier

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SPECIFICATIONS & TOLERANCES

TORQUE VALUE & SEQUENCES
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SPECS & TORQUES
Table of Contents
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Standard Application Torque Recommendations...3

KSeries Single Cylinder Engine Specifications & Tolerances....4-5
KSeries Twin Cylinder Engine Specification & Tolerances..6-7

KSeries Single Cylinder Torque Values & Sequences for Fasteners...8
KSeries Twin Cylinder Torque Values & Sequences for Fasteners..9
Magnum Single Cylinder Engine Specifications & Tolerances.10-11
Magnum Twin Cylinder Engine Specifications & Tolerances12-13
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Magnum Single Cylinder Torque Values & Sequences for Fasteners..14
Magnum Twin Cylinder Torque Values & Sequences for Fasteners.15

Command Single Cylinder Engine Specifications & Tolerances..16-21
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Command Twin Cylinder Engine Specification & Tolerances...22-25
Command Single Cylinder Torque Values & Sequences for Fasteners..26-27
Command Twin Cylinder Torque Values & Sequences for Fasteners.28-29
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Conversion Factors30
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TP-2469-A 12/07
Standard Application Torque Recommendations

Torque values are in Nm. Values in parenthesis ( ) are English equivalents.
English Fastener
Metric Fastener
Tightening Torque Nm (in. lb.) + or- 20%

Bolts, Screws, Nuts and Fasteners
Assembled Into Cast Iron or Steel
Tightening Torque Nm (in. lb.) + or -10%

Property Class
Non-critical
Fasteners
into
Aluminum
Size
M4
M5
M6
M8
1.2 (11)
2.5 (22)
4.3 (38)
10.5 (93)
1.7 (15)
2.9 (26)
4.1 (36)
5.0 (44)
3.2 (28)
5.8 (51)
8.1 (72)
9.7 (86)
5.7 (50)
9.9 (88) 14.0 (124) 16.5 (146)
13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360)
2.0 (18)
4.0 (35)
6.8 (60)
17.0 (150)
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Tightening Torque Nm (in. lb.) + or -10%
Property Class
M10
M12
M14
21.7 (16)
36.6 (27)
58.3 (43)
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27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60)

47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103)
76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162)
Oil Drain Plugs (All Models)
Size
Into Cast Iron
Into Aluminum
4.5 (40 in. lb.)

1/8" NPT
11.3 (100 in. lb.)
17.0 (150 in. lb.)
1/4"
20.3 (180 in. lb.)
13.6 (120 in. lb.)
3/8"
27.1 (20 ft. lb.)
17.6 (13 ft. lb.)
1/2"
33.9 (25 ft. lb.)
21.7 (16 ft. lb.)
3/4"
X-708-11 27.1/33.9 (20/25 ft. lb.) 27.1/33.9 (20/25 ft. lb.)
Non-critical
Fasteners
into
Aluminum
33.9 (25)
61.0 (45)
94.9 (70)
Torque
Conversions
Nm = in. lb. x 0.113
Nm = ft. lb. x 1.356
in. lb. = Nm x 8.85
ft. lb. = Nm x 0.737
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Size
8-32
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
Grade 2
2.3 (20)
3.6 (32)
3.6 (32)
7.9 (70)
9.6 (85)
17.0 (150)
18.7 (165)
29.4 (260)
33.9 (300)
Grade 5
2.8 (25)
4.5 (40)
4.5 (40)
13.0 (115)
15.8 (140)
28.3 (250)
30.5 (270)
Grade 8
18.7 (165)
22.6 (200)
39.6 (350)
Tightening Torque Nm (ft. lb.) + or- 20%

Size
5/16-24
40.7 (30)
3/8-16
47.5 (35)
67.8 (50)
3/8-24
54.2 (40)
81.4 (60)
7/16-14 47.5 (35)
74.6 (55)
108.5 (80)
7/16-20 61.0 (45)
101.7 (75) 142.4 (105)
1/2-13
67.8 (50)
108.5 (80) 155.9 (115)
1/2-20
94.9 (70) 142.4 (105) 223.7 (165)
9/16-12 101.7 (75) 169.5 (125) 237.3 (175)
9/16-18 135.6 (100) 223.7 (165) 311.9 (230)
5/8-11 149.2 (110) 244.1 (180) 352.6 (260)
5/8-18 189.8 (140) 311.9 (230) 447.5 (330)
3/4-10 199.3 (150) 332.2 (245) 474.6 (350)
3/4-16 271.2 (200) 440.7 (325) 637.3 (470)
Grade 2 or 5
Fasteners into
Aluminum
2.3 (20)
3.6 (32)
7.9 (70)
17.0 (150)
3/8" thread with hex head nut and fiber gasket.
TP-2469-A 12/07
K-Series Single Cylinder Engine Specifications Tolerances

Model (Horsepower)
General
Bore x Stroke
Displacement Cu. In.
Max. Operating RPM
Balance Gear
Camshaft
Shaft O.D.
New
Max. Wear Limit
End Play
End Play
Running
Connecting Clearance
Rod
Rod to Crankpin (New)

Rod to Crankpin
Wear Limit
Rod to Piston Pin (New)
Small End I.D. (New)

Main PTO &
Flywheel End O.D.
C
Crankshaft
N
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P
Cylinder
Head
Ignition
New
2.938 x 2.500
16.94
2.938 x 2.750
18.64
4000
0.005/0.020
0.001/0.0025
3600
0.005/0.010
0.001/0.002
3600
0.005/0.010
0.001/0.002
0.003
0.0025
0.0025
K241 (10)
K301 (12)
K321 (14)
K341 (16)
3.251 x 2.875
23.85
3.375 x 3.250
29.07
3.500 x 3.250
31.27
3.750 x 3.250
35.9
3600
0.4998/0.5001
0.4996
0.002/0.010
0.005/0.010
0.001/0.002
3600
0.4998/0.5001
0.4996
0.002/0.010
0.005/0.010
0.001/0.002
3600
0.4998/0.5001
0.4996
0.002/0.010
0.005/0.010
0.001/0.002
0.0025
0.0025
0.0025
0.0025
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0.4998/0.5001
0.4996
0.002/0.010
0.005/0.010
0.001/0.002
0.0007/0.0008
0.5630/0.5633
0.0006/0.0011 0.0006/0.0011
0.6255/0.6258 0.6255/0.6258
0.0003/0.0008
0.8596/0.8599
0.0003/0.0008
0.8757/0.8760
0.0003/0.0008
0.8757/0.8760
0.0003/0.0008
0.8757/0.8760
0.9841/0.9844
0.9841
1.1811/1.1814 1.1811/1.1814
1.1811
1.1811
1.5745/1.5749
1.5745
1.5745/1.5749
1.5745
1.5745/1.5749
1.5745
0.9360/0.9355
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1.5745/1.5749
1.5745
1.1860/1.1855
1.1860/1.1855
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
in
Max. Wear Limit
0.935
1.185
1.185
1.499
1.499
1.499
1.499
Max. Out of Round
0.0005
0.0005
0.0005
0.0005
0.0005
0.0005
0.0005
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.004/0.023
2.3755/2.3745
2.378
0.003
0.003
0.002/0.023
2.9380/2.9370
2.941
0.003
0.003
0.002/0.023
2.9380/2.9370
2.941
0.003
0.003
0.003/0.020
3.2515/3.2505
3.254
0.003
0.002
0.003/0.020
3.3755/3.3745
3.378
0.003
0.002
0.003/0.020
3.5005/3.4995
3.503
0.003
0.002
0.003/0.020
3.7505/3.7495
3.753
0.003
0.002
0.003
0.003
0.003
0.003
0.003
0.003
0.003
RCJ-8
RCJ-8
RCJ-8
RH-10
RH-10
RH-10
RH-10
0.025
0.025
0.018
0.02
0.025
0.025
0.018
0.02
0.025
0.025
0.018
0.02
0.035
0.025
0.018
0.02
0.035
0.025
0.018
0.02
0.035
0.025
0.018
0.02
0.035
0.025
0.018
0.02
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Max. Taper
N
End Play
Inside
Diameter
Max. Out of Round
Max. Taper
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Max. Out of Flatness
Spark Plug
Type & Gap
Nominal Point Gap
TP-2469-A 12/07
2.375 x 2.000
8.86
R
A
Cylinder
Bore
New
Max. Wear Limit
All dimensions in inches.

K91 (4)
K161 (7)
K181 (8)
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New
Max. Wear Limit
Type (Champion
or Equivalent)
Battery
Magneto
Gaseous Fuels
K-Series Single Cylinder Engine Specifications Tolerances (cont'd)

Model (Horsepower)
K91 (4)
K161 (7)
All Pistons Service Replacement Sizes

Thrust
New
Face O.D.2
Max. Wear Limits
Thrust Face to
Bore Clearance (New)1
New Bore
Ring End Gap
Used Bore (Max.)
Max. Ring Side Clearance
Thrust
New
Face O.D.4
Max. Wear Limits
Thrust Face to
Bore Clearance (New)1
New Bore5
Ring End Gap
Used Bore (Max.)5
Thrust Face
New
O.D.4
Max. Wear Limits
Thrust Face to Bore
Clearance (New)1
New Bore5
Ring End Gap
Used Bore (Max.)5
Piston Pin
Valves
Outside Diameter
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Nominal Angle Valve Seat

Guide I.D. Max.
Wear Limit 1
Intake
Exhaust
Subtract O.D. of inner part from I.D. of outer part.

Measure just below oil ring groove at right angles to piston pin.
1800 RPM generator sets .005/.007.
TP-2469-A 12/07
K241 (10)
K301 (12)
K321 (14)
0.003 0.010 0.020 0.030

2.9297/2.9281
2.9297/2.9281
3.2432/3.2413
3.368/3.365
3.4941/3.4925
2.925
2.925
3.238
3.363
3.491
2.371/2.369
2.366
0.0035/0.006
0.007/0.010
0.007/0.010
0.007/0.017
0.027
0.006
0.007/0.017
0.027
0.006
0.007/0.017
0.027
0.006
2.9329/2.9336
2.931
0.0034/0.0051
0.5623/0.5625
0.25
0.005/0.009
0.011/0.015
0.2035
0.1768
0.2478
0.2458
K341 (16)
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3.7425/3.7410
3.738
0.007/0.010
0.007/0.010
0.007/0.010
0.007/0.010
0.010/0.020
0.03
0.006
0.010/0.020
0.03
0.006
0.010/0.020
0.03
0.006
0.010/0.020
0.03
0.006
3.7465/3.7455
3.3700/3.3693
3.367
0.0045/0.0062
3.4945/3.4938
3.492
0.0050/0.0067
3.744
0.0030/0.0050
0.010/0.020
0.03
0.004
3.7433/3.7426
3.7406
0.0062/0.0079
0.010/0.023
0.032
0.006
0.010/0.020
0.03
0.006
0.010/0.020
0.03
0.006
0.013/0.025
0.033
0.004
0.6247/0.6249
0.6247/0.6249
0.8591/0.8593
0.8752/0.8754
0.8752/0.8754
0.8752/0.8754
0.3125
0.006/0.008
0.017/0.019
0.2718
0.2482
0.3103
0.3088
0.3125
0.006/0.008
0.017/0.019
0.2718
0.2482
0.3103
0.3088
0.3125
0.008/0.010
0.017/0.019
0.318
0.318
0.3103
0.3088
0.3125
0.008/0.010
0.017/0.019
0.318
0.318
0.3103
0.3074
0.3125
0.008/0.010
0.017/0.019
0.318
0.318
0.3103
0.3074
0.3125
0.008/0.0103
0.017/0.019
0.318
0.318
0.3103
0.3074
45
45
45
45
45
45
45
0.005
0.007
0.005
0.007
0.005
0.007
0.006
0.008
0.006
0.008
0.006
0.008
0.006
0.008
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Guide Reamer Size

Tappet
Intake
Clearance (Cold) Exhaust
Minimum Lift
Intake
(Zero Lash)
Exhaust
Minimum Valve
Intake
Stem O.D.
Exhaust
K181 (8)
Measure 1/2" above the bottom of the piston skirt.
Top and center compression rings.
K-Series Twin Cylinder Engine Specifications Tolerances

Model (Horsepower)
General
Camshaft
KT17 (17)
3.125 x 3.063
47
3600
Sleeve I.D. Installed
Connecting Running Clearance

Rod

Sleeve Bearing
New
Journal
Wear Limit
Ball/Roller
New
M Bearing Journal
Wear Limit
A Max. Out of Round (Sleeve)
I Max. Taper (Sleeve)
N Running Clearance
New Max.
Wear Limit 1
(Sleeve)
New Sleeve Bearing I.D.Installed
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New
R
A
Max. Wear Limit
N
K
Max. Out of Round
P
I
Max. Taper
N
End Play
Inside
New
Diameter
Max. Wear Limit
Max.Out of Round
Max. Taper
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Cylinder
Bore
Cylinder
Head
TP-2469-A 12/07

Rod to Crankpin Wear Limit
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0.003/0.013
0.0012/0.0024
0.0029
0.0006/0.0011
0.6255/0.6258
1.7412/1.7422
1.7407
0.0005
0.001
0.0049
0.0059
1.7439/1.7461
0.003/0.013
0.0012/0.0024
0.0029
0.0006/0.0011
0.7507/0.7510
1.7412/1.7422
1.7407
0.0005
0.001
0.0049
0.0059
1.7439/1.7461
3.500 x 3.000
57.73
3600
Rear 1.251/1.252
Front 1.876/1.877
0.003/0.024
0.001/0.002
0.0025
0.0003/0.0008
0.8757/0.8760
1.7495/1.7500
1.749
1.7716/1.7721
1.7711
0.0005
0.001
0.004
0.005
1.7515/1.7535
1.3738/1.3733
1.4998/1.4993 2
1.6250/1.6245
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3.125 x 2.750
42.18
3600
End Play
Crankshaft
KT19 (19)
Bore x Stroke
Max. Operating RPM
1.3728
1.4988
1.624
0.0005
0.0005
0.0005
0.001
0.001
0.001
0.002/0.014
3.1255/3.1245
3.128
0.002
0.0015
0.002/0.014
3.1255/3.1245
3.128
0.002
0.0015
0.004/0.010
3.5005/3.4995
3.503
0.005
0.002
0.003
0.003
0.003
K-Series Twin Cylinder Engine Specifications Tolerances (cont'd)

Model (Horsepower)
Ignition
Spark Plug

KT17 (17)
Type (Champion or Equivalent)

Battery
RY17YC
0.025
Gaseous Fuels
Nominal Point Gap
Service Replacement Sizes
Thrust Face
New
O.D.3
Max. Wear Limits
Thrust Face to Bore Clearance (New) 1
Ring End Gap
New Bore
Used Bore (Max.)
O.D.
New
Max. Wear Limits
Max. Ring Size Clearance
Piston Pin
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Valves
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Outside Diameter
Guide Reamer Size
Tappet
Intake
Clearance (Cold)
Exhaust
Minimum Lift
Intake
(Zero Lash)
Exhaust
Minimum Valve
Intake
Stem O.D.
Exhaust
Guide I.D. Max
Intake
Wear Limit 1
Exhaust
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0.010/0.020
0.03
0.010/0.020
0.03
0.004
0.004
0.006
0.003 0.010 0.020 0.030
3.1210/3.1203
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Thrust Face to Bore Clearance (new) 1, 4

New Bore5
Ring End Gap
Used Bore (Max.)5
RH-10
0.025
0.010/0.020
0.03
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4
K582 (23)
RV17YC
0.025
0.018
0.018
0.018
0.02
0.02
0.02
0.003 0.010 0.020 0.030
3.118/3.117
3.121/3.120
3.4941/3.4925
3.113
3.113
3.491
0.0065/0.0085
0.0035/0.0055
0.007/0.010

Thrust Face
KT19 (19)
3.1215/3.1208
3.118
3.119
0.0035/0.0052
0.0030/0.0047
0.010/0.020
0.010/0.023
0.032
0.032
0.006
0.006
0.6247/0.6249
0.3125
0.003/0.006
0.011/0.014
0.28
0.28
0.3103
0.3088
45
0.005
0.007
0.7499/0.7501
0.3125
0.003/0.006
0.011/0.014
0.28
0.28
0.3103
0.3088
45
0.005
0.007
0.8752/0.8754
0.3125
0.008/0.010
0.017/0.020
0.318
0.318
0.3103
0.3074
45
0.006
0.008
Subtract O.D. of inner part from I.D of outer part.
Measure 1/2" above bottom of piston skirt.
Pre Series II 1.3733/1.3738, maximum wear 1.3728.
3, 4
TP-2469-A 12/07
Measure just below oil ring groove and at right angles to piston pin.
K-Series-Single Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
Connecting
Rods1
K91 (4)
K161 (7)
K181 (8)
Posi-Lock1, 2
New 140 in. lbs.
New 260 in. lbs.
Used 100 in. lbs.
Used 200 in. lbs.
Capscrew1, 3
140 in. lbs.
200 in. lbs.
18-22 ft. lbs.
18-22 ft. lbs.
Spark Plugs
Cylinder Head1
Nut1
Flywheel
5
Screw1
Retaining
Governor Bushing
Grass
Metal
Screen
Plastic
Oil Pan
Cast Iron1
Sheet Metal1
Non Metallic Fuel Pump
Mounting Screws
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250 in. lbs.
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40-50 ft. lbs.

