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 Post subject: Engine REBUILD With PICTURES
PostPosted: Fri May 10, 2013 11:45 pm 
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Posts: 397
I'm going to give it a shot at an amatuer tutorial. Feel free to add comments. The first picture is the newly purchased engine that had little to no run time on it. It is a clean engine to start with but I am going to give it a complete going thru. Seals go bad and dirt accumulates over time.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Fri May 10, 2013 11:52 pm 
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The next picture is with it completely dismantled. Don't worry, I can put these back together blind folded. I do recommend that you watch for flying bearings. These engines are loaded with them. I remove the fly wheel by backing off the nut half way, holding the weight of the engine by the fly wheel, and taking a couple of quick snaps with a hammer to the nut to release the pressed on fly wheel. Works every time. Don't go crazy with the hammer because you will screw up the threads on the nut or shaft.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 12:00 am 
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Next is cleaning all of the individual parts including the points, screws and small parts.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 12:02 am 
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Posts: 397
Take the starter apart, clean the spring, reinstall it, and use a light oil to lubricate it. This is a whole experience in itself.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 12:12 am 
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Thoroughly clean and rebuild the carb with my diaphragm. A clean fuel system is a happy one. A great tutorial is this link: carb-repair-t1184614.html Install a new element in the air cleaner. The two tier air cleaners like this one are easy, cutting a circle out of a generic Briggs filter. You have to stuff them if you have the earlier single tier filters.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 12:15 am 
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When bearings fall, you will have to reload them. Lithium grease works great to hold them in place. Check, clean and/or rebuild the feather valve.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 12:25 am 
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Clean the crankcase. These engines are notorious for sucking in the old, dry rotted air filters. I have seen cases where they have scored and ruined the pistons and cylinders. The bearings on the crankshaft/connecting rod are a "you know what" to reload. It never fails that they fall out. Make sure that your cylinder is tight and the gaskets are either seated well or replaced.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 12:30 am 
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I almost always replace and lubricate the PTO seal. The right sized "O" ring in diameter and thickness will work.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 12:32 am 
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I also replace the crank side seal. I have these available. Reinstall the cleaned points and gap to .20". Notice that the copper conducter arm on the moving contact is on the inside of the post. They will not spark, otherwise.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 9:19 am 
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Location: Leicester MA
Nice!
What do you use to gap the coil to the flywheel? 2 one dollar bills, a business card, 2 feeler gages, or something else?

I agree, those bearings can be a PITA when they fall all over the place, not to mention cleaning them and putting them back in. They caught me by surprise on the first engine I opened up and it took me forever to find them all. Plus I was looking for more than there actually was to begin with so that didn't help.

Very good pic showing the old air cleaner debris inside the crank case.



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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 10:42 am 
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I then install the feather valve, PTO, and freshly greased gearbox. Personally, I use lithium grease.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 10:52 am 
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Next, install the carburetor. It takes a real skinny screwdriver to tighten the rear carb screw. I like to put the cylinder shroud in place at this time. It can be really hard to get between the carb and cylinder if you wait until you install the starter shroud. Then goes the governer vane. The little finger on the tip goes in to the slot on the carb throttle
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 10:55 am 
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Here you go, John. I install the fly wheel next by lining up the key way (don't forget the woodruff key) and snugging the nut and washer. I install the coil and gap it with a business card.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 10:59 am 
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Here's a top view. I then install the pull starter, second cylinder shroud, muffler and air cleaner.
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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 11:04 am 
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I will test fire it and try to make a video today to make sure that it is ready for my customer to install on his go-kart. Those of us in the know, realize that some of these engines fire up like a breeze, and some are a "you know what" to get running. Do not store with fuel in the tank and preferably run the gas thru with a preserver. Bad gas is the biggest demise to these little guys!


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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sat May 11, 2013 3:41 pm 
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Here is a video of it running. It is idling a little high and needs some fine tuning. http://www.youtube.com/watch?v=ATSurZnl ... e=youtu.be


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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sun May 12, 2013 10:20 pm 
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Location: Leicester MA
Thanks for taking the time to do the tutorial and this makes a great reference thread.
Any chance you can shed some light on this go-kart project that this engine is for?



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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Sun May 12, 2013 10:49 pm 
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It is a very early Scat Car made by AMF. Most of the Scat cars were pedal powered, a few came with O&R engines. It had one of the earliest engines that I have ever seen, but it was trashed. Just as he sent me the engine, one popped up on Ebay that was a little later, but it had the exact gear box and the fuel tank that he needed. I recommended that he buy it because it was worth every dime to use for the car that he has. I will have him post pictures of the completed project.


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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Wed Jan 08, 2014 10:46 am 

Joined: Tue Jan 07, 2014 12:18 pm
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Location: Oxford, CT
What is the purpose of the black, finger pointing shaped, lever just below the carburetor and needle valve? It is spring supported in two places but I cannot get it to move into the other slotted positions. It appears to be fixed in the center slot.



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 Post subject: Re: Engine REBUILD With PICTURES
PostPosted: Wed Jan 08, 2014 8:01 pm 
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Location: Leicester MA
That's a governor adjuster. It applies more tension or decreases tension on the spring for the throttle butterfly to adjust and govern the RPMs. To move it, you will need to pull up on the little "lock thingy" and then you can move the lever. Having it adjusted properly will limit the high RPMs so the engine doesn't over rev. above 6300 rpm



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