10.1
Section 10
Reassembly
10
Section 10
Reassembly
General
NOTE: Make sure the engine is assembled using
all specifi ed torque values, tightening
sequences, and clearances. Failure to observe
specifi cations could cause severe engine wear
or damage. Always use new gaskets. Apply a
small amount of oil to the threads of critical
fasteners before assembly, unless a Sealant or
Loctite
®
is specifi ed or preapplied.
Make sure all traces of any cleaner are removed before
the engine is assembled and placed into operation.
Even small amounts of these cleaners can quickly
break down the lubricating properties of engine oil.
Check the oil pan, crankcase, and cylinder heads to be
certain that all old sealing material has been removed.
Use gasket remover, lacquer thinner, or paint remover
to remove any remaining traces. Clean the surfaces
with isopropyl alcohol, acetone, lacquer thinner, or
electrical contact cleaner.
Typical Reassembly Sequence
The following sequence is suggested for complete
engine reassembly. This procedure assumes that all
components are new or have been reconditioned, and
all component subassembly work has been completed.
The sequence may vary to accommodate options or
special equipment. Detailed procedures follow:
1. Install fl ywheel end oil seal.
2. Install cranksha .
3. Install connecting rods with pistons and rings.
4. Install governor cross sha .
5. Install camsha .
6. Install oil pan assembly.
7. Install stator and backing plate.
8. Install fl ywheel and fan.
9. Install cylinder heads and hydraulic li ers.
10. Install push rods and rocker arms.
11. Install spark plugs.
12. Install intake manifold.
13. Install fuel injectors.
14. Install manifold absolute pressure sensor.
15. Install cranksha position sensor.
16. Install valve covers.
17. Install breather cover and inner baffl es.
18. Install oil temperature sensor.
19. Install Oil Sentry
TM
.
20. Install blower housing and outer baffl es.
21. Install grass screen.
22. Install oil separator and hardware.
23. Install electronic control unit bracket and electric
starter motor.
24. Install electronic control unit.
25. Install thro le body.
26. Install li fuel pump and fuel pump module.
27. Install external governor controls.
28. Install thro le control panel.
29. Install air cleaner assembly (see Section 4).
30. Install muffl er.
31. Install oil cooler.
32. Install oil fi lter and fi ll crankcase with oil.
33. Connect spark plug leads.
Install Flywheel End Oil Seal
1. Make sure that the seal bore of the crankcase is
clean and free of any nicks or burrs. See Figure
10-1.
Figure 10-1. Seal Bore of Crankcase.
2. Apply a light coat of engine oil to the outside
diameter of the oil seal.
3. Drive the oil seal into the crankcase using a seal
driver. Make sure the oil seal is installed straight
and true in the bore to the depth shown in Figure
10-2.
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