Carburetor Repair Cushman Truckster Haulster

A smooth running easy starting Cushman Truckster or Haulster can be a joy to operate. These machines will out work and out last many of their competitors. That is why they have lasted for decades and people are still using Trucksters and Haulsters that are decades old.

When the engine begins to be hard to start, it misses under a load, or if the engine stalls it could mean the carburetor needs adjustment.

The folowing instructions will guide you through the process of cleaning and adjusting your carburetor so you will again have  maximum enjoyment from your Cushman Truckster or Haulster.

The carburetor on any gasoline engine should be cleaned and inspected at regular intervals depending on the service conditions.

Select a clean work area. Dirt and carelessness are the causes of most carburetor trouble.

CAUTION: Some solvents and cleaners will damage the synthetic rubber parts used in carburetors. If you are in doubt about the solvent you are using, test a part in it and observe the results.

Clean and dry the outside of the carburetor and check for cracks in the casting, bent or broken shafts, loose levers and damaged threads before proceeding with disassembly.

  1. Remove the idle speed screw and spring. Check for damaged threads.
  2. Remove the bowl nut and remove the bowl.
  3. Remove the float lever pin and remove the float. Inspect the float for damage which may cause it to leak. The inlet needle can now be removed from the inlet seat.
  4. Remove the inlet seat from the carburetor body. Inlet needle and seats are in matched sets and should never be interchanged. Always use a new gasket when reinstalling the inlet seat.
  5. Remove the high speed and idle mixture screws and inspect the tips. Either screw tip can be bent or distorted from being forced into the casting seat. If either screw is damaged, be sure to inspect the condition o the seats. If the adjustment seats are damaged, the carburetor body must be replaced.
  6. Remove the choke, valve screws, choke valve and pull the choke shaft and lever out of the body.
  7. Remove the throttle valve screws, throttle valve and pull the throttle shaft and lever out of the body.
  8. Examine the throttle and choke shafts and the carburetor body for wear. Replace any worn parts.
  9. Clean and dry all parts before reassembling the carburetor. Carefully blow out each channel and orfice in the body.

When reinstalling the float, it must be adjusted to acquire 3/32″ clearance between the top of the float and the bottom of the carburetor body. A handy tool for this is a 3/32″ drill shank or a piece of 3/32″ bar stock.

Carburetor Cushman Truckster Haulster

 

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Manual Starter for M109 Engines Cushman Truckster / Haulster

If you own a Cushman Truckster or Haulster  you already know what a work horse these machines are. They have been around for decades and are now becoming great collector items. But just like any other machine, parts begin to wear and have to be replaced.

If you have one of the older Cushmans that still has a manual starter you can begin to have difficulty starting your Cushman and may need to replace the starter.

There are plenty of reasons why these starters may need replaced including loss of compression or a broken spring. Whatever the reason you need to replace yours the following instructions will take you through the disassembly and reassembly of your manual starter so you can be back in business with your Cushman and enjoy its classic charms. When you show off your Cushman it makes a much greater impression when it starts easily.

Make a mark on the end of the segment shaft corresponding with a mark on the starter arm. This is so the correct position of the starter arm in relationship to the segment shaft may be easily recognized upon reassembly. Loosen the screw that holds the starter arm to the splined shaft. Remove starter arm, remove spacer sleeve and spacer washer (if so equipped) from the starter shaft.

Caution:  Do not hold hands in such a position that they would be struck by the accidental release of the return spring.

Lay starter housing with shaft and segment facing down over a block of wood or other projection. See figure 1. Lightly tap end of splined shaft with a hammer until return spring releases. Inspect all component parts for cracks or excessive wear, replace if necessary. See figure 2.

Manual Starter for M109 Engine Cushman Truckster Haulster

Manual Starter for M109 Engines Cushman Truckster Haulster

Reassembly

Secure starter housing in upright position in a vise. Position the return spring on the segment shaft. See figure 3. Insert segment shaft with spring attached in the segment shaft hole in the housing. Push shaft all the way in until segment touches lip of starter housing. See figure 4. Install spacer washer, spacer sleeve, and starter arm and securely tighten retaining screw. This will prevent shaft from moving out and releasing spring while it is being wound. Viewing the starter assembly from the rear, wind spring approximately 1-3/4 turns clockwise. Spring retaining notch in housing will now be exposed. See Figure 3. Take a large screw driver or some other appropriate tool and lift up on spring; then lower spring into notch. See figures 6 and 7.

