71
0742-746
34. Install the two cylinder O-rings (lightly coated with
oil) on the top of each cylinder making sure they are
correctly positioned in the grooves.
FC077
35. Place new O-rings (lightly coated with oil) onto each
of the head cap screws. Place four of these cap
screws into the cylinder head. Thread the spark plugs
in part way; then while holding the head above the
cylinder, carefully start and finger-tighten all four
cap screws while observing the cylinder O-rings to
make sure they remain in position. Slowly place the
head into position on top of the O-rings. Start and
finger-tighten the remaining cap screws being very
careful not to move the cylinder head.
36. From step 35 in two steps, tighten the 8 mm cap
screws to 19 ft-lb using the appropriate pattern
shown. Install the spark plugs.
0738-204
NOTE: After tightening the 8 mm cap screws,
tighten the two remaining 6 mm cap screws to 96
in.-lb.
NOTE: At this point, pressure test the engine (see
Section 3).
37. Secure the stator plate to the crankcase with the
Allen-head cap screws (coated with blue Loctite
#243) and tighten to 96 in.-lb.
FC021
38. Secure the ignition timing sensor with screws coated
with blue Loctite #243. Tighten to 48 in.-lb. Install
the stator assembly with wires and a grommet into
the crankcase and secure with the Allen-head screws
(coated with blue Loctite #243). Tighten to 96 in.-lb.
FC018
39. Install the key in the crankshaft.
40. Thread two puller bolts into the flywheel; then slide
the flywheel onto the crankshaft making sure the
keyways match. Remove the puller bolts.
NOTE: Before installing the flywheel, be sure to
wipe the crankshaft and flywheel tapers clean using a
clean towel.
41. Apply red Loctite #271 to the threads of the flywheel
cap screw; then finger-tighten with a large flat
washer. DO NOT TIGHTEN AT THIS TIME.
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