Install Breather Cover and Inner Baf
fl
es
Breather Cover Torque Sequence
1
2
3
4
1. Be sure sealing surfaces of crankcase and breather
cover are clean of old gasket material. Do not scrape
surfaces as this could result in leakage.
2. Check to make sure there are no nicks or burrs on
sealing surfaces.
3. Install breather reed and breather reed retainer onto
crankcase and secure with screw. Hold assembly in
line when tightening. Torque screw to 3.9 N·m
(35 in. lb.).
4. Insert
breather
fi
lter into position in crankcase. Make
sure no
fi
lter strands are on sealing surface.
5. Install new breather gasket.
6. Carefully position breather cover on crankcase.
Install
fi
rst two screws at positions shown and
fi
nger
tighten at this time.
7. Install inner baf
fl
es using two remaining screws and
fi
nger tighten. Do not torque screws at this time; they
will be tightened after blower housing and outer
baf
fl
es are installed.
Install Blower Housing and Outer Baf
fl
es
NOTE: Do not completely tighten screws until all items
are installed to allow shifting for hole alignment.
1. Connect plug to key switch in blower housing (if
equipped).
2. Slide blower housing into position over front edge of
inner baf
fl
es. Start a few screws to hold it in place.
Lift debris shield up above mounting surface, as
blower housing is installed. Make sure ground lead,
fuel solenoid lead, and oil pressure switch leads are
accessible and in proper position.
3. Position outer baf
fl
es and loosely start mounting
screws. M6 screws go into back of cylinders. Short
M5 screws go into lower holes closest to blower
housing. Short screw on oil
fi
lter side is also used to
mount wire harness clip. Be sure any wire harnesses
or leads are routed out through proper offsets or
notches, so they will not be pinched between blower
housing and baf
fl
es.
4. If
recti
fi
er-regulator was not removed, attach ground
wire or metal grounding bracket for recti
fi
er-
regulator, using silver colored screw and washer, to
lower blower housing hole.
5. Tighten all shrouding fasteners. Torque blower
housing screws to 6.2 N·m (55 in. lb.) in a new hole,
or to 4.0 N·m (35 in. lb.) in a used hole. Torque
shorter M5 side baf
fl
e screws to 4.0 N·m (35 in. lb.).
Torque upper M5 side baf
fl
e screws (into cylinder
head) to 6.2 N·m (55 in. lb.) in a new hole, or to 4.0
N·m (35 in. lb.) in a used hole. Torque two rear M6
baf
fl
e mounting screws to 10.7 N·m (95 in. lb.) in a
new hole, or to 7.3 N·m (65 in. lb.) in a used hole.
6. If an overlapping style
fl
ywheel screen is used,
attach it to supports or
fl
ywheel. For a metal
fl
ywheel
screen, apply Loctite
®
242
®
to screw threads (M6)
and torque to 9.9 N·m (88 in. lb.). Torque plastic
screen mounting screws (M4) to 2.2 N·m (20 in. lb.).
7. Torque breather cover screws to 11.3 N·m (100 in.
lb.) into new holes or 7.3 N·m (65 in. lb.) into used
holes in sequence shown. Note
fi
rst screw is torqued
a second time.
Reconnect Recti
fi
er-Regulator
1. Install
recti
fi
er-regulator in blower housing, if
removed previously, then connect recti
fi
er-regulator
ground lead with washer and silver screw through
eyelet as shown. If a grounding bracket is used,
secure with lower mounting screw and washer,
against outer side of recti
fi
er-regulator.
2. Install B+ terminal/lead into center position of
recti
fi
er-regulator plug and connect plug to recti
fi
er-
regulator.
Install Electric Starter Motor
NOTE: If engine uses a side mount muf
fl
er on starter
side, be sure to tie wires close to starter to avoid
contact with hot exhaust parts.
1. Install starter motor using two screws.
2. Torque screws to 15.3 N·m (135 in. lb.).
Reassembly
65
24 690 34 Rev. D
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