ENGINE
3.
When replacing reeds, install smooth edge down
centered over openings in crankcase (see Figure
and use Loctite 271 on threads of screws.
Torque per specifications.
2. Several piston and ring combinations have been
used. Pistons have been plated and unplated.
Pistons have used two keystone rings and others
used one semi-keystone and one standard ring.
The pistons made for one type of ring will not accept
the other type. However, any piston and ring
assembly can be used in any cylinder.
78),
Install keystone piston ring in top groove with bevel
facing up. The square bottom ring can be installed
either way. Note that there are pins in the ring
grooves. The open ends of the rings must line up
with the pins.
3.
4.
Assemble ball bearings to crankshaft and install
crankshaft.
Note: One side of the paper is sticky; remove
paper carefully while installing needle bearings.
There should be 32 needle bearings on the lower
connecting rod. When reinstalling original needle
bearings, use a little #2 bearing grease to stick the
needles to the rod.
Figure 78
0720-020
Reassembly
Assemble the piston and connecting rod. Note the
piston has the letters EX and an arrow stamped into
the top. The arrow should point towards the exhaust
port. The connecting rod can be assembled to the
piston two ways. As the rod is symmetrical, either way
is acceptable. We will phase in match marks on the
rod and rod caps. Some of the very early engines may
not have these marks. Use a permanent marker if
match marks are not visible.
5. Install rod cap (A). Ensure that mating marks are
aligned. Clean old screws (B) thoroughly and
apply Loctite 271. (See Figure 80.) Torque to
specifications.
A
1.
Secure wrist pin using snap ring. Make sure
square edge of snap ring faces out and ring
opening faces up (toward top of piston). (See
Figure 79.)
B
Figure 80
0893-023
6.
Oil parts. Use ring compressor to install piston
with EX mark and arrow pointing towards the
exhaust port. Install seals before fully seating the
crankshaft. Install new oil seals. Clean seal bore
with alcohol before installing seals. Oil in the bore
may cause the seal to blow out when the engine
is hot.
Figure 79
Note: Ring Compressor P/N TOR 4089 (order
from OTC, see page 5 for address and phone).
0893-028
44
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