Small Engine Disassembly and Reassembly Briggs And Stratton 4 Cycle. Activity Guide
|
|
- Job Potter
- 7 years ago
- Views:
Transcription
1 Small Engine Disassembly and Reassembly Briggs And Stratton 4 Cycle Activity Guide
2 Section Title Table Of Contents Page Number ENGINE DISASSEMBLY...3 GETTING READY... 3 REMOVING EXTERNAL PARTS... 5 REMOVING INTERNAL PARTS INSPECTING OF THE PARTS...16 CLEANING THE PARTS CRANKCASE VALVES VALVE GUIDES CAMSHAFT CRANKSHAFT PISTON & CONNECTING ROD CONCLUSIONS ABOUT ENGINE CONDITION...23 REASSEMBLY...24 PREPARING THE CRANKCASE INSTALLING THE PISTON INSTALLING THE CAMSHAFT INSTALLING CRANKCASE COVER INSTALLING THE VALVES CYLINDER HEAD FINAL ASSEMBLY TESTING THE ENGINE...38 Page 2 of 38
3 Ask the instructor for the: Small Engine Rebuilding (Briggs & Stratton) Video Tape Watch the "Disassemble" section of the tape. The video will give you a general idea of the procedure even if your engine is not a Briggs & Stratton. Get the repair manual for your engine. You will be required to look up specifications in the repair manual. ENGINE DISASSEMBLY CAUTION!! Never use excess force when working on the engine. Hammering on parts will cause damage. Clamping unprotected engine parts in the vise will damage the metal surfaces. Always use wooden blocks on each side of the part. Page 3 of 38
4 GETTING READY Remove the fuel from the gas tank. Carefully drain all gasoline into the red gas container marked "Waste Fuel". Use two wooden boards to support the engine above an oil drain pan. Remove the oil plug from the bottom of the engine and drain the oil into the pan. Page 4 of 38
5 Pour the oil into the large oil drum. Get some containers to put your parts in. All the parts you remove must go into containers. (Muffin trays and egg cartons are handy for organizing small parts.) REMOVING EXTERNAL PARTS Remove the fuel line from the gas tank and drain any remaining fuel from the tank. Page 5 of 38
6 Remove the gas tank and pull start housing. Remove the air filter. Remove the muffler. Page 6 of 38
7 In the next step you will be removing the carburetor and governor linkages. Do not proceed until you have taken a digital photograph of the engine to help locate the parts during reassembly. Remove the carburetor. Remove the carburetor and governor linkages. Page 7 of 38
8 Remove the carburetor gasket or rubber O-Ring. Remove the bolts holding the magneto coil to the engine. Disconnect the kill switch wire from the magneto coil. Page 8 of 38
9 Remove the flywheel brake if one is fitted. Remove any screen or other fittings from the flywheel. Ask the instructor to help you determine if the nut holding the flywheel is left or right hand thread. Use an impact gun and socket or special flywheel tools to remove the nut holding the flywheel. Page 9 of 38
10 Use a flywheel puller (special tool) to pull the flywheel off. Ask your instructor for help if you are not sure how to use it. Remove the small shaft key from the crankshaft. Use a spark plug socket and ratchet to remove the spark plug. Page 10 of 38
11 Remove the bolts holding the cylinder head in place. Remove the cylinder head. Remove the cylinder head gasket. Remove the valve spring chamber cover. Page 11 of 38
12 Use fine sandpaper to remove any burrs or rust from the crankshaft. REMOVING INTERNAL PARTS Remove the bolts holding the crankcase cover. Use a soft mallet to tap the crankcase cover off the crankcase. Do not remove any of the internal parts yet. Complete the ** Operating Theory For A 4 Cycle Gas Powered Small Engine ** INFORMATION BOOK. Page 12 of 38
13 Ask the instructor to quiz you on the names of the engine parts. Be prepared to use your partially disassembled engine to explain the four stroke cycle to the instructor. Sign up to have your work checked, then proceed. Instructor's Initial Use the valve spring compressor to compress the valve springs. Remove the retainers holding the valve springs to the valves. Remove the valve springs and valves. Remove oil pump or oil slinger parts if your engine has them. Remove the governor mechanism if your engine has one. Page 13 of 38
14 Rotate the crankshaft until the valve timing marks on the camshaft gear and the crankshaft gear are inline. Remove the camshaft. Remove the valve lifters. Use a hammer and punch to put small locating marks on the connecting rod and connecting rod bearing cap. Page 14 of 38
15 Remove the two bolts holding the connecting rod bearing cap and remove it. Push the piston and connecting rod out of the cylinder. Place the connecting rod bearing cap back on the connecting rod. Be sure that the cap is in its original position. Be sure the marks or tabs line up. Page 15 of 38
16 Carefully remove the crankshaft from the crankcase. Sign up to have your work checked, then proceed. Instructor's Initial INSPECTING OF THE PARTS Watch the video program called "Inspection" on the Small Engine Rebuilding (Briggs Stratton) Video Tape Select the Microsoft Word button at the bottom of this screen. Use Word during the next steps to record your findings as you inspect the engine. CLEANING THE PARTS Wash all engine parts in the parts cleaner. Do not allow parts cleaner to contact the magneto coil or other electrical parts. Page 16 of 38
17 Blow the crankcase dry using compressed air. Be sure to blow compressed air into all the bolt holes. Take care not to lose any parts in the parts washer. CRANKCASE Check the outside of the crankcase for any signs of damage and record your findings. VALVES Use the wire wheel to remove carbon deposits from the stem and face of the valves. Ask for the instructor's help if you are not sure how to do this. Page 17 of 38
