sEctioN 4.4DiaGNostic tEstsPage 143PROCEDURE: (INTAkE AND EXHAUST)Make sure that the piston is at Top Dead Center(TDC) of it’s compression stroke (both valvesclosed). The valve clearance should be 0.05-0.1mm(0.002-0.004 in.) cold.Check and adjust the valve to rocker arm clearanceas follows:1. Remove the four (4) screws from the rocker cover.2. Remove the rocker cover and rocker cover gasket.3. Loosen the rocker arm jam nut. Use a 10mm allen wrenchto turn the pivot ball stud and check the clearancebetween the rocker arm and the valve stem with a flatfeeler gauge (see Figure 44).4. When the valve clearance is correct, hold the pivot ballstud with the allen wrench and tighten the rocker armjam nut. Torque the jam nut to 174 inch pounds. Aftertightening the jam nut, recheck the valve clearance tomake sure it did not change.0.076 mm(0.003") SHIMJAM NUTBALL STUDFigure 445. Re-install the rocker cover gasket, rocker cover andthe four (4) screws.RESULTS:Adjust valve clearance as necessary, then retest.teSt 78 – check Wire 18 continuityDISCUSSION:During cranking and running the printed circuit boardreceives a pulse from the ignition magnetos via Wire18. This signal has an AC voltage of 4-6 volts onV-Twin engines only. If this signal is not received bythe printed circuit board the unit will shut down due tono RPM sensing.PROCEDURE: (V-TWIN ONLY)1. Set a VOM to measure AC voltage.2. Connect one meter test lead to Wire 18 that is connectedto the bolt connector shown in Figure 46. Connect theother meter test lead to a clean frame ground.3. Set the AUTO-OFF-MANUAL switch to the MANUALposition.4. When the generator comes up to rated speed, measure andrecord the voltage reading. 4-6 VAC should be measured.5. If the correct voltage was not measured in Step 4, referback to flow chart. If the correct voltage was measured,proceed to Step 6.WIRE 18CONNECTIONFigure 45. Wire 18 Connection 8 kW UnitsWIRE 18 CONNECTIONFigure 46. Wire 18 Connection 10-20 kW Units6. Set a VOM to measure resistance.7. Disconnect the J1 Connector from the printed circuitboard.8. Verify the continuity of Wire 18. Connect one metertest lead to a clean frame ground. Connect the othermeter test lead to Pin Location J1-4 for all models. Areading of 275K - 325K ohms should be measured. IfCONTINUITY is measured (0.1 ohms) a short to groundcould be present.9. Disconnect Wire 18 from the stud connector. Continue toleave J1 disconnected from Step 7.DC CONTROL Part 40G9266revA.indd 143 10/15/2008 11:28:22 AM