250 in. lbs.
70-90 in. lbs.
85-90 ft. lbs.4
130-150 in. lbs.

70-140 in. lbs.
Grade 5-250 in. lbs.

Grade 8-350 in. lbs.
K241 (10) K301 (12) K321 (14) K341 (16)
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37-45 in. lbs.
285 in. lbs.
18-22 ft. lbs.
50-60 ft. lbs.

22-27 ft. lbs.
100-120 in. lbs.
70-140 in. lbs.
20-30 in. lbs.
35 ft. lbs.
200 in. lbs.
37-45 in. lbs.
Lubricate fastener threads with engine oil.

Do not over torque-Do not loosen and retorque hex. nuts on Posi-Lock connecting rods.
Over torque 20%, loosen below torque value and retorque to final value.
Prior to Serial No. 23209832 - 45-55 ft. lbs.
NEW - Component directly from stock.
Flywheel and crankshaft tapers must be clean and dry.
TP-2469-A 12/07
USED - Component from a running engine.
K-Series Twin Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
KT17 & KT19
K582 (23)
Posi-Lock1, 2
New 140 in. lbs.

Used 100 in. lbs.
Capscrew1,3
200 in. lbs.
5/16-200 in. lbs.

3/8-300 in. lbs.
10-15 ft. lbs.
18-22 ft. lbs.
Connecting
Rods1
Spark Plugs
KT17 & KT19

Crankcase
#2 Side Crankcase
Half Exterior
Cylinder Head1
Flywheel
Nut
Retaining Screw1
Grass
Metal
Screen
Plastic
Aluminum1
Oil Pan
Cast Iron1
Manifold Screw/Nut
Camshaft Nut
Non-Metallic Fuel Pump
Mounting Screws
115 ft. lbs.
40 ft. lbs.
70-140 in. lbs.
70-140 in. lbs.
20-30 in. lbs.
150 in. lbs.
30 ft. lbs.
35 ft. lbs.
210 in. lbs.
40 ft. lbs.
K582
Gear Cover
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Install two
shoulder
capscrews
(1/2" thread
depth) in
second and
third holes as
indicated.
Tighten to 150 in. lbs.,
then install other capscrews
and torque to 150 in. lbs.
TP-2469-A 12/07
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37-45 in. lbs.
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Cylinder Barrel
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#2 Side Crankcase
Half Interior
Apply sealant to crankcase.*

Preliminary torque - 100 in. lbs.
Final torque - 200 in. lbs.
(Engines with 5/16-18 studs)
Final torque - 360 in. lbs.
Closure Plate 150 in. lbs.
Closure Plate
*When reinstalling a closure plate or
Bolt No.
30 ft. lbs
Torque
1, 2, 3, 4,
260 in. lbs.
(12, 14 Grade 8)
5-11,13, 15
150 in. lbs.
16
35 in. lbs.
Bolt No. Torque
cylinder barrels with a gasket, use a
260 in. lbs.

1-4
5-6
200 in. lbs.
Torque remaining bolts
in most expedient
new gasket. When reinstalling one
sequence to 200 in. lbs.
use new sealant.
with sealant, use new sealant. When

installing a service replacement
closure plate or cylinder barrels,
Magnum Single Cylinder Engine Specifications and Tolerances

M8 (8)
M10 (10)
M12 (12)
M14 (14)
M16 (16)
Bore x Stroke
2.94 x 2.75
18.64
3.25 x 2.88
29.07
3.38 x 3.25
29.07
3.500 x 3.25
31.27
3.750 x 3.25
35.9
Max. Operating RPM
3600
3600
3600
3600
3600
0.4998/0.5001 0.4998/0.5001
0.4996
0.4996
0.002/0.010
0.002/0.010
0.4998/0.5001
0.4996
0.002/0.010
0.4998/0.5001
0.4996
0.002/0.010
0.005/0.010
0.001/0.002
0.0025
0.0003/0.0008
0.8757/0.8760
0.005/0.010
0.001/0.002
0.0025
0.0003/0.0008
0.8757/0.8760
0.005/0.010
0.001/0.002
0.0025
0.0003/0.0008
0.8757/0.8760
0.005/0.010
0.001/0.002
0.0025
0.0003/0.0008
0.8757/0.8760
1.5745/1.5749
1.5745
1.5745/1.5749
1.5745
1.5745/1.5749
1.5745
1.5745/1.5749
1.5745
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
1.5000/1.4995
1.499
1.499
1.499
1.499
0.0005
0.0005
0.0005
0.0005
0.0005
0.001
0.001
0.001
0.001
0.001
0.002/0.023
2.9380/2.9370
2.941
0.005
0.003
0.003/0.020
3.2515/3.2505
3.254
0.005
0.002
0.003/0.020
3.3755/3.3745
3.378
0.005
0.002
0.003/0.020
3.5005/3.4995
3.503
0.005
0.002
0.003/0.020
3.7505/3.7495
3.753
0.005
0.002
0.003
0.003
0.003
0.003
0.003
RCJ-8
RH-10
RH-10
RH-10
RH-10
Model (Horsepower)
General
Balance
Gear
Camshaft
New
Max. Wear Limit
Shaft O.D.
End Play
End Play
Connecting Running Clearance

Rod

Rod to Crankpin Max. Wear Limit
r
a

Main PTO & Flywheel
End O.D.
C
New - O.D.
R
A
Crankshaft N Max. Wear Limit
K
Max. Out of Round
P
I
Max. Taper
N
End Play
Cylinder
Bore
Cylinder
Head
Ignition
Inside Diameter
r
P
1.1811/1.1814
1.1811
Max. Wear Limit
m
i
l
e
in
Max. Out of Round (I.D.)

Max. Taper (I.D.)
Spark Plug
Module Air Gap
TP-2469-A 12/07
New
New
Max. Wear Limit
Type (Champion or Equivalent)

Gap
0.005/0.010
0.001/0.002
0.0025
0.0006/0.0011
0.6255/0.6258
1.1860/1.1855
1.185
y
p
o
C
y
0.025
0.025
0.025
0.025
0.025
0.012/0.016
0.012/0.016
0.012/0.016
0.012/0.016
0.012/0.016
10
Magnum Single Cylinder Engine Specifications and Tolerances (cont'd)

All Pistons
Model (Horsepower)

M8 (8)
M10 (10)

Thrust
New
Face O.D.2
Max. Wear Limits
New Bore
Ring End Gap
Used Bore (Max.)
0.003 0.010 0.020 0.030

2.9297/2.9281
3.2432/3.2413
3.368/3.365
3.4941/3.4925
2.925
3.238
3.363
3.491
0.007/0.010
0.007/0.010
0.007/0.010
0.007/0.010
0.007/0.017
0.010/0.020
0.010/0.020
0.010/0.020
0.027
0.03
0.03
0.03

Thrust
New
Face O.D.3
Max. Wear Limits

New Bore4
Ring End Gap
Used Bore (Max.)4
New
Thrust Face O.D.3
Max. Wear Limits
New Bore4
Ring End Gap
Used Bore (Max.)4
Piston Pin
Guide Reamer Size

Tappet
r
P
Clearance (Cold)
Exhaust
Minimum Lift
Intake
(Zero Lash)
Valves
Intake
Minimum Valve
Exhaust
Intake
Stem O.D.
Exhaust
Guide I.D. Max.
Intake
Wear Limit 1
Exhaust
TP-2469-A 12/07
0.006
2.9329/2.9336
2.9312
0.0034/0.0051
0.010/0.023
0.032
0.006
0.6247/0.6249
M14 (14)
M16 (16)
y
p
o
C
y
0.006
0.006
3.7465/3.7455
3.3700/3.3693
3.3673
0.0045/0.0062
0.010/0.020
3.4945/3.4938
3.4918
0.0050/0.0067
0.010/0.020
3.7435
0.0030/0.0050
0.010/0.020
0.03
0.004
3.7433/3.7426
3.7406
0.0062/0.0079
0.013/0.025
0.03
0.006
0.03
0.006
0.033
0.004
r
a
n
i
m
i
l
e
Outside Diameter
0.006
M12 (12)
0.8591/0.8593
0.8752/0.8754
0.8752/0.8754
0.8752/0.8754
0.3125
0.3125
0.3125
0.3125
0.3125
0.006/0.008
0.0080/.010
0.008/0.010
0.008/0.010
0.008/0.010
0.017/0.019
0.017/0.019
0.017/0.019
0.017/0.019
0.017/0.019
0.2718
0.318
0.318
0.318
0.318
0.2482
0.318
0.318
0.318
0.318
0.3103
0.3103
0.3103
0.3103
0.3103
0.3074
45
0.006
0.008
0.3074
45
0.006
0.008
0.3074
45
0.006
0.008
0.3074
45
0.006
0.008
0.3074
45
0.006
0.008
11
Magnum Twin Cylinder Engine Specifications and Tolerances

MV16 (16)
M18 & MV18 (18)
M20 & MV20 (20)
General
Bore x Stroke
Model (Horsepower)
3.125 x 2.750
42.18
3.125 x 2.750
42.18
3.125 x 3.062
46.98
Camshaft
Max. Operating RPM

End Play
3600
0.003/0.013
0.0012/0.0024
0.0029
0.0006/0.0011
0.6255/0.6258
1.7412/1.7422
3600
0.003/0.013
0.0012/0.0024
0.0029
0.0006/0.0011
0.6255/0.6258
1.7412/1.7422
3600
0.003/0.013
0.0012/0.0024
0.0029
0.0006/0.0011
0.7507/0.7510
1.7412/1.7422
1.7407
0.0005
1.7407
0.0005
1.7407
0.0005
Connecting
Rod

Rod to Crankpin Wear Limit
Running Clearance
PTO & Flywheel
New
M End O.D.
Max. Wear Limit
A Max. Out of Round (Sleeve)
r
a
I Max. Taper (Sleeve)

N Running Clearance
Max. New
Wear Limit 1
(Sleeve)
Crankshaft
Cylinder Bore
New Sleeve Bearing I.D. Installed

C
New
R
A
Max. Wear Limit
N
K
Max. Out of Round
P
I
Max. Taper
N
End Play
New
Inside Diameter
Max. Wear Limit
Max. Out of Round
Max. Taper
m
i
l
e
r
in
Cylinder Head Max. Out of Flatness

Ignition
Spark Plug
Module Air Gap
TP-2469-A 12/07
Type (Champion or equivalent)

Gap
y
p
o
C
y
0.001
0.001
0.001
0.0049
0.0049
0.0049
0.0059
0.0059
0.0059
1.7439/1.7461
1.7439/1.7461
1.7439/1.7461
1.3738/1.3733
1.3738/1.3733
1.4998/1.4993
1.3728
1.3728
1.4988
0.0005
0.0005
0.0005
0.001
0.001
0.001
0.002/0.014
3.1255/3.1245
3.128
0.002
0.0015
0.002/0.014
3.1255/3.1245
3.128
0.002
0.0015
0.002/0.014
3.1255/3.1245
3.128
0.002
0.0015
0.003
0.003
0.003
RV17C
0.035
RV17C
0.035
RV17C
0.035
0.008/0.012
0.008/0.012
0.008/0.012
12
Magnum Twin Cylinder Engine Specifications and Tolerances (cont'd)

MV16 (16)
Model (Horsepower)

New Bore3
Ring End Gap
Used Bore (Max.)3
0.0035/0.0052
0.010/0.023
0.0035/0.0052
0.010/0.023
0.0030/0.0047
0.010/0.023
0.032
0.032
0.032
0.006
0.006
0.6247/0.6249
0.6247/0.6249
0.7499/0.7501
0.3125
0.003/0.006
0.3125
0.003/0.006
0.3125
0.003/0.006
0.016/0.019
0.016/0.019
0.016/0.019
0.011/0.014
0.011/0.014
0.011/0.014
0.013/0.016
0.013/0.016
0.013/0.016
0.274
0.274
0.274
0.006
Outside Diameter
Guide Reamer Size
Intake
r
a
Before Serial No.

Tappet
Clearance
181600646
Serial No. 18100656
Exhaust
(Cold)
to 191780296
n
i
m
After Serial No.
Valves
1917809296
Minimum Lift
(Zero Lash)
Intake
Exhaust
i
l
e
Minimum Valve
Intake
Stem O.D.
Exhaust
Nominal Angle -
Serial No. 1816500646 & Earlier
Valve Seat
Guide I.D. Max.
Wear Limit 1
Serial No. 181650056 & Later

Intake
Exhaust
r
P
Subtract O.D. of inner part from I.D. of outer part.
Measure 1/2" above the bottom of the piston skirt.
TP-2469-A 12/07
M20 & MV20 (20)
0.003 0.010 0.020 0.030

3.1215/3.1208
3.1210/3.1203
3.1210/3.1203
3.1186
3.1181
3.1181
Piston Pin
M18 & MV18 (18)

New
Thrust Face O.D.2
Max. Wear Limits
y
p
o
C
y
0.274
0.274
0.274
0.3103
0.3103
0.3103
0.3088
0.3088
0.3088
45
45
45
30
0.005
0.007
30
0.005
0.007
30
0.005
0.007
13
Magnum Single Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
Connecting New
Rods1, 2
Used
Spark Plugs
M8 (8)
M10 (10)
140 in. lbs.

100 in. lbs.
18-22 ft. lbs.
Cylinder Head
Flywheel
Governor
Screw1
Nut1
Fan
Anti-Lock
85-90 ft. lbs.

115 in. lbs.
15 in. lbs.
Bushing
Mounting Screws
Ignition Module
Cam Gear Cover
Key Switch Nut
Isolation Mount
Fuel Tank
Bracket3
Mounting
Speed Control Remote4
Wing/Hex. Nut Local
r
P
37-45 in. lbs.

32 in. lbs.
Hand Tighten (2-12 in. lbs.)

150 in. lbs.
90 in. lbs.
10-15 in. lbs.
15-25 in. lbs.
i
l
e
Lubricate fastener threads with engine oil.
DO NOT overtorque DO NOT loosen and retorque the hex nuts on Posi-Lock connecting rods.
NEW Component directly from stock.
r
a
n
i
m
100-120 in. lbs.
M14 (14)
M16 (16)
260 in. lbs.

200 in. lbs.
18-22 ft. lbs.
M12 (12)
y
p
o
C
y
35-40 ft. lbs.
115 in. lbs.
100-120 in. lbs.
37-45 in. lbs.

32 in. lbs.
115 in. lbs.
90-100 in. lbs.
Hand Tighten (2-12 in. lbs.)
10-15 in. lbs.

15-25 in. lbs.
3
To cylinder head, electric start side.
Torque, then loosen 1/2 turn.
Flywheel and crankshaft tapers must be clean and dry.
USED Component that was in a running engine.
TP-2469-A 12/07
14
Magnum Twin Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
MV16, M18 & MV18, M20 &MV20
Connecting New
Rods1,2
Used
Spark Plugs
140 in. lbs.

100 in. lbs.
10-15 ft. lbs.
Screw1
Fan
Manifold Screw/Nut
Mounting Screws
Ignition Module
Oil Filter
Lines
Oil Line
Remote Flared Nuts
Oil Filter Adapter
Adapter Fittings
Cover Plate
#2 Side Crankcase Half Exterior
40 ft. lbs.
115 in. lbs.
150 in. lbs.
37-45 in. lbs.
i
l
e
Cylinder Barrel (All)
r
a
n
i
m
32 in. lbs.
Snug Plus 1/2 Turn (50/80 in. lbs.)
65-80 in. lbs.
r
P
Oil Pan (MV16, MV18,

MV20) 150 in. lbs
y
p
o
C
y
Crankcase (All)
Cylinder Head1
Flywheel5
Twin Cylinder Engines
100-120 in. lbs.

