Hobbies And Interests
Things You'll Need
Instructions
Unscrew the four bolts that fasten the engine to the vehicle chassis. Pull the entire engine and exhaust out of the chassis out of the vehicle. Loosen the two screws that mount the exhaust pipe and header to the engine. Separate the engine from these two components by pulling them apart.
Loosen the three screws that fasten the EZ-start mechanism to the engine. The EZ-start consists of a gear housing, which is connected to the side of the engine encasement. Remove the screws, then pull the gear housing off the engine.
Detach the 5.0 E-clip from the crankshaft, then push the clutch bell off the end of the crankshaft.
Use an 8-millimeter socket to unscrew the flywheel nut, then remove the nut from the crankshaft. Separate the flywheel from the crankshaft, then part the split-cone washer from the crankshaft by wedging a flat head screwdriver in between them. Pull the slip-cone washer off the crankshaft, then slide out the four clutch shoes from within the flywheel. Set everything aside.
Unscrew the glow-plug from inside the cooling head, then loosen the four mounting screws that affix the back plate of the engine to the crankcase. Pull the back plate off.
Loosen the five head bolts from the cooling head, then separate the cooling head from the engine case. Remove the copper head gasket and set it aside.
Access the bottom of the sleeve through the rear of the crankcase, then pry it up and out using a wooden utensil. Push the utensil underneath the sleeve, then leverage it out of its snug position. Heat the engine with a hair dryer to help loosen a tight-fitting sleeve.
Spin the rod and piston to top dead center --- the 12 o'clock position --- then slide the connecting rod off the crankpin with the needle-nose pliers. Pull the rod and piston out of the top of the engine encasement.
Face the oiler hole in the connecting rod toward the crankshaft, then drip a drop of synthetic motor oil onto the crankpin. Insert the replacement rod and piston down into the crankcase, then use the pliers to key the crankpin through the connecting rod.
Lubricate the piston with synthetic motor oil, then slide the sleeve back into the crankcase. Press the sleeve down as far as it will go. Key the slot on the backside of the sleeve into the pin located at the back gap of the engine encasement; in other words, the pin of the engine case should slide into the slot on the sleeve.
Insert the copper head gasket, then fit the cooling head onto the sleeve.Tighten the five head bolts into the cooling head in a cross-shaped pattern; in other words, turn one screw a half-rotation, then repeat this with the screw located diagonally across from the first. Continue this process until all five screws are snug.
Push the starter shaft into the engine case, then key it into the crankpin. Secure the backplate onto the engine case with the four screws removed in Step 5. Screw the glow plug back into the cooling head.
Install the split cone washer onto the pilot shaft so that the largest opening faces the engine encasement. Place the flywheel onto the pilot shaft, then connect it with the the slit cone washer. Tighten the flywheel nut until it holds the flywheel firmly in place.
Install the clutch shoes into the flywheel, then key the flywheel pins into each corresponding clutch shoe. Attach the EZ-start housing to the engine by fastening it to the back plate with three screws removed in Step 2.
Reattach the exhaust header and pipe assembly to the rear of the engine encasement by tightening the two fastener screws removed in Step 1. Replace the engine into the chassis of the vehicle.