10.1
Section 10
Reassembly
10
Section 10
Reassembly
General
NOTE
: Make sure the engine is assembled using all
specified torque values, tightening sequences,
and clearances. Failure to observe
specifications could cause severe engine wear
or damage. Always use new gaskets. Apply a
small amount of oil to the threads of critical
fasteners before assembly, unless a Sealant or
Loctite
®
is specified or preapplied.
Make sure all traces of any cleaner are removed before
the engine is assembled and placed into operation.
Even small amounts of these cleaners can quickly
break down the lubricating properties of engine oil.
Check the closure plate, crankcase, cylinder heads,
and valve covers to be certain that all of the old
gasket material has been removed. Use gasket
remover, lacquer thinner, or paint remover to remove
any remaining traces. Clean the surfaces with
isopropyl alcohol, acetone, lacquer thinner, or
electrical contact cleaner.
Typical Reassembly Sequence
The following sequence is suggested for complete
engine reassembly. This procedure assumes that all
components are new or have been reconditioned, and
all component subassembly work has been
completed. The sequence may vary to accommodate
options or special equipment. Detailed procedures
follow:
16. Install push rods and rocker arms.
17. Install valve covers.
18. Install spark plugs.
19. Install oil filter adapter.
20. Install intake manifold.
21. Install oil filter housing assembly.
22. Install backing shroud assembly.
23. Install stator, wiring harness, and rectifier-
regulator.
24. Install flywheel.
25. Install ignition modules.
26. Install outer cylinder baffles.
27. Install oil cooler.
28. Install cooling fan and grass screen.
29. Install electric starter.
30. Install valley baffles.
31. Install carburetor
32. Install governor lever.
33. Install control bracket and air cleaner assembly.
34. Install throttle and choke linkages.
35. Install Oil Sentry
™
switch (if equipped).
36. Install blower housing and cylinder shrouds.
37. Install control panel (if equipped).
38. Install muffler.
39. Install oil filter and add oil to crankcase.
40. Connect spark plug leads.
Install Flywheel End Oil Seal
1. Make sure that the seal bore of the crankcase is
clean and free of any nicks or burrs. See Figure
10-1.
Figure 10-1. Seal Bore of Crankcase.
1. Install flywheel end oil seal.
2. Install lifter feed chamber gaskets and cover.
3. Install flywheel end main bearing.
4. Install governor shafts, seal, and governor gear.
5. Install crankshaft.
6. Install connecting rods with pistons and rings.
7. Install camshaft.
8. Install closure plate main bearing and oil seal.
9. Install closure plate assembly.
10. Install oil pickup screen.
11. Install oil reservoir.
12. Check crankshaft end play.
13. Install breather assembly.
14. Install hydraulic lifters.
15. Assemble and install cylinder heads.
