The heads are shipped in a separate box

  tms-cyl-blk73                                                            tms-case-assem181

INSTALLING EMC CYLINDER to CRANKCASE

·        1.  Do a dry interference checking installation of cylinder, piston without rings, and install onto the crankcase. Press the cylinder assembly until seated.  Now rotate the crankshaft and inspect for any interference.  Three types of interference can occur: first, check the cylinder to cylinder bind at the sleeve and at the aluminum fin area; second, check the piston to piston bind at bottom dead center of the crankshaft and the piston to cylinder clearances; finally, check the connecting rod-to-rod angle while rotating through bottom dead center.  Now you are ready to do final assembly.

·        2.  File the piston rings to the appropriate gap and install on the piston.  See dimension details in the piston ring package.

·        3.  Using a ring compressor, install the front piston stamped on top with (F2) into the front cylinder.  Push piston to the bottom of the cylinder but do not allow the oil ring to be exposed.  Install one oil seal o-ring to the front cylinder drain tube and one to the back cylinder drain tube.

·        4.  Rotate the connecting rod so the wrist pin hole is 1 inch above the crankcase deck.

·        5.  Apply Yamabond #4 to the oil o-ring.

·        6.  Place both cylinders upside down on a clean workbench.  Clean the base of the cylinder and 1/8 inch of the iron liner.  Apply 1/16 thickness coat of Yamabond #4 and allow 30 seconds of drying time.  Be sure the edge between the iron sleeve and the base of the cylinder is thoroughly coated.  This ensures that no oil seeps up the liner walls and comes out between the fins.

·        7.  Press the wrist pin ½ way into the piston.  Do the same for the rear piston stamped with (R2 for the rear cylinder.  Note F2=+.002 over sized Front piston. 

·        8.  Now you are ready to slide the rear cylinder and piston assembly on the crankcase.  Align the rear connecting rod and finish the wrist pin assembly.  Do the same for the front. 

·        9.  You are now ready for the next step, which is installing the cylinder heads.

INSTALLING CYLINDER HEADS

      ·       Do a dry interference check. 

·       Install head on to the cylinder without any orings and check for total seating of head to cylinder.  Verify that at most .005 inch gap exist. 

·       Now check the head oring depth using the 4.25 oring and the s.s. arc gauge.  Depress the oring into the .157 deep groove and check the depth using the arc gauge.  This gauge must not protrude more than .005 inch from the surface of the cylinder head.  See drawing 425CYL13.

·       Check the compression release depressed and pulls out and is leak tight.  Blow air into the head surface release hole and check for leaks at the blue release assembly.

·       Now you are ready to install the heads.

·       Apply a thin layer Yamabond #4 to the cylinder top oil drain tube oring.

·       Apply a thin layer of Yamabond #4 into the bottom of the 4.25 inch cylinder head oring groove.  Press the oring into the groove.

·       Now your ready for final assembly of the heads onto the cylinder.  Install heads and torque the heads to 20 ft-lb and check for approximately .010 inch uniform gap between the top of the cylinder and the bottom of the head.  Now torque down the heads to 35, 40, and 45 ft-lb.  Wait overnight to allow for oring squish to give zero head to cylinder top clearance.  Recheck torque for 45 ft-lbs.

Enclosed:

        6 viton oring 3/32 T x 5/16 ID  p/n –109v ……..(   )

        4 viton roing 3/32 T x 4/25 ID  p/n-156v ……….(   )

        1 stainless steel ¼ arc gauge …………………..(   )

        3 drawings 425cyl51, 425pis20, 425cyl13 …….(   )

        1 Yamabond #4 ………………………………….(   )