Turn segment about three quarter more turns or until it is just lower than the rubber stop and then push segment shaft all the way in until it bottoms. Starter arm may now be released. See figure 8. Loosen screw holding starter arm segment shaft, and push arm all the way onto shaft. There should be .010 endplay in segment shaft.

Manual Starter for M109 Engines Cushman Truckster HaulsterManual starter for M109 engines Cushman Truckster HaulsterFigure 5 Manual Starters_edited-2Figure 6 Manual  Starters_edited-3Figure 7 Manual  Starters_edited-3Figure 8 Manual Starters_edited-3

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Used Cushman Parts for Truckster Haulster

It’s hard to find replacement parts for the older Cushman Truckster and Haulster. I have a large selection of body parts and motor parts for the M109 and M218 motors for the Cushman Truckster and Haulster.

If you are looking for something to fit your Truckster or Haulster check out my ebay store Cushmans N More. You can find a wide variety of used Cushman parts.

If you can’t find what you are looking for in my ebay store just send a post telling me what you are looking for and I’ll get back to you.

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Used Cushman Parts

Owning and restoring a Cushman Truckster, Haulster, or Golf Cart can be a fun and rewarding experience. People that own a Cushman love to talk about where they found their Cushman, what it was originally used for, or the challenges they have met while restoring their Cushman.

I have owned several Cushman Trucksters and Haulsters and sold a few. One of the biggest challenges I faced was where to buy parts. Many of the older Cushman vehicles have parts that are either not being made anymore or are very expensive.  So I resorted to buying old Cushman Trucksters and Haulsters and using parts from them.

I began to notice other people have had the same difficulty I had when it came to finding parts for their Truckster or Haulster. Well, I am now selling a variety of used Cushman parts for the Truckster and the Haulster. I also have some Cushman golf cart parts.

If you are looking for used Cushman parts check out my ebay store Cadiescorner or give me a call and let me know what you are looking for. Keith 417-399-3590.

If I’m working on one of my Cushman vehicles I may not hear your call so leave a message and I’ll get back to you soon.

 

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Valve Tappet Adjustment M109 Motor Cushman Truckster Haulster

Engine must be cold before tappet adjustment is attemped.

Turning the flywheel until the timing mark on the front fan housing and the timing mark on the one fin of the flywheel line up. If both valves are closed, the tappets are then ready to be adjusted. If both valves are not closed, rotate the flywheel one complete revolution, nut at the top of each rocker arm and turn the adjusting screw until .005 clearance is obtained between each rocker arm and valve stem. Be sure lock nuts are securely tightened. Recheck valve tappet clearance. See figure 20 Using a new valve cover “O” ring, the valve cover and the retaining nuts may be installed. Be sure the proper washers are used under the valve cover retaining nut.

Valve Tappet Adjustment M109 Motor Cushman Truckster Haulster

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Flywheel Installation Cushman Truckster Haulster

Install the rear fanhousing to the crankcase. Be sure all screws are properly tightened.

Insert the spark plug wire into the opening of the coil. The contact pin in the opening of the coil must be straight and true so that it will make contact with the spark plug wire.

Install the coil and lamination assembly, being sure that it is properly seated around the hub of the crankcase. Attach the spark plug wire to the inside of the rear fan housing with the proper wire clip.

Place the flywheel key into the key way in the end of the crankshaft. NOTE: A letter “C” on the flywheel casting adjacent to the fin with the timing mark, indicates that a straight key should be used. If flywheel has no markings an offset key should be used. Position the offset flywheel key so that the word TOP and the letter X are exposed. Install the flywheel, lockwasher and nut. Be sure the flywheel nut is securely tightened, or serious damage may result to the flywheel or crankshaft, or both. Check specifications section of the manual for proper torque values. Install the starter assembly to the rear fan housing.

Position the front fan housing and install mounting screws.

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Oil Pump Installation M109 Motor Cushman Truckster Haulster

With the oil pump gears and the oil pump drive shaft thoroughly cleaned, place the two gears into position in the oil pump cavity. Note the retainer ring on the oil pump drive shaft. See figure 18. This retainer prevents the shaft from being pulled out from its position in the pump drive gear when the timer assembly is removed from the engine; consequently, it is imperative that the retainer is in position. Use a new seal and install the oil pump cover.

