55
CAUTION:
See base gasket selection at the beginning of service section.
13. Install the cylinder being sure that the piston rings are properly aligned with
the indexing pins.
CAUTION:
Never force the cylinder. If resistance is felt, determine the problem and solve it.
Once installed slightly rotate the cylinder back and forth insuring that the rings
are properly seated.
14. Install cylinder head insert.
NOTE: A light application of silicone grease can help hold the O-rings into
position during assembly.
15. Install O-RINGs as shown in the Parts-Engine Top End page.
16. Install the cylinder head.
17. Install the flange nuts. Torque to 123 in-lb (14 Nm)
18. Install reed and intake manifold with new gasket. Torque to 55 in-lb. (6.2
Nm).
CAUTION:
The intake manifold bolts will require being checked and torque values reset after
a few heat cycles.
19. Leak check the engine to 20 psi to ensure proper seal.
20. Install stator reinstalling the grommet and wires (snug the bolts).
21. Install the rotor per Rotor Installation section, under the S3: Ignition portion of
this manual.
22. If necessary install the water pump outlet pipe (apply gray Permatex gasket
maker to the threads before assembly).
23. Install the CFD.
24. Install the clutch per Clutch Installation section in this manual.
25. Install the coolant drain plug.
26. Make sure that the exhaust spacer is on the cylinder (53 in-lb, 6 Nm).
27. Install the spark plug with a fresh gasket (to apply the proper torque to the
spark plug when inserting, one must first screw the spark plug in until the
metal gasket ring causes resistance and then turn another 1/8 to ¼ turn).
Clutch
The sleeve bolts of the 5GX provide a low uniform stress, minimal heat transfer,
and allow channels for flushing the clutch fibers out of the washer stacks allowing
a long time between part replacement provided you operate with 10 oz of clean
Clutch Milk.
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