Remove the fixing screws of the starting pulley and remove the pulley
Using the special puller supplied, fit it to the flywheel with screws and tighten the puller centre screw against the end of the crankshaft
Tap the head of the puller screw lightly with a hammer to loosen it. The flywheel should then be easily removed from the cone. Webmaster's Note: Take care not to lose the Woodruff key when removing the flywheel.
Note: If the crankshaft is damaged, return it to the Manufacturer or to a Workshop recommended by the Manufacturer, to be repaired.
Oil lightly all the moving parts and shaft seals, paying particular attention to cleanliness.
The assembly is carried out in the following sequence:
Assemble the bearings on the crankshaft and, using a suitable sleeve, tap against the inner ring of the bearing until it is in its correct position
Assemble the shaft seals, taking care not to damage them
Fit the crankshaft to the rear part of the crankcase, coat the sealing surfaces evenly with sealing compound and assemble the front part of the crankcase on the crankshaft, ensuring that the cylinder head
joint surface is level
Tighten the fixing screws
Check the assembly of all parts installed so far by rotating the crankshaft
Fit the piston assembly, ensuring that the piston ring grooves face the front (flywheel end) of the engine
Assemble the cylinder and its gasket
Assemble the magneto armature, flywheel and starting pulley
Refit the reversing gearbox
Assemble the starter generator, V belt, V belt cover, carburettor and exhaust gas collector
Assemble the flywheel on the crankshaft, ensuring that the Woodruff key enters the keyway provided
Replace the nut on the flywheel and tighten it with a torque spanner (torque wrench) to 10 kpm. If a torque spanner is not available, adopt the following procedure:
tighten the nut with a suitable socket wrench or box spanner as much as possible while holding the flywheel with the other hand
tighten the nut 1/6 (one sixth) of a turn by tapping the end of the spanner with a hammer
If the fixing holes of the starting pulley do not line up with the corresponding holes in the flywheel, the nut must be tightened still further until the holes line up. The torque must never be reduced in order to effect the lining-up of the holes.
Separate the reversing gearbox from the engine as described above.
Remove the water pump from the rear of the reversing gearbox by removing the housing fixing screws, then removing the case, impellor and gasket
Using the impellor puller provided, remove the coupling flange
Remove the shafts from the casing by pulling them forward. Use a hide hammer on the rear part of the shaft if difficulty is experienced
Remove the gear lever (coupling rod) from the coupling crank by removing the elastic taper pin in the end of the shaft. When removing the gear lever, take care not to lose the spring and locating pin
Remove the coupling crank from inside the gearbox
The gear wheel of the reversing gear and its bearing can be removed by removing the locking ring from the shaft end
Remove the bearings, taking care not to damage the cone surfaces and the splined shaft
