4
45612751_ed1
Needle Bearing Inserting Tool for Planet Gears
Shoulder to
Regulate Depth
Shoulder Diameter
Assembled Planet Gear
Gear Length – Bearing Length
2
Pilot to Fit I.D. of Bearing.
Length of Pilot to be
Approximately 1/8”
Less than Length of
Bearing
15°
Shoulder Length =
(Dwg. TPC488)
Assembly of the Shutoff Valve (for 6WT or 6WRT)
1. Using a wooden dowel, push the Shutoff Valve Stop (25) to the
bottom of the Shutoff Valve opening.
2. Install the Regulator Body Seal (32) in the groove near the
bushing inside the Shutoff Valve opening.
NOTICE
Make certain the Shutoff Valve Spring (26) seats in the Shutoff
Valve (24) recess.
3. Insert the Shutoff Valve Spring and the Shutoff Valve into the
Motor Housing (1).
4. Screw the Regulator Body (27) into the Housing and tighten it to
12 to 15 ft-lb (16 to 20 Nm) torque.
Assembly of the Reverse Valve (for 6WRS or 6WRT)
1. For 6WRS, install the Reverse Valve Bushing Seal (3A).
2. Insert the Reverse Valve Lock Pin (21) into the hole in the side of
the Reverse Valve (19).
3. Slip the Reverse Valve Spring (23) into the end of the Reverse
Valve opposite the Reverse Valve knob.
NOTICE
If the Reverse Valve comes out of the Housing, the Lock Pin did not
enter the L-shaped slot.
4. Holding the Reverse Valve with the Lock Pin upward, align the
L-shaped slot inside the reverse valve bushing with the Lock Pin.
Slide the Reverse Valve into the bushing until the Reverse Valve
Spring is partially compressed. Rotate the assembled Housing
and Valve one-half turn (180°) and tap the Housing opposite the
Lock Pin with a plastic hammer until the Lock Pin drops into the
L-shaped slot. Slowly release the Reverse Valve.
5. Install the Lock Pin Retainer (20) and Retainer Setscrew (22) in the
end of the Reverse Valve. The Setscrew must not protrude from
the Reverse Valve.
6. Operate the Reverse Valve to make certain it functions properly.
Assembly of the Motor and Throttle
1. If the Throttle Plunger Bushing (2) was removed, proceed as
follows:
a. Insert the Throttle Plunger Bushing into the Motor Housing (1)
to a depth approximately one-half the length of the Bushing.
b. Put a few drops of Permabond®* sealant in the counterbore
surrounding the outside diameter of the Bushing.
c. Rotate the Bushing approximately 180° to make certain the
sealant makes complete contact around the outside of the
Bushing.
d. Push the Bushing into the Housing until it bottoms against the
shoulder inside the Housing.
e. Allow the sealant to cure for eight hours at room temperature.
2. Carefully grasp the flats on the Motor Housing (1) in leather-
covered or copper-covered vise jaws, inlet end facing upward.
3. If the Throttle Valve Seat (8) and Throttle Valve Seat Support (9)
were removed, use a flat-faced rod 1/2” (12.7 mm) in diameter
by 3” (76 mm) long to push the Seat Support into the Motor
Housing until it seats. Use the same rod to push the Valve Seat
into the Housing until it seats against the Seat Support.
4. Install the Throttle Plunger Seal (7) in the groove of the Throttle
Plunger (6).
5. Insert the Throttle Plunger into the Plunger Bushing and rotate
the Plunger until the hole in the Plunger aligns dead center with
the hole in the Throttle Valve Seat.
6. Using needle nose pliers to hold the short-stem end of the
Throttle Valve (10), install the Valve inserting the long stem end
through the hole in the Throttle Valve Seat and Throttle Plunger.
7. After folding the Muffler Element (15) lengthwise, and with the
fold trailing, install the Element by wrapping it horseshoe fashion
around the inside of the Rear Muffler (14) covering all exhaust
holes.
8. Install the Exhaust Deflector Seal (13) into the groove on the front
end of the Rear Muffler.
9. Install the Silencer Seal Ring (12) over the hub of the Motor
Housing approximately halfway down the hub.
NOTICE
Tabs on the Rear Muffler match notches on the Motor Housing. Do
not force the Muffler into place.
10. Install the Rear Muffler over the hub of the Motor Housing,
aligning the wide tab on the Rear Muffler with the Throttle
Plunger hole in the Motor Housing.
11. Insert the Air Strainer Screen (18), closed end first, inside the Inlet
Bushing (17).
12. Insert the Throttle Valve Spring (11), large coil end first, into the
Inlet Bushing making sure it contacts the Air Strainer Screen.
13. Install the Inlet Bushing Spacer (16) in the large hole in the Rear
Muffler.
14. Thread the Inlet Bushing into the Motor Housing, making certain
the Throttle Valve Spring encircles the short-stem end of the Throttle
Valve. Tighten the Inlet Bushing to a minimum 26 ft-lb (35 Nm)
torque. The Inlet Bushing must securely clamp the Rear Muffler.
15. Note that the Throttle Lever pinhole in the Rear Muffler is larger at
one end than the other. Install the Throttle Lever (4), pressing the
Throttle Lever Pin (5) into the large end of the pinhole.
16. If the Rear Rotor Bearing (35) was removed, use a sleeve that
contacts the outer ring of the Rear Rotor Bearing, press the Rear
Rotor Bearing into the Rear End Plate (36).
NOTICE
The Rotor (37) must spin freely while holding the Rear End Plate.
17. Place the Rear End Plate, bearing end trailing, on the threaded hub
of the Rotor. Insert a 0.001” feeler gauge or shim between the face
of the Rotor and End Plate. Place the Bearing Thrust Washer (34A)
on the threaded hub of the Rotor. Thread the Rear Rotor Bearing
Retaining Nut (34) onto the hub of the Rotor and tighten it until
the feeler gauge has a slight drag during removal.
* Registered trademark of Permabond International