18 VALVES Check the faces of the valves and the valve seats for signs of pitting or burning. Record your findings. VALVE GUIDES Record the specification for valve guide wear from the manual. Slide a short piece of rubber onto the valve stem. The rubber must be long enough to hold the valve off the seat when it is placed in the valve guide. Page 18 of 38
19 Blow the valve guides out with compressed air, insert the valve. Use the dial indicator gauge to measure the amount of movement when you move the head of the valve back and forth. Record your measurements. Exhaust Intake CAMSHAFT Inspect the camshaft bearing, surfaces and lobes for signs of wear and or roughness. Record your findings. Page 19 of 38
20 CRANKSHAFT Inspect the crankshaft bearing journals for score marks or roughness. Use a digital vernier to measure the diameter of the journals. Record the values as shown. Journal 1: Journal 2: Journal 3: Look up the crankshaft bearing journal specifications from the shop manual and record the values. How do your readings compare to the specifications? Write a paragraph describing the condition of the crankshaft and state whether or not it should reinstalled in the engine. Page 20 of 38
21 Note the position of the connecting rod bearing cap. Remove the connecting rod bearing cap from the connecting rod. Use the shop manual to look up the torque specification for the bolts holding the connecting rod bearing cap. Record the value. Ask the instructor for a piece of Plastigage. You will use the Plastigage to measure the clearance between the crankshaft journal and connecting rod. Break off a piece of plastigauge, the length should be the same as the width of the crankshaft journal. Position the connecting rod on the crankshaft journal as shown in the picture. Put a piece of plastigauge on the journal. Page 21 of 38
22 Be careful not to rotate the crankshaft while you install the bearing cap. Use a torque wrench to tighten the conntecting rod bolts to specifications. This will squeeze the plastigage between the connecting rod and crankshaft. PISTON & CONNECTING ROD Remove the bearing cap. Use the envelope from the Plastigage to measure the width of the Plastigage strip on the crankshaft. The thinner the Plastigage strip the wider the clearance between the connecting rod and crankshaft. Acceptable clearance is.001" to.002" Record the value for your engine. CAUTION!! In the next step you will be removing the piston rings. They break very easily, do not stretch them any farther than required to remove them. Page 22 of 38
23 Use a piston ring expander to remove the rings from the piston. Do not overstretch the rings! Be sure to note the order and direction of the rings so they can be installed exactly the same. Remove any carbon which has built up in the piston ring grooves. Check that the oil holes in the lower ring groove are clear. With the connecting rod in one hand and the piston in the other, pull up and down on the piston. If you feel any play, the piston or piston pin is worn and must be replaced. Record your findings. Check the piston and skirt for any sign of scoring, cracking or damage. Record your findings. Page 23 of 38
24 CONCLUSIONS ABOUT ENGINE CONDITION Create a short report. List your measurements and observations. Describe the generall condition of the engine. Sign up to have your work checked, then proceed. Instructor's Initial REASSEMBLY Watch the video program called "Assembly" on the Small Engine Rebuilding (Briggs & Stratton) Video Tape CAUTION!! Be sure to coat all engine parts with clean oil before assembly. Parts not oiled will be damaged during initial start up. Page 24 of 38
25 PREPARING THE CRANKCASE If no problems have been found with the valves, you will use lapping compound to lap the valves onto the seats. The lapping compound and tool can be found in the botton of the Sioux Valve grinding machine. Put a small amount of lapping compound on the face of the valve. Do not allow any of the lapping compound to get on the stem of the valve! Page 25 of 38
26 Place the valve into the valve guide. Do not allow lapping compound to get into the valve guide! Use the lapping tool to spin the valve so the lapping compound refinishes the valve face and seat. Clean the crankcase and valves in the parts washer. Blow the crankcase dry using compressed air. Be sure to blow out the valve guides. Page 26 of 38
27 Check the rubber lip of each crankshaft oil seal for signs of wear, if required replace it. Be sure to put lots of oil on the rubber lip of the oil seals where they contact the rotating crankshaft. Oil all of the crankshaft bearing journals. Page 27 of 38
28 Install the crankshaft in the crankcase. INSTALLING THE PISTON Wipe the cylinder walls with a clean cloth, then oil them thoroughly. Unpack the new piston rings (if provided) and determine which ring belongs in which groove. Also note which side of the ring is to face up. Page 28 of 38
29 Put each of the upper piston rings into its groove and use a feeler gauge to measure the side clearance of the ring. Record the ring side clearance: Record the specification for ring side clearance from the manual. Is the ring side clearance within specifications? Position each of the compression rings near the bottom of the cylinder and use the feeler gauge to measure the gap between the ends of the ring. Record the End Gap for each ring. A gap which is too large indicates a worn cylinder or ring. A gap which is too small will not allow for expansion and will cause the piston to sieze in the cylinder. Compare your readings to the specifications in the manual. Page 29 of 38
30 The first ring to go on the piston is the oil ring. If your engine uses a three part oil ring, follow the directions below. Use the piston ring installation tool to install the compression rings. Position the rings so the gaps of the rings are staggered. Put lots of oil on the piston, piston rings and piston pin. You will use a piston ring compressor to install the piston into the cylinder. Pressing the lever on the compressor unlocks it for adjustment. You will need a 1/4" ratchet and extension to adjust the compressor. Page 30 of 38
