14
STEP 36:
Reinstall the carburetor with a new o-ring, header,
a
NEW glow plug, and engine mount. Use a new
header
gasket when re-installing the header on
the engine. Reinstall the engine in the truck in the
reverse order of removal. Don’t forget to reconnect
the yellow grounding wire to the engine mount. The
rebuilt engine must now be broken in.
STEP 31:
Reinstall the backplate and a new backplate gasket
with
the
3x8mm
cap-head
machine
screws.
Tighten
the screws in small increments, in a criss-cross pattern
until all the screws are tight.
STEP 32:
Install the appropriate size ball bearing into one side of
the clutch bell gear. The Nitro Sport comes stock with
an 18-tooth clutch bell gear which requires 5x11mm
ball bearings.
STEP 33:
Turn the gear over and install the other ball bearing.
STEP 34:
Install the split-beveled cone onto the crankshaft.
Next, install the flywheel. Install the clutch adapter
nut
with
a
10mm deep
socket. Grip the flywheel
with pliers while tightening
the adapter nut.
STEP 35:
Install the clutch shoes
exactly as shown in the
drawing (leading edge
engagement). Next, install
a 5x8mm washer followed
by the clutch bell gear
(with bearings installed).
Install the remaining
5x8mm washer followed
by the E-clip (see step 14).
STEP 25:
To
assemble
the
connecting
rod
and
piston,
place
a drop of castor oil in the top end of the connecting
rod. Insert the wrist
pin through the piston and the
top
of
the
connecting
rod.
Secure
the
wrist
pin
with
the G-clip. Make sure the G-clip fits securely into
the groove machined in the piston. Be careful not to
scratch the sides of the piston.
STEP 26:
Reinstall
the
crankshaft
into
the
engine
and
make
sure that it spins freely. Insert the connecting rod and
piston assembly through the top of the crankcase. The
G-clip
should
face the carburetor. Put
a drop of castor
or after-run oil in the bottom end of the connecting
rod. Use your fingers to gently push the end of the
connecting rod over the crankshaft journal.
STEP 27:
Place another drop of oil on the connecting rod bushing.
Rotate the
crankshaft several times
to distribute
the oil.
STEP 28:
Insert the sleeve into the top of the crankcase. Rotate
the sleeve so that the notch in the sleeve will line
up with the pin in the crankcase. Holding the engine
upside down will make it easier for the sleeve to go
over the piston.
STEP 29:
Install new head gaskets on the head. Use one
thick and one thin gasket. Reinstall the head using
the 3x12mm cap-head machine screws. Tighten the
screws in small increments, in a criss-cross pattern,
until all the screws are tight.
STEP 30:
Reinstall the starter shaft. Align the notch in the starter
shaft with the crankshaft journal pin (arrow).
