Operating instructions
Table Of Contents
- 1 Introduction
- 2 General Description
- 3 Special Tools and Equipment
- 4 Disassembly
- 5 Cleaning, Repair and Replacement
- 6 Inspection
- Definitions
- Magnetic Particle Inspection
- Critical New Part Dimensions
- Fluorescent Particle Inspection
- Dimensional Inspection
- Protective Coatings
- Crankcase Inspection
- Crankshaft Inspection
- Camshaft Inspection
- Connecting Rod Inspection
- Gear Inspection
- Piston Inspection
- Cylinder Inspection
- Inspection Chart
- Crankcase Stud Heights
- Mag Particle Inspection Procedures
- Table of Limits
- Torque Specifications
- General Torques
- Table of Limits Chart
- 7 Assembly of Subassemblies
- 8 Final Assembly and Test
- 9 IO-520-M
- 10 IO-520-BB, CB and MB

6-21
New Parts
Ref.
No.
Chart
No.
Model Description Serviceable
Limit
Min. Max.
70
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
87
88
89
90
90
91
92
93
94
95
96
97
98
3
2
3
2
3
4
2
2
2
2
3
3
2
3
4
4
4
4
4
4
4
4
4
4
4
2
3
2/3
2/3
2/3
2/3
2/3
All
S
P
S
P
All
All
All
S
S
P
P
S
P
All
All
All
All
S
P
All
All
S
P
All
S
P
All
All
All
All
All
Governor drive shaft in crankcase. ........................ Diameter:
Idler gear support pin in crankcase (front). ........... Diameter:
Idler gear support bushing in crankcase (front) ..... Diameter:
Idler gear support pin in crankcase (rear) ............. Diameter:
Idler gear support bushing, flanged,
in crankcase (rear) ...........................................Diameter:
Magneto and accessory drive adapter
pilot in crankcase ............................................. Diameter:
Oil pump housing pilot in crankcase. ..................... Diameter:
OIL PRESSURE RELIEF VALVE ASSEMBLY
Oil pressure relief valve adjusting screw
in plunger ......................................................... Diameter:
ACCESSORY DRIVE IDLER ASSEMBLY
Bushing in idler gear ............................................. Diameter:
Idler gear support in bushing. ................................ Diameter:
Idler gear in support bushing (front). ..................... Diameter:
Idler gear in support bushing (rear) ....................... Diameter:
Idler gear ......................................................End Clearance:
Idler gear ......................................................End Clearance:
LEFT AND RIGHT MAGNETO AND ACCESSORY
Bushing in magneto and accessory
drive adapter ......................................................... Diameter:
Magneto and accessory drive gear in
adapter bushing ............................................... Diameter:
Oil seal in adapter ................................................. Diameter:
Sleeve in magneto and accessory drive gear. ...... Diameter:
Magneto and accessory drive gear. .............End Clearance:
Magneto and accessory drive gear. .............End Clearance:
Magneto coupling retainer on magneto
and accessory drive gear sleeve. .................... Diameter:
Magneto coupling retainer in magneto
drive gear slot Side ........................................ Clearance:
Magneto coupling rubber bushings
on magneto drive lugs. .......................... Side Clearance:
Magneto coupling rubber bushings
on magneto drive lugs. .......................... Side Clearance:
Magneto pilot in crankcase. ................................... Diameter:
OIL PRESSURE PUMP ASSEMBLY
Oil pump driver gear in pump housing. ................. Diameter:
Oil pump driver gear in pump housing. ................. Diameter:
Oil pump driver gear shaft in pump housing. ......... Diameter:
Oil pump driven gear in pump housing. ........End Clearance:
Oil pump driver gear in pump housing. ........End Clearance:
Oil pump driver gear shaft in cover
oil pump ........................................................... Diameter:
Oil pump driver gear shaft in tachometer
drive bevel gear ............................................... Diameter:
0.005 L
0.0010L
--
--
--
--
--
0.0030 L
--
0.0050 L
0.0040L
0.0040L
0.043
0.075
--
0.0050L
--
--
--
--
0.055 L
0.040 L
--
--
--
0.0060L
0.0070L
0.0045 L
0.0050
0.0050
0.0045 L
0.0040 L
0.0014L
0.0005 L
0.0005 L
0.0005 L
0.0015L
0.000
0.001 L
0.0005 L
0.001 T
0.0015 L
0.001 L
0.001 L
0.002
0.020
0.001 T
0.0015 L
0.007 T
0.004 T
0.0015 L
0.011 L
0.025 L
0.0082 L
0.010 L
0.014 L
0.001 L
0.0015L
0.003 L
0.0015 L
0.0011
0.0011
0.0015 L
0.0005 L
0.0034L
0.0015 L
0.0015 L
0.0025 L
0.0035L
0.003 l
0.003 L
0.0020 L
0.003 T
0.0035 L
0.003 L
0.003 L
0.033
0.067
0.004 T
0.0035 L
0.001 T
0.001 T
0.0086 L
0.077 L
0.040 L
0.0182 L
0.052 L
0.052 L
0.005 L
0.0040L
0.005 L
0.0030 L
0.0030
0.0030
0.0030 L
0.0025 L
P Permold crankcase.
S Sandcast crankcase.