remove
glow plug extension - if you use one
remove fuel line and pressure line - I
usually take the pressure line loose from the tank side
so as to reduce stress on the muffler end of the tubing.
This area has a decreased lifetime due to the high heat.
take off the muffler - it is held on
with two bolts
remove throttle link - page 15, step 17,
item 5
remove the four bolts from engine mount
- page 10, step 10, items 1
take out engine - the engine, fan, and
clutch all drop down togetherremove start
coupler - held on with two set screws
remove start shaft - if the shaft does
not easily slide through the bearings then it probably
because the set screws caused the shaft to bulge out and
make it too big to go through the bearings. You can use a
dremel with a grinding stone to grind down the bulged
area. I recommend placing a paper towel over the shaft
and poke the shaft up through it so that the paper towel
catches the grindings. You don't want the metal grindings
to get in the top bearing. BTW: Do not try to force the
shaft through the bearings, you will end up pitting the
bearing races.
remove screws in pitch arm - page 8,
step 6, item 2 and 3. The bolts have collars on them that
you don't want to lose. Also the bolt on the right side
has a small washer. I usually place a small diameter
piece of fuel tubing on the end of the screw to keep from
loosing the parts.
remove collective link - page 15, step
17, item 6
lift pitch arm off and hold up out of the way
with a rubberband
remove screws in bearing blocks all the way back
to the main shaft - remove all the screw in this
area that keep you from spreading the frames
spread frames - the plastic flexes
enough for you to get the bearings out.
remove top bearing and pinion bearing -
page 6, step 3, item 2 & page 5, step 2, item 1
Trim plastic from bearing block - use a
dremel and cut 1mm from each side of the bearing blocks.
I colored this area red in the picture.
reverse order to put it back together, some
things to note are:
+start shaft installation - you have to
push it up all the way. If you look at the bottom of the
shaft the top edge of the big end should be up against
the bearing. in the clutch bell. And when you put the
start coupler on make sure you get the flat sides in the
top of the shaft aligned so the set screws will engage
them. Use blue loctite on the set screws. As you tighten
the set screws you need to push upward on the shaft and
downward on the start coupler. That will eliminate any up/down
play in the shaft.
+engine alignment - I use the start
coupler to tell me if the engine is aligned. When you
rotate the start coupler counter clockwise it should spin
with little to no resistance. I twist the engine left/right
or twist forward/backward until I can spin the start
coupler backwards and have little to no resistance. In
some cases I have to increase the size of the bolt holes
to allow me to angle the engine just right.
+install muffler - If the bolts thread
into the muffler then be sure to use some blue loctite,
if the bolts extend through the muffler exhaust flange
and go into some nyloc nuts then do not use loctite.
After the first tank of fuel, retighten these bolts while
the engine is still hot.
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