31 Install the piston ring compressor on the piston. Make sure that the dimpled end of the compressor is pointing toward the connecting rod. Use a ratchet and extension to tighten the compressor onto the piston. Position the crankshaft so the connecting rod journal is at the bottom of its travel. Page 31 of 38
32 Slide the piston and connecting rod into the cylinder. The compressor should be resting on the engine. Some pistons may have locating marks, the manual should tell you which side of the engine the mark should be facing. Be sure the ring compressor is tight on the piston. Use a hammer handle to tap the piston into the cylinder. Guide the connecting rod onto the crankshaft journal as the piston moves downward. Take care not to damage the journal of the crankshaft. Oil the connecting rod bearing cap and place it on the connecting rod. Make sure the marks you made earlier line up with each other! Install the bolts and tighten them finger tight for now. Page 32 of 38
33 Find the torque setting for the connecting rod nuts in the manual. Record the value. Use the inch pound torque wrench to tighten the nuts. (Ask the instructor if you are not sure how to use the torque wrench.) After the nuts are tight try to turn the crankshaft. You should be able to turn the crankshaft if everything has been assembled correctly. Sign up to have your work checked, then proceed. Instructor's Initial INSTALLING THE CAMSHAFT Lubricate the valve lifters and install them. Lubricate all parts of the camshaft and install it. Remember that for correct valve timing the marks on the camshaft gear and crankshaft gear must line up. Stop here until the instructor has checked your work. Instructor's Initial Page 33 of 38
34 INSTALLING CRANKCASE COVER Install any other oil pumps, governors etc... as shown in your manual. Install a new crankcase cover gasket. Oil the bearing surfaces in the crankcase cover. Install the crankcase cover. Install and tighten the crankcase bolts. Page 34 of 38
35 Position a dial indicator on the end of the crankshaft. Move the crankshaft back and forth. Use a dial indicator to check the crankshaft end play. Record it. Look up the specification for end play and compare to your measurement. INSTALLING THE VALVES Lubricate the valve guides. Page 35 of 38
36 Lubricate the stems of the valves, then insert them in the valve guides. Use the valve spring compressor to compress the valve springs and install the springs and retainers. CYLINDER HEAD Look up and record the torque setting for the cylinder head bolts. Record the value. Install a new head gasket. Page 36 of 38
37 Install the cylinder head and torque the bolts to specifications. Follow the tightening sequence shown in the manual. FINAL ASSEMBLY [Need a redirector for understanding ignition.] Install the ignition parts. Look up and record the ignition breaker point gap. (point type ignitions only) Set the ignition breaker point gap to specifications. (point type ignitions only) Sign up to have your work checked, then proceed. Instructor's Initial Install the flywheel key into the crankshaft. Install the flywheel along with any washer and other parts. Start the nut by hand, then use the impact gun to tighten the nut holding the flywheel. Page 37 of 38
38 If the air gap between the ignition coil and the magnet is adjustable you should adjust it to specifications. Install the rest of the parts on the outside of the engine. Be very careful to install the carburetor linkages correctly. Install the spark plug. CAUTION!! Do not attempt to start the engine without the instructor's approval. Fill the crankcase to the correct level with oil. Fill the fuel tank 1/4 full with gas. TESTING THE ENGINE Design and build some type of mounting for the engine so it is secure when you test run it. Stop here until the instructor has checked your work. Instructor's Initial Connect an exhaust hose to the engine and start it up. Page 38 of 38
PISTON AND CYLINDER WALLS SCORING
PISTON AND CYLINDER WALLS SCORING Most instances of piston & cylinder scoring can be traced to lack of oil, use of improper oil fuel mixture, foreign particles in cylinder, heating caused by plugged cooling
More informationSLP 1.85 Ratio Offset Rocker Arms with Valve Springs, LS3
PART #50190 SLP 1.85 Ratio Offset Rocker Arms with Valve Springs, LS3 PACKING LIST Before installation, use this check list to make sure all necessary parts have been included. ITEM QTY CHECK PART NUMBER
More information1.8 CRANKSHAFT OIL SEALS
SERIES 60 SERVICE MANUAL 1.8 CRANKSHAFT OIL SEALS An oil seal is fitted between each end of the crankshaft and the bores of the flywheel housing and gear case cover to retain the lubricating oil in the
More information1/29/2008 DR70. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 43
DR70 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 43 CYLINDER & CYLINDER HEAD 1 DR70-001 883099044472 CYLINDER 1 1 2 DR70-002 883099044489 GASKET, CYLINDER 1 1 3 DR70-003 883099044496
More informationChar-Lynn Hydraulic Motor. Repair Information. 10 000 Series. October, 1997
Char-Lynn Hydraulic Motor October, 1997 Repair Information Geroler Motor Two Speed 001 27 Retainer inside bore of valve plate bearingless motors only 4 15 16 3 6 35 Parts Drawing 25 2 2 1 19 17 36 40 47
More informationTUTORIAL. REbUILdING. front CALIpER O-RING CONVERSION CORVETTE 1965-82. Part #: HT-1
Part #: HT-1 1965-82 CORVETTE O-RING CONVERSION front CALIpER REbUILdING TUTORIAL Choosing a Brake Caliper Rebuild Kit Standard Lip Seals vs. O-Ring Seals Lip seal design seals are used on 1965-1982 Corvette
