WARNING! IF YOU HAVE DIRT OR DEBREE IN YOUR MOTOR YOU WILL NEED TO COMPLETLY DISASSEMBLE THE CASE AND CLEAN EVERYTHING
Now That You've Got everything apart it's time to put it all back together
Fist you need to do some work on the cylinder head (optional but recommended)
start by Remove the valve spring cotters using the valve
Now Remove the Following:
inner and outer valve springs
valve spring seat
Check that the valve moves smoothly in the guide.
Check the valve for bending, burning or abnormal wear.
replace the valve's if necessary.
Now Blow through the oil passage (stud bolt hole) in the cylinder head with compressed air. Install the valve spring seats. Install new stem seals. Lubricate the valve stem sliding surface with molybdenum oil solution. Insert the valve into the guide while turning it slowly to avoid damage to the stem seal.
Install the inner and outer valve springs with the tightly wound coils facing the combustion chamber. Install the spring retainer.
Now Install the valve spring cotters using the valve spring compressor.
Next Support the cylinder head so that the valve heads will not contact anything that cause damage. Tap the valve stems gently with two plastic hammers as shown to seat the cotters firmly. Install the spark plug.
Now You can install the rings on the piston
Now Place a clean shop towel over the crankcase to prevent the clip fromfalling into the crankcase. Apply molybdenum oil solution to the piston pin
outer surface. Apply engine oil to the piston pin hole and connecting rod inner surface. Install the piston with the ‘‘IN’’ mark toward the intake side and insert the piston pin through the piston and connecting rod. Install new piston pin clips into the grooves in the piston pin hole. Make sure that the piston pin clips are seated securely. Do not align the piston pin clip end gap with the
Clean the gasket surfaces of the cylinder and crankcase thoroughly, being careful not to damage it, and being careful not to allow gasket material
into the crankcase. Blow through the oil passage (stud bolt hole) in the cylinder with compressed air. Apply liquid sealant to the crankcase mating areas as shown. Install the dowel pins and a new gasket.
Now Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Install the cylinder over the piston while compressing the piston rings with your fingers. Make sure that the cylinder touches the crankcase
Now its time to install the cylinder Head
Clean the mating surface of the cylinder and head Install the following:
two dowel pins new gasket
Now install the cylinder head, push rods and two dowel pins
Now Rotate the crankshaft clockwise using the recoil starter knob to align the T mark on the flywheel with the index mark on the rear crankcase cover. Make sure the piston is TDC (Top Dead Center) on the compression stroke. If not, rotate the crankshaft one full turn and match up the T mark again.
Next Apply engine oil to rocker arm followers and adjusting screw tips. Install the rocker arm holder onto the cylinder head. Install the following and tighten them in a crisscross pattern in 2 or 3 steps (our cap nuts with new sealing washers (apply engine oil) rocker arm holder bolt (apply engine oil) two cylinder head bolts.
(Cap Nuts 29 lbf-ft)
(Holder Bolt 22 lbf-ft)
(Rocker arm holder point 5.1 lbf-ft)
(Spark Plug 13 lbf-ft)
Next Install the following and tighten the bolts and nut:
engine hanger bracket
mounting rubbers (large I.D. side toward inside)
10 mm bolt (from front side) and nut
Upper engine hanger nut (frame side 40 lbf-ft)
Upper engine hanger bolt (engine side 24 lbf-ft)
Next Coat a new O-ring with engine oil and install it into
the groove in the carburetor insulator.
Install the insulator onto the cylinder head and
tighten the two bolts.
Install the following:
Next you'll need to adjust the valve's
now you can reinstall the head cover
NOW YOU DONE