USAfixTM - Repair Guide (RG) - Master Email RG
- Replace Heads
 Level of Difficulty - High  Estimated Completion Time - 125 minutes
CLARKE-ALT - 27PROPANE BURN

Tools Required
Tool 
Feeler gauge-metric 0.10mm
Feeler gauge-metric .006in / 0.152mm
Ratchet-Deep socket metric 12mm
Ratchet-Deep socket standard 1/2 in
Ratchet-Socket metric 10mm
Ratchet-Socket metric 12mm
Ratchet-Socket metric 14mm
Ratchet-Socket standard 11/16 in
Ratchet-Socket standard 13/16 in
Screwdriver-flat tip
Screwdriver-phillips
Torque wrench
Wrench-1/4 in
Wrench-Allen standard 7/64 in

Parts Required
PartDescriptionPriceAvailablePurchase
178-0211 Left (while operating) cylinder head assembly (FH500V) $366.28 Back Order Qty:
178-0212 Right (while operating) cylinder head assembly (FH500V) $366.28 Back Order Qty:


Step Procedure & Parts & Tools
1 SEE "PULLING THE HEADS" RG

2 MAKE SURE GASKET PIN IS STILL ON ENGINE, MAY COME OFF WITH THE HEAD, IF SO, PULL OFF OLD HEAD AND PUSH BACK IN ENGINE

3 RECONNECT AIR BREATHER HOSE

4 HOLD LEFT SIDE HEAD AND HEAD GASKET (STANDING IN THE OPERATOR POSITION) ON ENGINE. THIS PART NO. IS A KIT FOR THE LEFT HEAD THAT INCLUDES ALL THE GASKETS.

PartDescriptionPriceQty
178-0211 Left (while operating) cylinder head assembly (FH500V) $366.28 Qty:  
5 REINSTALL 5 HEAD BOLTS LOOSELY
Ratchet-Socket metric 12mm

6 TORQUE THE 5 HEAD BOLTS IN NUMERICAL ORDER. EACH BOLT NEEDS TO BE TORQUED TO 25 N-M OR 19.0 FT-LB.
Torque wrench

7 SLIDE THE ROCKER ARM GUIDE INTO PLACE

8 HOLDING THE ROCKER ARM GUIDE IN PLACE, REPLACE THE 2 ROCKER ARM STUDS

9 TIGHTEN THE 2 ROCKER ARM STUDS
Ratchet-Deep socket metric 12mm

10 SLIDE PUSH RODS BACK INTO PLACE (IF PUSH RODS ARE BENT, PURCHASE SEPARATELY)

11 HOLD THE ROCKER ARMS IN PLACE

12 TIGHTEN THE 2 ROCKER ARM BOLTS
Ratchet-Socket metric 14mm

13 TURN THE FLYWHEEL UNTIL EACH ROCKER ARM GOES IN AND OUT AND STOPS (MAY NOT BE AT THE SAME TIME)
Ratchet-Socket standard 11/16 in

14 STICK LONG SCREWDRIVER IN SPARK PLUG HOLE AND TURN THE FLYWHEEL UNTIL IT PUSHES THE SCREWDRIVER OUT AND STOPS-THIS IS TOP DEAD CENTER
Ratchet-Socket standard 11/16 in
Screwdriver-flat tip

15 INSERT FEELER GAUGE BETWEEN ROCKER ARM AND SPRING (CHECK GAP ON TOP AND BOTTOM ROCKER ARMS)
Feeler gauge-metric .006in / 0.152mm

16 IF GAP IS TOO TIGHT OR TOO BIG, LOOSEN NUT (ON TOP AND BOTTOM ROCKER ARMS)
Ratchet-Socket metric 14mm

17 HOLD THE NUT AND LOOSEN SET SCREW (ON TOP AND BOTTOM ROCKER ARMS)
Wrench-Allen standard 7/64 in

18 INSERT FEELER GAUGE BETWEEN ROCKER ARM AND SPRING, HOLD AND TIGHTEN NUT (TOP AND BOTTOM ROCKER ARMS)
Feeler gauge-metric .006in / 0.152mm

19 HOLD BOLT WITH WRENCH AND HOLD SET SCREW AND TIGHTEN BOLT AT THE SAME TIME. RECHECK GAP. (TOP AND BOTTOM ROCKER ARMS)
Wrench-Allen standard 7/64 in
Ratchet-Socket metric 14mm

20 SET A NEW GASKET ON THE NEW HEAD

21 HOLD THE VALVE COVER AND GASKET TO THE HEAD AND TIGHTEN THE 2 BOLTS
Ratchet-Socket metric 10mm

22 REPEAT STEPS 2 THRU 21 TO REPLACE RIGHT HEAD (STANDING IN THE OPERATOR POSITION) THIS PART NO. IS A KIT FOR THE RIGHT HEAD THAT INCLUDES ALL THE GASKETS.