More informationRebuild Instructions for 70001 and 70010 Transmission
Rebuild Instructions for 70001 and 70010 Transmission Brinn, Incorporated 1615 Tech Drive Bay City, MI 48706 Telephone 989.686.8920 Fax 989.686.6520 www.brinninc.com Notice Read all instructions before
More informationVolkswagen New Beetle 2.0 Liter 4-cyl General, Engine (Engine Code AEG) 15 Engine- Cylinder head, Valvetrain (Page GR-15)
15 Engine- Cylinder head, Valvetrain (Page GR-15) Cylinder head, removing and installing Compression, checking Valve train, servicing Camshaft oil seal, replacing Camshaft, removing and installing Hydraulic
More informationRound Housing with Side Ports
Power Steering Steering Control Unit (SCU) Parts and Repair Information 5 Series Steering Control Units 001 Square Housing with Side Ports Round Housing with Side Ports T E L RP Round Housing with End
More informationTUTORIAL. REbUILdING. REAR CALIpER O-RING CONVERSION CORVETTE 1965-82. Part #: HT-2
Part #: HT-2 1965-82 CORVETTE O-RING CONVERSION REAR CALIpER REbUILdING TUTORIAL Choosing a Brake Caliper Rebuild Kit Standard Lip Seals vs. O-Ring Seals Lip seal design seals are used on 1965-1982 Corvette
More informationSTATE UNIVERSITY OF NEW YORK COLLEGE OF TECHNOLOGY CANTON, NEW YORK COURSE OUTLINE AUTO 220 INTERNAL COMBUSTION ENGINES
STATE UNIVERSITY OF NEW YORK COLLEGE OF TECHNOLOGY CANTON, NEW YORK COURSE OUTLINE AUTO 220 INTERNAL COMBUSTION ENGINES Prepared By: BRANDON BALDWIN CANINO SCHOOL OF ENGINEERING TECHNOLOGY AUTOMOTIVE TECHNOLOGY
More informationPiston Diagnosis A rough Guide
Piston Diagnosis A rough Guide The process of examining used pistons can tell us a lot of helpful information on the condition of an engine. When engine failure does occur the piston is likely to take
More informationChar-Lynn Spool Valve Hydraulic Motors. Repair Information. W Series Geroler Motors
Char-Lynn Spool Valve Hydraulic Motors Repair Information W Series Geroler Motors with Parking Brake 004 Nut Key Ring, Retaining Bearing Ring, Retaining Ring, Retaining Washer (Thick), Pressure Washer,
More informationDR90. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51
DR90 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51 CYLINDER & CYLINDER HEAD 1 DR90-001 842645048166 CYLINDER 1 1 2 DR90-002 842645048173 GASKET, CYLINDER 1 1 3 DR90-003
More informationP7100 PUMP INSTALLATION INSTRUCTIONS Diesel Care & Performance Inc
P7100 PUMP INSTALLATION INSTRUCTIONS Diesel Care & Performance Inc Installation Timing Pin Location CAUTION: Before installing the injection pump, be sure that number 1 cylinder is at the Top Dead Center
More informationINSTRUCTIONS. FLHR/C/S (Road King) FRONT END LOWERING KIT 1WARNING -J03242 REV. 10-19-04. General. Removal (Left and Right Forks) Kit Number 54614-05
INSTRUCTIONS -J04 REV. 0-9-04 General FLHR/C/S (Road King) FRONT END LOWERING KIT This kit is designed for installation on 00 and later FLHR/C/S Model Motorcycles. Road King models use the conventional
More information1/29/2008 DR50. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 45
DR50 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 45 CYLINDER & CYLINDER HEAD Part UPC Number Description Baja Description 1 DR50-001 842645074424 CYLINDER 1 1 2 DR50-002 842645074431
More informationOregon Fuel Injection
Corporate Office: P.O. Box 21121, VE Pump Removal and Installation Cummins Lock Timed Applications Removal Clean the exterior of the injection pump and mounting surfaces. 1. Disconnect the fuel return
More informationEM 58. 19. REMOVE NO. 2 MANIFOLD STAY (a) Remove the bolt, nut and stay.
57 ROVAL 1. DISCHARGE FUEL SYST PRESSURE (See page FU-9) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
More information13. REAR WHEEL/BRAKE/SUSPENSION
13. REAR WHEEL/BRAKE/SUSPENSION 13 3.5~4.5kg-m 8.0~10.0kg-m 0.8~1.2kg-m 3.0~4.0kg-m 2.4~3.0kg-m 3.5~4.5kg-m 6.0~8.0kg-m 13-0 13. REAR WHEEL/BRAKE/SUSPENSION 13 REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION...
More informationVolkswagen Jetta, Golf, GTI 1999, 2000 Brake System 47 Brakes - Hydraulic Components (Page GR-47)
47 Brakes - Hydraulic Components (Page GR-47) FS III front brake calipers, servicing Front brake caliper piston, removing and installing FN 3 front brake calipers, servicing Front caliper piston, removing
More informationFJ2. 2 Ton Trolley Floor Jack Assembly & Operating Instructions
FJ2 2 Ton Trolley Floor Jack Assembly & Operating Instructions READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT. This manual provides important information on proper operation & maintenance.
More informationCYLINDER HEAD (4A FE)
EM81 CYLINDER HEAD (4AFE) COMPONENTS EM82 ENGINE MECHANICAL REMOVAL OF CYLINDER HEAD (See page EM81) 1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION: Work must be started after approx. 20
More information2740 Whitten Rd Bldg 103 Memphis, TN 38133 Telephone 901-380-9290 Email Bwilliams@Dieselcare.net
Fuel Injection Pump Replacement REMOVAL Diesel Care & Performance Inc 1. Disconnect negative battery terminal. 2. Remove throttle linkage. Fuel Injection Pump Bracket 3. Remove injection pump bracket.
More information1/29/2008 DR125 / DR150. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PARTS AND PRICES ARE SUBJECT TO CHANGE 1 of 55
DR125 / DR150 Toll Free: 888-863-2252 PARTS AND PRICES ARE SUBJECT TO CHANGE 1 of 55 CYLINDER HEAD ASSY. 1 125-001 883099006937 CYLINDER HEAD COVER 1 1 2 125-002 883099006944 BOLT M6X28 2 3 3 125-003 883099006951
More informationSlide the new steering column shaft through the steering column from the driver compartment.
Slide the new steering column shaft through the steering column from the driver compartment. Push the column shaft through the steering column until the machined end is out past the column lower bushing.
