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VIN Info - What Model Do I Have
Engine Assembly Part 1 - Large Frame
Start with the Flywheel side of the engine case
Using the torch Heat up the case (for about a minute or two at the
Selector Rod Bearing
DON'T BE SCARED YOU WONT MESS IT UP
Apply a thin layer of Grease to the
Selector Rod Bearing
Using the
Punch for the Flyside Seal and Bearing
gently tap the bearing in (if you heated the case up long enough it should just fall in)
Next install the
Flyside Bearing
into the case on this Model it is a two part Bearing (one half goes into the case and the other on the
Crankshaft
Apply a thin layer of Grease
Heat up the Case
Use the
Punch for the Flyside Seal and Bearing
Gently Tap it in
Now Install the NEW
Kick Start Buffer
ALWAYS Replace these
Remember there are TWO of them
The Best way to install them is to apply a thin layer of Grease to each side
Use a Flat Head Screwdriver the guide them all the way in
Now flip the case over and install a new O-ring into the
Kick Start Quadrant
Opening
It comes in the
Gasket Set
Get the
Kick Start Quadrant
and
Spring
ready
Inspect the
Kick Start Quadrant
for any damage at the splines where the
Kick Start Lever
attaches.
It is a good idea to test fit the lever before you install it, this could save you a headache later
Also inspect the teeth
Also inspect the other side to make sure there are no dents dings or other defects
Apply a thin layer of Grease
Slide it in (It should Slide in EASY)
If there is any resistance it may be Bent in which case REPLACE it
NOTE: This hole accepts the tab on the
Spring
This is the Tab
Install the
Spring
Now Hold the
Kick Start Quadrant
all the way to you right and twist the spring to the left until the tab on the top fits into the Slot on the
Kick Start Quadrant
This is what it should look like
Get your
Engine Stand
out
Put the other side of the Engine Case into the Stand
Install the
Oil Sling
It can only go in one way
Now the
Cush Drive
Push the
Spindle
all the way out and slide the Cush into place
Push the
Spindle
slightly in just enough to hold it up
You still have to install the
Needle Bearings
Begin by liberally applying Grease to the Race on the
Spindle
Depending on your model you should have either 21 or 24 of these
Grease your finger (so you will be able to pick them up easier)
Start to put them in
It may take you a few tries just stick with it
Make sure you keen an eye out it you drop one
If you do drop any clean them off all that grease will make EVERYTHING stick to them (bearings + dirt = bad)
Once they are all in push the
Spindle
all the way in
Spin the motor around
Install the
Lock Washer
NOTE the tap on the washer
It lines up with a slot on the
Spindle
Next install the Nut (13mm)
Now bend the tabs over the nut to lock it on place
This is what it should look like
Now the
Rear Hub Bearing
Heat the Case
Grease the
Rear Hub Bearing
Slide it in
If you need to you can use the old one to tap it in but usually these slid right in by hand
Install the Circlip
Now install the
Drive Shaft
Slide it in as far as you can by hand
Use the
Crank Installer
tool
Slide the sleeve over the tool
Screw it onto the
Drive Shaft
and tighten the nut while holding the tool still
Now install
4TH Gear
3RD
2ND
And Finally
1ST
Now install the
Shoulder Washer
(when you rebuilt the gear stack you would have decided the correct size)
Now install the circlip
Now install the
Main Bearing
on the Clutch Side
First a little Grease
Heat the Case
Heat it some more
Place the
Main Bearing
evenly into the hole
Use the
Punch Tool for the Clutch Side
Tap it in
DON'T beat the crap out of it there is a circlip on the other side that you can break out of its recess (if you do this you ruin the case)
Tap it a little check to other side, Tap it a little check the other side, ect.....
Install the
Circlip
Moving on the
Crankshaft
Install the Crankshaft Wedge
Apply a thin layer of Grease
Grab the Inner part of the
Fly Side Bearing
Heat it up (NOT TOO MUCH)
Grab it with the Channel Locks
It should slide right on
If you need to you can use part of the
Crank Installer
to tap it on
Grease the outside of the
Clutch Side Seal
Put it in
If you need to you can use the
Punch Tool for the Clutch Side
to tap it in
Grease the clutch side of the
Crankshaft
(the shorter side)
Also Grease the Seal (this will help it
Crankshaft
slide in without popping the spring out of the Seal
Get the
Crankshaft
started
Use the
Crank Installer
with the proper tip
Screw it onto the
Crankshaft
Use a Rubber Band to keep the Connecting Rod from binding up on the Case half
Tighten the Nut while holding the tool
Install the Case Gasket form your NEW
Gasket Set
A little dab of Grease in a few spots will help it stay in place
Inspect the
Kick Star Gear
for worn teeth
If you have the motor apart I would REPLACE it
Grease the Cush Drive
INSTALL the
Kick Star Gear
with the teeth facing the Cush
On the other half of the case apply a dab if grease to hold the
Kick Start Spring
Install the
Kick Start Spring
(wide side down)
Put the
Kick Start Lever
on
You don't need to put the bolt in at this point
NOTE: This Dowel....................
................lines up with this hole
Grease
Grease
As you begin to put the halves together push down slightly on the
Kick Start Lever
to allow the
Kick Start Quadrant
to mesh with the
Kick Star Gear
Now tap it the rest of the way together with a rubber hammer
and here
Install all 12 of the
Engine Bolts
Each one has a
Flat Washer
,
Lock Washer
, and
Nut
in that order
Start in the middle making an x pattern and work your way around tightening them more each time the final torque setting should be
Don't forget the
Gear Cable Holder
It goes on the long case bolt that probably didn't come out when you took the motor apart
Spin the motor around and install the
Clutch Side Woodruff Key
Now install the Clutch Washer NOTE: it has a bevel on one side, this faces the
Crankshaft
Also NOTE: the slot for the
Clutch Side Woodruff Key
The Clutch also has a slot for the
Clutch Side Woodruff Key
Line them up and slide it on.
You may need to spin the CushDrive with a screwdriver to get the teeth to mesh with the clutch teeth.
Install the
Clutch Tab Washer
Hand tighten the
Clutch Nut
Put on of the
Clutch Cover Bolts
in
Install the
Clutch Holding Tool
Clutch Nut Tool
Tighten the nut
Pull the
Clutch Holding Tool
and the Bolt
Bend one of the tabs from the
Clutch Tab Washer
into the
Clutch Nut
to lock it in place
Install the
Pressure Plate
Start it on the bottom
Use a Screwdriver to push the
Retaining Clip
down and it will slide in
Now install the
Clutch Cover
Install the Three
Clutch Cover
bolts
Each should have a
Flat Washer
,
Lock Washer
, and
Bolt
Now for the
Piston and Cylinder
Install the
Cylinder Base Gasket
Install the
Small End Bearing
NOTE: The
Piston
has an arrow stamped on it that will face the Exhaust port or DOWN.
Put the Wrist pin through the piston then through the Small end Bearing
It should slide in easy with very little resistance (A little two stroke oil will help you alot put some on the pin before you start.
Install both Circlips to lock the Wrist pin in
Coat the inside of the Cylinder with a bit of 2 Stroke
Slightly pinch the Piston Rings (they fit into two grooves on the Piston) to allow the Cylinder to slide over
Once you get past the Rings slide it the rest of the way on.
Now you are ready for the
Head