125 in. lbs.
90-130 in. lbs.
125 in. lbs.
#2 Side Crankcase Half Interior
Bolt No.
Torque
1-4
260 in. lbs.
5-6
200 in. lbs.
Torque remaining bolts in
most expedient sequence

to 200 in. lbs.
Closure Plate (M18 & M20) 150 in. lbs.
Apply sealant to crankcase*

Preliminary Torque - 100 in. lbs.
Final Torque - 200 in. lbs.
*When reinstalling a closure

plate or cylinder barrels
with a gasket, use a new
gasket. When reinstalling
Final Torque - 360 in. lbs.
one with sealant, use new
sealant. When installing a

service replacement
closure plate or cylinder
barrels, use new sealant.
NOTE: Do not use gasket on MV

oil pans.
TP-2469-A 12/07
15
Command Single Cylinder Engine Specifications and Tolerances

All dimensions in millimeters (inches).
Model (Horsepower)
Kilowatt (kW) Output (@3600 RPM - net rating per SAE J1349)
Horsepower (@3600 RPM - net rating per SAE J1349)
General
Bore
Stroke
Displacement
End Play (With Shims)
In Crankcase
Bore I.D. Max. Wear Limit
Camshaft
In Closure Plate
Camshaft Bearing Surface
Crankcase End
O.D. - Max. Wear Limit
Closure Plate End
Connecting Connecting Rod to Crankpin Running Clearance - New
Rod
Connecting Rod to Crankpin Running Clearance - Max. Wear Limit
End Play (Free)
Crankshaft Bore to Crankshaft Running Clearance - New (Sleeve Bearing)
Crankshaft Bore to Crankshaft Running Clearance - Max. Wear Limit
O.D - New
O.D. Max. Wear Limit
Flywheel End Main
Max. Taper
Bearing Journal
Max. Out of Round
Crankshaft
O.D - New
PTO End Main
Bearing Journal
Max. Taper
Max. Out of Round
O.D - New
Connecting Rod Journal
Max. Taper
Max. Out of Round
New
Max. Wear Limit
Cylinder Bore Cylinder Bore I.D.
Max. Out of Round
Max. Taper
Governor Cross Shaft O.D. - Max. Wear Limit
Governor Gear Shaft O.D. - Max. Wear Limit
Governor
Governor Cross Shaft Bore (In Crankcase) I.D. - Max. Wear Limit
r
P
TP-2469-A 12/07
i
l
e
n
i
m
r
a
CH5 (5)
CH6 (6)
3.73
5
4.47*
6*
y
p
o
C
y
67 (2.64)
51 (2.01)
180 cm (10.98 in.)
0.15/0.55 (0.005/0.0217)
16.030 (0.6311)
25.430 (1.001)
15.954 (0.6281)
25.350 (0.9980)
0.030/0.056 (0.0012/0.0022)
0.0635 (0.0025)
0.000/0.056 (0.000/0.0022)
0.02/0.09 (0.0008/0.0036)
0.115 (0.0046)
30.000/30.008 (1.20/1.2003)
29.95 (1.198)
0.020 (0.0008)
0.025 (0.0010)
29.971/29.980 (1.988/1.992)
29.93 (1.1972)
0.020 (0.0008)
0.025 (0.0010)
30.947/30.960 (1.2184/1.2189)
30.934 (1.2179)
0.025 (0.0010)
0.013 (0.0005)
67.00/67.03 (2.6378/2.6390)
67.049 (2.6397)
0.150 (0.0059)
0.100 (0.0039)
0.076 (0.003)
6.296 (0.2479)
9.960 (0.3921)
6.425 (0.2530)
16
Model (Horsepower)
Ignition
CH5 (5)
Spark Plug Type (Champion or equivalent)

Spark Plug Gap
Ignition Module Air Gap
Top Compression Ring to Groove Side Clearance
r
P
TP-2469-A 12/07
0.040/0.072 (0.0016/0.0028)
0.140/0.275 (0.0055/0.0108)
0.25/0.45 (0.010/0.018)
0.75 (0.030)
r
a
i
l
e
n
i
m
Measure 6 mm above the bottom of piston skirt at right angles to piston pin.
y
p
o
C
y
0.203/0.305 (0.008/0.012)
0.040/0.085 (0.0016/0.033)
Middle Compression Ring to Groove Side Clearance

Oil Control Ring to Groove Side Clearance
New Bore
Piston Ring End Gap
Used Bore (Max.)
Pistons,
O.D. - New
Piston Rings, Piston Thrust Face 1 (@D1)
and Piston Pin to Cylinder Bore
New - Running Clearance
Intake Valve to Tappet Cold Clearance
Exhaust Valve to Tappet Cold Clearance
I.D. - Std.
Intake Valve Guide
I.D. - Max. Wear Limit
Valves and
I.D. - Std.
Valve Lifters Exhaust Valve Guide
Intake Valve Minimum Lift
Exhaust Valve Minimum Lift
Nominal Valve Seat Angle
*@ 4000 RPM (Gross rating per SAE J1995).
CH6 (6)
RC12YC
1.02 (0.040)
66.941/66.959 (2.635/2.636)
66.816 (2.630)
0.016/0.059 (0.0006/0.0023)
0.000/0.0508 (0.000/0.0020)
0.000/0.508 (0.000/0.0020)
4.990/5.010 (0.1965/0.1972)
5.085 (0.2002)
4.990/5.010 (0.1965/0.1972)
5.080 (0.2000)
5.4 (0.213)
5.4 (0.213)
45
17

CH & CV11 (11) CH & CV12.5 (12.5) CH & CV13 (13)
Model (Horsepower)
General
Balance
Shaft
Bearing
Camshaft
Kilowatt (kW) Output (@3600 RPM-SAE J1995)
8.2
Horsepower (@ 3600 RPM-SAE J1995)

Bore
Stroke
Displacement
End Play (Free)
Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)
Balance Shaft Bearing Surface O.D. Max. Wear Limit
11
End Play
With Shims 0.076/0.127 (0.003/0.005) Without Shims 0.10/0.39 (0.004/0.015)

20.038 (0.7889)
20.038 (0.7889)
19.959 (0.7858)
19.959 (0.7858)
0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
0.0575/0.4925 (0.0023/0.0194)

Connecting Connecting Rod to Crankpin
Rod
Running Clearance
End Play (Free)
In Crankcase
In Oil Pan
Crankcase End
Oil Pan End
New
Max. Wear Limit
i
l
e
Crankshaft Bore to Crankshaft
New
Running Clearance
Max. Wear Limit

O.D. New
Crankshaft Flywheel End Main
r
P
Bearing Journal
PTO End Main

Bearing Journal
TP-2469-A 12/07
r
a
n
i
m
Crankshaft Sleeve Bearing I.D. - Max. Wear Limit

I.D. - New Installed
Crankshaft PTO Bearing
Max. Wear Limit
9.33
9.75
CH & CV14 (14)
y
p
o
C
y
12.5
13
87 (3.43)
67 (2.64)
398 cm (24.3 in.)
0.0575/0.3625 (0.0023/0.0143)
20.038 (0.7889)
19.959 (0.7858)
14
45.016 (1.7723)
44.965/45.003 (1.7703/1.7718)
45.016 (1.7723)
0.03/0.09 (0.0012/0.0035)
0.115 (0.0045)
44.913/44.935 (1.7582/1.7691)
45.016 (1.7723)
Max. Taper
0.022 (0.0009)
Max. Out of Round
0.025 (0.0010)
O.D. - New
O.D.- Max. Wear Limit
Max. Taper
Max. Out of Round
O.D. New
Max. Taper
Max. Out of Round
10.5
41.915/41.935 (1.6502/1.6510)
41.86 (1.648)
0.020 (0.0008)
0.025 (0.0010)
38.958/38.970 (1.5338/1.5343)
38.94 (1.5328)
0.012 (0.0005)
0.025 (0.0010)
18
Model (Horsepower)
CH & CH11 (11) CH & CV12.5 (12.5) CH & CV13 (13) CH & CV14 (14)
New
Max. Wear Limit
Max. Out of Round
Max. Taper
Cylinder Bore Cylinder Bore I.D.
87.000/87.025 (3.4252/3.4262)
87.063 (3.4277)
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)

Governor
Ignition

Governor Cross Shaft Bore (In Crankcase) I.D. Max. Wear Limit
Spark Plug Gap
New Bore
Piston Ring End Gap
Used Bore (Max.)
Pistons,
Piston Rings, Piston Thrust Face1 (@D1)
Exhaust Valve Guide
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Intake Valve Guide
I.D. - Std.
I.D. - Std.
Valves and Exhaust Valve Minimum Lift

Valve Lifters Rocker Arm I.D. - Max. Wear Limit
Rocker Shaft O.D. - Max. Wear Limit

Hydraulic Lifter to Crankcase Running Clearance
Intake Valve Stem to Valve Guide Running Clearance
Exhaust Valve Stem to Valve Guide Running Clearance
6.063 (0.2387)
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O.D. - New
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RC12YC
1.02 (0.040)
0.203/0.305 (0.008/0.012)
0.040/0.105 (0.0016/0.0041)
0.040/0.072 (0.0016/0.0028)
0.55/0.675 (0.0217/0.0266)
0.3/0.5 (0.012/0.020)
0.77 (0.030)
86.941/86.959 (3.4229/3.4236)
86.814 (3.4179)
0.041/0.044 (0.0016/0.0017)
7.038/7.058 (0.2771/0.2778)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.96 (0.353)
9.14 (0.360)
16.13 (0.640)
15.727 (0.619)
45
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
Measure 6 mm above bottom of piston skirt at right angles to piston pin.
TP-2469-A 12/07
19

Model (Horsepower)
CH & CV15 (15)
Kilowatt (kW) Output (@3600 RPM-SAE J1995)
General
11.2
Horsepower (@ 3600 RPM-SAE J1995)

Bore
Stroke
Displacement
Balance
End Play (Free)
Shaft
Bearing
Bore I.D. (In Crankcase and Oil Pan, Max. Wear Limit)
0.0575/0.3625 (0.0023/0.0143)
20.038 (0.7889)
19.959 (0.7858)
Balance Shaft Bearing Surface O.D. Max. Wear Limit

End Play
Camshaft
Connecting
Rod

In Crankcase
In Oil Pan
Crankcase End
Oil Pan End
Connecting Rod to Crankpin
New
Running Clearance
End Play (Free)
Max. Wear Limit
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Crankshaft Bore to Crankshaft
New
Running Clearance
Max. Wear Limit

O.D. New
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Flywheel End Main Bearing
Closure Plate or Oil Pan

End Main Bearing
TP-2469-A 12/07
With Shims 0.076/0.127 (0.003/0.005) Without Shims 0.10/0.39 (0.004/0.015)

20.038 (0.7889)
20.038 (0.7889)
19.959 (0.7858)
19.959 (0.7858)
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Crankshaft Sleeve Bearing I.D. - Max. Wear Limit

I.D. - New Installed
Crankshaft PTO Bearing
Max. Wear Limit
Crankshaft
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15
90 (3.60)
67 (2.64)
426 cc (26.0 cu. in.)
0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
0.0575/0.4925 (0.0023/0.0194)
45.016 (1.7723)
44.965/45.003 (1.7703/1.7718)
45.016 (1.7723)
0.03/0.09 (0.0012/0.0035)
0.115 (0.0045)
44.913/44.935 (1.7582/1.7691)
44.84 (1.765)
Max. Taper
0.022 (0.0009)
Max. Out of Round
O.D. - New
O.D.- Max. Wear Limit
Max. Taper
Max. Out of Round
O.D. New
Max. Taper
Max. Out of Round
0.025 (0.0010)
41.915/41.935 (1.6502/1.6510)
41.86 (1.648)
0.020 (0.0008)
0.025 (0.0010)
38.958/38.970 (1.5338/1.5343)
38.94 (1.5328)
0.012 (0.0005)
0.025 (0.0010)
20
Command Single Cylinder Engine Specifications and Tolerances (cont'd)

Model (Horsepower)
Cylinder
Bore
Cylinder Bore I.D.
CH & CV15 (15)
New
Max. Wear Limit
Max. Out of Round
Max. Taper
90.000/90.025 (3.5433/3.5443)
90.063 (3.5457)
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)

Governor Cross Shaft Bore (In Crankcase)
Governor
6.063 (0.2387)

Spark Plug Gap
New Bore
Piston Ring End Gap
Used Bore (Max.)
Ignition
Pistons,
Piston Rings, Piston Thrust Face 1 (@D1)
Exhaust Valve Guide
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RC12YC
1.02 (0.040)
0.203/0.305 (0.008/0.012)
0.060/0.105 (0.0023/0.0041)
0.040/0.085 (0.0015/0.0002)
0.176/0.026 (0.0069/0.0010)
0.27/0.51 (0.010/0.020)
0.77 (0.030)
89.951/89.969 (3.5413/3.5420)
89.824 (3.5363)
0.031/0.043 (0.0012/0.0016)
I.D. - Std.
7.038/7.058 (0.2771/0.2778)
7.134 (0.2809)
I.D. - Std.
7.038/7.058 (0.2771/0.2779)
Valves and
Valve Lifters
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O.D. - New
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Intake Valve Guide
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Rocker Arm I.D. - Max. Wear Limit

Rocker Shaft O.D. - Max. Wear Limit
7.159 (0.2819)
8.96 (0.353)
9.14 (0.360)
16.13 (0.640)
15.727 (0.619)
45
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
Measure 6 mm above bottom of piston skirt at right angles to piston pin.
TP-2469-A 12/07
21
Command Twin Cylinder Engine Specifications and Tolerances

Model (Horsepower)
CH & CV18 (18) CH & CV20 (20) CH & CV22 (22)
General
Camshaft
Connecting
Rod
Main Bearing Journals
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Cylinder
Bore
Cylinder Bore I.D.
O.D - New
Max. Taper
Max. Out of Round
O.D - New
Max. Taper
Max. Out of Round
New
Max. Wear Limit
Max. Out of Round
Max. Taper
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Governor
TP-2469-A 12/07
14.9
20
77 (3.03)
67 (2.64)
624 cm (38.1 in.)
0.076/0.127 (0.003/0.005)
20.038 (0.7889)
16.4
22
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19.959 (0.7858)
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Crankshaft Bore to Crankshaft Running Clearance - New
Crankshaft
13.4
18
Kilowatt (kW) Output (@3600 RPM - SAE J1995)

Horsepower (@3600 RPM - SAE J1995)
Bore
Stroke
Displacement
In Crankcase
Oil Pan End
New
Running Clearance
Max. Wear Limit
End Play (Free)
Crankshaft Main Bearing I.D. - Max. Wear Limit
Crankshaft to Sleeve Bearing Running Clearance New (Early CH models only)

0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
0.070/0.480 (0.0028/0.0189)
41.016 (1.6148)
0.03/0.09 (0.0012/0.0035)
0.039/0.074 (0.0015/0.0029)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
77.000/77.015 (3.0315/3.0325)
77.063 (3.0340)
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)
6.063 (0.2387)
22
Command Twin Cylinder Engine Specifications and Tolerances (cont'd)

CH & CV18 (18) CH & CV20 (20) CH & CV22 (22)
Model (Horsepower)
Ignition

Spark Plug Gap
RC12YC
0.76 (0.030)
0.040/0.072 (0.0016/0.0028)

New Bore
Piston Ring End Gap
Used Bore (Max.)
Pistons,
O.D. - New
Piston Rings,
and Piston Pin Piston Thrust Face 1 (@D1)
to Cylinder Bore
I.D. - Std.
Intake Valve Guide
I.D. - Std.
Exhaust Valve Guide
Valves and Intake Valve Minimum Lift
Valve Lifters Exhaust Valve Minimum Lift
1
0.060/0.202 (0.0024/0.0080)
0.25/0.45 (0.0098/0.0177)
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0.28/0.33 (0.011/0.013)
0.040/0.080 (0.0016/0.0031)

0.77 (0.030)
76.967/76.985 (3.0302/3.0309)
76.840 (3.0252)
0.015/0.058 (0.0006/0.0023)
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.07 (0.3177)
8.07 (0.3177)
45
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
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TP-2469-A 12/07
23
Command Twin Cylinder Engine Specifications and Tolerances

Model (Horsepower)
General
Camshaft
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Governor
TP-2469-A 12/07
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19.959 (0.7858)
Connecting
Rod

New
Running Clearance
Max. Wear Limit
End Play (Free)
End Play (With Thrust Bearing Components).
End Play (CH25 below Serial No. 2403500008)
Crankshaft Main Bearing I.D. - Max. Wear Limit
Crankshaft to Main Bearing Running Clearance - New
Crankshaft Bore to Crankshaft Running Clearance - New
O.D - New
Crankshaft
Max. Taper
Max. Out of Round
O.D - New
Max. Taper
Max. Out of Round
New
Max. Wear Limit
Cylinder Bore I.D.
Cylinder Bore
Max. Out of Round
Max. Taper
CH & CV25 (25)

18.6
25
83 (3.27)
67 (2.64)
725 cm (44 in.)
0.076/0.127 (0.003/0.005)
20.038 (0.7889)
Kilowatt (kW) Output (@3600 RPM - SAE J1995)

Horsepower (@3600 RPM - SAE J1995)
Bore
Stroke
Displacement
In Crankcase
Oil Pan End

0.030/0.055 (0.0012/0.0022)
0.07 (0.0025)
0.070/0.480 (0.0028/0.0189)
0.050/0.5 (0.0020/0.0197)
0.050/0.75 (0.0020/0.0295)
41.016 (1.6148)
0.03/0.09 (0.0012/0.0035)
0.039/0.074 (0.0015/0.0029)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
82.988/83.013 (3.2672/3.2682)
83.051 (3.2697)
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
5.962 (0.2347)
5.977 (0.2353)
6.063 (0.2387)
24
Command Twin Cylinder Engine Specifications and Tolerances (cont'd)

Model (Horsepower)
Ignition
CH & CV25 (25)

Spark Plug Gap
RC12YC
0.76 (0.030)
0.015/0.037 (0.0006/0.0015)

New Bore
Piston Ring End Gap
Used Bore (Max.)
Pistons,
O.D.
- New1
Piston Rings,
O.D. - Max. Wear Limit 1
and Piston Pin Piston Thrust Face 1
to Cylinder Bore
I.D. - Std.
Intake Valve Guide
I.D. - Std.
Exhaust Valve Guide
Valves and
Valve Lifters Exhaust Valve Minimum Lift
1
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0.28/0.33 (0.011/0.013)
0.025/0.048 (0.0010/0.0019)

0.026/0.176 (0.0010/0.0070)
0.25/0.56 (0.0100/0.0224)
0.94 (0.037)
82.986 (3.2672)
82.841 (3.2615)
0.002/0.045 (0.001/0.0018)
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
8.07 (0.3177)
8.07 (0.3177)
45
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
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TP-2469-A 12/07
25
Command Single Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
CH5 (5)
Air Cleaner Base Nuts - M6

Fuel Bowl Screw
Carburetor
Mounting Nuts
Charging Stator Mounting Screw
Connecting Rod Cap Fastener Torque
Closure Plate
Fastener
Cylinder
Head
Valve Cover
Rocker Studs
Electric Starter Mounting
Flywheel Retainer Screw
Fasteners - M6
Fuel Tank
Fasteners - M8
Spark Plug (14 mm w/gasket)
Ignition
Ignition Module
Muffler Retaining Nuts
Oil Sentry Switch
Throttle Control Lever
Valve Cover
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CH5 & CH6
CH6 (6)
6.8 Nm (58 in. lb.)