PartDescriptionPriceQty
178-0212 Right (while operating) cylinder head assembly (FH500V) $366.28 Qty:  
23 PUSH TO REPLACE VALVE COVER CAP

24 SLIDE THE EXHAUST MANIFOLD IN PLACE

25 TIGHTEN 4 BOLTS HOLDING THE EXHAUST MANIFOLD
Ratchet-Socket metric 12mm

26 REPLACE THE CYLINDER SHROUD

27 TIGHTEN THE BOLT ON THE FRONT OF THE CYLINDER SHROUD
Ratchet-Socket metric 12mm

28 TIGHTEN THE BOLT FROM THE BOTTOM OF THE CYLINDER SHROUD
Ratchet-Socket metric 10mm

29 SLIDE THE INTAKE MANIFOLD ONTO THE ENGINE

30 TIGHTEN THE 4 BOLTS ON THE INTAKE MANIFOLD
Ratchet-Socket metric 10mm

31 HOLD THE IGNITION MODULE TO THE ENGINE

32 SPIN THE FLYWHEEL UNTIL THE MAGNETS LINE UP WITH IGNITION MODULE

33 ATTACH IGNITION MODULE USING 2 BOLTS

34 USE FEELER GAUGE TO GAP IGNITION MODULE (.010) AND TIGHTEN THE BOLTS
Ratchet-Socket metric 10mm
Feeler gauge-metric 0.10mm

35 RECONNECT THE WIRE CONNECTOR TO THE HARNESS

36 SET THROTTLE PLATE IN PLACE

37 RECONNECT THE SPRING ON THE THROTTLE PLATE

38 SET AND TIGHTEN THE RIGHT BOLT ON THROTTLE PLATE (RETURN TO PREVIOUS POSITION)
Ratchet-Socket metric 10mm

39 PLACE CARBUREATOR ONTO INTAKE MANIFOLD BOLTS

40 RECONNECT THROTTLE WIRE TO CARBUREATOR LINKAGE

41 SET AND TIGHTEN THE LEFT BOLT ON THROTTLE PLATE
Ratchet-Socket metric 10mm

42 TIGHTEN 2 BOLTS TO RECONNECT THE BRACKET
Ratchet-Socket metric 10mm

43 TIGHTEN THE 2 SCREWS ON THE SIDE OF THE BACK COVER
Screwdriver-phillips

44 TIGHTEN 2 BOLTS ON BACK COVER
Ratchet-Socket metric 10mm

45 TIGHTEN THE 4 BOLTS ON THE SHROUD
Ratchet-Socket metric 10mm

46 INSTALL THE AIR FILTER

47 INSTALL THE PRE FILTER

48 INSTALL THE WING NUT

49 REINSTALL THE AIR BREATHER COVER

50 RECONNECT OXYGEN SENSOR PLUG

51 TIGHTEN SPARK PLUG
Ratchet-Socket standard 13/16 in

52 PUSH TO RECONNECT SPARK PLUG WIRE

53 SLIDE MUFFLER INTO PLACE

54 REINSTALL BOLT AND 2 WASHERS

55 TIGHTEN BOLT HOLDING MUFFLER
Wrench-1/4 in

56 SLIDE CLAMP UP

57 TIGHTEN NUT ON MUFFLER CLAMP
Ratchet-Deep socket standard 1/2 in

58 TIGHTEN THE 4 ACORN NUTS
Ratchet-Socket metric 10mm

59 PUT THE BONNET ON THE CAGE

60 SET TANK ON MACHINE

61 CLOSE TANK STRAP

62 RECONNECT FUEL LINE

63 TURN TANK ON ONLY IF TURNING THE UNIT ON