(4) Turn the crankshaft to raise the connecting rod to its highest point in the crankcase and install piston (20) on the
connecting rod, securing the piston with piston pin (19) and snap rings (21).
With piston at top dead center, piston and cylinder should be flush. Adjust with
gaskets under cylinder as necessary.
(5) Clamp cylinder (17) to crankcase with a force of 9±3 ft-lbs. (12±4 Nm)and measure from top of piston (20) to
top of cylinder (17).
(6) Clamp cylinder head (3) in vise, top down.
(7) Install new discharge valve assembly (16) in cylinder head in the following order.
(a) Install gasket (24) in bottom of valve bore.
(b) Install valve seat (25) in bore, flat face down.
Disk must be centered on raised portion of seat.
(c) Place valve disk (26) in position on valve seat (25).
Make sure spring is properly seated in plug
(d) Install wide diameter of spring (27) in plug (28).
Use valve key tool to tighten plug until it bottoms out.
Plug must be below surface of head when properly installed. If plug did not go in all
the way, remove it and make sure valve disk is properly centered in bore.
(e) Install plug (28) and spring (27) in head (3).
(f) To lock in place, center punch the plug and head in three places.
(8) Turn cylinder head (3) over.
(9) Install new pressure valve assembly (10) in cylinder head (3) in the following order:
(a) Install gasket (29) in bore.
(b) Install valve seat (30) flat face down.
Valve disk must be centered on raised portion of valve seat.
(c) Place valve disk (31) on top of valve seat (30).
Spring and disk must be centered in bore.
(d) Place spring (32) on top of valve disk (31).
When properly installed, legs of valve insert will be free to contact valve seat with no
interference from disk.
(e) Place valve insert (33) over spring (32).
(10) Install preformed packing (8) on plug (7). Preformed packing must be in large groove.