Oil Pump Installation M109 Motor Cushman Truckster Haulster

Installing Oil Pump Strainer Screen

Wash the oil strainer screen and cover thoroughly and re-install into the bottom of the crankcase. A new gasket must be used when installing the strainer cover.

Pressure Relief Valve

Oil pressure is controlled by the relief valve that is located on the left side of the engine when facing the flywheel. When functioning properly, the valve will limit oil pressure to 40 psi. This will be achieved at 2500 RPM with engine at operating temperature.

Completely disassemble oil pressure relief valve (figure 19) and thoroughly clean with a solvent, removing all dirt particles and varnish. Do not use emery cloth or abrasive material to clean varnish from relief valve. Due to the high oil pressures encountered in certain sections of the relief valve housing, it is essential that the mating surface on this housing, along with the machined surface of the crankcase, be perfectly true. Check these surfaces with a straight edge. If there is any warpage or misalignment, either replace with a new housing or correct the old housing by truing the mating surface with emery cloth placed on a flat surface, using a figure eight motion.

Oil Pump Installation M109 Motor Cushman truckster Haulster

Using an air hose, determine that all oil channels and crevices are free from dirt and foreigh particles (pressure relief valve and chamber must be free of any nicks or burns). Assemble oil pressure relief valve and spring with new gasket on valve screw, then attach assembly to engine using new gaskets, torque all bolts evenly and securely. Check torque recommendations in Specifications Section of this manual.

CAUTION:  If the relief valve is assembled carelessly, cleaned improperly, or the valve or chamber has been nicked or marred in any way, causing the valve to stick, the engine may be subjected to adamaging oil pressure of several hundred psi.

 

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Reconditioning Cylinders and Valves M109 Motor Cushman Truckster Haulster

Using a valve spring compressor such as those used on overhead valve automotive engines, remove the valve springs, valve washers, (valve stem seal set, intake only and valves from the cylinder.

Clean the valves with a wire-wheel brush. All carbon must be removed from the top and bottom of the head. Do not overlook the varnish which might have accumulated on the stem.

In refacing valves, take off only the  minimum of metal required to clean up the valve faces. If the outer edge of the valve becomes too thin or sharp due to excessive grinding, the valve must be replaced. The valve head margin must be at least 3/64″. This margin is the area above the contact surface of the valve face. See figure 14.

Figure 14

Inspect the valve seats in the combustion chamber for cracks, burns, pitting, ridges or improper angle. If any of the above conditions are noted, the seats must be reground. NOTE: Valve seats are permanently installed and cannot be replaced. Therefore, a minimum of metal should be removed when grinding the valve seats.

The valve seat width after refacing should be a liberal 1/16″ for intake seats, but not more than 3/32″ in any case. The width of exhaust seats should be 3/64″ to 1/16″.

Test valve for concentricity with seat and also for tight seating. Valves can be tested by coating the valve face with Prussian Blue and turning the value against its seat. This indicates whether the seat in concentric with the valve guide, but does not prove that the valve face is concentric with the valve stem, or that the valve is seating all around.

After making this test, wash all blue from the surfaces, lightly coat the valve seat with blue and repeat the test to see whether a full mark is obtained on the valve. Both tests are necessary to prove that a proper seat is being obtained.

Excessive clearance between valve stems and guides will cause improper seating and burned valves. When there is too much clearance between intake valve stems and guides, there is a tendency to draw oil vapor through the guide on the suction stroke, causing excessive oil consumption, fouled spark plugs and poor low speed performance.

If the valve guides are to be replaced, the old guides should be pressed out with an Arbor Press and new guides pressed in. The intake guide should be so positioned that it will extend 1/64″ above the guide boss.

This is to allow the valve seal washer to be properly seated. After the new guides have been pressed into the bosses, they must be sized with a hand reamer to between .3115 and .3125. Although the inside diameter of both valve guides are the same, the stem clearance of the exhaust valve is different than that of the stem clearance of the intake valve. Due to the fact that the diameter of the exhaust valve stem and the intake valve stem are as follows:

NOTE:  Valve guide reamer Part No. 111275

Exhaust valve stem diameter .3110 to .3093   Clearance .0032 to .0015

Intake Valve stem diameter .3110 to .3103      Clearance .0022 to .0005

NOTE:  It is essential that the valve seats be refaced after new guides are installed.

