Engine Assembly Part 2 - Large Frame

Side the Head on with the Spark Plug hole facing up

• Use a Torque Wrench to tighten the Nuts
• You should have a Flat Washer, Lock Washer, and Nut in that order

• Tighten the nuts in an X Pattern
• The Torque should be 16 Foot-Pounds
• Start with 8 Foot-Pounds then slowly move up to 16 Foot-Pounds always moving an X pattern

Now install the Spacer Nut

• Next install the Fly Wheel Side Oil Seal
• Apply some Grease to the outside and inside of the Seal

Press it in by hand

You can use part of the Crank Installer Tool to tap it the rest of the way flush to the way in

Tape the end of the wires coming off the end of the Stator.

This will make it easier to feed them through the hole

Feed them up the hole until you can grab them on the other side

Now position the Stator using the mark you made during disassembly (we will set the timing later)

Screw the Stator in with the three Securing Screws

Install the Fly Wheel Side Woodruff Key into the Crankshaft

Put a little 2-Stroke oil on the Felt Pad (this will help extend the life of your points)

Line up the Key way in the Flywheel with the one you just installed on the Crankshaft

Install the Star Washer

Start the Nut by hand

Use the Fly Wheel Holding Tool

Torque the nut to 45 Foot-Pounds

Install the Rubber Fly Wheel Plug

Now install the Rear Brake Axle

Grease up the Axle

Slide it in

Before you get it all the way in put the Rear Brake Lever and Spring in

Install the Cotter pin and bend it over to lock the Axle in

Finally pull the Spring around the Rear Brake Lever

• Next install the Backing Plate
• You should have these Three O-rings in your Gasket Set

The big one goes here

The single one goes here

And the double one goes here

Now install the backing plate

It requires three small screws

• Now install the Brake Shoes
• Start with a TINY bit of Grease on the pivot pins

• As well as the Axle
• NOTE: Brakes and Grease don't get along so use the slightest bit just enough to keep everything moving freely

Put the Brake Spring on the Brake Shoes

Start at the top

Put the Front of the Bottom shoe in and use a Pry bar the leverage the back part in

I will look like this

Next install the Retaining Clips

Start them with your finger

Then squeeze them on with a pair of pliers

It should look like this

Now Grease the Read Hub Oil Seal

Push it in with your fingers until it bottoms out

It is a good idea to sand the Rear Hub a little bit before you install it

Just make it not shiny

Install the Rear Hub Washer

Install the Rear Hub Nut

If you have an Impact Driver use it to install this nut

Install the Cotter Pin

Bend the two ends over the nut

Install the Hub Cover

• Spin the Motor around
• Install the