Generac Power Systems GTV99O Manuel utilisateur

Malual Part

No.OE2Oal

fr SERVICE

MANUAL

["J

*.1

POWER

P.O.

Box297

Phone:

(262)473-5514

P nted

lJ.s.A

GiENEFIAC'

SYSTEMS, INC.

. Whitewater,Wl . 53190

GTV

-1990/760

V-TWIN

OHVIENGINE

Fax:.

(262)

472-6505

FirslEditionlssued

-bi/xrxx

FOREWORD

This

manualhasbeenwritten andpublishedbyetHeUC@ pOWe

SYSTEMS,

lNc.to aid our dealers'mechanics,

company

servlce

per_

sonneland

general

consumerswhen servicingthe

products

des(ribed

herein.

Itisassumed

thatthese

personnelare

familiarwiththe servi(ing

pro_

cedures

torthese products,^orlikeor similar

products,

manu{actured

and

marketed

byGENERAC@

PowER

sYsTEM

s,lNc.lt isalto assumed

thattheyhavebeen

trained

inthe recommended

servicing

procedures

for the5e

products,which includes

the use

of mechanics

handtools

and

anyspecialtools

that might berequired.

Proper

service

andrepairisimPonant to the safe,

economical

and

reliableoperation

of the products

de5cribed

h€rein Thetrou'

bleshootirlg,

testing,

service

andrePair

procedures

recommended

cEtltnlc@ PowrR sysTEMs,

lNc.anddescribed

inthis manual

are

effective

methods

of performingsuahoperation5.

Some

oftheseoper-

ations

or procedures

may require

the use

of specialized

equipment'

Suchequipment

shouldbeused

when andasrecommended

we (outd not possibly

know oI andadvise

the sewice

trade of all

conceivable

pro(eduresot methodsbywhichaservice

might beper-

formed,

norot anypossiblehazards

and/orresults

ot each

procedure

ormethod,Wehavenotundertakenanysuchwideevaluation There-

{ore,anyone

who usesa Procedure

or methodnot recommended

themanu{acturer

must{irstsatisly

himselfthatneither

hissa{ety,

nor

the product'ssatety,

will be endangered

by the service

or oPerating

procedure

selected,

Atl information, illustrations and sPe(ifications

contained in this

manual

arebased

onthe latestproductinformation available

at the

iliili "'tri.n", However,

GENERAC@

PowER

sYsrEMs,

lNc'

reservesihe

rightto (hange,

alter orotherwise improve

the product

atanytime without Priornoti(e.

somecomponents

or assemblies

o{ the Product

degcribed

in this

manuat

may not be (onsidered rePairable.

Disassembly,

repairand

reassembly

oI such

components

maynot beinctuded

inthis manual'

Theengines

described

hereinmaybeused

to powerawide variety

oI Droducts.

Service

andrepairinstructions

relatingtoany such

prod'

uatsare

notcoveredinthismanual.Forinformationpertainingto use

of these

engines

with other products,

re{erto anyowne/s or service

manuals

pertaining

to said

products.

?., TABLEOF

CONTENTS

RULESFOR

SAFEOPERATION

DIMENSIONS

AND

FEATURES

4-CYCLE

ENGINE

THEORY

SEcTION

1:GENERAL

INFORMATION

SECTION

2:IGNITION

SECTION3;

CARBURETION

SECTION

4: GOVERNOR

CONTROLS

ANDGOVERNOR

SECTION

5:CYLINDER

HEADANDVALVES

SECT|oN

6:El.ECTRlc

SIARIER

SECNON7:

ALTERNATORS

SECTION8: LUBRICATION

SYSTEM

SECTION

ENGINEDISASSEMBLY

SECTION

lO:CYLINDER

ANDCRANKCASE

COVER

SECTION

11:CRANKSHAFT

ANDCAMSHAFT

SECTION

12:PISTON,

RINGSAND

CONNECTING

RODINSPECTION

AND

ASSEMBLY

SECTION

13rENGINE

ASSEMBLY

AWORDABOUT

SPECIALTOOLS

Manyot theprccedurcs

depictedin thismanual

rcquitetheuseof special

tools.Someof

thetools

reouiredareavailable

asGenetac

patts

andatelistedassuchin thismanual.

ATTENTION!

cenerac

PowerSystems

doesnotapproveorauthorizethe

useolthese

engines-onAllTerrain

Vehicles

(AW"s);

go-carts,

motorbikes,aircraft

products,

personal

watercraft,

orvehicles

intended

foruse

(ompetitive

events.Use

oftheseengines

insuch

applicationscould

result

property

damage,serious

injury

(in.luding

paralysis),

oteven

death.

RULES

FORSAFEOPERATION

lfyou

donotunderstandany

podion

ofthismanual,con-

tad Cenerac

or your

nearest

Generac

AuthorizedS€rvice

Dealerforstarting,operatingand

setulclng

procedures.

Throughoutthis

pubIcilion

andontags

anddecaGaffixed

tothe

engine,DANGER,

WARNING

andCAUTIONblocks

a€ usedtoaled

you

tospeclalinstrudion

about; panicu,

laropefalionthatmaybehazardous

performed

lncorrectly

orcarclessly.ObseNethem

carefully.

