15
STEP
36:
Reinstall the carburetor with a new o-ring, header,
a
NEW glow plug, and engine mount. Use a new
header
gasket when reinstalling the header on
the engine. Reinstall the engine in the truck in the
reverse order of removal. Don’t forget to reconnect
the yellow grounding wire to the engine mount.
The rebuilt engine must now be broken in.
STEP
31:
Reinstall the backplate and a new backplate gasket
with the 3x8mm cap-head machine screws. Tighten
the screws in small
increments in a criss-cross
pattern until all the screws are tight.
STEP
32:
Install the appropriate size ball bearing into one
side of the clutch bell gear. The Nitro Sport comes
stock
with an
18-tooth
clutch
bell gear
that
requires
5x11mm ball bearings.
STEP
33:
Turn the gear over and install the other ball bearing.
STEP
34:
Install the split-beveled cone onto the crankshaft.
Next, install the flywheel. Install the clutch adapter
nut with a 10mm deep
socket. Grip the flywheel
with pliers while
tightening the adapter
nut.
STEP
35:
Install the clutch shoes
exactly as shown in the
drawing (leading edge
engagement). Next,
install a 5x8mm PTFE
washer followed by the
clutch bell gear (with
bearings installed). Install
the remaining 5x8mm
PTFE washer followed by
the E-clip (see step 14).
STEP
25:
To assemble the connecting rod and piston, place
a drop of castor oil in the top end of the connecting
rod. Insert the wrist pin through
the piston and the
top of the connecting rod. Secure the wrist pin with
the G-clip. Make sure the G-clip fits securely into
the groove machined in the piston. Be careful not to
scratch the sides of the piston.
STEP
26:
Reinstall the crankshaft into the engine and make
sure that it spins freely. Insert the connecting
rod and piston assembly through the top of the
crankcase. The G-clip should face the carburetor.
Put a drop of castor or after-run oil in the bottom
end of the connecting rod. Use your fingers to
gently push the end of the connecting rod over the
crankshaft journal.
STEP
27:
Place another
drop of oil
on the connecting
rod
bushing.
Rotate
the
crankshaft
several
times
to
distribute the oil.
STEP
28:
Insert the sleeve into the top of the crankcase.
Rotate the sleeve so that the notch in the sleeve will
line up with the pin in the crankcase. Holding the
engine upside down will make it easier for the sleeve
to go over the piston.
STEP
29:
Install
new
head
gaskets
on
the
head.
Use
one
thick
and one thin gasket. Reinstall the head using the
3x12mm
cap-head
machine
screws.
Tighten
the
screws in small increments, in a criss-cross pattern,
until all the screws are tight.
STEP
30:
Reinstall the starter shaft. Align the notch in the
starter shaft with the crankshaft journal pin (arrow).