The intake valve only utilizes a valve stem seal set, which consists of a neoprene gasket, a Teflon lip seal and a hold-down spring. See figure 154. Never attempt to re-use the above mentioned seals.

Place the flat neoprene gasket over the valve stem on the top of the valve guide.

Cushman Truckster Haulster M109 Motor Intake Valve

With the Teflon lip seal thoroughly oiled, position the seal over the valve stem with the flat side toward the cylinder. Extreme caution must be exercised when installing the lip seal over the valve stem to avoid andy damage to the seal by the valve stem grooves. A plastic installer is provided for seal protection.

Place the hold-down spring on the lip seal assembly, being sure the spring seats properly on the sseal body. Install intake valve spring, retainer and keepers.

It is possible to install these seals without removing the cylinder from the engine. Remove the spark plug and in its place install an air plug valve holder to which an air line can be attached.

The air pressure in the cylinder will hold the valve tight against its seat, making it possible to remove the valve spring using a lever type valve spring compressor, without losing the valves in the cylinder.

Lever type valve spring compressosrs and air plug valve holders are available through automotive suppliers.

When new rings are installed without reboring cylinder the glazed cylinder walls should be slightly dulle, but without increasing the bore diameter. This is done with a “glaze-buster” or with a hone equipped with the finest grade of stones.

Using an inside micrometer, check the cylinder for a taper or out of round condition, a cylinder with more than .005 out of round should be rebored, and proper oversize piston and rings used. Following are the dimensions that the cylinder should be bored for a given oversize:

Oversize                         Cylinder Diameter

.020                              3.5200-3.5210

.030                               3.5300-3.5310

Honing the cylinder after reboring is necessary to remove machine marks left by the boring tool. Approximately .001 to .0015 of metal should be removed from the cylinder bore with the hone, using a 150 grit stone.

This will leave a 25 to 35 RMS micro inch finish to the surface of the cylinder. Allowances must be made for the honing operation when the cylinder is bored, so that after honing, the cylinder will be the correct size. The cyinder bore should then be scrubbed, using a stiff bristle brush, warm water and soap suds, to loosen any metal particles left by the honing operation. Wash with clean water, and dry thoroughly to prevent any rust from forming.

If through continued use, the spark plug hole in the cylinder becomes damaged, or the threads stripped, it is possible to repair the damaged threads by installing a Heli-Coil.

We recommend an AC-C85 spark plug for use with a Heli-Coil. This is a gasketed plug; under no circumstances should a tapered seat plug be used with a Heli-Coil, as the tapered seat in the cylinder is removed when the Heli-Coil is installed.

Cushman Motors does not offer the Heli-Coil repair kit, as it is generally available through automotive suppliers.

Fit a new “O” ring around the outside diameter of the oil return tube and push it down until it bottoms against the lip. Install the oil return tube through the ridge of the cylinder and up through the fins. With a new gasket in position on the cylinder and a new “O” ring fitted to the oil drain block, secure drain block to cylinder with the proper screws and at the same time, position oil drain tube into oil drain block.

Thoroughly lubricate the piston rings on the piston and install the ring compressor. Install the cylinder gasket. Slide the piston into the cylinder until all three rings have entered the cylinder bore, See figure 16.

Remove the ring compressor. Install the cylinder retaining lock nuts with flat washers and tighten to the proper torque. Check the specification section of this manual for proper torque values. Install the cam followers and push rod tubes. Use only new “O” rings, and be certain they are in position before making installation fo the tubes. Install new “O” rings on each end of the oil supply tube. Make certain that the oil supply tube hole in the crankcase is free of obstructions and does not contain an old “O” ring. Insert the oil supply tube through the hole in the valve cover base and into the supply hole of the crankcase. Position the oil supply tube housing retainer and secure with the proper screw.

Cushman Truckster Haulster M109 Motor Overhaul

Cushman Truckster Haulster M109 Motor Rocker Arm Assembly

Install the push rods with the cup ends up. Assemble the rocker arm assembly to the cylinder and install the mounting hardware in the reverse manner of which it was removed. See figure 17. The ball end of the rocker arm must fit into the cup of the push rod. Do not install the valve covers at this time.

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M109 Engine Crankcase & Crankshaft Preparation for Assembly

Reassembly Procedure

Before proceeding with the various steps in the following paragraphs, it will be necessary to thoroughly clean all parts. Any parts requiring special care or cleaning will be covered in their respective paragraphs.