9.8 Nm (87 in. lb.)
6.8 Nm (58 in. lb.)
4.0 Nm (35 in. lb.)
9.0 Nm (80 in. lb.)
22.6 Nm (200 in. lb.)
22.6 Nm (200 in. lb.)
13.6 Nm (120 in. lb.)

17/19 Nm (150/170 in. lb.)
67.8 Nm (50 ft. lb.)
6.8 Nm (60 in. lb.)
17.0 Nm (150 in. lb.)
24.4/29.8 Nm (18/22 ft. lb.)
4.0*/6.2 Nm (35*/55 in. lb.)1
22.6 Nm (200 in. lb.)
13.6 Nm (120 in. lb.)
4.3 Nm (38 in. lb.)
3.4 Nm (30 in. lb.)
Closure Plate
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Valve Cover
CH11-15 & CV11-15

Closure Plate (CH)/Oil Pan (CV)
For self-tapping (thread forming) fasteners: The higher torque value is for initial
installation into a new cored hole. *The lower torque value is for subsequent
installation into tapped holes and weld nuts.
TP-2469-A 12/07
26
Command Single Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
CH & CV11 (11)
Air Cleaner Base Nuts - M6

Carburetor Fuel Bowl Screw
Fastener
CH & CV12.5 (12.5)
CH & CV13 (13)
Cylinder Head
Rocker Pedestal (Pivot)

Electronic Starter Mounting
Fan Fasteners
Flywheel
Retaining Screws
Fuel Pump Fasteners
Spark Plug
Ignition
Ignition Module
Oil Filter
Oil Filter
Oil Drain Plug (1/8" NPT)
Oil Sentry Switch
Oil Pump Cover Fasteners
Throttle/Choke Governor Control Lever
Controls
Speed Control Assembly
Valve Cover
1
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CH & CV 14 (14)
CH & CV15 (15)
9.9 Nm (88 in. lb.)

5.1/6.2 Nm (45/55 in. lb.)
4.0 Nm (35 in. lb.)
8mm straight 22.7 Nm (200 in. lb.), 8mm step-down 14.7 Nm (130 in. lb.), 6mm straight 11.3 Nm (100 in. lb.)
24.4 Nm (216 in. lb.)
40.7 Nm (30 ft. lb.) 2
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Rocker bridge type 9.9 Nm (88 in. lb.), Guide plate type 11.3 Nm (100 in. lb.)
15.3 Nm (135 in. lb.)
9.9 Nm (88 in. lb.)
66.4 Nm (49 ft. lb.)
7.3*/9.0 Nm (65*/80 in. lb.) 1
38.0/43.4 Nm (28/32 ft. lb.)
4.0*/6.2 Nm (35*/55 in. lb.)
24.4 Nm (216 in. lb.)
5.7/9.0 Nm (50/80 in. lb.)
7.3/9.0 Nm (65/80 in. lb.)
7.9 Nm (70 in. lb.)
4.0*/6.2 Nm (35*/55 in. lb.) 1
9.9 Nm (88 in. lb.)
7.3*/10.7 Nm (65*/95 in. lb.) 1
7.3*/10.7 Nm (65*/95 in. lb.)
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For self-tapping fasteners, the higher torque value is for initial installation into a new cored hole. *The lower torque value is for subsequent installation, and installation into tapped holes and weld nuts.
Tighten in two stages. First torque to 15 ft. lb., following the sequence. Then tighten to final torque value of 30 ft. lb.
TP-2469-A 12/07
27
Command-Twin Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
CH & CV18 (18)
CH & CV20 (20)
CH & CV22 (22)
Breather Plate
7.3 Nm (65 in. lb.)
Carburetor Mounting Nuts
9.9 Nm (88 in. lb.)
CH & CV25 (25)
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4.0 Nm (35 in. lb.)

Fastener
8mm straight 22.7 Nm (200 in. lb.), 8mm step-down 14.7 Nm (130 in. lb.), 6mm straight 11.3 Nm (100 in. lb.)
24.4 Nm (216 in. lb.)
Two step process: First torque to 22.6 Nm (200 in. lb.), Second torque to 41.8 Nm (370 in. lb.)
Cylinder
Head
Rocker Pedestal (Pivot)

Electronic Starter Mounting
Fan Fasteners
Flywheel
Retaining Screw
Spark Plug
Ignition
Ignition Module
Manifold (Intake)
Rectifier Fasteners
Oil Filter
Oil Filter
Oil Drain Plug (1/8" NPT)
Oil Sentry Switch
Throttle/Choke Governor Control Lever
Controls
Speed Control Assembly
Gasket/Sealant Type
Valve Cover
O-Ring Type
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TP-2469-A 12/07
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11.3 Nm (100 in. lb.)

15.3 Nm (135 in. lb.)
9.9 Nm (88 in. lb.)
66.4 Nm (49 ft. lb.)
24.4/29.8 Nm (18/22 ft. lb.)
4.0*/6.2 Nm (35*/55 in. lb.)
9.9 Nm (88 in. lb.)
24.4 Nm (216 in. lb.)
4.0 Nm (35 in. lb.)
5.7/9.0 Nm (50/80 in. lb.)
13.6 Nm (10 ft. lb.)
7.9 Nm (70 in. lb.)
9.9 Nm (88 in. lb.)
7.3*/10.7 Nm (65*/95 in. lb.)1
3.4 Nm (30 in. lb.)
7.9 Nm (70 in. lb.)
28
Command-Twin Cylinder Torque Values and Sequences for Fasteners

Valve Cover
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TP-2469-A 12/07
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Breather Plate
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29
Conversion Factors
Inches x 25.4 = Millimeters (mm)
Inches x 2.54 = Centimeters (cm)
Cubic Inches x 16.387 = Cubic Centimeters (cu cm3)
Inch Pounds x 0.113 = Newton-meter (Nm)
Foot Pounds x 1.356 = Newton-meter (Nm)
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Ounce (Weight) x 28.350 = Grams (g)

Pound x 0.4536 = Kilograms (kg)
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Horsepower x 0.746 = Kilowatt (kW)
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TP-2469-A 12/07
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30
Aegis Twin Cylinder Engine Specifications and Tolerances

Model (Horsepower)
Page 31
General Horsepower (@3600 RPM J1940)

Bore x Stroke
Displacement
End Play (With Shim)
Running Clearance
New
Camshaft
Bore I.D.
Max. Wear Limit
New
Camshaft Bearing Surface O.D.
Max. Wear Limit
New
Rod-to-Crankpin Running
Clearance
Max Wear Limit
Rod-to-Crankpin Side Clearance
Connecting Rod-to-Piston Pin Running Clearance
New
Rod
Piston Pin End I.D.
Max. Wear Limit
New
Crankcase Governor Cross Shaft Bore I.D
Max. Wear Limit
End Play (Free)
Crankshaft Sleeve
New
Bearing I.D. (Crankcase) Max. Wear Limit
New
Crankshaft Bore (in closure plate)
Max. Wear Limit
Crankshaft Bore (in closure plate)-to-Crankshaft
Running Clearance - New
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LH630 (22)
LH640 (24)
LH685 (25)
LH690 (26)
16.4
17.9
18.6
19.4
22
77 (3.03) x 67 (2.64)
624 cc (38.1)
20.038 (0.7889)
19.959 (0.7858)
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0.083 (0.0032)
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O.D. - New
Max. Taper
Crankshaft
Max. Out-of-Round
Crankshaft to Sleeve Bearing (crankcase)
O.D. - New
Max. Taper
Max. Out-of-Round
PTO End, Crank in Engine
Crankshaft T.I.R.
Entire Crank, in V-Blocks
TP-2469-A 12/07
17.036 (0.6707)
8.088 (0.3184)
41.000 (1.6141)
41.038 (1.6156)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
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24
25
77 (3.03) x 67 (2.64)
80 (3.15) x 67 (2.64)
624 cc (38.1)
674 cc (41.1)
0.076/0.127 (0.0030/0.0050)
0.025/0.063 (0.0010/0.0025)
20.000/20.025 (0.7874/0.7884)
20.038 (0.7889)
20.038 (0.7889)
19.962/19.975 (0.7859/0.7864)
19.959 (0.7858)
19.959 (0.7858)
0.043/0.068 (0.0016/0.0026)
0.083 (0.0032)
0.083 (0.0032)
0.26/0.63 (0.0102/0.0248)
0.015/0.028 (0.0006/0.0011)
17.015/17.023 (0.6699/0.6702)
17.036 (0.6707)
17.036 (0.6707)
8.025/8.075 (0.3159/0.3179)
8.088 (0.3184)
8.088 (0.3184)
0.070/0.590 (0.0028/0.0230)
40.974/40.987 (1.6131/1.6136)
41.000 (1.6141)
41.000 (1.6141)
40.974/41.000 (1.6131/1.6141)
41.038 (1.6156)
41.038 (1.6156)
26
80 (3.15) x 67 (2.64)
674 cc (41.1)
20.038 (0.7889)
19.959 (0.7858)
0.083 (0.0032)
17.036 (0.6707)
8.088 (0.3184)
41.000 (1.6141)
41.038 (1.6156)
0.039/0.087 (0.0015/0.0034)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
40.84 (1.608)
0.022 (0.0009)
0.022 (0.0009)
0.025 (0.0010)
0.025 (0.0010)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
0.039/0.074 (0.0015/0.0029)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
0.15 (0.0059)
0.10 (0.0039)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
35.94 (1.415)
0.018 (0.0007)
0.018 (0.0007)
0.025 (0.0010)
0.025 (0.0010)
0.15 (0.0059)
0.15 (0.0059)
0.10 (0.0039)
0.10 (0.0039)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
0.15 (0.0059)
0.10 (0.0039)
31
Model (Horsepower)
Cylinder
Bore
Cylinder Bore I.D.
LH630 (22)
New
Max. Wear Limit
Max. Taper
Max. Out-of-Round
Cylinder Head Max. Out-of-Flatness
77.063 (3.0340)
0.05 (0.0020)
0.12 (0.0047)
0.076 (0.003)
Governor Cross Shaft to

New
Max. Wear Limit
New
Governor Gear Shaft O.D.
Max. Wear Limit
Gear Shaft-to-Governor Gear Running Clearance
Spark Plug Gap
Ignition
Piston-to-Piston Pin
New
Piston Pin Bore I.D.
Max. Wear Limit
New
Piston, Piston
Piston Pin O.D.
Max. Wear Limit
Rings, and
Piston Pin Top Compression Ring-to-Groove Side Clearance
Middle Compression Ring-to-Groove Side Clearance
Oil Control Ring-to-Groove Side Clearance
Top and Middle Compression Top Ring
Ring End Gap - New Bore
Middle Ring
Used Bore (Max.)
New
1
Piston Thrust Face O.D.
Max. Wear Limit
Piston Thrust Face-to-Cylinder
Governor Cross Shaft O.D.
r
P
1
LH690 (26)
80.065 (3.1522)
0.05 (0.0020)
0.12 (0.0047)
y
p
o
C
y
0.076 (0.003)
0.076 (0.003)
0.076 (0.003)
7.949/8.000 (0.3129/0.3149)
7.936 (0.3124)
7.936 (0.3124)
7.936 (0.3124)
5.990/6.000 (0.2358/0.2362)
5.977 (0.2353)
5.977 (0.2353)
5.977 (0.2353)
5.977 (0.2353)
0.090/0.160 (0.0035/0.0063)
RC14YC
RC14YC
RC14YC
RC14YC
0.76 (0.030)
0.76 (0.030)
0.76 (0.030)
0.76 (0.030)
0.203/0.305 (0.008/0.012)
0.006/0.018 (0.0002/0.0007)
17.006/17.013 (0.6695/0.6698)
17.025 (0.6703)
17.025 (0.6703)
17.025 (0.6703)
17.025 (0.6703)
16.995/17.000 (0.6691/0.6693)
16.994 (0.6691)
16.994 (0.6691)
16.994 (0.6691)
16.994 (0.6691)
0.040/0.086 (0.0016/0.0034)
0.050/0.096 (0.0020/0.0038)
0.040/0.086 (0.0016/0.0034)
0.030/0.076 (0.0012/0.0030)
0.046/0.196 (0.0018/0.0077)
0.180/0.430 (0.0071/0.0169)
0.180/0.380 (0.0071/0.0150)
0.250/0.450 (0.0098/0.0177)
0.250/0.460 (0.0098/0.0181)
0.77 (0.030)
0.77 (0.030)
0.80 (0.0315)
0.80 (0.0315)
76.968/76.986 (3.0302/3.0309)
79.963/79.981 (3.1481/3.1488)
76.840 (3.0252)
76.840 (3.0252)
79.831 (3.1430)
79.831 (3.1430)
7.936 (0.3124)
r
a
n
i
m
i
l
e
Bore Running Clearance
LH685 (25)
80.000/80.025 (3.1496/3.1506)
77.063 (3.0340)
80.065 (3.1522)
0.05 (0.0020)
0.05 (0.0020)
0.12 (0.0047)
0.12 (0.0047)
0.025/0.126 (0.0009/0.0049)
Crankcase Running Clearance
Governor
LH640 (24)
0.014/0.057 (0.0005/0.0022)
0.019/0.062 (0.0007/0.0024)
Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.
TP-2469-A 12/07
32
Model (Horsepower)
LH630 (22)
Hydraulic Valve Lifter to Crankcase Running Clearance

Intake Valve Stem-to-Valve Guide Running Clearance
Exhaust Valve Stem-to-Valve Guide Running Clearance
New
Intake Valve Guide I.D.
Max. Wear Limit
Intake Valve Stem Diameter - New
New
Valves and
Exhaust Valve Guide I.D.
Max. Wear Limit
Valve Lifters
Exhaust Valve Stem Diameter - New
Standard
Valve Guide Reamer Size
0.25 mm O.S.
Intake Valve Lift
TP-2469-A 12/07
LH690 (26)
y
p
o
C
y
7.298 (0.2873)
8.88 (0.3496)
r
a
r
P
LH685 (25)
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
6.982/7.000 (0.2749/0.2756)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
6.970/6.988 (0.2744/0.2751)
7.048 (0.2775)
Exhaust Valve Lift
n
i
m
i
l
e
LH640 (24)
8.88 (0.3496)
45
33

LH750 (27)
Model (Horsepower)
Horsepower (@3600 RPM) - Maximum kW (HP)
Bore x Stroke
Running Clearance
New
Camshaft
Bore I.D.
Max. Wear Limit
New
Max. Wear Limit
New
Clearance
Max Wear Limit
New
Rod
Piston Pin End I.D.
Max. Wear Limit
New
Max. Wear Limit
End Play (Free)
Crankshaft Sleeve Bearing I.D.
New
(Crankcase)
Max. Wear Limit
New
Max. Wear Limit
20.1 kW (27 HP)
General
r
P
i
l
e
n
i
m
O.D. - New
Max.
Taper
Crankshaft
Max. Out-of-Round
O.D. - New
Max. Taper
Max. Out-of-Round
Crankshaft T.I.R.
TP-2469-A 12/07
r
a
LH755 (28)
LH760 (29)
LH775 (31)
20.9 kW (28 HP)

21.6 kW (29 HP)
83 (3.3) x 69 (2.7)
747 cc (45.6)
0.076/0.127 (0.0030/0.0050)
0.025/0.063 (0.0010/0.0025)
20.000/20.025 (0.7874/0.7884)
20.038 (0.7889)
19.962/19.975 (0.7859/0.7864)
19.959 (0.7858)
0.043/0.068 (0.0016/0.0026)
0.083 (0.0032)
0.26/0.63 (0.0102/0.0248)
0.015/0.028 (0.0006/0.0011)
17.015/17.023 (0.6699/0.6702)
17.036 (0.6707)
8.025/8.075 (0.3159/0.3179)
8.088 (0.3184)
0.070/0.590 (0.0028/0.0230)
40.974/40.987 (1.6131/1.6136)
41.000 (1.6141)
40.974/41.000 (1.6131/1.6141)
41.038 (1.6156)
23.1 kW (31 HP)
y
p
o
C
y
0.039/0.087 (0.0015/0.0034)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
0.039/0.074 (0.0015/0.0029)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
0.15 (0.0059)
0.10 (0.0039)
34