Thesesafetywarnings

cannoteliminate

the

hazards

that

theyindicate.

Stict

compliancewith

thespecialinsVuctions

whrle

per{or"l

theserv

(

plLs

'comaor.Frse'

ara

majo.

Thefollowingdefinitions

applyio oANGER,

WARNING,

CAUTIONandNOTE

blocksfoundthrouqhoutthe

manua

Thesesafetysynbolsindicate

thefollawing:

DANGER:Afterlhis heading

you canreadhan-

dling,installing,

op€rating

orsewicinginstructions

that,if not rtrictlycompiied

with,witt resuttin

personalinjnry

WARNING:

After

thisheading

you

canreadhan-

dling.

installing,

operatingorservicing

instructions

that,ifnotnrictlycompli€d

with,

mayresultin

per-

sonalinjury,

CAUTION:After

thisheadingyou

canreadinstruc-

tionsfor

handling,installing,

operating

orservi(ing

the

enginethat,il notstri.tly

compliedwirh,may

result

indamage

to€qu;pnent

and/or

property

NOTE:

After this heading you <anrcad explanatory

statements

that rcquirc specialemphasis.

These

symbolsindicate

thefolowing:

Points

outimportantsaiety

inlormationthat,ilnot

lollowed,

could

endanger

personal

saletyand/or

Prope

ofyourseli

andothers.

RULESFORSAFEOPERATION

StudytheseRIJLESFORSAFEOPERATION

carefu

ybefore

operalinq

orservicingthisequipment.Becomefamilia

rwth

TfpOWNFR'5N.4ANUA

adwith _eergirF

Tl-eengrnecar

operalesa{€ly,

efficientlyandreliablyonlyifitis

properly

oper

ated

andmaintained.Many

accrdentsar€caused

failing

totolow

simp

eandfundamentalrules

orprecauttons.

Generac

cannot

possiby

anticipate

every

possible

circ!m-

nance

thatmightinvolve

a hazard.

Thewarninqsinthis

manualand

ontags

anddecals

affixedtothe

equipmeni,arc

therelore,noi all-inclusive.

tfyouusea procedure,

work

method

oroperatingtechnique

Generacdoesnotspecifically

recommend,you

mustsatsfyyoLr6elf

thatlt is

safefor

you

and

olhers.Youmustalsomake

sLirethe

procedlre,

work

method

oroperaiingt€chnique

that

you

choose

doesnot

renderthe

enginetobeunsafe.

DANGERTDonottamper

with the engine

gov-

erned

tpeed.Highoperatingspeeds

aredang€rous

andincreare

therhkof personal

injury

ordamag€

totheequipment.Operating

atlowspeedswith

heavyloadmayshorten

theengine'sljfe.

A Potential

explosionhazard.

A Potentialfiretrazard.

BEFORE

OPERATING

. Gasoine

shighlyFIAMMABLE

and

itsvaporsare

EXPLO-

slVE.

Donot

p€fmlismoklng,

openflames,

sparksorheat

theareawhilehandlng

gasoline.

Avoidspilling

gasoline

onahotengine.

Complywithallofthe awsregutaiing

storage

and

handling

ofgasol

ne.

. Slore

gasol

neandotherfuels

onlylncontainers

designed

andapprovedforthe

norageoi suchmateials.

. Add

gaso

in€ina

clean,welfventlated

area.Wipeupany

spllled

gasollne

immediatey.

t gasoline

hasbeenspiled,

letridry

completelybefo.estartirg

theengine.

. Donot

ovediIthelueltank.Alu/ays

alowroomforfuel

expansionll thetankisoverfilled,the

fuelcanovedlow

ontoahot

engineandcauseaFIREor

anEXPLOSION.

. Allow

atlean

two

(2)

feetofclearanceonalsides

ofthe

engine,even

whleoperating

it outdoors.or you

could

damagetrieengrne.

. Thofoughyinspecttheenqineforooseordamagedparts

beforeeachuse,

nolusethe

engne

untladjustments

orTeparfsare

maoe.

. Checktheolllevelln

theengine

before

eachuse.

A Pobntial

electricat

shockhazard.

RULESFORSAFEOPERATION

The engine exhaust lrom thls ptoducl contains

chemicals known to the Stale of Calilornia io

cause cancer,birth d6fects, or other repro-

ductive harm.

Inspecttheengine

periodically.

Repairorreplacealldamaged

ordefective

parts

immediately.

Inspect

fuel

system

frequently

forleaksordamage.

Repair

orreplaceanydamagedorleakingcomponentimmediately,

Neverattemptto change,alterormodit theenginefuel

slstem

inanywaythatmight

affectsafetyorcompliance

with

applicablecodesandstandards.

WHILE

OPERATING

Thisenginewasdesignedandmanufacturedfor specific

applications-

Donot

attempttomodirytheequipmento.use

itforanyapplicationforwhichitwasnotdesigned.

