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EP20-XXXXX-XXX-XXX (en)
PARTS LIST / CRANKCASE EP20-XXXXX-XXX-XXX
145
133
143
146
144
18 / 20
13
147
17
16
138
137
132
148
130
131
148
136
135
134
142
NOTE: DO NOT OVERTIGHTEN FASTENERS.
ASSEMBLY TORQUE REQUIREMENTS
(17) Screw, tighten to 50 - 60 ft lbs (6 - 7 Nm).
(131) Screws, 30 - 35 ft lbs (40 - 47 Nm).
(146) Screw, 25 - 30 ft lbs (35 - 40 Nm).
Figure 15
Remove internal snap ring (136) and the wrist pin (135).
Remove the piston rod (134) and rider band (133).
Journal Bearing (139) is press fitted in to the connecting
rod (140) from the factory. Remove the connecting rod
(140) along with Journal (139).
All bearing races are press fitted. However lower bearing
(111) is separable between its Inner and outer race.
Remove Housing cap (102), crank shaft assembly (118),
Bearing housing (121) from Crankcase Housing (101).
Ensure bearing housing (121) oriented in the same direc-
tion in order to remove from the Crankcase housing (101).
CRANKCASE ASSEMBLY
Reassemble parts in reverse order from the in a sequence
in which they were are removed.
Clean and inspect all parts. Replace worn or damaged
parts with new parts as required.
If cam (124) needs to be replaced. It should be serviced
prior to installing the Crankshaft (118) into the housing
(101).
If wrist pin journal (139) needs to be replaced. It should
be serviced prior to installing the connecting rod (140).
To replace Journal (139), arbor press need to be use to
press new Journal while simultaneously pushing out the
old journal.
Install lower shaft seal (112) into Crankcase housing (101).
Ensure O-ring (103) is installed onto housing cap.
Lower Crankshaft assembly vertically inside Crankcase
housing (101) and allow inner race of lower bearing to
gently engage with outer race. Secure housing cap to
housing (101) with socket head screws (104).
Install lower cap (114) and secure with socket head screws
(115). Ensure O-rings (116 and 117) are installed onto the
lower cap (114).
Assemble each of the connecting rods (140) to bearing
housings (121) securing with 12 point ferry cap head
screws (141).
Install wrist pin (135) to connect piston (134) to con-
necting rod (140). Ensure slotted side of wrist pin (135) is
facing down and engages with dowel pin (137) to prevent
rotation.
Install retaining ring (136) to hold wrist pin (135) in place.
Install rider band (133) onto the piston (134).
Install cylinder (130) over piston (134) and secure to hous-
ing (101) with hex head screws (131). Ensure O-ring (132)
is installed onto the cylinder (130).
Install Piston wear ring (142), Piston seal (143), vent bush-
ing (144), Bellows (15) and retaining ring (16) on to the air
cap (147) and secure with socket head screws (17).
Install air cap (147) to the cylinder (130) and secure with
socket head screws (131). Ensure O-ring (145) is installed
onto the air cap (147).
NOTE
: Connecting rod housing (121) need to be oriented in
the same direction to fit in the Crankcase housing (101).