LH750 (27)
Model (Horsepower)
Bore x Stroke
Running Clearance
New
Camshaft
Bore I.D.
Max. Wear Limit
New
Max. Wear Limit
New
Clearance
Max Wear Limit
New
Rod
Piston Pin End I.D.
Max. Wear Limit
New
Max. Wear Limit
End Play (Free)
New
(Crankcase)
Max. Wear Limit
New
Max. Wear Limit
20.1 kW (27 HP)
General
r
P
i
l
e
n
i
m
O.D. - New
Max.
Taper
Crankshaft
Max. Out-of-Round
O.D. - New
Max. Taper
Max. Out-of-Round
Crankshaft T.I.R.
TP-2469-A 12/07
r
a
LH755 (28)
LH760 (29)
LH775 (31)
20.9 kW (28 HP)

21.6 kW (29 HP)
83 (3.3) x 69 (2.7)
747 cc (45.6)
0.076/0.127 (0.0030/0.0050)
0.025/0.063 (0.0010/0.0025)
20.000/20.025 (0.7874/0.7884)
20.038 (0.7889)
19.962/19.975 (0.7859/0.7864)
19.959 (0.7858)
0.043/0.068 (0.0016/0.0026)
0.083 (0.0032)
0.26/0.63 (0.0102/0.0248)
0.015/0.028 (0.0006/0.0011)
17.015/17.023 (0.6699/0.6702)
17.036 (0.6707)
8.025/8.075 (0.3159/0.3179)
8.088 (0.3184)
0.070/0.590 (0.0028/0.0230)
40.974/40.987 (1.6131/1.6136)
41.000 (1.6141)
40.974/41.000 (1.6131/1.6141)
41.038 (1.6156)
23.1 kW (31 HP)
y
p
o
C
y
0.039/0.087 (0.0015/0.0034)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
0.039/0.074 (0.0015/0.0029)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
0.15 (0.0059)
0.10 (0.0039)
35
Model (Horsepower)
Cylinder
Bore
LH750 (27)
New
Max. Wear Limit
Max. Taper
Max. Out-of-Round
Cylinder Bore I.D.
Governor Cross Shaft to

Crankcase Running Clearance
New
Governor
Max. Wear Limit
New
Max. Wear Limit
Spark Plug Gap
Ignition
New
Max. Wear Limit
New
Piston, Piston
Piston Pin O.D.
Max. Wear Limit
Rings, and
Top Compression Ring-to-Groove Side Clearance
Piston Pin
Top and Middle Compression New Bore
Used Bore
New
1
Max. Wear Limit
LH775 (31)
y
p
o
C
y
0.025/0.126 (0.0009/0.0049)
i
l
e
7.949/8.000 (0.3129/0.3149)
7.936 (0.3124)
5.990/6.000 (0.2358/0.2362)
5.977 (0.2353)
0.090/0.160 (0.0035/0.0063)
RC14YC
0.76 (0.030)
0.203/0.305 (0.008/0.012)
0.006/0.018 (0.0002/0.0007)
17.006/17.013 (0.6695/0.6698)
17.025 (0.6703)
16.995/17.000 (0.6691/0.6693)
16.994 (0.6691)
0.014/0.041 (0.0005/0.0016)
0.012/0.039 (0.0004/0.0015)
0.026/0.176 (0.0010/0.0070)
0.250/0.56 (0.0098/0.022)
0.94 (0.037)
82.973/82.991 (3.2666/3.2673)
82.841 (3.3136)
r
a
n
i
m
Bore1 Running Clearance

1
LH760 (29)
83.006/83.031 (3.2679/3.2689)
83.069 (3.2704)
0.05 (0.0020)
0.12 (0.0047)
0.076 (0.003)
r
P
LH755 (28)
0.015/0.058 (0.005/0.0022)
Measure 6 mm (0.236 in.) above the bottom of the piston skirt, at right angles to the piston pin.
TP-2469-A 12/07
36
Model (Horsepower)
Valves and
Valve Lifters
LH750 (27)

New
Max. Wear Limit
New
Max. Wear Limit
Standard
0.25 mm O.S.
Intake Valve Lift
Exhaust Valve Lift
r
P
TP-2469-A 12/07
LH760 (29)
LH775 (31)
y
p
o
C
y
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
r
a
n
i
m
i
l
e
LH755 (28)
6.982/7.000 (0.2749/0.2756)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
6.970/6.988 (0.2744/0.2751)
7.048 (0.2775)
7.298 (0.2873)
8.88 (0.3496)
8.88 (0.3496)
45
37
Model (Horsepower)
Valves and
Valve Lifters
LH750 (27)

New
Max. Wear Limit
New
Max. Wear Limit
Standard
0.25 mm O.S.
Intake Valve Lift
Exhaust Valve Lift
r
P
TP-2469-A 12/07
LH760 (29)
LH775 (31)
y
p
o
C
y
0.0124/0.0501 (0.0005/0.0020)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
r
a
n
i
m
i
l
e
LH755 (28)
6.982/7.000 (0.2749/0.2756)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
6.970/6.988 (0.2744/0.2751)
7.048 (0.2775)
7.298 (0.2873)
8.88 (0.3496)
8.88 (0.3496)
45
38
Aegis Twin Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
Intake Manifold Fastener
LH630 (22)
LH640 (24)
Step 1
Carburetor and (torque in two increments)
Step 2
6.2-7.3 Nm (55-65 in. lb.)

9.9 Nm (88 in. lb.)
Connecting Rod Cap Fastener - Incrementally torque to:
11.3 Nm (100 in. lb.)
Into new hole
10.7 Nm (95 in. lb.)
Into used hole
7.3 Nm (65 in. lb.)
Oil Drain Plug
Closure Plate
r
a
Closure Plate Fastener

Cylinder Head Fastener
Cylinder Head (torque in two increments)
Step 1
Step 2
n
i
m
Rocker Pivot Fastener

Starter Thru Bolt
Starter Mounting Screw
i
l
e
Electric Starter Starter Brush Holder Fastener

Starter Solenoid Fastener
Starter Solenoid Positive (+)
r
P
Brush Lead Retaining Nut
Closure Plate
TP-2469-A 12/07
y
p
o
C
y
9.9 Nm (88 in. lb.)
Carburetor Mounting Fastener
Breather Cover Fastener
LH690 (26)
7.4 Nm (66 in. lb.)
Intake Manifold Thermostat Housing Mount Fastener
Crankcase
LH685 (25)
13.6 Nm (10 ft. lb.)
24.4 Nm (216 in. lb.)
16.9 Nm (150 in. lb.)

33.9 Nm (300 in. lb.)
11.3 Nm (100 in. lb.)
5.6-9.0 Nm (49-79 in. lb.)

15.3 Nm (135 in. lb.)
2.5-3.3 Nm (22-29 in. lb.)
4.0-6.0 Nm (35-53 in. lb.)
8.0-11.0 Nm (71-97 in. lb.)
Cylinder Head #2
Cylinder Head #1
Intake Manifold
39
Model (Horsepower)
LH630 (22)
Rear Fan Shaft to Mounting Bracket Nut

Front Fan Assembly to Fan Shaft Nut
Fan/Pulley/Hub Assembly Fastener
Fan/Flywheel Flywheel Retaining Screw
Into hex or weld nuts
Lower Flywheel Cover
Into Timmerman clips/nuts
Mounting Screw
Lower Pulley Mounting Screw
Governor Lever Nut Torque
Governor
Spark Plug
Into new hole
Ignition Module Fastener
Ignition
Into used hole
Rectifier-Regulator Fastener
Muffler
Oil Filter
Speed Control
Water Pump
r
a
Speed Control Bracket

Assembly Fastener
Stator Mounting Screw
Breather Cover
TP-2469-A 12/07
in
Into new hole

Into used hole
m
i
l
e
Mounting Screw
Pulley Mounting Screw
r
P
LH685 (25)
LH690 (26)
15.8 Nm (140 in. lb.)

15.8 Nm (140 in. lb.)
6.8 Nm (60 in. lb.)
66.4 Nm (49 ft. lb.)
9.9 Nm (88 in. lb.)
2.2-2.8 Nm (20-25 in. lb.)
24.3 Nm (215 in. lb.)
6.8 Nm (60 in. lb.)
24.4-29.8 Nm (18-22 ft. lb.)
6.2 Nm (55 in. lb.)
4.0 Nm (35 in. lb.)
4.0 Nm (35 in. lb.)
24.4 Nm (216 in. lb.)
y
p
o
C
y
Rotate filter 3/4-1 turn after gasket contact
Oil Filter Instructions:
Stator
Valve Cover/
Valve Cover Fastener
Rocker Arms
LH640 (24)
Valve Cover
10.7 Nm (95 in. lb.)

7.3 Nm (65 in. lb.)
6.2 Nm (55 in. lb.)
6.2 Nm (55 in. lb.)
9.9 Nm (88 in. lb.)
9.9 Nm (88 in. lb.)
Water Pump
40
Aegis Twin Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
LH750 (27)
Intake Manifold Fastener
LH755 (28)
Step 1
Carburetor and (torque in two increments)
Step 2
6.2-7.3 Nm (55-65 in. lb.)

9.9 Nm (88 in. lb.)
Connecting Rod Cap Fastener - Torque in Increments to:
11.3 Nm (100 in. lb.)
Into new hole
10.7 Nm (95 in. lb.)
Into used hole
7.3 Nm (65 in. lb.)
Oil Drain Plug
Closure Plate
13.6 Nm (10 ft. lb.)
r
a

Cylinder Head (torque in two increments)
Step 1
Step 2
in
Rocker Pivot Fastener

Starter Thru Bolt
Starter Mounting Screw
Electric Starter
m
i
l
e
Starter Brush Holder Fastener

Starter Solenoid Fastener
Starter Solenoid Positive (+) Brush

Lead Retaining Nut
r
P
Closure Plate
TP-2469-A 12/07
y
p
o
C
y
9.9 Nm (88 in. lb.)
Carburetor Mounting Fastener
Crankcase
LH775 (31)
7.4 Nm (66 in. lb.)
Intake Manifold Thermostat Housing Mount Fastener
Breather Cover Fastener
LH760 (29)
24.4 Nm (216 in. lb.)
16.9 Nm (150 in. lb.)

33.9 Nm (300 in. lb.)
11.3 Nm (100 in. lb.)
5.6-9.0 Nm (49-79 in. lb.)

15.3 Nm (135 in. lb.)
2.5-3.3 Nm (22-29 in. lb.)
4.0-6.0 Nm (35-53 in. lb.)
8.0-11.0 Nm (71-97 in. lb.)
Cylinder Head #2
Cylinder Head #1
Intake Manifold
41
Model (Horsepower)
LH750 (27)
LH755 (28)
Rear Fan Shaft to Mounting Bracket Nut

Front Fan Assembly to Fan Shaft Nut
15.8 Nm (140 in. lb.)
Into hex or weld nuts
Mounting Screw
Into Timmerman clips/nuts
9.9 Nm (88 in. lb.)
2.2-2.8 Nm (20-25 in. lb.)
Lower Pulley Mounting Screw
Ignition
Into new hole
6.2 Nm (55 in. lb.)
Into used hole

Oil Filter
Oil Filter Instructions:

Into new hole
Assembly Fastener
Into used hole
Mounting Screw
Pulley Mounting Screw
r
P
in
m
i
l
e
Breather Cover
TP-2469-A 12/07
r
a
4.0 Nm (35 in. lb.)

4.0 Nm (35 in. lb.)
24.4 Nm (216 in. lb.)
Rotate filter 3/4-1 turn after gasket contact
Speed Control Bracket

Stator
Valve Cover/
Rocker Arms
Water Pump
6.8 Nm (60 in. lb.)

24.4-29.8 Nm (18-22 ft. lb.)
Fastener
Muffler
Speed Control
24.3 Nm (215 in. lb.)
Governor Lever Nut Torque

Spark Plug
Ignition Module
y
p
o
C
y
66.4 Nm (49 ft. lb.)

Lower Flywheel Cover
LH775 (31)
6.8 Nm (60 in. lb.)
Fan/Pulley/Hub Assembly Fastener
Governor
LH760 (29)
15.8 Nm (140 in. lb.)
Valve Cover
10.7 Nm (95 in. lb.)

7.3 Nm (65 in. lb.)
6.2 Nm (55 in. lb.)

6.2 Nm (55 in. lb.)
9.9 Nm (88 in. lb.)
9.9 Nm (88 in. lb.)
Water Pump
42

Model (Horsepower)
General
Bore x Stroke
Displacement
Running Clearance
New
Camshaft
Bore I.D.
Max. Wear Limit
New
Max. Wear Limit
New
Rod-to-Crankpin Running Clearance
Max Wear Limit
New
Rod
Piston Pin End I.D.
Max. Wear Limit
New
Max. Wear Limit
End Play (Free)
New
Crankshaft Bore (in crankcase)
Max. Wear Limit
New
Crankshaft Bore (in oil pan)
Max. Wear Limit
i
l
e
r
P
O.D. - New
Max. Taper
Max. Out-of-Round
Crankshaft Bore (in crankcase)-to-Crankshaft

Crankshaft T.I.R.
TP-2469-A 12/07
r
a
n
i
m
Crankshaft Bore (in oil pan)-to-Crankshaft

Crankshaft
LV560
12.7 kW (17 HP)
73 (2.87) x 67 (2.64)
561 cc (34.2 cu. in.)
O.D. - New
Max. Taper
Max. Out-of-Round
LV625
14.9 kW (20 HP)
77 (3.03) x 67 (2.64)
624 cc (38.1 cu. in.)
0.076/0.127 (0.0030/0.0050)
0.025/0.063 (0.0010/0.0025)
20.000/20.025 (0.7874/0.7884)
20.038 (0.7889)
19.962/19.975 (0.7859/0.7864)
19.959 (0.7858)
0.043/0.068 (0.0016/0.0026)
0.083 (0.0032)
0.26/0.63 (0.0102/0.0248)
0.015/0.028 (0.0006/0.0011)
17.015/17.023 (0.6699/0.6702)
17.036 (0.6707)
8.025/8.075 (0.3159/0.3179)
8.088 (0.3184)
0.070/0.590 (0.0028/0.0232)
40.974/40.987 (1.6131/1.6136)
41.000 (1.6141)
40.974/41.000 (1.6131/1.6141)
41.038 (1.6156)
LV675
17.1 kW (23 HP)
80 (3.14) x 67 (2.64)
674 cc (41.1 cu. in.)
y
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0.039/0.087 (0.0015/0.0034)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
0.039/0.074 (0.0015/0.0029)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
0.15 (0.0059)
0.10 (0.0039)
43
Model (Horsepower)
Cylinder
Bore
New
Max. Wear Limit
Max. Out-of-Round
Max. Taper
Cylinder Bore I.D.
LV560
LV625
LV675
73.006/73.03 (2.8742/2.8752)
73.070 (2.8767)
77.000/77.025 (3.0315/3.0325)
77.063 (3.0340)
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
80.000/80.025 (3.1496/3.1506)
80.065 (3.1522)

Governor Cross Shaft to Crankcase
Governor
Governor
Ignition
Piston, Piston
Rings, and
Piston Pin
New
Max. Wear Limit
New
Max. Wear Limit
Spark Plug Gap
New
Max. Wear Limit
New
Piston Pin O.D.
Max. Wear Limit
Top and Middle Compression Top Ring
Middle Ring
Used Bore (Max.)
New
Piston Thrust Face O.D. 1
Max. Wear Limit
r
P
0.040/0.096 (0.0016/0.0037)
0.030/0.080 (0.0012/0.0031)
0.046/0.201 (0.0018/0.0079)
0.180/0.380 (0.0071/0.0150)
0.180/0.440 (0.0071/0.0173)
0.76 (0.029)
72.966/72.984 (2.8727/2.8734)
72.839 (2.8677)
7.949/8.000 (0.3129/0.3149)
7.936 (0.3124)
5.990/6.000 (0.2358/0.2362)
5.977 (0.2353)
0.090/0.160 (0.0035/0.0063)
RC14YC
0.76 (0.030)
0.2/0.3 (0.008/0.012)
0.006/0.018 (0.0002/0.0007)
17.006/17.013 (0.6695/0.6698)
17.025 (0.6703)
16.995/17.000 (0.6691/0.6693)
16.994 (0.6691)
0.040/0.086 (0.0016/0.0034)
0.040/0.086 (0.0016/0.0034)
0.046/0.196 (0.0018/0.0077)
0.180/0.380 (0.0071/0.0150)
0.250/0.450 (0.0098/0.0177)
0.77 (0.030)
76.967/76.985 (3.0302/3.0309)
76.840 (3.0252)
0.050/0.096 (0.0012/0.0030)
0.030/0.076 (0.0012/0.0030)
0.046/0.196 (0.0018/0.0077)
0.180/0.430 (0.0071/0.0169)
0.250/0.460 (0.0098/0.0181)
0.80 (0.0315)
79.963/79.981 (3.1481/3.1488)
79.831 (3.1430)
0.022/0.065 (0.0009/0.0026)
0.014/0.057 (0.0005/0.0022)
0.019/0.062 (0.0007/0.0024)
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in
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Bore1 Running Clearance
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0.025/0.126 (0.0009/0.0049)
Running Clearance
TP-2469-A 12/07
44
Model (Horsepower)
LV560

New
Max. Wear Limit
Valves and Intake Valve Stem Diameter - New

Valve Lifters Exhaust Valve Guide I.D.
Standard
0.25 mm O.S.
r
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r
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TP-2469-A 12/07
y
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6.982/7.000 (0.2749/0.2756)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
New
Max. Wear Limit
n
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LV675
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)

LV625
0.0124/0.0501 (0.0004/0.0020)
6.970/6.988 (0.2744/0.2751)
7.048 (0.2775)
7.298 (0.2873)
8.88 (0.3496)
8.88 (0.3496)
45
45
Aegis LV17-23 Twin Cylinder Torque Values and Sequences for Fasteners
Model (Horsepower)
Blower Housing
(Lower)
Carburetor and
Intake Manifold
Connecting Rod
Crankcase
LV560
M5 Fasteners
M6 Fasteners
Rectifier Fastener
Intake Manifold Mounting Fasteners
Carburetor Mounting Fasteners
Cap Fastener - Incrementally torque to:
Into new as-cast hole
Breather Cover Fasteners
Into used hole
Oil Drain Plugs
Cylinder Head #1
Cylinder Head #2
Step 1
Step 2
Rocker Pivot Fastener Torque (screw)
Rocker Pivot Fastener Torque (nut)
Starter Mounting Fastener
Fan Fastener
Flywheel Retaining Screw
Spark Plug
Into used hole
Electric Starter
Fan/Flywheel
Ignition
TP-2469-A 12/07
r
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LV675
y
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11.3 Nm (100 in. lb.)
10.7 Nm (95 in. lb.)
7.3 Nm (65 in. lb.)
13.6 Nm (120 in. lb.)
Valve Cover #1
r
a
n
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Cylinder Head
LV625
4.0 Nm (35 in. lb.)
6.8 Nm (60 in. lb.)
4.0 Nm (35 in. lb.)
6.2 Nm (55 in. lb.)
6.2 Nm (55 in. lb.)
Valve Cover #2
16.9 Nm (150 in. lb.)