More informationUnit: mm(in) Item Standard value Service limit Axle shaft run out - 0.2(0.008)
Rear Wheel/Brake/Suspension 13. Rear Wheel/Brake/Suspension Service Information 13-1 Troubleshooting 13-2 Rear Wheel 13-3 Rear Cushion 13-4 Rear Swing Arm 13-7 Service Information General Safety If the
More informationSTEERING SYSTEM - POWER
STEERING SYSTEM - POWER 1990 Nissan 240SX 1990 STEERING Nissan - Power Rack & Pinion Axxess, Maxima, Pulsar NX, Sentra, Stanza, 240SX, 300ZX DESCRIPTION The power steering system consists of a rack and
More informationMAINTENANCE OF WHEELMOVE IRRIGATION SYSTEMS
MAINTENANCE OF WHEELMOVE IRRIGATION SYSTEMS F. Richard Beard, Agricultural Equipment, Structures and Electricity Robert W. Hill, Biological & Irrigation Engineering Boyd Kitchen, Uintah County Extension
More informationDR50 Hensim Dirt Runner 49cc Dirt Bike (VIN PREFIX LLCH or LUAH)
Page 1 of 21 Product Information Baja Web > Product Information > Parts Lists > DIRTBIKE > DR50 Hensim Dirt Runner 49cc Dirt Bike (VIN PREFIX LLCH or LUAH) DR50 Hensim Dirt Runner 49cc Dirt Bike (VIN PREFIX
More informationEngine, disassembling and assembling
13-1 Engine, disassembling and assembling Note: Replace the oil cooler and thoroughly clean the oil passages if you find metal shavings or larger quantities of small metal particles in the engine oil,
More informationFuel Injection Pump, Rotary (005-014)
Fuel Injection Pump, Rotary View Related Topic Page 1 of 30 Fuel Injection Pump, Rotary (005-014) Table of Contents Summary General Information Preparatory Steps Remove Front Gear Train Rear Gear Train
More informationSTORAGE, INSTALLATION AND MAINTENANCE PROCEDURES
GATE VALVE O.S. & Y 1.0 Periodic Inspections 1.1 The valve stem packing should be inspected at least monthly. If the stem packing shows signs of leakage, simply tighten the adjusting nuts to compress the
More informationDR125 and DR150 Hensim Dirt Runner 125cc and 150cc Dirt Bike (VIN PREFIX LLCH or LUAH)
Parts Lists - DR125 and DR150 Hensim Dirt Runner 125cc and 150cc Dirt Bike (VIN PR... Page 1 of 25 Product Information Baja Web > Product Information > Parts Lists > DIRTBIKE > DR125 and DR150 Hensim Dirt
More informationVolkswagen Jetta, Golf, GTI 1999, 2000 2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP 17 Engine-Lubrication (Page GR-17)
17 Engine-Lubrication (Page GR-17) Lubrication system components, removing and installing Oil filter housing, disassembling and assembling Oil pan, removing and installing Oil pressure and oil pressure
More informationPARTS MANUAL EH12-2 ENGINE. Model. PUB-EP5713 Rev. 7/99
PARTS MANUAL Model EH12-2 ENGINE PUB-EP5713 Rev. 7/99 940 Lively Blvd. Wood Dale, IL 60191 Phone: 630-350-8200 Fax: 630-350-8212 e-mail: sales@robinamerica.com www.robinamerica.com Copyright 1999 Robin
More informationCooling system components, removing and installing
Engine BHW Cooling system components, removing and installing Page 1 / 24 19-1 Cooling system components, removing and installing Warning! When doing any repair work, especially in the engine compartment,
More informationEngine. 204-1890 Strobe light, 110V 204-1891 Strobe light, 220V 204-458 Replacement bulb. 204-1057 Compression gauge. 204-166 Dial indicator
The Strobe light checks the unit for: Balance of operating machinery RPM of motors, engine pulleys, fans, etc. Observe belt slippage Strobe light will stop action at speeds from 200 to 6000 RPM 204-1890
More informationThe cylinder head bolts tightening stages have been updated as listed in Table 1.
NUMBER: 07 EPA04 MBE 4000-6 S.M. REF.: 1.2.2 ENGINE: MBE 4000 DATE: November 2007 SUBJECT: CYLINDER HEAD BOLTS TIGHTENING STAGES PUBLICATION: 6SE412 The cylinder head bolts tightening stages have been
More informationDR90. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51
DR90 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51 CYLINDER & CYLINDER HEAD Part UPC Number Description Baja Description 1 DR90-001 842645048166 CYLINDER 1 1 2 DR90-002
More informationCylinder head, removing and replacing
15-1 Cylinder head, removing and replacing WARNING! Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once, and are unreliable and may fail
More information2006 HEADSHOK Service Video #1
LEFTY SPEED DLR DAMPING CARTRIDGE This document explains how to properly remove, disassemble, inspect, reassemble and reinstall the Lefty Speed DLR2 damping cartridge. It is a document to be used in conjunction
More informationENGINE FUEL FUEL FILTER... FUEL HEATER... INJECTOR... SUPPLY PUMP... COMMON RAIL... FUEL PRESSURE LIMITTER...
FUEL FILTER............................ FUEL HEATER.......................... INJECTOR.............................. SUPPLY PUMP.......................... COMMON RAIL.......................... FUEL PRESSURE
More informationDiscPlus DX195 and DX225 Air Disc Brakes
Revised 11-04 Technical Bulletin Revised 1 Technical 11-04 Bulletin DiscPlus DX195 and DX225 Air Disc Brakes Inspection, Installation and Diagnostics Air Disc Brake Inspection Intervals and Procedures
More informationFor exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.rockshox.com.
For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.rockshox.com. Information contained in this publication is subject to change at anytime
More informationK&T Saw Shop 606-678-9623 or 606-561-4983. 12-400165 MC 91C 11/74 to 04/76 IPL 84456 Page 1 of 11 Accessories
12-400165 MC 91C 11/74 to 04/76 IPL 84456 Page 1 of 11 Accessories 12-400165 MC 91C 11/74 to 04/76 IPL 84456 Page 2 of 11 Accessories 68899 Piston Assy - 0.005 in. oversize 66790 Ring Set - Piston 0.005
More informationContents. Description Page Description Page
Contents Description Page Description Page Auger Housing Assembly 1 Muffler 18 Handle and Control Assembly 3 Fuel Tank r Assembly 19 Engine and Drive Assembly 5 Clutch Retarder 20 Cylinder Head 7 Retarder
More informationTABLE OF CONTENTS. iii
TABLE OF CONTENTS GENERAL INFORMATION 1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 5 ENGINE 9 LUBRICATION SYSTEM 24 FUEL SUPPLY SYSTEM 28 TRANSMISSION COMPONENTS 33 ELECTRICAL STARTING SYSTEM 36 BELT
More informationDO NOT attempt to repair hub and wheel bearing assembly.
