User's Manual

12
ASSEMBLY
General Note: All torques specifi ed in this manual are
assembly torques and typically can be expected to fall off
after assembly is accomplished. Do not re-torque after
initial assembly torques fall unless instructed otherwise.
A compiled listing of torque specifi cations is presented at
the end of this manual.
INCH POUNDS TO FOOT POUNDS
To convert inch pounds to foot pounds of torque, divide
inch pounds by 12.
Example: 12 Inch Pounds = 1 Foot Pound
12
FOOT POUNDS TO INCH POUNDS
To convert foot pounds to inch pounds of torque, multiply
foot pounds by 12.
Example: 1 Foot Pound
x 12 = 12 Inch Pounds
CRANKCASE COVER
1. Position one of the two crankcase cover gaskets (27)
on either the crankcase or crankcase cover and install
the crankcase cover (29) using the position marks made
prior to disassembly. Tighten the four cap screws (28),
securing the crankcase cover to a torque of 101-111
inch pounds for crankcase cover or cover in a crossing
pattern after fi rst snugging all 4 screws.
2. Repeat this assembly for the second crankcase cover
(29).
CRANKCASE END COVER OR END COVER
ADAPTER
1. Install the end cover o-ring (30) on the crankcase end
cover.
2. Orient the crankcase end cover or end cover adapter to
the crankcase using the reference marks made during
disassembly. Carefully install the end cover or end
cover adapter in the crankcase making certain not to
damage the crankshaft bearing surface in it.
3. Install the four 13mm x 20mm end cover or end cover
adapter bolts or studs (31) and tighten to 195 to 212
inch pounds.
CYLINDER HEAD INLET CHECK VALVES
1. Locate one of the two inlet check valve seats (7) and
note that one side is fl at while the other has three
protruding tabs around the bolt hole. Position one of
the two inlet check valves (6) on the inlet check valve
seat (7) so that the three positioning and locating tabs
interlock with the corresponding tabs on the seat. When
properly fi tted together, the valve (6) should lay fl at
against the seat (7) and cover the slotted opening of
the seat.
2. Locate one of the two inlet check valve holders (5).
Place the holder (5) on the inlet check valve (6) making
certain that the three indentations around the bolt hole,
on the holder, interlock with the tabs on the inlet check
valve (5). When properly assembled the seat (7), valve
(6) and holder (5) should be parallel and interlocked.
3. Place the three components over one of the two
slotted inlet openings in the cylinder head making
certain that the bolt holes in the components and head
correspond.
4. Insert one of the two 10mm x 25mm bolts (3) through
a spacer sleeve (4). Using the bolt and sleeve, secure
the assembled seat (7), valve (6) and holder (5) in the
cylinder head. Tighten the bolt fi nger tight and check
that the seat (7), valve (6) and holder (5) are still
interlocked. This can be done by attempting to rotate
the holder (5) and noting that the valve and seat follow
and are locked together.
5. Torque the 10mm bolt to 101 to 111 inch pounds.
6. Repeat steps one through fi ve for the other inlet check
valve assembly.
DISCHARGE VALVES
1. Locate and place one of the two discharge valves
(12) on the valve body assembly with its bolt hole
corresponding with the threaded hole on the outside
edge of the valve body assembly. When correctly
placed, the discharge valve (12) will cover the two
discharge holes in the valve body assembly. Refer to
Figure 11.
DISCHARGE VALVE
HOLDER
DISCHARGE
VALVE BOLT
HOLE
GUIDE LUG
VALVE
BODY
ASSEMBLY
FIGURE 11 - DISCHARGE VALVE INSTALLATION
2. Locate one of the two discharge valve holders (11) and
install it over the discharge valve (12) so that the free
end of the discharge valve (12) is contained between
the two guide lugs on the sides of the holder. Refer to
Figure 11.
3. Insert one of the four 10mm x 25mm bolts (9) through
a spacer sleeve (10). Using the bolt and sleeve,
loosely secure one end of the discharge valve (12)
and holder (11) to the valve body assembly. Insert a
second 10mm x 25mm bolt (9) through a spacer sleeve
(10) and loosely secure the other end of the discharge
valve (12) and holder (11) to the valve body assembly.