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CCW TWO CYLINDER MODELS


CONDENSED SERVICE DATA
CCW290/1 58.5 2.30 54 2.13 2 290.1 17,7 20(5)6000 17.2@6000 Tlt'sn HR 1 CCW290/2 58.5 2.30 54 2.13 2 290.1 17.7 23@6500 18.2(^6000 Tlt'sn HR 1 CCW340 /(1&2) 60 2,36 60 2.36 2 339 20.7 25(0)5800 23@5250 Tlt'sn HR 1 CCW340/3 60 2.36 60 2.36 2 339 20,7 28(56500 22.4(5;6000 Axial Fan Third Port Tlt'sn HR 1 gy Transfer Ma 0.3-0.4 0.012-0.016 CCW340/4 60 2.36 60 2,36 2 339 20,7 32(5:6500 26(56500 Tlt'sn HR 1 CCW400 /(1&2) 65 2.56 60 2.36 2 398 24,3 30(55800 27,3@5500 Tlt'sn HR 1

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ENGINE MODEL Bore(mm) , Inches Stroke(mm) Inches No. of Cylinders Displacement(cc) . . . Cubic Inches Horsepower @ RPM .. Max Torque @ RPM .. Cooling Type Induction Type Carburetor Model . . . . Number Used Ignition: Type Point Gap(mm) .. Inch Edge Gap(mm) . . . Timing Advance? .. Timing BTDC Degrees Inch Measured at Spark Plug: NGK Electrode Gap (mm) Inch Fuel/Oil Ratio

CCW400/3 65 2.56 60 2.36 2 398 24.3 33(56500 26,7(5)6000 Tlt'sn HD 1

10 0.020

10 0.020

8 0,015 B8H 0.5-0.6 0.020-0.024

10 0,023 B8H 0,5-0,6 0,020-0.024 20:1

10 0,023 B9HS 0,5-0,6 0,020-0.024

8 0,015 B8H 0.5-0,6 0,020-0,024

10 0.023 B8H 0,5-0,6 0.020-0.024

0.6-6.7 0.024-0,028

0.6-0.7 0.024-0.028

ENGINE MODEL Bore(mm) Inches Stroke(mm) Inches No. of Cylinders Displacement(cc) Cubic Inches Horsepower @ RPM Max Torque @ RPM Cooling Typ Induction Type Carburetor Model Number Used Ignition: Type Point Gap(mm) Inch Edge Gap(mm) Timing Advance? Timing BTDC Degrees Inch Measured at Spark Plug: NGK Electrode Gap (mm) Inch Fuel/Oil Ratio ,.

CCW400/4 65 2.56 60 2.36 2 398 24.3 36@6500 28.7@6500 Third Port Tlt'sn HD 1

CCW400/21 63 2,48 64 2.52 2 398,8 24.3 39(5)6500 31@6000 ' Reed Valve Tlt'sn HD 1 "

CCW440/1 CCW440/2&3 68 68 2.68 2.68 60 60 2.36 2.36 2 2 436 436 26,6 ' 2 6 , 6 33^6000 37@6500 30.5(56000 29,6@5750 Axial Fan Third Port Third Port Tlt'sn HD Tlt'sn HR 1 1 Energy Transfer Magneto 0,3-0,4 0.012-0,016 Yes
go go

CCW440/4 68 2.68 60 2,36 2 436 26.6 40^^6500 30@6500 Third Port Tlt'sn HD 1

CCW440/21 66 2,6 64 2.52 2 437.7 26.7 43(5.6500 34,7^6000 Reed Valve Tlt'sn HD 1

10" 0,023 B8HS 0,5-0.6 0,020-0.024

5 * * 0,006 ~ B8HS 0,6-0,7 0.024-0.028

0,015

Retard

0.015

10 0.023 B8HS 0.5-0.6 0,020-0.024

10 0.024 B8HS 0.6-0.7 0,024-0,028

B8H 0.5-0.6 0,020-0,024 20:1

B8H 0,5-0.6 0,020-0,024

MAINTENANCE CARBURETOR. Tillotson or Walbro carburetors are used. Refer to the appropriate CARBURETOR SERVICE Sections elsewhere in this manual for service specifications. SPARK PLUG. NGK Spark Plugs are standard equipment. The recommendations given in CONDENSED 278

SERVICE DATA Tables are for normal operation. A different heat range plug may improve performance under some conditions. Refer to Spark Plug Selection paragraphs of SERVICE FUNDAMENTALS Section for additional information on spark plug selection. IGNITION AND TIMING. Breaker point gap should be 0.3-0.4 mm (0.012-