Page 1 of 6 HUB & WHEEL BEARINGS (WITH PULSE VACUUM HUBLOCK) DO NOT attempt to repair hub and wheel bearing assembly. Removal DO NOT remove hub lock assembly by prying on hub lock legs. This can crack
More informationDiesel Fuel Systems. Injection Nozzles
Diesel Fuel Systems Injection Nozzles Unit Terms Injection nozzle Nozzle, nozzle holder, valve, spring assembly Nozzle assembly Valve, body, and spray valve Orifice Small hole Pintle Valve which the end
More informationMARK-3 DIS Digital Ignition Solution
Overview: MARK-3 DIS Digital Ignition Solution WATERAX offers a conversion kit Digital Ignition Solution (DIS) for users that want to convert a MARK-3 from breaker points and mechanical cut-out switch
More informationTurbocharger system components, servicing
21-1 Turbocharger system components, servicing Engine codes: AAZ, 1Z, AHU Observe rules of cleanliness Page 21-10 Turbocharger hoses and lines, connecting Page 21-11 WARNING! Do not re-use any fasteners
More informationService Manual Rol-Lift
R 2000 Service Manual Rol-Lift Series: T and E Developed by Generic Parts Service This manual is intended for basic service and maintenance of the Rol-Lift pallet jack. The pallet jacks you are servicing
More information1993 VOLKSWAGEN ENGINES 2.5L 5-Cylinder. EuroVan
Article Text ARTICLE BEGINNING 1993 VOLKSWAGEN ENGINES 2.5L 5-Cylinder EuroVan * PLEASE READ THIS FIRST * NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES
More informationINSTRUCTIONS AND PARTS LIST FOR MODEL 70H & 75H HAND-OPERATED HYDRAULIC PRESS
INSTRUCTIONS AND PARTS LIST FOR MODEL 70H & 75H HAND-OPERATED HYDRAULIC PRESS SETTING UP THE PRESS FOR OPERATION For shipping convenience, the gauge, pump handle, hoist crank, screw nose and base angles
More informationNUMBER: 08 DD15-10 S.M. REF.: 3.2 ENGINE: DD15 DATE: September 2008
NUMBER: 08 DD15-10 S.M. REF.: 3.2 ENGINE: DD15 DATE: September 2008 SUBJECT: 3.2 OIL PAN PUBLICATION: DDC-SVC-MAN-0002 Oil pan section 3.2 has been updated. Section Change 3.2 Oil Pan Call-outs have been
More information2100 AD 015 0009 Mirror Elevator Ball Nut Replacement Procedure
2100 AD 015 0009 Mirror Elevator Ball Nut Replacement Procedure Derek Guenther 1/28/2015 Rev. Purpose The purpose of this document is to describe the procedure necessary to replace one of the ball nuts
More informationSystem Saver 318 Air Compressor for Mack E-Tech and ASET Engines
Maintenance Manual 31 System Saver 318 Air Compressor for Mack E-Tech and ASET Engines Revised 08-05 NON-THROUGH DRIVE THROUGH DRIVE Service Notes About This Manual This manual provides service and repair
More informationChar-Lynn Hydraulic Motors. Repair Information. W Series Geroler Motors 002, 003. April, 1999
Char-Lynn Hydraulic Motors April, 1999 Repair Information W Series Geroler Motors 002, 003 W Series Geroler Motors Tools Required 5/16 inch Hex Key Bullet for Shaft Installation - Eaton Tool No. 600633
More informationPERFORMER RPM CNC MACHINED CYLINDER HEADS For 1984 & Later Harley-Davidson Evolution Big Twin Engines. Catalog #1604, 1606, 1607, 1624, 16041 & 16061
PERFORMER RPM CNC MACHINED CYLINDER HEADS For 1984 & Later Harley-Davidson Evolution Big Twin Engines INSTALLATION INSTRUCTIONS PLEASE study these instructions carefully before beginning this installation.
More informationTool And Material Checklist
HOW - TO CV JOINTS CV JOINTS Tool And Material Checklist Screwdriver Metal Shears Breaker Bar or Torque Wrench Assorted Wrenches Wire Evaporating Spray Solvent Pusher Tool Vise Snap Ring or Duckbill Pliers
More informationBR150 Pmi Baja Reaction 150cc Go Kart (VIN PREFIX L4VM)
Page 1 of 21 Product Information Baja Web > Product Information > Parts Lists > GOKART > BR150 Pmi Baja Reaction 150cc Go Kart (VIN PREFIX L4VM) BR150 Pmi Baja Reaction 150cc Go Kart (VIN PREFIX L4VM)
More informationTrouble Shooting. Pump
Trouble Shooting Pump Trouble Possible Cause Remedy Oil leaking in the area of water pump crankshaft Worn crankshaft seal, bad bearing, grooved shaft, or failure of retainer o-ring. Excessive play on crankshaft
More informationhttp://waterheatertimer.org/troubleshoot-rheem-tankless-water-heater.html
http://waterheatertimer.org/troubleshoot-rheem-tankless-water-heater.html TECHNICAL SERVICE DEPARTMENT Removal, Cleaning, & Reinstallation of the Burner Assembly For models 74 & GT199 Required tools -
More informationTri-Homo Style Operation and Maintenance Instructions
Tri-Homo Style Operation and Maintenance Instructions One Research Drive Stratford, CT 06615 (203) 375-0063 www.sonicmixing.com 1 Installation and Start-up Do not perform following adjustments without
More informationModel No: VS4815 1. SAFETY INSTRUCTIONS VS4800 2. INTRODUCTION & APPLICATIONS VS4815 3. CONTENTS. 2.1 Introduction. 2.