GeneracPowerSystemsdoesnotapproveorauthorizethe

useoftheseengineson

AliTe(ain

Vehicles

(ATV3),go-cads,

motorbikes,alrcraft

pfoducts,personal

watercraft,orvehi-

clesintendedfor useincompetitiveevents.lJseof these

enginesinsuchapplications

could

resultin

property

damage,

serious

injury

(including

paralysis),

orevendeath.

Englneexhaust

gases

containDEADLY

carbon

monoxide

gas-

Thisdangerous

gas,

lf breathedinrufficient

concen-

trations,

cancau5eunconsciousness

orevendeath,Operate

thisequipmentonlyintheopenairwhereadequateventi

lationlsavailable.

Donotinsertanyobject

thrcughthecoolingslotsof the

engine.You

coulddamagetheequipmentorinjure

yourself.

Donotoperatetheenginefanerthanihespeednecessary

to operatetheequipment.Donot

runtheengineathigh

speedwhennotoperating

theequipment,

Thisenginerequires

anadequateflowofcooingairforits

contrnued

proper

operation.Never

operaletheequlpment

insideanyroom

orenclosurewherethefreeflowol cool-

ingairintoand

outoftheequipmentmightbeobnructed.

Withouisufficienlcoolingairilow,theenglne

quicklyover-

heats.damagingtheengineornearby

propefty.

Donotsmokearound

theengine.Wipeupanyfueloroil

spillsrmmediately.

Neverleave

oilyorfuelsoakedragsaround

theengine.Keeptheareaaroundthe€nglne

clean

andlree

ofdebrls.

Keephands,feet,clothing,etc.,awayfrommoving

parts

thisenqine.

Neveroperatetheengine

(a)in

therain;(b)lnanyencosed

compadment;

(c)

if theenginespeedchanges;

(d)

if the

enginespa*s;

(e)

ifflame

orsmokesobservedwhilethe

engineisrunning,

Neverworkonthisenglneorhandle

anye€ctricaldevice

while

standlng

inwater,whiebarefoot,orwhilehands

feet

arcwet.DANGEROUSELECTRICSHOCKwiIresult.

SERVICE

INFORMATION

Seruiceonthisengine

withinandatlerthewaffanty

period

canbe

pedormed

byanyaulhozedservice

dealerSeruice

iechniciansarcfaclorytrainedand

capableoihandlingallservice

needs.

Whenconlaclinganaulhor,zedservicedealeraboul

pads

andservice.auAys_sllBlflhclgnllgE

nodelnumberand

serialnumberoi

your

unitas

given

onilsdala

plale

decal.Seetheilllstration

belowiorthelocationoithedecal.

Thewafiantyforthisengineisincludedinthe

0wnersmanuat.

DIMENSIONSANDfEATURES

MODfL GTV99O

TYPE I]LCEOLED 4-STREKE

lHV

BOREX STREKF 90 x7A

DISPLAC

EMENT 99?cc

CBMPRESSlEN

RAT]D 8.5'1

LUBPICAIIIN

SYSTEI.l

rUI

L PAES-UO]7'D

V/LO\"/

!I . PPE\SLPf

SI.LIIE i

IGNlIIUN SYSTEI.I ELICTPDNIC

SPEAKfRLESS

CYL]NDER CAST IRDN SLEfVL-

IARTING

SYSTEM ELECTRICSTART

IIL CAPACITY C030mlV/FILTEP, 1750nl V/B FILTER

VE]GHT 454!a€/)]Dtbs

DIMENSIONSANDFEATURES

DIMENSIONS

AND FEATURES

P,/NOC2965A

P/N OC2955C

P,/N

OC2965t

+CYCLE

ENGINE

THEORY

ftheengineisto

run

properly,

four

(4)

eventsrnustoccurin

the

proper

sequenceanda!thecorecttime.These

eventsare

(a)

intake,

(b)

compression,

(c)

ignition

and

power,

and

(d)

exhaust.

A INTAKE

The

piston

istravellinqfromtopdeadcenter

(IDC)

tobottom

deadcenter(BDC).

The

cam

has

openedtheintakevalve.The

piston

downwardmovementinthe

cylindercreatesa

partial

vacuurninthecylinderAiratatmosphefic

pressure

isdrawn

intothecylinderthroughthecarburetorandismixedwithfuel

inthecalburetor.Thefuelairmixturcflows

thrcughtheopen

intakevalveintothecylinderWhenthe

piston

reachesBDC,

theintakestokeisover.

CrcNrT|oN

AND

powER

thetimethe

piston

reachesTDC

,combustionisakeady

progress.

Theintakeandexhaustvalvesremain

closedasthe

exprnding

gases

ofcombustion

force

the

piston

downwad.

EXHAUsr

Theexhauststroke

beginswhenthe

piston

has

rcachedBDC

and

has

starteditsupwardmovement.Theintake

valveis

closed.Theexhaunvaveis

opentolet

gases

escape.

coMPREsstoN

the

piston

reaches

bottomde6d

center

(BDC),

boththe

intake

andexhaustvalves

areclosed.The

piston

movesupward

toward

TDCand

thefuel-airmixtureis

compressed.lustbefore

the

piston

rcachesTDC,ignition

occLirs.

Ce manuel convient aux modèles suivants

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