33.9 Nm (300 in. lb.)
11.3 Nm (100 in. lb.)
15.8 Nm (140 in. lb.)
15.3 Nm (135 in. lb.)
13.6 Nm (120 in. lb.)
66.4 Nm (49 ft. lb.)
24.4-29.8 Nm (18-22 ft. lb.)
6.2 Nm (55 in. lb.)
3.9 Nm (35 in. lb.)
46
Model (Horsepower)
Muffler
LV560
LV625
LV675
24.4 Nm (216 in. lb.)
y
p
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8.1-9.4 Nm (72-84 in. lb.)
Oil Filter
24.4 Nm (216 in. lb.)
Oil Pan Fastener
Oil Pan/Filter
Oil Pan
Speed Control
Bracket Assembly Fastener
e
r
Breather Cover
P
TP-2469-A 12/07
in
m
i
l

Stator
Throttle/Choke Controls Governor Control Lever Fastener
Valve Cover/Rocker Arms Valve Cover Fastener
r
a

Into used hole
Intake Manifold
10.7 Nm (95 in. lb.)

7.3 Nm (65 in. lb.)
6.2 Nm (55 in. lb.)
9.9 Nm (88 in. lb.)
6.2 Nm (55 in. lb.)
Water Pump
47
Command PRO CS Single Cylinder Engine Specifications and Tolerances

CS4
CS6
2.9
4.47
5.4
8.5
56.0 (2.20) x 50.0 (1.97)
66.0 (2.60) x 50.0 (1.97)
75.0 (2.95) x 57.0 (2.44)
123 cc (7.50 cu. in.)
171 cc (10.43 cu. in.)
251 cc (15.30 cu. in.)
0.05 (0.0020)
0.05 (0.0020)
14.95 (0.583)
15.95 (0.627)
15.05 (0.592)
16.05 (0.649)
Model (Horsepower)
General
Camshaft
Kilowatt (kW) Output (@3600 RPM)

Horsepower (@3600 RPM)
Bore x Stroke
Displacement
End Play
0.05 (0.0020)
14.95 (0.583)
Camshaft Bearing Surface O.D. Max. Wear Limit

Connecting
Rod
15.05 (0.592)
New
Max Wear Limit
0.1 (0.004)
r
a
0.2/0.6 (0.008/0.024)
0.006/0.025 (0.0002/0.0001)
New
16.006/16.020 (0.6301/0.6307) 16.006/16.020 (0.6301/0.6307) 18.006/18.020 (0.7089/0.7094)
Max. Wear Limit
16.10 (0.634)
16.10 (0.634)
18.10 (0.713)
New
28.000/28.015 (1.1023/1.1029) 28.000/28.015 (1.1023/1.1029) 32.000/32.015 (1.2598/1.2604)
Max. Wear Limit
28.115 (1.1069)
28.115 (1.1069)
32.115 (1.2644)
n
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Journal End I.D.
y
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0.016/0.046 (0.0006/0.0018)

Rod-to-Piston Pin Running Clearance
Piston Pin End I.D.
CS8.5 (spec. 95xxxx)
0.04 (0.0015)
End Play (Free)
End Play (Threaded Pump Shaft Models Only)
0.0/0.2 (0.0/0.007)
New
52 (2.047)
Flywheel End Main Bearing Journal O.D
Max. Wear Limit
52.05 (2.0492)
New
52 (2.047)
Crankshaft PTO End Main Bearing Journal O.D.
Max. Wear Limit
52.05 (2.0492)
New
27.969/27.984 (1.011/1.017)
27.969/27.984 (1.011/1.017)
31.969/31.984 (1.2586/1.2592)
Connecting Rod Journal O.D.
Max. Wear Limit
27.9 (1.098)
27.9 (1.098)
31.9 (1.2559)
Runout (Either End)
0.02 (0.0008)
Limit (Either End)
0.04 (0.0016)
New
56.005/56.015 (2.2049/2.2053) 66.005/66.015 (2.5986/2.5990) 75.005/75.015 (2.9530/2.9533)
Cylinder Bore I.D.
Cylinder
56.15 (2.211)
66.15 (2.604)
75.15 (2.959)
Max. Wear Limit
Max. Out-of-Round
Bore
0.05 (0.002)
0.1 (0.004)
NGK
BPR4ES (13/16 hex)
Spark Plug Type
Champion
RN14YC (13/16 hex)
Ignition
Champion
RC14YC (5/8) hex)
Spark Plug Gap
0.76 (0.030)
0.4/0.6 (0.015/0.023)
r
P
TP-2469-A 12/07
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48

CS10
CS12
6.33
7.45
8.95
8.5
10
12
Model (Horsepower)
General
78.0 (3.07) x 63.0 (2.48)
78.0 (3.07) x 63.0 (2.48)
85.0 (3.35) x 63.0 (2.48)
301 cc (18.37 cu. in.)
301 cc (18.37 cu. in.)
357 cc (21.79 cu. in.)
End Play
Camshaft
0.05 (0.0020)
15.95 (0.627)
16.05 (0.649)
0.016/0.046 (0.0006/0.0018)
New
0.1 (0.004)
Max Wear Limit
Connecting
Rod
0.2/0.65 (0.0079/0.0256)
New
Piston Pin End I.D.
Max. Wear Limit

New
n
i
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Max. Wear Limit
End Play (Free)
End Play (Threaded Pump Shaft Models Only)

Flywheel End Main Bearing Journal O.D.
i
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PTO End Main Bearing Journal O.D.

Connecting Rod Journal O.D.
r
P
Runout (Either End)
Cylinder
Bore
Limit (Either End)
Cylinder Bore I.D.
New
Max. Wear Limit

New
Max. Wear Limit
Max. Wear Limit

Spark Plug Type
Spark Plug Gap
TP-2469-A 12/07
20.10 (0.791)
36.000/36.015 (1.4173/1.4179)
36.115 (1.4219)
0.04 (0.0015)
0.0/0.2 (0.0/0.007)
80 (3.149)
80.05 (3.1515)
72 (2.834)
35.969/35.984 (1.4161/1.4167)
Max. Wear Limit
New
0.006/0.025 (0.0002/0.0001)
20.006/20.020 (0.7876/0.7882)
72.05 (2.836)
New
Max. Out-of-Round
Ignition
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Rod-to-Piston Pin Running Clearance
Journal End I.D.
Crankshaft
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Bore x Stroke
Displacement
35.9 (1.4134)
0.02 (0.0008)
0.04 (0.0016)
78.00/78.02 (3.0709/3.0717)
78.00/78.02 (3.0709/3.0717)
85.00/85.02 (3.3465/3.3472)
78.65 (3.096)
78.65 (3.096)
85.65 (3.372)
0.05 (0.002)
0.1 (0.004)
NGK
BPR4ES (13/16 hex)
Champion
RN14YC (13/16 hex)
Champion
RC14YC (5/8) hex)

0.76 (0.030)
0.4/0.6 (0.015/0.023)
49

Model (Horsepower)
Piston-to-Piston Pin Clearance
New
Piston, Piston
Max Wear Limit
Rings, and
New
Piston Pin O.D.
Piston Pin
Max Wear Limit
Top Compression Ring to
Groove Side Clearance
Middle Compression Ring to
Groove Side Clearance
Top Compression Ring End Gap
Middle Compression Ring End Gap
Oil Control Ring End Gap
New
1, 2
Max Wear Limit
1, 2
Bore Running Clearance
Intake Valve Stem-to-Valve
Guide Running Clearance
Exhaust Valve Stem-to-Valve
Guide Running Clearance
New
Max Wear Limit
New
Valves and
Max Wear Limit
Valve Lifters
Valve Guide Reamer Size - STD
Valve-to-Tappet Clearance (Cold)
1
r
P
CS4
CS6
0.002/0.018 (0.0001/0.0007)
16.002/16.013 (0.6300/0.6304)
16.03 (0.6311)
15.995/16.000 (0.6297/0.6299)
15.98 (0.6291)
0.004/0.020 (0.0002/0.0008)
18.004/18.015 (0.7088/0.7093)
18.03 (0.7098)
17.995/18.000 (0.7084/0.7086)
17.98 (0.7079)
0.04/0.08 (0.0016/0.003)
0.04/0.08 (0.0016/0.003)
0.02/0.06 (0.0008/0.0024)
0.03/0.07 (0.0012/0.0028)
0.2/0.4 (0.008/0.016)
0.2/0.4 (0.008/0.016)
0.2/0.4 (0.0079/0.0157)
55.975/55.990 (2.2037/2.2043)1 65.975/65.990 (2.597/2.598)1
55.900 (2.20)
65.900 (2.60)
0.25/0.4 (0.010/0.016)
0.25/0.4 (0.010/0.016)
0.2/0.7 (0.0079/0.028)
74.954/74.998 (2.9509/2.9527)2
74.898 (2.9487)
0.015/0.040 (0.0006/0.0016)1
0.002/0.066 (0.0001/0.0026)
0.04/0.06 (0.0016/0.0024)
0.037/0.064 (0.0015/0.0025)
0.06/0.08 (0.002/0.003)
0.045/0.072 (0.0018/0.0028)
5.5 (0.22)
5.60 (0.220)
5.5 (0.22)
5.60 (0.220)
5.5 (0.216)
2.4 (0.094)
2.7 (0.106)
45
0.1 (0.004)
6.0/6.012 (0.2362/0.2367)
6.10 (0.240)
6.0/6.012 (0.2362/0.2367)
6.0 (0.236)
6.0 (0.236)
2.7 (0.106)
2.9 (0.114)
45
0.1 (0.004)
m
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2
TP-2469-A 12/07
50

Model (Horsepower)
Piston-to-Piston Pin Clearance

Piston, Piston
Rings, and
Piston Pin
New
19.995/20.000 (0.7872/0.7874)
19.98 (0.7866)
Top Compression Ring to Groove
0.04/0.08 (0.0016/0.003)
Side Clearance
Middle Compression Ring to Groove
0.03/0.07 (0.0012/0.0028)
Side Clearance
Top Compression Ring End Gap
0.2/0.4 (0.008/0.016)
r
a
0.2/0.4 (0.008/0.016)
Oil Control Ring End Gap

New
Running Clearance 2
Intake Valve Stem-to-Valve Guide
Running Clearance
i
l
e
Exhaust Valve Stem-to-Valve Guide
Valves and
Valve Lifters
r
P
New
Max Wear Limit

New
Max Wear Limit
77.898 (3.0669)
0.2/0.4 (0.008/0.016)
0.25/0.4 (0.010/0.016)
0.2/0.4 (0.008/0.016)
0.25/0.4 (0.010/0.016)
0.2/0.7 (0.0079/0.028)
77.954/77.998 (3.0691/3.0708) 2
84.954/84.998 (3.3446/3.3464) 2
77.898 (3.0669)
84.898 (3.3424)
0.002/0.066 (0.0001/0.0026) 2
0.037/0.064 (0.0015/0.0025)
0.045/0.072 (0.0018/0.0028)
6.0/6.012 (0.2362/0.2367)
6.10 (0.240)
6.0/6.012 (0.2362/0.2367)
6.0 (0.236)
Valve Guide Reamer Size - STD
6.0 (0.236)
2.7 (0.106)
2.9 (0.114)
Valve-to-Tappet Clearance (Cold)
TP-2469-A 12/07
77.954/77.998 (3.0691/3.0708) 2
n
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Max Wear Limit
Piston Thrust Face-to-Cylinder Bore
Running Clearance
y
p
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20.03 (0.7886)
Max Wear Limit
CS12
20.004/20.015 (0.7876/0.7880)
Max Wear Limit

New
Piston Pin O.D.
CS10
0.004/0.020 (0.0002/0.0008)
45
0.1 (0.004)
51
Command PRO CS Single Cylinder Torque Values and Sequences for Fasteners
Model (Horsepower)
Air Cleaner
Carburetor
CS4
Base Bolt
5-8 Nm (44-71 in. lb.)
Base Nut
5-8 Nm (44-71 in. lb.)
Fuel Bowl Retaining Screw
7 Nm (62 in. lb.)
Crankcase
Cylinder Head
Electric Starter
Rod Fastener
22 Nm (195 in. lb.)
Oil Drain Plug
17 Nm (150 in. lb.)
17 Nm (150 in. lb.)
Head Bolt
20 Nm (177 in. lb.)
20 Nm (177 in. lb.)
Thru Bolt (Case)
Mounting Bolts (to block)
Fuel Tank
Fastener Screws
Spark Plug
Ignition
12 Nm (106 in. lb.)

22 Nm (195 in. lb.)
Retaining Screw
Oil Sentry
i
l
e
Flange Nuts and Bracket Bolts
r
P
Float Switch
Indicator Light Retaining Nut
Reduction System
n
i
m
8-12 Nm (71-106 in. lb.)
Muffler
r
a
65 Nm (48 ft. lb.)
Ignition Module Mounting Screws
Case Mounting Bolts
CS4 & CS6
7 Nm (62 in. lb.)
Flywheel
CS8.5 (spec. 95xxxx) Closure Plate
Crankshaft Gear Bolt
30 Nm (265 in. lb.)

20 Nm (177 in. lb.)
50 Nm (36 ft. lb.)
5.3 Nm (47.7 in. lb.)

16 Nm (141 in. lb.)
Stator
10 Nm (88 in. lb.)
5-8 Nm (44-70 in. lb.)

18-22 Nm (159-195 in. lb.)
10 Nm (88 in. lb.)
Cylinder Head
0.6-0.8 Nm (5-7 in. lb.)

10 Nm (88 in. lb.)
30 Nm (22 ft. lb.)
22 Nm (195 in. lb.)
Retractable Starter Blower Housing Screws
6.5 Nm (57 in. lb.)
6.5 Nm (57 in. lb.)
7 Nm (62 in. lb.)
Stud into Cylinder Head
10 Nm (88 in. lb.)
10 Nm (88 in. lb.)
Rocker Arm
7 Nm (62 in. lb.)
Adjusting Jam Nut
Throttle Control
Valve Cover
TP-2469-A 12/07
Control Lever Fastener

Valve Cover
CS8.5
20 Nm (14.7 ft. lb./177 in. lb.)
8-12 Nm (71-106 in. lb.) 8-12 Nm (71-106 in. lb.)
10 Nm (88 in. lb.)
y
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9 Nm (79 in. lb.)
1.5-2.5 Nm (13-22 in. lb.)
Throttle/Choke Plate Screws
Connecting Rod
CS6
7-9 Nm (62-80 in. lb.)
7-9 Nm (62-80 in. lb.)
9-11 Nm (80-97 in. lb.)
10 Nm (88 in. lb.)
10 Nm (88 in. lb.)
11 Nm (97 in. lb.)