Instructions for: Petrol Engine Twin Camshaft Setting / Locking Tool Kit - (incorporating Vanos Alignment) - BMW N42 & N46 Engines Model No: VS4800 Associated kit: Camshaft/Carrier Bracket Remover & Installer
More informationDrive shaft, servicing
Volkswagen Passat B6 - Drive shaft, servicing Стр. 1 из 41 40-7 Drive shaft, servicing Drive shafts, overview I - Assembly overview: Drive axle with CV joint VL100 40-7, Drive axle with CV joint VL100,
More informationGEET Fuel Processor Plans
GEET Fuel Processor Plans This is a greatly simplified Proof of Concept version of the GEET Fuel Processor that just about anyone can build from parts from a local Hardware store in a weekend for very
More informationDRIVE AND DRIVEN PULLEY
11 DRIVE AND DRIVEN PULLEY SCHEMATIC DRAWING ------------------------------------------------- 11-1 SERVICE INFORMATION------------------------------------------------ 11-2 TROUBLESHOOTING-----------------------------------------------------
More informationThe Ford Model A Water Pump
The Ford Model A Water Pump George Washington Chapter, Inc. 3903 Old Lee Highway Fairfax, VA 22030 1 Table of Contents Introduction/Specifications.. 3 1. Water Pump Inspection and Removal. 4 a. Removal..
More informationGENERATOR MODEL NO: FG3050 OPERATION & MAINTENANCE INSTRUCTIONS PART NO: 8857705 LS0310
GENERATOR MODEL NO: FG3050 PART NO: 8857705 OPERATION & MAINTENANCE INSTRUCTIONS LS0310 INTRODUCTION Thank you for purchasing this CLARKE Generator. Before attempting to use this product, please read this
More informationK&T Saw Shop 606-678-9623 or 606-561-4983
11-600097F MINI-MAC 35AS 07/76 to 04/77 IPL 92754A-R1 Page 1 of 12 Accessories www.ktoutdoor.com 11-600097F MINI-MAC 35AS 07/76 to 04/77 IPL 92754A-R1 Page 2 of 12 Accessories 91753 Case - Carrying 88756
More informationINDEX INTRODUCTION. Reference No. 10-21L-01 R E V I S E D : 2 0 0 5 0 2
10-21L-01 SRM-2305, SRM-2305SI 1 1 INTRODUCTION We are constantly working on technical improvement of our products. For this reason, technical data, equipment and design are subject to change without notice.
More information11-600036D PRO MAC 60 07/72 to 12/76 IPL 89321 Page 1 of 19 Accessories
11-600036D PRO MAC 60 07/72 to 12/76 IPL 89321 Page 1 of 19 Accessories 11-600036D PRO MAC 60 07/72 to 12/76 IPL 89321 Page 2 of 19 Accessories 84453 Kit - Piston tool 69191 Kit - Pressure test adaptor
More informationLF-1 CYLINDER HEAD COVER
PITBIKE AB, SWEDEN LIFAN 50cc SOHC parts catalogue Copyright PITBIKE AB, SWEDEN LF- CYLINDER HEAD COVER 5 6 7 8 9 0 5 /P5FMI 0/P5FMI /P50FMH /P5FMI-B /P5FMI /P5FMI 5/P50FMH GB/T9 /P5FMI 5/P5FMI 8/P50FMG
More informationTomos A3 1988 Workshop Manual
Tomos A3 1988 Workshop Manual The following is a modified and English-only version of the A3 manual found at the MRA: http://www.mopedriders.org/article_view.php?faq=2&fldauto=27 Please note that this
More informationWhite Industries Rear Hub Instructions
White Industries Rear Hub Instructions Tool required: 2mm allen/hex wrench, 19mm socket, 20mm socket, and mallet. 1. Loosen the set screws located in the adjusting collar by using a 2mm allen wrench inserted
More informationCylinder head gasket, replacement
"VCC065612 EN 20110604" 1(7) Cylinder head gasket, replacement Special tools: 999 5098 Disconnect battery earth lead Drain coolant Remove heat shield over exhaust manifold. (Only the two bottom bolts on
More information12. REAR WHEEL/BRAKE/SUSPENSION
12 12 12-0 SERVICE INFORMATION... 12-1 REAR BRAKE... 12-5 TROUBLESHOOTING... 12-2 REAR SHOCK ABSORBER... 12-8 REAR WHEEL... 12-3 REAR FORK... 12-9 SERVICE INFORMATION GENERAL INSTRUCTIONS When installing
More information2003 Audi A4. AUDI' '3.0L V6 - AVK Engine - A4 & A6
Installation (A4) CAUTION: Before installation, ensure camshafts are aligned, crankshaft is locked in place and camshaft gear bolts are loose as described in removal procedures. When turning camshaft,
More informationC O N T E N T S 1 ABOUT THIS PARTS LIST... 2 ENGINE GROUP... 3 3 CONTENTS-FRAME GROUP
C O N T E N T S 1 ABOUT THIS PARTS LIST... 2 2 CONTENTS-ENGINE ENGINE GROUP ENGINE GROUP... 3 3 CONTENTS-FRAME GROUP FRAME GROUP... 5 4 ENGINE PARTS LIST... 9 5 FRAME PARTS LIST...37 1 ABOUT THIS PARTS
More informationSpicer Axles & Brakes ABIB-0302
Information Bulletin Bulletin Type: Parts / Service Information Topic: Dana LMS Hub Assembly Procedure Steer and Drive Axles Spicer Axles & Brakes ABIB-0302 Note: Bulletin ABIB-0302 replaces the original
More informationVolkswagen New Beetle 2.0 Liter 4-cyl General, Engine (Engine Code AEG) 17 Engine-Lubrication system (Page GR-17)
17 Engine-Lubrication system (Page GR-17) Lubrication system components, removing and installing Oil pan, removing and installing Oil pressure and oil pressure switch, checking Dynamic oil pressure warning
More informationAprilia.no. RS 50 96-98 Eng.6M
01 Carburettor - oil pump 02 Drive shaft 03 Head - piston 04 Primary gear shaft 05 Gearbox driven shaft 06 Selector 07 Clutch 08 Clutch cover 09 Right crankcase 10 Left crankcase 11 Ignition unit RS 50
More informationINGROUND, ROPED, AND HOLELESS JACK SEAL REPLACEMENT
D. L. Martin Company INGROUND, ROPED, AND HOLELESS JACK SEAL REPLACEMENT TYPICAL HYDRAULIC JACK HEAD ASSEMBLY 1 TOOLS REQUIRED: 1) Container to hold hydraulic fluid. 2) Clean rags and protective covers
More informationThis is the civilian transfer case with the cooling loop only found in the driven gear half of the front case.
