Service Manual
Engine Assembly
Thoroughly inspect and clean
all
engine parts prior to
assembly.
All
moving parts and
"0"
rings should be
lubricated with
SAE
30
engine oil
on
installation.
No
sealant is required on head, valve cover, breather, muf-
fler, carburetor or sump gaskets.
Piston Pin Installation
1.
Install one retaining ring
in
one side of the piston.
2.
Make certain the arrow on the big end of the connect-
ing rod and the arrow on the face
of
the piston are on
the same side.
3.
Lubricate the piston pin with
SAE
30
engine oil and
slide the piston pin through the piston and connecting
rod.
4.
Install the second retaining ring.
Piston Ring
-
Installation
1.
Install the oil scraper ring expander. This will not
2.
Install one scraper ring above and one scraper ring
3.
Install the second and top Compression rings.
Piston Installation
1.
Tighten a ring compressor around the piston. Piston
ring groove alignment is not a concern
as
the rings are
free to rotate during the operation of the engine.
2.
Lubricate the cylinder walls with
SAE 30
engine oil.
3.
Push the piston
out
of the ring compressor and into the
require
a
piston ring expander.
below the oil scraper ring expander.
cylinder. See Figure
76.
Figure
76
4.
Make sure the piston is
in
the cylinder with the arrow
on the face of the piston toward the push rod side of
the engine. The word
"MAG"
on the connecting rod
should face the magneto side of the engine. See
Figure
77.
5.
Push the piston the rest
of
the way into the cylinder of
the engine.
Crankshaft Installation
1.
Make sure the cam drive gear and key are installed on
the crankshaft with the timing marks on the gear
visible.
2.
Place a protective sleeve around the crankshaft and
insert the magneto (flywheel end) of the crankshaft
through the seal in the magneto end
of
the engine. The
connecting rod will have to be pushed to one side and
the counterweight turned to provide installation
clearance.
3.
Install the rod cap with the arrow facing the push rod
side of the engine. See Figure
78.
.
4.
Torque the rod cap bolts to
100
in Ibs
(1
1.5
N-m).
5.
Rotate the crankshaft
two
complete revolutions to
disclose any binding or interference.
Engine
40
GTS
150