rings, pins, rods and related parts were also balanced. The flywheels were
statically balanced at 60%. Then the pinion shaft was installed; the nut was
lapped flat using 4(X) paper on glass. The pinion was torqued to 275
foot-pounds. The process was repeated on the sprocket shaft, which was
torqued to 400 foot-pounds, with 350 foot-pounds on the crank pin nuts.
up the pinion shaft hearings we used the one-piece caged pinion bearing as
opposed to the multiple-piece caged hearing for a better fit. The one piece
appears to carry more of a straight load, has less rotating parts and less
area for friction due to less pieces.
shaft bearing was heated slightly on the inner race with map gas to ease in
its installation. It was allowed to cool then was lubricated and installed
in the left case half. The outer hearing was installed and the end play
checked. The seal was installed so that it was cup shaped, which is not how
you would normally see it. This keeps the primary oil out of the engine.
bearing was lubricated and the right case half installed and torqued to 25
foot-pounds using the Harley-Davidson pattern.
flywheels were being set up the cylinders were being prepared for boring and
honing. Special aluminum torque plates were used along with gaskets and
torqued to 25 foot-pounds, then 35 and finally, 45 foot-pounds. They were
bored and then honed using a AN500 Sunnen hone and finished to .0001 of
final size and then plateau brush finished, which is a 280 grit.
cylinders are honed and cleaned, the ring end gap was set. The top ring was
set up with .006 per inch of bore and the second ring was set up with .005
per inch. The pistons with rings installed were put on the rods and the
cylinders installed and secured.
indicator was installed and measured top dead center of the front piston. A
degree wheel was installed and the engine was then turned backwards
(clockwise) and the 25-degree timing mark installed. This turned out to be
the same as our calculations of .281 using the dial indicator. The same
procedure was performed on the rear cylinder. The oil pump had the check
ball seat reestablished using a special cutter before installation.