0.016 inch) on all models. Points can be adjusted after removing recoil starter, starting pulley and fan drive sheave. All models are equipped with a centrifugal timing advance which provides retarded timing for starting only. On all models, both cylinders must be timed as nearly as possible alike. It is suggested that point gap and timing

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be checked on one cylinder; then timing synchronized by varying the point gap on other cylinder if necessary. LUBRICATION. The engine is lubricated by oil mixed with the fuel. The manufacturer recommends regular gasoline and Special Air Cooled, Two Stroke engine oil mixed at a ratio of 20:1. Refer also to vehicle manufacturer's recommendations. COOLING FAN AND BELT. There should be sufficient belt tension at all times to p r e v e n t belt from touching housing when deflected with the fingers with engine stopped (approximately y4-inch deflection measured midway between pulleys). Refer to Figs. 3 or 11. To adjust the belt, transfer shims (6) from between sheave halves (5) to the front of front half. Tighten fan shaft nut to a torque of 30 ft.-lbs. REPAIRS TIGHTENING TORQUES. Tightening torques are as follows. Measurements are given in ft.-lhs. Cylinder to crankcase Third Port Models 15-18 Reed Valve Models . See Cyl. Head Cylinder head Third Port Models 15-18 Reed Valve Models Long stud nuts 12-15 Short stud nuts 5-7 Crankcase Third Port Models 12-15 Reed Valve Models 13-18 Flywheel 45-50 Fan shaft 28-31 Intake manifold Reed Valve Models 5-7 Remainder of bolts should be tightened to standard torque. DISASSEMBLY AND REASSEMBLY. Although similar in appearance, disassembly procedures differ between the Third Port engines shown in Fig. 1 and Reed Valve models shown in Fig. 2. Refer to the appropriate following paragraphs for proceH11 rfs

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Use a heat gun or other suitable means to thoroughly warm the piston before removing piston pin. Be sure that bearing retaining half-washers are properly installed in crankcase lower half. Lubricate crankshaft components thoroughly. Coat sealing surface of both crankcase halves with a good non-hardening sealant. Note that center bearing left-hand spacer on CCW290 engine has a drain groove as shown in Fig. 6. Drain groove must be installed at bottom of crankcase. Fit upper crankcase, install the four center topside bolts (1, 8, 9 and 10Fig. 7) and tighten the four bolts evenly with fingers until crankcase halves meet. Install remainder of bolts using Fig. 7 as a guide and tighten evenly in se-

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THIRD PORT ENGINES. Refer to Fig. 3 for an exploded view of cooling fan and associated parts and to Figs. 4 & 5 for engine parts. To disassemble the removed engine, first remove spark plugs and cylinder shroud (15Fig. 3), then remove inlet and exhaust manifolds leaving carburetor attached to inlet manifold. Cylinder heads and cylinders can now be removed for top-end work. Crankcase disassembly will require removal of fan housing, flywheel and housing plate.

Fig. I^View of CCW twin engine with third port induction. Normal finger pressure midway between pulleys should not deflect belt into fan housing.

Fig. 4~Exploded view of crankcase housing and associated parts used on two cylinder models. Cylinder heads can only be Installed In one position. When assembling engine, fasten cylinders lightly to crankcase, then install and tighten manifolds to ensure proper alignment. Optional manifolds are shown at (5A and
1. Crankcase 6. Gasket 2. Crankcase screw 7. Cylinder 3. Port plugs 8. Gasket 4. Impulse nipple 9. Cylinder head 5. & 5A. Intake manifold 10. & lOA. Exhaust manifolds

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Fig. 2-Wew of CCW twin engine with reed valve induction system. Engine is similar in general appearance to third port engine shown in Fig. T excepf for tow positioning of carburetor and intake manifold. Most late engines have the completely enclosed cooling fan and belt shown In Fig, 2. Fig. 3-Exploded view of axial cooling fan, fan housing and associated parts used on early models.
1. 2. 3. 4. 5. 6. 7. 8. Shaft nut Lockwasher Washer Spacer Sheave half Spacer shims Belt Drive pulley 9. Housing 10. Bearings 11. Snap ring 12. Fan 13. Housing plate 14. Cover 15. Cylinder shroud

Fig. 5-Exploded view of crankshaft, pistons and associated parts. Refer to Fig. 4 for housings.

