106852-4020 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1068524020 121091002

To ensure safety, make sure that bolts and bar for the prevention of crankshaft rotation have sufficient strength.
Flywheel
Installation of flywheel housing(1) Install the oil seal to the flywheel housing.(2) Coat the contact surfaces of the crankcase and flywheel with ThreeBond 1104.(3) Align the holes in the flywheel housing and gasket with the dowel pins on the crankcase, and install them to the crankcase.Installation of Flywheel
Installation of flywheel(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.Measurement of Flywheel Runout
Measurement of face runout and circular runoutMeasure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles. Cylinder Head and Valve Mechanisms
Installation of valve stem seal(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide. Installation of Valves and Valve Springs
Installation of valve and valve spring(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Confirmation of secure valve cotter installation(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.Installation of Cylinder Head Gasket
Installation of cylinder head gasket(1) Make sure the top surface of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of Cylinder Head
Installation of cylinder head assemblyPlace the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.Tightening of Cylinder Head Bolts
Cylinder head bolt tightening sequenceTighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.Assembly of Rocker Arm and Rocker Shaft Assembly
Assembly of rocker shaft assemblyWhen installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.Installation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
Installation of rocker shaft assembly(1) Install the valve caps.(2) When installing the rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (reversal of removal