52
Command PRO CS Single Cylinder Torque Values and Sequences for Fasteners
Model (Horsepower)
Air Cleaner
5-8 Nm (44-71 in. lb.)
Base Nut
10-12 Nm (88-106 in. lb.)

9 Nm (79 in. lb.)
Throttle/Choke Plate Screws
Connecting Rod
Crankcase
Cylinder Head
Electric Starter
20 Nm (177 in. lb.)
30 Nm (265 in. lb.)
Oil Drain Plug
20 Nm (177 in. lb.)
Head Bolt
5.3 Nm (47.7 in. lb.)
Mounting Bolts (to block)
16 Nm (141 in. lb.)
Fuel Tank
Fastener Screws
8-12 Nm (71-106 in. lb.)
m
i
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Ignition Module Mounting Screws

e
r
Flange Nuts and Bracket Bolts
Oil Sentry
Float Switch
Indicator Light Retaining Nut
Reduction System
Case Mounting Bolts
Crankshaft Gear Bolt
Retractable Starter Blower Housing Screws

Rocker Arm
Stud into Cylinder Head

Adjusting Jam Nut
Throttle Control
Valve Cover
TP-2469-A 12/07
Control Lever Fastener

Valve Cover
in
120 Nm (85 ft. lb.)
Spark Plug
Muffler
r
a
50 Nm (36 ft. lb.)
Thru Bolt (Case)
Retaining Screw
Closure Plate
CS8.5-12
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1.5-2.5 Nm (13-22 in. lb.)
Rod Fastener
Flywheel
Ignition
CS12
Base Bolt
Fuel Bowl Retaining Screw
Carburetor
CS10
Stator
20 Nm (14.7 ft. lb./177 in. lb.)

10 Nm (88 in. lb.)
5-8 Nm (44-70 in. lb.)
18-22 Nm (159-195 in. lb.)

10 Nm (88 in. lb.)
0.6-0.8 Nm (5-7 in. lb.)
Cylinder Head
30 Nm (22 ft. lb.)

65 Nm (48 ft. lb.)
7 Nm (62 in. lb.)
7 Nm (62 in. lb.)

9-11 Nm (80-97 in. lb.)
11 Nm (97 in. lb.)
53
Courage SV Twin Cylinder Engine Specifications and Tolerances

Model (Horsepower)
General
Camshaft
SV710, SV810

Bore x Stroke
Displacement
Running Clearance
New
Bore I.D.
Max Wear Limit
New
Max Wear Limit
Connecting Rod-to-Crankpin Running Clearance
Connecting Connecting Rod-to-Crankpin Side Clearance

Rod
Piston Pin End I.D.
Crankcase Governor Cross Shaft Bore I.D.

End Play (Free)
n
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New
Max Wear Limit
New
Max Wear Limit
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Crankshaft Bore (In Crankcase)
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New
Max Wear Limit
New
Max Wear Limit
Crankshaft Bore (In Oil Pan) - New

Crankshaft Bore (In Oil Pan)-to-Crankshaft Running Clearance - New
O.D. - New
Flywheel End Main Bearing Journal
Max. Taper
Max. Out-of-Round
Crankshaft
O.D. - New
Oil Pan End Main Bearing Journal
Max. Taper
Max. Out-of-Round
O.D. - New
Max. Taper
Max. Out-of-Round
Crankshaft T.I.R.
TP-2469-A 12/07
r
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SV715
SV720, SV820
SV725
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14.9
20
16.4
17.2
22
23
83 (3.27) x 67 (2.64 )
725 cc (44 cu. in.)
0.076/0.127 (0.0030/0.0050)
0.025/0.063 (0.0010/0.0025)
20.000/20.025 (0.7874/0.7884)
20.038 (0.7889)
19.962/19.975 (0.7859/0.7864)
19.959 (0.7858 )
0.030/0.055 (0.0012/0.0022)
0.070 (0.0028)
0.26/0.63 (0.0102/0.0248)
0.015/0.028 (0.0006/0.0011)
17.015/17.023 (0.6699/0.6702)
17.036 (0.6707)
8.025/8.075 (0.3159/0.3179)
8.088 (0.3184)
0.070/0.590 (0.0028/0.0230)
40.965/41.003 (1.6128/1.6143)
41.016 (1.6148)
40.987/40.974 (1.6136/1.6131)
0.039/0.074 (0.0015/0.0029)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
0.279 (0.0110)
0.10 (0.0039)
17.9
24
54
Model (Horsepower)
Cylinder
Bore
Cylinder Bore I.D.
SV710, SV810 SV715
New
Max. Wear Limit
Max.Out-of-Round
Max. Taper

Governor Cross Shaft-to-Crankcase Running Clearance
New
Max. Wear Limit
Governor
Governor Gear Shaft-to-Governor Gear Running Clearance
New
Max. Wear Limit
Spark Plug Type (Champion or Equivalent)
Ignition
Spark Plug Gap
Piston-to-Piston Pin Running Clearance
New
Max. Wear Limit
New
Piston Pin Bore O.D.
Piston, Piston
Max. Wear Limit
Rings, and
Piston Pin
Top and Center Compression
New Bore
Ring End Gap
Used Bore (Max.)
New
1
Max. Wear Limit
Piston Thrust Face-to-Cylinder Bore 1 Running Clearance - New
Valve Clearance
Valve Tappet to Crankcase Running Clearance
Valves and
Valve Tappets Intake Valve Stem-to-Valve Guide Running Clearance
1
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SV720, SV820 SV725
83.031/83.006 (3.2689/3.2679)
83.069 (3.2704)
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
0.025/0.126 (0.0009/0.0049)
7.949/8.000 (0.3129/0.3149)
7.936 (0.3124)
0.015/0.140 (0.0006/0.0055)
5.990/6.000 (0.2358/0.2362)
5.977 (0.2353)
RC12YC, XC12YC, or Platinum 3071
0.76 (0.030)
0.28/0.33 (0.011/0.013)
0.006/0.017 (0.0002/0.0007)
17.006/17.012 (0.6695/0.6698)
17.025 (0.6703)
16.995/17.000 (0.6691/0.6693)
16.994 (0.6691)
0.025/0.048 (0.0010/0.0019)
0.015/0.037 (0.0006/0.0015)
0.026/0.176 (0.0010/0.0070)
0.25/0.56 (0.0100/0.0224)
0.94 (0.037)
82.947 (3.2656)
82.802 (3.2599)
0.06/0.100 (0.0023/0.0039)
0.101/0.152 (0.004/0.006)
0.013/0.073 (0.0005/0.0029)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
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TP-2469-A 12/07
55
Model (Horsepower)
Valves and
Valve Tappets
SV710, SV810 SV715
New
Max. Wear Limit
New
Max. Wear Limit
Standard
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TP-2469-A 12/07
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7.048 (0.2775)
7.298 (0.2873)
8.07 (0.3177)
8.07 (0.3177)
45
0.25 mm O.S.

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SV720, SV820 SV725
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
56
Courage SV Twin Cylinder Engine Specifications and Tolerances

Model (Horsepower)
General
Camshaft
SV730, SV830 SV735

Bore x Stroke
Displacement
Running Clearance
New
Bore I.D.
Max Wear Limit
New
Max Wear Limit
Connecting Rod-to-Crankpin Running Clearance
Connecting
Connecting Rod-to-Crankpin Side Clearance
Rod
New
Max Wear Limit
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New
Piston Pin End I.D.
Max Wear Limit
New
Crankcase Governor Cross Shaft Bore I.D.
Max Wear Limit
End Play (Free)
New
Crankshaft Bore (In Crankcase)
Max Wear Limit
Crankshaft Bore (In Oil Pan) - New
Crankshaft Bore (In Oil Pan)-to-Crankshaft Running Clearance - New
O.D. - New
Max. Taper
Max. Out-of-Round
Crankshaft
O.D. - New
Oil Pan End Main Bearing Journal
Max. Taper
Max. Out-of-Round
O.D. - New
Max. Taper
Max. Out-of-Round
Crankshaft T.I.R.
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TP-2469-A 12/07
n
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SV740, SV840
18.6
25
19.4
20.1
26
27
83 (3.27) x 67 (2.64 )
725 cc (44 cu. in.)
0.076/0.127 (0.0030/0.0050)
0.025/0.063 (0.0010/0.0025)
20.000/20.025 (0.7874/0.7884)
20.038 (0.7889)
19.962/19.975 (0.7859/0.7864)
19.959 (0.7858 )
0.030/0.055 (0.0012/0.0022)
0.070 (0.0028)
0.26/0.63 (0.0102/0.0248)
0.015/0.028 (0.0006/0.0011)
17.015/17.023 (0.6699/0.6702)
17.036 (0.6707)
8.025/8.075 (0.3159/0.3179)
8.088 (0.3184)
0.070/0.590 (0.0028/0.0230)
40.965/41.003 (1.6128/1.6143)
41.016 (1.6148)
40.987/40.974 (1.6136/1.6131)
0.039/0.074 (0.0015/0.0029)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
40.913/40.935 (1.6107/1.6116)
40.84 (1.608)
0.022 (0.0009)
0.025 (0.0010)
35.955/35.973 (1.4156/1.4163)
35.94 (1.415)
0.018 (0.0007)
0.025 (0.0010)
0.279 (0.0110)
0.10 (0.0039)
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57
Model (Horsepower)
Cylinder
Bore
Cylinder Bore I.D.
SV730, SV830 SV735
New
Max. Wear Limit
Max.Out-of-Round
Max. Taper

Governor Cross Shaft-to-Crankcase Running Clearance
Governor Cross
New
Shaft O.D.
Max. Wear Limit
Governor
Governor Gear Shaft-to-Governor Gear Running Clearance
Governor Gear
New
Shaft O.D.
Max. Wear Limit
Spark Plug Type (Champion or Equivalent)
Ignition
Spark Plug Gap
Piston-to-Piston Pin Running Clearance
Piston Pin
New
Max. Wear Limit
Bore I.D.
Piston Pin
New
Piston, Piston Bore O.D.
Max. Wear Limit
Rings, and
Piston Pin
Top and Center Compression
New Bore
Ring End Gap
Used Bore (Max.)
New
Max. Wear Limit
Piston Thrust Face-to-Cylinder Bore 1 Running Clearance - New
Valve Clearance
Valve Tappet to Crankcase Running Clearance
Valves and
Valve Tappets Intake Valve Stem-to-Valve Guide Running Clearance
1
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SV740, SV840
83.031/83.006 (3.2689/3.2679)
83.069 (3.2704)
0.12 (0.0047)
0.05 (0.0020)
0.076 (0.003)
0.025/0.126 (0.0009/0.0049)
7.949/8.000 (0.3129/0.3149)
7.936 (0.3124)
0.015/0.140 (0.0006/0.0055)
5.990/6.000 (0.2358/0.2362)
5.977 (0.2353)
RC12YC, XC12YC, or Platinum 3071
0.76 (0.030)
0.28/0.33 (0.011/0.013)
0.006/0.017 (0.0002/0.0007)
17.006/17.012 (0.6695/0.6698)
17.025 (0.6703)
16.995/17.000 (0.6691/0.6693)
16.994 (0.6691)
0.025/0.048 (0.0010/0.0019)
0.015/0.037 (0.0006/0.0015)
0.026/0.176 (0.0010/0.0070)
0.25/0.56 (0.0100/0.0224)
0.94 (0.037)
82.947 (3.2656)
82.802 (3.2599)
0.06/0.100 (0.0023/0.0039)
0.101/0.152 (0.004/0.006)
0.013/0.073 (0.0005/0.0029)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
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TP-2469-A 12/07
58
Model (Horsepower)
Valves and
Valve Tappets Valve Guide Reamer Size
SV730, SV830 SV735
New
Max. Wear Limit
New
Max. Wear Limit
7.038/7.058 (0.2771/0.2779)
7.134 (0.2809)
7.038/7.058 (0.2771/0.2779)
7.159 (0.2819)
Standard

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TP-2469-A 12/07
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7.048 (0.2775)
7.298 (0.2873)
8.07 (0.3177)
8.07 (0.3177)
45
0.25 mm O.S.
r
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SV740, SV840
59
Courage SV Twin Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
Blower
Housing
and Sheet
Metal
Carburetor
and Intake
Manifold
Connecting
Rod
Intake Manifold Mounting Fastener - Torque in Two Stages
Step 1
Step 2
Carburetor Mounting Nut

Cap Fastener - Torque Incrementally to:
Inner Cover Fastener
Crankcase
SV710, SV810
M4 HI-LO Screws
M5 Fasteners
M6 Fasteners
Breather Assembly
Outer Cover Stud
Oil Drain Plug

Oil Pan Fastener
Into new hole

Into used hole
Into new hole
Into used hole
r
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Cylinder Head Fastener - Head Bolt: Torque in Two Stages

Rocker Arm Screw
Cylinder Head
Rocker Arm Stud
Rocker Arm/Valve Adjustment Jam Nut
Rocker Arm/Valve Adjustment Setscrew
Governor Lever Nut
Governor
Spark Plug
Ignition
Muffler
Oil Filter
r
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Step 1
Step 2
M8 Hex Nuts
5/16-18 Capscrews
Oil Filter Installation

Nipple Torque (Oil Filter/Oil Cooler Adapter)
Speed Control
Fastener
Bracket
TP-2469-A 12/07
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Muffler Fasteners
SV720, SV820 SV725
2.8 Nm (25 in. lb.)

4.0 Nm (35 in. lb.)
6.8 Nm (60 in. lb.)
4.0 Nm (35 in. lb.)
7.4 Nm (66 in. lb.)
9.9 Nm (88 in. lb.)
6.2-7.3 Nm (55-65 in. lb.)
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11.3 Nm (100 in. lb.)
Hex Nut
Oil Pan
SV715
Into new hole

Into used hole
10.7 Nm (95 in. lb.)

7.3 Nm (65 in. lb.)
6.2 Nm (55 in. lb.)
4.0 Nm (35 in. lb.)
1.3 Nm (11.5 in. lb.)
13.6 Nm (120 in. lb.)
24.4 Nm (216 in. lb.)
22.6 Nm (200 in. lb.)
41.8 Nm (370 in. lb.)
11.3 Nm (100 in. lb.)
11.3 Nm (100 in. lb.)
7.3 Nm (65 in. lb.)
7.9 Nm (70 in. lb.)
74.5 Nm (55 ft. lb.)
6.8 Nm (60 in. lb.)
24.4-29.8 Nm (18-22 ft. lb.)
4.0-6.2 Nm (35-55 in. lb.)
24.4 Nm (216 in. lb.)
16.9 Nm (150 in. lb.)
Rotate Filter 3/4-1 Turn After Gasket Contact
33.9 Nm (300 in. lb.)
10.7 Nm (95 in. lb.)
7.3 Nm (65 in. lb.)
60

Model (Horsepower)
Blower
Housing
and Sheet
Metal
Carburetor
and Intake
Manifold
Connecting
Rod
Step 1
Step 2

Crankcase
SV710, SV810
M4 HI-LO Screws
M5 Fasteners
M6 Fasteners
Breather Assembly
Outer Cover Stud
Oil Drain Plug

Oil Pan Fastener
Into new hole

Into used hole
Into new hole
Into used hole
r
a
n
i
m

Rocker Arm Screw
Cylinder Head
Rocker Arm Stud
Governor Lever Nut
Governor
Spark Plug
Ignition
Muffler
Oil Filter
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Step 1
Step 2
M8 Hex Nuts
5/16-18 Capscrews

Speed Control
Fastener
Bracket
TP-2469-A 12/07
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Muffler Fasteners
SV720, SV820 SV725
2.8 Nm (25 in. lb.)

4.0 Nm (35 in. lb.)
6.8 Nm (60 in. lb.)
4.0 Nm (35 in. lb.)
7.4 Nm (66 in. lb.)
9.9 Nm (88 in. lb.)
6.2-7.3 Nm (55-65 in. lb.)
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11.3 Nm (100 in. lb.)
Hex Nut
Oil Pan
SV715
Into new hole

Into used hole
10.7 Nm (95 in. lb.)

7.3 Nm (65 in. lb.)
6.2 Nm (55 in. lb.)
4.0 Nm (35 in. lb.)
1.3 Nm (11.5 in. lb.)
13.6 Nm (120 in. lb.)
24.4 Nm (216 in. lb.)
22.6 Nm (200 in. lb.)
41.8 Nm (370 in. lb.)
11.3 Nm (100 in. lb.)
11.3 Nm (100 in. lb.)
7.3 Nm (65 in. lb.)
7.9 Nm (70 in. lb.)
74.5 Nm (55 ft. lb.)
6.8 Nm (60 in. lb.)
24.4-29.8 Nm (18-22 ft. lb.)
4.0-6.2 Nm (35-55 in. lb.)
24.4 Nm (216 in. lb.)
16.9 Nm (150 in. lb.)
33.9 Nm (300 in. lb.)
10.7 Nm (95 in. lb.)
7.3 Nm (65 in. lb.)
61
Model (Horsepower)
Starter
Assembly
Solenoid
(Starter)
Stator
Valve Cover
Thru Bolt
Mounting Screw
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Oil Pan
Breather Cover
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SV720, SV820 SV725
4.5-5.7 Nm (40-50 in. lb.)