Crankcase preparation

The mating surfaces of both crankcase halves must be thoroughly cleaned to insure proper sealing upon reassembly. Use lacquer thinner or some suitable solvent for removing the old sealer. NEVER use a scraper or any tool which will mar the surfaces. This also applies to places where gaskets are used, such as oil pressure valve assembly, oil pump cover, etc., See figure 4.

Cushman Truckster Haulster M109 Engine Crankcase Crankshaft AssemblyUsed Parts

Crankshaft Preparation

After the crankshaft has been thoroughly cleaned, the crank throws should be measured with a micrometer to detect any undersize or out-of-round condition. If the bearing surfaces are undersize or out-of-round in excess of .001, they should be reground. The following are the dimensions that the crankshaft should be ground for a given undersize:

Grind to                             Main Journals                          Crank Pin Journals

Std.                                     1.9985-1.9990                               1.7485-1.7490

.015 U.S.                            1.9840-1.9835                               1.7340-1.7335

.030 U.S.                          1.9690-1.9685                                1.7190-1.7185

Inspect surface of the gear spacer that faces the crankshaft main bearing for any mars or roughness. Replace if necessary. The crankshaft timing gear should also be replaced for the same reason. If it is necessary to replace either the gear spacer or the timing gear an automotive type gear puller is necessary.

Never re-use a gear spacer if it has been marred in any way when being removed by a puller. When installing a gear spacer, the inside bevel must face crank to clear crank radius. To install the timing gear, heat gear to 400° F. by submerging in hot oil or heating with a torch. Caution must be exercised when using a torch so that 400 ° is not exceeded, otherwise, loss of temper from the gear may result. When gear is properly heated it may then be easily fitted to the crankshaft.

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M109 Crankcase Assembly Cushman Truckster / Haulster

Crankcase Assembly

Install main bearings in both halves of the crankcase as illustrated in Figure 5.

Crankcase assembly M109 Engine Cushman Truckster Haulster Used Cushman Parts

Lubricate both the crankshaft and camshaft bearing surfaces on both halves of the crankcase. Place the crankshaft and camshaft assemblies in position in one half o fhte crankcase. Be sure the timing marks on the crank gear and cam gear line up. rotate the two assemblies and double check the timing marks; this will also eliminate the possibility of any bind in either the crankshaft or camshaft assemblies. See figure 6

Crankcase crankshaft assemblies Cushman Truckster Haulster Used Parts

The two crankshaft halves are now ready to be rejoined. Minnesota Mining Sealer No. EC-1022 or equivalent is recommended. Place a bead of sealer approximately 1/8″ wide on one half of the crankcase. Special care must be taken that none of this sealer is placed into the oil channels. See figures 6 and 7.  A sealer bead which is no wider than 1/8″ will not be forced into the oil channels after the crankcase halves have been bolted tightly. Install the remaining half of the crankcase, and install the aligning pins. Install the crankcase retaining screws and tighten to the recommended torque. Check specifications for proper torque values.

Crankcase Assembly Cushman truckster Haulster Used Cushman Parts

After the crankcase sealer has been applied, the two crankcase halves should be assembled as quickly as possible, before the sealer dries sufficiently to lose its adhering qualities.

Crankcase assembly Cushman Truckster Haulster Used Parts

Using oil seal protector No. 112013, and oil seal driver No. 160360, install the camshaft breather oil seal. The seal should be driven in until it bottoms in the crankcase. See figure 8.

Using oil seal protector No. 112014 and oil seal driver No. 112011, install the main bearing oil seal on the driveout end of the crankshaft. See figure 9.

The seal must be driven in until the driver bottoms against the crankcase.

Using seal protector No. 112012, and seal driver No. 112017, install the main bearing oil seal on the flywheel side of the engine. The seal should be driven into the crankcase until the driver has reached the limit of its travel. See figure 10.

Crankcase assembly Cushman Truckster Haulster Used Cushman Parts

Crankcase assembly Cushman Truckster Haulster Used Parts

Crankcase assembly M109 Cushman truckster Haulster Used Parts

After installation of these oil seals the assembly should be rotated several times to be sure that there is no bind due to a cocked or improperly installed oil seal.

Coat the edge of the timing gear expansion plug with Permatex or crankcase sealer and install into the crankcase. See figure 11.

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