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ENGINE REASSEMBLY
Page D-3
Engine Shop Rebuild and Parts Manual
Install New Crankshaft Bearing
(See Fig. D-6 “Crankshaft, Pistons and Balancer Shaft con’t” on page
D-11)
Press only against the inner race of the
bearing when installing it on the shaft.
A. If the bearing (ITEM 4) was removed from the crank-
shaft (ITEM 5), use a mechanical press to install a
new bearing. (DETAIL A)
Install New Crankshaft Seal
(See Fig. D-5 “Crankshaft, Pistons and Balancer Shaft” on page D-10)
A. Using a seal installation tool, install a new crankshaft
seal (ITEM 6) and new balancer shaft seal (ITEM 7)
into the crankcase. Lubricate the rubber inside diam-
eters of the seals with engine oil.
Install Crankshaft into Crankcase
(See Fig. D-6 “Crankshaft, Pistons and Balancer Shaft con’t” on page
D-11)
Be careful not to damage the seal while
installing crankshaft.
A. Insert the crankshaft, PTO end first, through the inte-
rior of the crankcase, into the bearing, and through
the seal. DO NOT DAMAGE THE SEAL. Seat the
shaft bearing in the bearing bore, and make sure that
the shaft rotates freely.
B. Lubricate the crankshaft journals and gear with
engine oil, use a “squirt” type oil can to fill the crank-
shaft oil passages with engine oil. (DETAIL A)
Install the Pistons in the Crankcase
(See Fig. D-3 “Pistons and Connecting Rods con’t” on page D-8)
(See Fig. D-5 “Crankshaft, Pistons and Balancer Shaft” on page D-10)
(See Fig. D-6 “Crankshaft, Pistons and Balancer Shaft con’t” on page
D-11)
It is critical that piston assemblies are
properly oriented and installed in their
original positions on the crankshaft.
A. Remove the cap (ITEM 9) from the PTO (clutch) side
connecting rod (ITEM 10). Apply a coat of assembly
lube to the rod and cap bearing surfaces, and lightly
oil the sides of the piston, rings, (ITEM 8) and cylin-
der bore. KEEP LUBRICANT OFF OF THE MATING
SURFACES OF THE ROD AND ROD CAP.
B. Make sure that the piston ring gaps are correctly
positioned on the piston. (DETAIL C)
C. Install a piston ring compressor on the piston, leaving
enough of the piston skirt protruding below the com-
pressor to start into the cylinder. (DETAIL B)
D. With the word “FAN“, on the connecting rod, oriented
toward the open side of the crankcase, and the
crankshaft at bottom dead center, insert the piston
into the PTO (clutch) side cylinder.
E. Reach into the crankcase and guide the rod onto the
crankshaft journal while lightly tapping the piston
head through the ring compressor and into the cylin-
der with a small wooden or rubber mallet.
F. Seat the rod on the crankshaft journal, and attach the
rod cap (ITEM 9).
1. Lubricate the wear surface of the cap with assem-
bly lube.
2. With the alignment notch on the cap facing out,
snap the cap onto the rod.
3. Install and tighten to specified torque two (2) bolts
(ITEM 11, 10mm socket).
G. Repeat steps A - F to install the second piston.
Install the Balancer Shaft
(See Fig. D-6 “Crankshaft, Pistons and Balancer Shaft con’t” on page
D-11)
The crankshaft and balancer shaft
gears must be aligned properly when
assembled in order to set engine valve timing.
A. Lubricate the balancer shaft gear with assembly lube.
B. Insert the keyway end of the balancer shaft into the
balancer shaft bearing in the crankcase. Position the
single dot on the crankshaft gear face between the
two dots on the balancer gear face before meshing
the gears and seating the balancer shaft in the bal-
ancer shaft bearing. (DETAIL C)
Set the Crankshaft and Balancer Shaft End-
play
(See Fig. D-7 “Crankshaft and Balancer Shaft Endplay” on page D-12)
A. Position the crankcase, with the open end up, on a
box or other surface that will leave the PTO (clutch)
end of the crankshaft free from any contact or pres-
sure.
B. Make sure the crankshaft and balancer shaft are
completely seated, and that their gear faces are per-
fectly flush.