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quence shown to the recommended torque of 12-15 ft.-lbs. Use a heat gun to warm pistons and install pin, with arrow on top of piston pointing toward exhaust ports. Chrome plated piston ring is installed in top groove. Cylinders are not interchangeable and are marked "L" (left) and "R" (right) by stamping on cylinder flange. Install cylinders using a suitable ring compresser, wooden blocks to hold piston steady, and new base gaskets. Tighten cylinder stud nuts just past finger tight, then install and tighten intake manifold to properly align the cylinders. Tighten cylinder nuts in a criss-cross pattern as shown in Fig. 8. Cylinder heads are not interchangeable and should be installed with machined sides together. The long standoff nuts which retain cylinder shroud should be installed at (3Fig. 9) on CCW290 engine or (5Fig. 10) on other models. Tighten cylinder head stud nuts to a torque of 15-18 ft.-lbs. in the sequence shown in Fig. 9 for CCW 290 engine or Fig. 10 for other models. REED VALVE ENGINES. Refer to Figs. 11, 12 and 13 for exploded views. Cooling fan differs from third port engines in that impeller assembly is outboard of drive pulley. Cooling shroud attaches to standoff nuts and cylinder heads at the four points indicated by arrows. Fig. 12. Cylinders, cylinder heads and pistons are not interchangeable for left and right cylinders. Cylinders are retained to crankcase by four through-studs which extend through

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cylinders and cylinder heads, forming four of the eight cylinder head studs. To disassemble the removed engine, first remove spark plugs and cylinder shroud, then remove inlet and exhaust manifolds and reed valve plates. Cylinder heads and cylinders can now be removed for top end overhaul. Crankcase disassembly will require removal of fan housing, flywheel and magneto plate. Use a heat gun or other suitable means to thoroughly warm the piston

Fig. 11-Exploded view of cooling fan, fan housing and associated parts used on reed vaive induction engines. Refer to Fig. 3 for parts identification.

Fig. S-On CCW 290, drain groove in center bearing spacer shouid be iocated at the bottom when crankshaft is instaiied. Fig. S-Tighten cyiinder stud nuts in criss-cross pattern as shown. Intake manifoid shouid be instaiied and tightened before cylinder nuts are torqued to align manifoid fianges. Fig. 12-Partially exploded view of reed vaive induction engine. CooUng shroud is attached at points indicated by black arrows.

Fig. 9-Cylinder head tightening sequence to be used on CCW290 engine. Standoff nuts which support cooling shroud are to be instaiied in No. 3 position on both heads.

'5)
(6)
Fig. 7-Tlghten crankcase screws In sequence shown. Upper view indicates proper iocation for short and long screws. Broken lines indicate heads are iocated on bottom of crankFig. iO-Cyiinder head tightening sequence for modeis with five-stud heads. Standoff nuts which support cooiing shroud are instaiied in No. 5 position.

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before removing piston pin. Note that exhaust port locating arrows on tops of pistons angle outward toward ends of shaft. To assemble the engine, suitably support upper half of crankcase on cylinder studs and position bearing r e t a i n i n g half-washers in t h e i r grooves. Lubricate components thoroughly and coat both crankcase flanges with a suitable non-hardening sealant. Reposition crankshaft assembly and install crankcase lower half, being sure locating dowels seat properly. Tighten retaining cap screw and stud nuts evenly to a torque of 13-18 ft.-lbs. in the sequence shown in Fig. 14. With crankcase assembled, reposition with cylinder studs uppermost. Warm the pistons and reinstall with exhaust valve locating arrows angling outward and away from reed valve opening side of crankcase. Chrome plated piston rings are installed in top grooves. Cylinders are not interchangeable and are stamped "L" (left) and '*R" (right) on cylinder flange. Install cylinders using a suitable ring compresser, wooden blocks to hold piston steady, and new base gaskets. Exhaust port side of cylinders must be on opposite side of engine from reed

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Fig. 15~When installing cylinders and cylinder heads first tighten through-studs (1 through 4) to indicated torque, then short studs (5 through 8). Recommended sequence is as shown.

valve openings in crankcase. Using new head gaskets, install cylinder heads with shroud retaining bosses (ArrowsFig. 12) on reed plate side of engine. Install cylinder head nuts, fiat washers and lockwashers finger tight. Long standoff nuts which secure cylinder shroud are installed at (2Fig. 15) as shown by black arrows, Fig. 12. Install and tighten exhaust manifold to assure cylinder alignment. Tighten cylinder head stud nuts in the sequence shown in Fig. 15, the large nuts (Nos. 1 through 4) being tightened to full torque before tightening the small nuts (5 through 8). Complete the assembly by reversing the disassembly procedure, adjusting fan belt, ignition points and timing as previously outlined. PISTONS, PINS, RINGS AND CYLINDERS. Piston pin should be a tight fit in piston bore at room temperature and needle bearing should not have perceptible clearance between piston pin and connecting rod bore. The two piston rings are pinned in place. Recommended side clearance is 0.0025-0.004 for upper ring and 0.00140.003 for lower ring. Recommended end gap is 0.004-0.012 for either ring. Recommended piston clearance in cylinder is 0.011-0.012 at top land and 0.0040.005 at skirt.

