Install counterweight onto crankshaft (62, 9, Fig. D-4). Secure counterweight with one pinch bolt, nut
and washer. (Tighten to 18 ft-lbF., (25NM))
Check connecting rod total side clearance. Clearance should be .015" (.38mm) to .035" (.89mm).
Install crank assembly into crankcase (17, Fig. D-4).
Assemble crankcase end housing, crankshaft and connecting rods into crankcase. Make sure
crankcase bearing enters crankcase properly. Make sure connecting rods come out of proper cylinder
Align holes in crankcase end housing with tapped holes in crankcase. Secure crankcase end housing
to crankcase with 6 socket head bolts and washers (1 and 2), Fig. D-4). Tighten bolts in a "star" pattern
to a torque of 18 ft-16f. (25NM).
Position oil pump drive cam (11, Fig. D-4) over end of crankshaft (9, Fig. D-4). Align bolt holes in cam
with tapped holes in crankshaft. Secure oil pump drive cam with 2 bolts and 1 tab washer (13, and 12,
Install O-ring on filter mount (14 and 15, Fig. D-4). Position filter mount over opening in crankcase.
Align bolt holes in filter mount over tapped holes in crankcase. Secure filter mount with socket head
Install one snap (52, Fig. D-4) into guide piston.
Install wristpin (51, Fig. D-4) into piston. Push wristpin only part way through guide piston.
Position guide piston over connecting rod. Align wristpin with connecting rod bearing. Push wristpin
Install third stage lower cylinder and upper cylinder (60 and 47, Fig. D-4).
Rotate crankshaft so that third stage guide piston (49, Fig. D-4) is at its top position.
Position lower cylinder (60, Fig. D-4) over guide piston, align stud holes in cylinder with studs and seat
cylinder onto crankcase.
Position third stage upper cylinder over studs as shown in Figure D-4 Secure upper and lower cylinders
to crankcase with 4 nuts and washers. Tighten nuts to a torque of 18 lb/ft. (25NM).
Install third stage piston and sleeve (45, Fig. D-4).
Press third stage piston and sleeve into third stage cylinder (47, Fig. D-4). Make sure shoulder at top of
sleeve seats against top of cylinder.
Install third stage cooling ring (44, Fig. D-4) over and around top shoulder of third stage piston and
Always install third stage piston sleeve as a factory matched set. O-rings (46, Fig. D-4) are supplied with