Engine Assembly Part 2

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Engine Assembly Part 2 - Large Frame

	Work In Progress - To Be Completed Soon
	Side the Head on with the Spark Plug hole facing up
	Use a Torque Wrench to tighten the Nuts You should have a Flat Washer, Lock Washer, and Nut in that order
	Tighten the nuts in an X Pattern The Torque should be 16 Foot-Pounds Start with 8 Foot-Pounds then slowly move up to 16 Foot-Pounds always moving an X pattern
	Now install the Spacer Nut
	Next install the Fly Wheel Side Oil Seal Apply some Grease to the outside and inside of the Seal
	Press it in by hand
	You can use part of the Crank Installer Tool to tap it the rest of the way flush to the way in
	Tape the end of the wires coming off the end of the Stator.
	This will make it easier to feed them through the hole
	Feed them up the hole until you can grab them on the other side
	Now position the Stator using the mark you made during disassembly (we will set the timing later)
	Screw the Stator in with the three Securing Screws

	Install the Fly Wheel Side Woodruff Key into the Crankshaft

	Put a little 2-Stroke oil on the Felt Pad (this will help extend the life of your points)
	Line up the Key way in the Flywheel with the one you just installed on the Crankshaft

	Install the Star Washer
	Start the Nut by hand
	Use the Fly Wheel Holding Tool

	Torque the nut to 45 Foot-Pounds
	Install the Rubber Fly Wheel Plug

	Now install the Rear Brake Axle
	Grease up the Axle
	Slide it in
	Before you get it all the way in put the Rear Brake Lever and Spring in

	Install the Cotter pin and bend it over to lock the Axle in
	Finally pull the Spring around the Rear Brake Lever
	Next install the Backing Plate You should have these Three O-rings in your Gasket Set
	The big one goes here
	The single one goes here
	And the double one goes here
	Now install the backing plate
	It requires three small screws

	Now install the Brake Shoes Start with a TINY bit of Grease on the pivot pins
	As well as the Axle NOTE: Brakes and Grease don't get along so use the slightest bit just enough to keep everything moving freely
	Put the Brake Spring on the Brake Shoes
	Start at the top
	Put the Front of the Bottom shoe in and use a Pry bar the leverage the back part in
	I will look like this
	Next install the Retaining Clips
	Start them with your finger
	Then squeeze them on with a pair of pliers
	It should look like this
	Now Grease the Read Hub Oil Seal
	Push it in with your fingers until it bottoms out
	It is a good idea to sand the Rear Hub a little bit before you install it
	Just make it not shiny

	Install the Rear Hub Washer
	Install the Rear Hub Nut
	If you have an Impact Driver use it to install this nut
	Install the Cotter Pin
	Bend the two ends over the nut
	Install the Hub Cover

	Spin the Motor around Install the