M3X10
103
147
149
151
099
M3X12
M3X10
147
MASTER
302
103
M3X10
097
096
101
M3X12
46 CUT THIS
AWAY
057
115
057
M3X8 Self
Tapping
M3X8 Self
Tapping
M3X6
098
101
bent here to fit
Step 2 Engine/Clutch Assembly
Slide the cooling fan (2002-115 Bag #1 for 30-size and 2002-097 Bag #2 for 46-size) onto the engine crankshaft. Then
slide the starter pulley (2002-149 Bag #4) on top of the fan. Add the engine nut and tighten it, but do not use any
Locktite. Install the centrifugal clutch (2002-147 Bag #4) to the pulley with two M3x10 bolts. Put the ball bearing
(2002-103 Bag #4) in the center of the clutch.
For 30-size engine: Install the engine to the engine mount (2002-099 bag #2) using four M3x12 bolts. Take the engine
assembly and slide it into the side frames from the top side. Use four M3x10 bolts and four washers to secure the
engine mount to the side frames. Do not tighten the four bolts completely. The position will be adjusted later. Drop
the fan shroud over the fan and between the lower frames. Use two M3x8 Philip head self-tapping screws to secure the
starter belt retaining clips (2002-057 bag #8) and the fan shroud to the side frames. The front end of the fan shroud is
secured by a M3x8 Philip head screw on each side of the frames. Now, hang the engine starting belt (2002-109 Bag
#4) around the fan shroud and secure in the starter belt retaining clips. It may be necessary to slightly squeeze the clips
in order to get a tight enough grip on the belt.
For 46-size engine: Install the engine to the engine mount (2002-101 Bag #2) using four M3x12 bolts. Take the
engine assembly and slide it into the side frames from the top side. Use six M3x12 bolts and six washers to secure the
engine mount to the side frames. Do not tighten the four bolts completely. The position will be adjusted later. The fan
shroud for the 46-size engine is different from the 30-size. The 46-size shroud (2002-107 bag #2) comes in two pieces.
Screw the two pieces together using two M3x8 Philip self-tapping screws. Add the fan bracket (2002-098 Bag #2 )
between the rear of the fan shroud and the engine mount and adjust the fan to proper height. The bottom of the fan
should be flush with the bottom of the shroud. Add the two starting belt retainer clips (2002-057 Bag #8) on the fan
shroud using two M3x8 Phillips screws and two washers. Now hang the engine starting belt (2002-109 Bag #4)
around the fan shroud and secure the belt in the clips.
The Pro Master has the addition of a top start system. This system is assembled and installed as a complete unit.! Do
not use any ABC engine for shaft start system. Start by sanding the inside of the clutch bell (2002-303 BAG #4M) with
220 grit sandpaper to aid the bond when installing the clutch lining. Thoroughly clean with solvent. Trim the liner so
it fits snugly in the bell. Remove and reinstall using JB weld epoxy or slow CA to hold the liner in place. Press the
4x9x4 ball bearing (2002-103 BAG #4M) into the inside of the clutch bell. Lightly grease the start shaft (2002-306
BAG #4M) and insert into the clutch bell from the bottom. Take the double bearing block (2002-307 BAG #4M) and
slip over the pinion shaft. It is advisable to use a little Locktite on the pinion shaft where it makes contact with the ball
bearing. Clean off the end of the start shaft and slide the one way start adapter (2002-304 Bag #4M) in place. Install the
set-screws that hold the adapter in place. Take note that one of the set-screws must seat on the flat on the start shaft and
Locktite must be used.
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