INTRODUCTION The Transfer case used in the AMG Hummer is a New Venture Gear, model 242. This case has been in use for the H-1/Hummer since the early 1990 s. There have been modifications to the internal
More informationK&T Saw Shop 606-678-9623 or 606-561-4983
11-600016C MAC 110 01/77 to 02/83 IPL 95807-R2 Page 1 of 16 Tools & Accessories www.ktoutdoor.com 11-600016C MAC 110 01/77 to 02/83 IPL 95807-R2 Page 2 of 16 Tools & Accessories 95169 Kit - Spark Arrester
More informationDive Rite 200 & 300 Bar Isolator Manifold Service Manual
Dive Rite 200 & 300 Bar Isolator Manifold Service Manual Principal Photography and Text by Pete Nawrocky Copyright 2003 Lamartek Inc. D/B/A Dive Rite 0 Warning This manual is only to be used as a guide
More informationAXLE SHAFTS - FRONT. 1998 Pontiac Bonneville MODEL IDENTIFICATION DESCRIPTION & OPERATION TROUBLE SHOOTING REMOVAL & INSTALLATION
AXLE SHAFTS - FRONT 1998 Pontiac Bonneville 1998-99 DRIVE AXLES FWD Axle Shafts - Cars - "C", "G" & "H" Bodies GM Aurora, Bonneville, Eighty Eight, LeSabre, LSS, Park Avenue, Regency, Riviera MODEL IDENTIFICATION
More informationDYNA RIDER FOOTBOARD KIT
-J0 REV. 0-0-0 DYNA RIDER FOOTBOARD KIT GENERAL Kit Number 000 Models For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English
More informationCAM-03, Camshaft Assembly Oil Seal Replacement
CAM-03, Camshaft Assembly Oil Seal Replacement Tools Jack stands Floor Jack Metric Socket set Metric Wrench set Porsche Timing Belt Tension tool (P9201) Flywheel Lock (P9206) Balance Shaft Pin Spanner
More informationOverview PARTS LIST. B. Lever mounting base C. Flush handle assembly D. Grey/Blue float stop E. Grey float (Full Flush) F. Flush valve washer
Overview READ ENTIRE INSTRUCTIONS BEFORE STARTING INSTALLATION PARTS LIST A. Flush valve B. Lever mounting base C. Flush handle assembly D. Grey/Blue float stop E. Grey float (Full Flush) F. Flush valve
More informationMAN - MERCEDES - BENZ
SAYFA: 1 10100 10102 10103 355 353 06 15 355 353 03 15 346 353 08 15 AXLE GEAR AXLE GEAR AXLE (WITH BUSHING TYPE) (WITH BUSHING TYPE) (WITH BUSHING TYPE) 2521 2517-2521-2622 10104 10105 10106 308 350 00
More information300 SERIES 331, 332, 333, 344, 356 AND 367 MODELS
Section: MOYNO 500 PUMPS Page: 1 of 8 Date: March 1, 1998 SERVICE MANUAL MOYNO 500 PUMPS 300 SERIES 331, 332, 333, 344, 356 AND 367 MODELS Mechanical Seal Models Packing Gland Models MODELS DESIGN FEATURES
More informationSection 6 Brake Drum Failure Analysis. Brake Drum Wear Conditions. What is Normal Wear? What is Deep or Excessive Wear? WARNING. Deep, Uniform Wear
Section Brake Drum 6 Failure Analysis WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Figure 6.1 ASBESTOS AND NON-ASBESTOS FIBERS
More informationSTEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER
14 14 STEERING HANDLEBAR/FRONT WHEEL/ SCHEMATIC DRAWING ------------------------------------------------- 14-1 SERVICE INFORMATION------------------------------------------------ 14-2 TROUBLESHOOTING-----------------------------------------------------
More informationService Manual. 150cc Product 6150/7150/200 Series
Service Manual 150cc Product 6150/7150/200 Series FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the 6150/7150
More informationCHROME FRONT BRAKE MASTER CYLINDER KIT
-J075 REV. 009-0-0 CHROME FRONT BRAKE MASTER CYLINDER KIT GENERAL Kit Number 5-99D, 5-99D Models These Chrome Master Cylinder Kits are designed to replace the original equipment front brake master cylinder
More informationWHAT YOU DON T KNOW ABOUT ACCUMULATORS CAN KILL YOU!
WHAT YOU DON T KNOW ABOUT ACCUMULATORS CAN KILL YOU! Atlanta (Monroe) GA 770-267-3787 gpm@gpmhydraulic.com www.gpmhydraulic.com What You Don t Know About Hydraulic Accumulators Can Kill You TABLE OF CONTENTS
More informationRear wheel brakes, servicing. Стр. 1 из 45. Note:
Volkswagen Touareg - Rear wheel brakes, servicing Стр. 1 из 45 46-2 Rear wheel brakes, servicing Rear brakes, FN 44 brake caliper, servicing Note: After replacing brake pads, depress brake pedal firmly
More information