[Silly Little Cars] help 89 truckster

Mon Jul 29 04:49:01 PDT 2013

thanks again looks like you are way ahead of me in fixing your cushman.
When you do get time I would love to have the parts numbers
Many thanks again
Charles

On Sun, Jul 28, 2013 at 12:29 PM, Charley <clent at carolina.rr.com> wrote:

> **
> Charles,
>
> You should go to the manuals section of Sillylittlecars.com and download
> the service manual and it's supplement. They contain a lot of information
> that you are going to need to revive your Truckster that I wish I had while
> doing mine.
>
> It's getting difficult to find many parts for Trucksters. The motor parts,
> like gaskets, etc. are quite readily available from places like
> Directparts.com but you will likely run into problems locating things like
> gas tank caps, brake cylinders, brake shoes, brake master cylinders, etc.
> Fortunately, Cushman used many standard parts that are still readily
> available from the automotive and forklift industry. The only problem in
> finding them is that there seems to be no industry cross reference
> information to the Cushman part numbers. One member of the service team at
> my local ORiley store, with many years of experience, was able to help me
> by using his experience and good memory to find parts that matched my
> needs. The older parts guy at the forklift shop also has many years of
> experience and has helped me the same way. Cushman Trucksters are
> industrial vehicles, so they were originally serviced by shops that
> repaired industrial vehicles, such as forklifts. Cushman didn't make all of
> the parts they used. Most were sourced from the automotive industry.
> Cushman made the body and chassis parts, but sourced many of the other
> parts and then assembled the Trucksters from them.
>
> I was able to find the exact same brake master cylinder (new on the shelf)
> at a forklift repair shop for $31. This same master cylinder is used in
> several models of forklifts. It is currently selling on the internet for
> 2-3 times that price when you search for it as a Cushman part. The wheel
> cylinder rebuilding kits for my truckster are identical to early 1980s Ford
> F-100 pickup trucks. I bought them from ORiley Auto Parts store for about
> $5 each. Identical brake shoes came from the forklift shop for $10 each.
> The fuel filters (even the bypass filter) are readily available through
> ORiley Auto Parts and other auto parts stores. I will post the source and
> part numbers for the parts that I found this way, but it may take me a few
> days to get this list together, I had intended to do this for myself, but
> other priorities in my life have delayed me. I saved the box tabs with the
> brand and part numbers for each part that I bought, but just put them in an
> envelope. I guess it's now time to put the list together from them.
>
> A note about the brake systems used in these Trucksters: They aren't
> sealed systems like the newer automotive brake systems. The master cylinder
> has a vent in the cap that allows air/moisture to enter/exit from the
> reservoir. The brake fluid used in the Truckster brake system is alcohol
> based and the alcohol part of the fluid will absorb water vapor. When
> sufficient water has been absorbed it will begin rusting the steel parts of
> the brake system from the inside.
>
> The brake system in my Truckster was a complete rusted mess internally
> from sitting in a damp forest and absorbing moisture through the vent with
> every atmospheric pressure and temperature change that occurred for the 12
> plus years that it had been sitting there. Now that my brake system has
> been completely rebuilt, I've considered trying to find a more modern
> sealed system alternative for the master cylinder, but will likely just
> completely remove the brake fluid from the system and replace it with new
> fluid on an annual schedule.
>
> Charley
>
> ----- Original Message -----
> *From:* Charles Shearin <joecool1456 at gmail.com>
> *To:* Silly Little Email List<silly_little_cars at lists.sillylittlecars.com>
> *Sent:* Sunday, July 28, 2013 7:09 AM
> *Subject:* Re: [Silly Little Cars] help 89 truckster
>
>  thanks for the info think i can fix it from your email.
> can't thank you enough
> charles
>
>
> On Sat, Jul 27, 2013 at 6:54 PM, Charley <clent at carolina.rr.com> wrote:
>
>> **
>> Charles,
>>
>> You have a 22 hp OMC 2 cylinder engine (22 hp = spark plugs on top of
>> cylinders - the 18 hp version has the spark plugs on the lower side of the
>> cylinders). The cylinders are horizontally opposed (one out each side of
>> the crank case). There are 2 coils, one for each spark plug. Both spark
>> plugs fire at the same time since they are connected in series to the same
>> points, but the cylinder that's on the compression stroke is the only one
>> that lights (this is called a "lost spark ignition system" ).
>>
>> It appears as though you have the original mechanical fuel pump and the
>> bypass filter (necessary when using the original fuel pump) and it is quite
>> likely that this pump is bad. These original fuel pumps are hard to find
>> and expensive if you do find one. I switched to an electric fuel pump. The
>> pump itself costs $53 and it self regulates the pressure, so you can
>> eliminate the bypass fuel filter and just use a single inline filter
>> between the tank and the electric fuel pump. The hole where the mechanical
>> fuel pump was mounted needs to be plugged with a thick metal plate and
>> gasket if you switch to the electric fuel pump.
>>
>> I would first check the inline fuel filter nearest to the tank.
>> Disconnect the fuel line on the output of the filter to see if gas comes
>> out. If it does, put the line back on the filter and go to the fuel pump
>> and disconnect the line that goes from it to the bypass filter (the filter
>> with three connections). Turn the engine over and see if fuel comes out of
>> the fuel pump. If it does the pump is OK, so you can replace the fuel line
>> connection. Now remove the fuel line connection from the carburetor and
>> turn the engine over. If you get fuel coming out of the line, the
>> carburetor is your problem and it will need to be cleaned and possibly
>> re-built. If it is a Keihin carburetor, first look in the end of the
>> carburetor connection where the fuel line connects. The Keihin carburetors
>> have a tiny fuel filter screen on a tubular plastic frame that is inserted
>> into the fuel fitting of the carburetor. You will need a sharp knife to
>> catch the edge of it to remove it. Before rebuilding the carburetor, check
>> this screen to be sure that it is clean. If there is no screen or the
>> screen is clean the next possible problem is a stuck needle valve and/or
>> damaged float inside the carburetor. If you have to go inside the
>> carburetor, be prepared with replacement gaskets, a replacement float and
>> needle valve, and an accelerator pump diaphram to completely rebuild the
>> carburetor. You will need to run a cleaning wire through all of the
>> internal ports and use carburetor cleaner to remove all of the varnish and
>> dirt before reassembly. Carburetors are complicated. If you have never done
>> this before, find someone who has and let them do it.
>>
>> My 1987 Truckster had been sitting untouched in a forest for a bit over
>> 12 years and it needed everything that I described above, plus the removal,
>> derusting, and cleaning of the fuel tank and all new fuel lines, fuel
>> filter, and electric fuel pump and a new fuel tank cap before I could get
>> my truckster running. For the tank cleaning I bought a cleaning/relining
>> kit from KBS Coatings through Amazon. Although the cleaning and relining of
>> the tank was time consuming, it wasn't hard to do and it worked very well.
>>
>> Charley
>>
>> ----- Original Message -----
>> *From:* Charles Shearin <joecool1456 at gmail.com>
>> *To:* silly_little_cars at lists.sillylittlecars.com
>> *Sent:* Saturday, July 27, 2013 8:15 AM
>> *Subject:* [Silly Little Cars] help
>>
>>   just bought my 1989 cushman and can anyone tell me the size of the
>> engine?
>> attached are pics of the engine it is a one spark plug engine
>> Also cannot get gas from tank to carb
>> pic of one of the gas filters it has three lines to it, can I just remove
>> this filter in the pic and will it matter?
>>
>> ------------------------------
>>
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