REED VALVE UNITS. Refer to Fig. 16 for an exploded view of reed valve unit used on models so equipped. Valve leaf (3) is of stainless spring steel and seating surface of reed plate (5) has a bonded plastic coating. One shim (4) must be installed underneath valve reed to properly position the reed. Reed stop (2) is carefully arched for best performance and should not be reformed. Do not attempt to straighten a bent or damaged reed or to reform reed or stop in an attempt to alter performance. Renew reed or reed stop if damaged in any way and reed plate if coating is damaged at reed seating area. Tighten reed plate retaining screws evenly and securely to slightly compress plastic coating beneath the shim. MAGNETO. Two different types of Energy Transfer Magneto have been used. Most models use two "piggybacked" ignition generating coils as shown in Fig. 17, but early 340 models with manual start used a Sawafuji magneto with a single generating coil as shown in Fig. 18. Note that on Sawafuji unit, low tension coil is insulated from armature plate and circuit is completed through both sets of points. On all other models, one end of each coil winding is grounded to the armature plate.

Fig. 13-Crankshaft, pistons and associated parts used in reed vaive engines. Note angied exhaust arrows and ported areas of piston skirt.

Fig. lA-Tighten crankcase retaining stud nuts and cap screw in sequence indicated, viewed from bottom.

CONNECTING RODS, CRANKSHAFT AND BEARINGS. The crankshaft and connecting rods, including center main bearings and seals, is only available as an assembly. Disassembly is not recommended in the average shop. Measure side shake of connecting rod at piston end after remo.ving cylinders and pistons. If shake exceeds 3.0 mm (0.118 inch), install a new or rebuilt assembly. Outer (end) bearings can be renewed if care is used in removal and installation to keep from damaging shaft in any of its built-up joints. Support shaft on vee-blocks on installed outer bearings and measure runout at ends of shafts using a dial indicator. If runout exceeds 0.1 mm (0.004 inch) renew or straighten shaft.

Fig. 16~Exploded view of reed valve plate and associated parts used on models so equipped. 1. Gasket 4. Shim 2. Reed stop 5. Reed plate 3. Valve leaf 6. Gasket

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Fig. IB-Exploded view of recoii starter of the type used on aii models. Fig. 1B-0n Sawafuji magneto, both systems share the common iow tension coii (5), which is insuiated from breaker piate. Refer to Fig. 17 for parts identification. Fig. 17-Wiring diagram of independent ignition system used on most rnodeis. Note the "piggybacked" iow tension ignition coiis. 1. Sparkplug 2. Ignition coil 3. Condenser 4. Breaker points 5. Low tension (generating) 1. 2. 3. 4. 5. 6. 7. 8. Housing Recoil spring Pulley Pawl Rope Guide Grip Retainer 9. 10. 11. 12. 13. 14. 15. 16. Spring seat Friction spring Return spring Friction plate Washer Lockwasher Nut Starter cup

On condensers with soldered connections, an iron and low heat should be used to prevent service damage. Primary Secondary Sawafiyi ..0.37 Ohms 8,350 Ohms Denso 0.37 Ohms 8,350 Ohms Kokusan .. 1.65 Ohms 5,200 Ohms Preferred method of timing is by piston position BTDC using a timing indicator in spark plug hole. The vertical spark plug location permits direct reading on all models. Static timing is as follows:

Piston Crankshaft Position Degrees Inch BTDC BTDC 10 CCW 290 (all) . 0.020 8 CCW340/1&2 . 0.015 10 CCW340/3 & 4 . 0.023 8 CCW400/1 & 2 . 0.015 10 CCW400/3 & 4 . 0.023 5 CCW400/21 . . . 0.006 8 CCW440/1, 2 & 3 0.015 10 CCW440/4&21 0.023 Both cylinders must be timed as nearly as possible alike and adjustment is by varying point opening for timing the second cylinder. Armature plate may be moved for major adjustment by loosening retaining screws, which requires flywheel removal. RECOIL STARTER. Refer to Fig.

19 for exploded view. Starter must be disassembled to renew rope or recoil spring. Return spring (11) enters a hole in rope pulley (3) and a notch in friction plate (12) and turns the plate at recoil to retract pawls (4). Wind return spring in housing counter-clockwise starting at oustide. Wind rope on pulley and fit outer end in notch in pulley rim. Install pulley and engage recoil spring inner end; then turn pulley three turns counter-clockwise to preload recoil spring. Feed free end of rope out through hole in housing and rope guide (6) and tie a loose slip knot in free end while installing grip (7). Complete the assembly by reversing the disassembly procedure.

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