5.6-9.0 Nm (49-79 in. lb.)
15.3 Nm (135 in. lb.)
2.5-3.3 Nm (22-29 in. lb.)
4.0-6.0 Nm (35-53 in. lb.)
8.0-11.0 Nm (71-97 in. lb.)
6.2 Nm (55 in. lb.)
6.2 Nm (55 in. lb.)
Mounting Screws (All)

Brush Holder Mounting Screw - Delco-Remy Starter
Mounting Hardware - Delco-Remy Starter
Nut, Positive (+) Brush Lead - Delco-Remy Starter
Oil Pan (Sealant)
TP-2469-A 12/07
SV710, SV810 SV715
FASCO (Inertia Drive)

Delco-Remy (Solenoid Shift)
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Cylinder Heads
#1
#2
62

Model (Horsepower)
Blower
Housing
and Sheet
Metal
Carburetor
and Intake
Manifold
Connecting
Rod
Step 1
Step 2
Breather Assembly
Outer Cover Stud
Into new hole

Into used hole
Into new hole
Into used hole
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a
Hex Nut
Oil Pan
Oil Drain Plug

Oil Pan Fastener
n
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m

Rocker Arm Screw
Cylinder Head
Rocker Arm Stud
Governor Lever Nut
Governor
Spark Plug
Ignition
Muffler
Oil Filter
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Step 1
Step 2
M8 Hex Nuts
5/16-18 Capscrews

Speed Control
Fastener
Bracket
TP-2469-A 12/07
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Muffler Fasteners
SV740, SV840
2.8 Nm (25 in. lb.)

4.0 Nm (35 in. lb.)
6.8 Nm (60 in. lb.)
4.0 Nm (35 in. lb.)
7.4 Nm (66 in. lb.)
9.9 Nm (88 in. lb.)
6.2-7.3 Nm (55-65 in. lb.)
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11.3 Nm (100 in. lb.)

Crankcase
SV730, SV830 SV735
M4 HI-LO Screws
M5 Fasteners
M6 Fasteners
Into new hole

Into used hole
10.7 Nm (95 in. lb.)

7.3 Nm (65 in. lb.)
6.2 Nm (55 in. lb.)
4.0 Nm (35 in. lb.)
1.3 Nm (11.5 in. lb.)
13.6 Nm (120 in. lb.)
24.4 Nm (216 in. lb.)
22.6 Nm (200 in. lb.)
41.8 Nm (370 in. lb.)
11.3 Nm (100 in. lb.)
11.3 Nm (100 in. lb.)
7.3 Nm (65 in. lb.)
7.9 Nm (70 in. lb.)
74.5 Nm (55 ft. lb.)
6.8 Nm (60 in. lb.)
24.4-29.8 Nm (18-22 ft. lb.)
4.0-6.2 Nm (35-55 in. lb.)
24.4 Nm (216 in. lb.)
16.9 Nm (150 in. lb.)
33.9 Nm (300 in. lb.)
10.7 Nm (95 in. lb.)
7.3 Nm (65 in. lb.)
63
Model (Horsepower)
Starter
Assembly
Solenoid
(Starter)
Stator
Valve Cover
SV730, SV830 SV735
FASCO (Inertia Drive)

Delco-Remy (Solenoid Shift)
Thru Bolt
SV740, SV840
4.5-5.7 Nm (40-50 in. lb.)

5.6-9.0 Nm (49-79 in. lb.)
15.3 Nm (135 in. lb.)
2.5-3.3 Nm (22-29 in. lb.)
4.0-6.0 Nm (35-53 in. lb.)
8.0-11.0 Nm (71-97 in. lb.)
6.2 Nm (55 in. lb.)
6.2 Nm (55 in. lb.)
Mounting Screws (All)

Brush Holder Mounting Screw - Delco-Remy Starter
Mounting Hardware - Delco-Remy Starter
Nut, Positive (+) Brush Lead - Delco-Remy Starter
Mounting Screw
Valve Cover
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Intake Manifold
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TP-2469-A 12/07
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64
OHC - Twin Cylinder Engine Specifications and Tolerances

Model (Horsepower)
General
Kilowatt (kW) Output (@ 3600 RPM SAE J1349)

Horsepower (@3600 RPM SAE
Bore x Stroke
Displacement
#1 Side
#2 Side
End Play
Running Clearance
Bore I.D. - New
Camshaft

Camshaft Bearing Surface O.D. New
Connecting
Rod
Crankcase
Crankshaft
TP-2469-A 12/07
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TH18
11.9
16
73 (2.87) x 62 (2.44)
519cc (31.7 cu. in.)
0.000/0.700 (0.000/0.0275)
0.000/1.300 (0.000/0.0512)
0.025/0.105 (0.0010/0.0041)
32.000/32.025 (1.2598/1.2608)
24.800/24.825 (0.9764/0.9774)
32.04 (1.2614)
24.84 (0.9779)
31.920/31.975 (1.2567/1.2589)
24.720/24.775 (0.9732/0.9754)
31.91 (1.2562)
24.71 (0.9728)
0.056/0.030 (0.0022/0.0012)
0.07 (0.0028)
0.250/0.740 (0.0098/0.0291)
17.015/17.023 (0.6699/0.6702)
17.04 (0.6708)
8.025/8.050 (0.3159/0.3169)
8.07 (0.3177)
Not Adjustable
45.071/45.111 (1.7744/1.7760)
45.12 (1.7764)
0.030/0.090 (0.0012/0.0035)
45.021/45.041 (1.7725/1.7735)
44.95 (1.7696)
0.02 (0.0008)
0.02 (0.0008)
13.4
18
75 (2.95) x 65 (2.56)
574cc (35.0 cu. in.)
0.000/0.700 (0.000/0.0275)
0.000/1.300 (0.000/0.0512)
0.025/0.105 (0.0010/0.0041)
32.000/32.025 (1.2598/1.2608)
24.800/24.825 (0.9764/0.9774)
32.04 (1.2614)
24.84 (0.9779)
31.920/31.975 (1.2567/1.2589)
24.720/24.775 (0.9732/0.9754)
31.91 (1.2562)
24.71 (0.9728)
0.056/0.030 (0.0022/0.0012)
0.07 (0.0028)
0.250/0.740 (0.0098/0.0291)
17.015/17.023 (0.6699/0.6702)
17.04 (0.6708)
8.025/8.050 (0.3159/0.3169)
8.07 (0.3177)
Not Adjustable
45.071/45.111 (1.7744/1.7760)
45.12 (1.7764)
0.030/0.090 (0.0012/0.0035)
45.021/45.041 (1.7725/1.7735)
44.95 (1.7696)
0.02 (0.0008)
0.02 (0.0008)
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New
Connecting Rod-to-Crankpin
Running Clearance
Max Wear Limit
Connecting Rod-to-Crankpin Side Clearance
New
Piston Pin End I.D.
Max Wear Limit
New
Governor Cross Shaft Bore I.D.
Max Wear Limit
End Play
New
Max Wear Limit
Crankshaft to Sleeve Bearing Running Clearance - New
O.D. - New
Max. Taper
Max. Out-of-Round
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Front
Rear
Front
Rear
Front
Rear
Front
Rear
TH16
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Model (Horsepower)
TH16
TH18
45.021/45.041 (1.6107/1.6116)
45.021/45.041 (1.6107/1.6116)
44.95 (1.7696)
44.95 (1.7696)
Max. Taper
Max. Out-of-Round
0.02 (0.0008)
0.02 (0.0008)
0.02 (0.0008)
0.02 (0.0008)
31.948/31.966 (1.2578/1.2585)
31.948/31.966 (1.2578/1.2585)
31.93 (1.2571)
31.93 (1.2571)
Max. Taper
0.02 (0.0008)
0.02 (0.0008)
Max. Out-of-Round
0.02 (0.0008)
0.02 (0.0008)
0.015 (0.0006)
0.015 (0.0006)
0.010 (0.0004)
73.006/73.031 (2.8742/2.8752)
0.010 (0.0004)
75.025/75.050 (2.9537/2.9547)
73.07 (2.8767)
75.09 (2.9563)
0.13 (0.005)
0.13 (0.005)
0.13 (0.005)
0.013/0.075 (0.0005/0.0030)
7.975/8.012 (0.3140/0.3154)
7.96 (0.3134)
0.045/0.160 (0.0018/0.0063)
0.13 (0.005)
0.013/0.075 (0.0005/0.0030)
7.975/8.012 (0.3140/0.3154)
7.96 (0.3134)
0.045/0.160 (0.0018/0.0063)
32.020/32.080 (1.2606/1.2630)
32.09 (1.2634)
RC12YC
0.76 (0.030)
32.020/32.080 (1.2606/1.2630)
32.09 (1.2634)
RC12YC
0.76 (0.030)
0.20/0.30 (0.008/0.012)
0.20/0.30 (0.008/0.012)
0.006/0.016 (0.0002.0.0007)
17.006/17.012 (0.6695/0.6698)
17.025 (0.6703)
16.996/17.000 (0.6691/0.6693)
16.995 (0.6691)
0.040/0.085 (0.0016/0.0033)
0.030/0.080 (0.0012/0.0031)
0.046/0.201 (0.0018/0.0079)
0.006/0.016 (0.0002.0.0007)
17.006/17.012 (0.6695/0.6698)
17.025 (0.6703)
16.996/17.000 (0.6691/0.6693)
16.995 (0.6691)
0.040/0.085 (0.0016/0.0033)
0.030/0.076 (0.0012/0.0030)
Minimum: 0.070 (0.0028)
O.D. - New
PTO End Main Bearing Journal
O.D. - New
Crankshaft
Crankshaft T.I.R.
Cylinder Bore I.D.

New
Cylinder Bore
Max. Wear Limit
Governor Cross Shaft to Crankcase Running Clearance

New
Max. Wear Limit
Governor Bushing to Camshaft Running Clearance
Governor
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New
Max. Wear Limit
Spark Plug Gap
Governor Bushing I.D.
Ignition
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Piston Pin Bore to Piston Pin (select fit)

New
Max. Wear Limit
New
Piston Pin O.D.
Max. Wear Limit
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Piston, Piston
Rings, and
Piston Pin
TP-2469-A 12/07
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Max. Out-of-Round
Max. Taper
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Model (Horsepower)
Piston (continued) Top Compression Ring End Gap
New
Max Wear Limit
Valves
Piston Thrust Face-to-Cylinder Bore 1 Running Clearance

New
Max Wear Limit
New
Exhaust Valve Guide
Max Wear Limit
Standard
0.25 mm O.S.
Intake
Valve Lash
Exhaust
Side 1
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TH18
0.180/0.380 (0.0071/0.0150)
0.180/0.440 (0.0071/0.0173)
72.966/72.984 (2.8727/2.8734)
72.839 (2.8677)
0.180/0.380 (0.0071/0.0150)
0.180/0.450 (0.0071/0.0177)
74.966/74.984 (2.9514/2.9521)
74.839 (2.9464)
0.022/0.065 (0.0009/0.0026)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
6.038/6.058 (0.2377/0.2385)
6.13 (0.2413)
6.038/6.058 (0.2377/0.2385)
6.19 (0.2437)
6.048 (0.2381)
6.298 (0.2480)
7.50 (0.295)
7.50 (0.295)
45
0.013/0.064 (0.0005/0.0025)
0.076/0.127 (0.0030/0.0050)
0.041/0.084 (0.0016/0.0033)
0.038/0.076 (0.0015/0.0030)
0.050/0.088 (0.0020/0.0035)
6.038/6.058 (0.2377/0.2385)
6.13 (0.2413)
6.038/6.058 (0.2377/0.2385)
6.19 (0.2437)
6.048 (0.2381)
6.298 (0.2480)
7.50 (0.295)
7.50 (0.295)
45
0.013/0.064 (0.0005/0.0025)
0.076/0.127 (0.0030/0.0050)
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TH16
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Side 2
67
OHC Twin Cylinder Torque Values and Sequences for Fasteners

Model (Horsepower)
Blower Housing
and Sheet Metal
Carburetor
Connecting Rod
Crankcase
Electric Starter
Timing Belt
Fan/Flywheel
Ignition
Muffler
Oil Filter
Speed Control
Stator
Throttle/Choke
Controls
Valve Cover
M6 Fasteners (into sheet baffle)

Rectifier Fastener
Carburetor Mounting Fasteners
Cap Fastener Torque (torque in increments) - 6 mm Step-Down
Breather Cover Mounting Fasteners
Oil Drain Plugs
Crankcase Halves Mounting Screw
Starter Mounting Fastener
Belt Tensioner Mounting Screw
Belt Tension
Fan Fastener
Flywheel Retaining Screw
Spark Plug
Oil Filter
Oil Filter Nipple
Oil SentryTM Pressure Switch
Speed Control Bracket Assembly Fastener
Governor Control Lever Fastener

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TH18
4.0 Nm (35 in. lb.)
7.3 Nm (65 in. lb.)
M5 Fasteners
M6 Fasteners (into crankcase)
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TP-2469-A 12/07
TH16
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4.0 Nm (35 in. lb.)
4.0 Nm (35 in. lb.)
9.9 Nm (88 in. lb.)
11.3 Nm (100 in. lb.)
5.6 Nm (50 in. lb.)
13.6 Nm (10 ft. lb.)
24.4 Nm (216 in. lb.)
7.9 Nm (70 in. lb.)
7.3 Nm (65 in. lb.)
3.4/4.5 Nm (30/40 in. lb.)
9.9 Nm (88 in. lb.)
66.4 Nm (49 ft. lb.)
24.4/29.8 Nm (18/22 ft. lb.)
4.0/6.2 Nm (35/55 in. lb.)
24.4 Nm (216 in. lb.)
5.6/9.0 Nm (50/80 in. lb.)
40.7 Nm (30 ft. lb.)
3.4 Nm (30 in. lb.)
9.9 Nm (88 in. lb.)
4.0 Nm (35 in. lb.)
9.9 Nm (88 in. lb.)
5.6 Nm (50 in. lb.)
68
OHC Twin Cylinder Torque Values and Sequences for Fasteners

Crankcase
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TP-2469-A 12/07
Breather Cover Gasket
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Oil Filter Adapter
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KOHLER CO. KOHLER, WISCONSIN 53044
FOR SALES AND SERVICE INFORMATION

IN U.S. AND CANADA, CALL
1-800-544-2444
FORM NO.: TP-2469-A

ISSUED:
5/95
REVISED: 12/07
MAILED:
LITHO IN U.S.A.

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SPECIFICATIONS & TOLERANCES

Standard Application Torque Recommendations...3

KSeries Twin Cylinder Engine Specification & Tolerances..6-7

KSeries Twin Cylinder Torque Values & Sequences for Fasteners..9

Magnum Single Cylinder Engine Specifications & Tolerances.10-11

Magnum Twin Cylinder Engine Specifications & Tolerances12-13

Magnum Single Cylinder Torque Values & Sequences for Fasteners..14

Magnum Twin Cylinder Torque Values & Sequences for Fasteners.15

Command Twin Cylinder Engine Specification & Tolerances...22-25

Command Single Cylinder Torque Values & Sequences for Fasteners..26-27

Command Twin Cylinder Torque Values & Sequences for Fasteners.28-29

Standard Application Torque Recommendations

Tightening Torque Nm (in. lb.) + or- 20%

Tightening Torque Nm (in. lb.) + or -10%

Tightening Torque Nm (in. lb.) + or -10%

27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60)

Oil Drain Plugs (All Models)

4.5 (40 in. lb.)

Tightening Torque Nm (ft. lb.) + or- 20%

3/8" thread with hex head nut and fiber gasket.

K-Series Single Cylinder Engine Specifications Tolerances

Rod to Crankpin (New)

Small End I.D. (New)

Max. Wear Limit

Max. Out of Round

Max. Out of Flatness

Nominal Point Gap

All dimensions in inches.

K-Series Single Cylinder Engine Specifications Tolerances (cont'd)

All Pistons Service Replacement Sizes

Nominal Angle Valve Seat

Subtract O.D. of inner part from I.D. of outer part.

0.003 0.010 0.020 0.030

Guide Reamer Size

Measure 1/2" above the bottom of the piston skirt.

Top and center compression rings.

K-Series Twin Cylinder Engine Specifications Tolerances

Sleeve I.D. Installed

Connecting Running Clearance

Small End I.D. (New)

Rod to Crankpin (New)

Max. Out of Flatness

K-Series Twin Cylinder Engine Specifications Tolerances (cont'd)

All dimensions in inches.

Type (Champion or Equivalent)

Max. Ring Size Clearance

0.003 0.010 0.020 0.030

Thrust Face to Bore Clearance (new) 1, 4

Service Replacement Sizes

Max. Ring Side Clearance

Subtract O.D. of inner part from I.D of outer part.

Measure 1/2" above bottom of piston skirt.

Pre Series II 1.3733/1.3738, maximum wear 1.3728.

Top and center compression rings.

K-Series-Single Cylinder Torque Values and Sequences for Fasteners

New 140 in. lbs.

New 260 in. lbs.

Used 100 in. lbs.

Used 200 in. lbs.

140 in. lbs.

200 in. lbs.