Category Archives: Engine Overhaul M109

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 … Continue reading

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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 … Continue reading

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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 … Continue reading

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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 … Continue reading

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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 … Continue reading

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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. Lubricate both the crankshaft and camshaft bearing surfaces on both halves of the crankcase. Place the crankshaft and camshaft assemblies in position in one … Continue reading

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Engine Overhaul M109 Cushman Truckster – Haulster

If the engine is equipped with a compression release, disconnect at actuating arm. Remove the screws securing the outer fan housing to the inner fan housing. If the engine is equipped with a kick starter, it is not necessary to … Continue reading

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