Instruction manual

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A. Select four #0003 M3 Flat Washers (large), four #0019 M3 Hex Locknuts, and four #0067 M3x14 Socket
Head Bolts. Additionally, select one each #119-50 Left Motor Mount and #119-51 Right Motor Mount.
Examine the drawing and note two 3.0mm holes (ahead of the vertical slots) passing through each side frame
and the #115-12 Vertical Front Channel. Prepare four #0067 M3x14 Socket Head Bolts by installing one
#0003 M3 Flat Washer on each. Loosely install the appropriate motor mount onto each side frame by
inserting a bolt and washer at each hole (through the vertical front channel) and adding one #0019 M3 Hex
Locknut inside, tighten each so that the mounts are secure but can be slid up/down for the next step.
B. Select two #0079 M3x35 Socket Head Bolts and add a little Blue Loctite. Select one #115-53 Inner Motor
Mount Block. Examine the drawing and note the opposite direction for the installation of each #0079 Socket
Head Bolt, and install the block and bolts. Tighten the bolts so that the motor mount can still slide up and
down. Using the two lower holes below the motor mounts, install two #0077 M3x30 Socket Head Bolts and
two #0019 M3 Locknuts on the opposite side. On the underside of the #122-41 lower plate, below the Inner
Motor Mount Block #115-53, install two #0063 M3x10 Socket Head Bolts and two #0003 M3 Washers. Use
Blue Loctite on the bottom bolts. Tighten all bolts securely (with exception of the two #0079 Socket Head
Bolts).
C. Select four #0080 M4x14 Socket Head Bolts, Motor Mount Shims (as appropriate for your gear ratio
requirements, see next step), and the #0549-19 Alignment Tool. Examine the alignment tool and note the slot
next to the half-round cut-out area. The tool is intended to set a gap between the clutch driver and the fan
hub, with the slot and cut-out providing clearance around the drive pins and Delrin ball on the clutch driver.
Prepare each engine mounting bolt by adding Blue Loctite. Prepare the engine by making sure the carburetor
stop screw is adjusted to allow for a fully closed carburetor (determined by visually observing the closed
barrel and the inability to blow air through fuel line connected to the fuel inlet).
D. The #0546-16 molded dampeners within the fan hub will accept the clutch driver pines in any one of three
ways: 1) dry, or lubricated with either 2) talcum powder or 3) a thin coat of petroleum jelly (Vaseline). Do
not lubricate the Delrin ball. Slide the engine into position, making sure each drive pin is properly in each
dampener. Install Motor Mount Shims (as appropriate for your gear ratio requirements) on each motor mount
and the four #0080 M4x14 Socket Head Bolts prepared with Blue Locktite to secure the engine, leaving the
bolts loose enough to allow engine movement. Insert the #0546-19 Alignment tool from either side and firmly
push the engine/fan assembly against it and the clutch driver. The most convenient method to apply this force
is by putting the thumbs of each hand (from each side) atop the clutch bell and the remaining fingers below
the fan, then squeezing with both hands until the two components are fully engaged.
E. The engine should Ahang@ naturally in alignment with the motor mount as viewed from all sides. Since the
Amotor mount to frame@ bolts are still loose enough to allow adjustment, you should be able to align all
components (it may be helpful to lightly tighten the Amotor to motor mounts@ at this point to clarify the
alignment. This procedure is important since poor alignment will prematurely wear out the clutch bearings,
ball and dampeners. Since the clutch ball can act as an Aarticulated joint@, the important factor is that, even if
the engine were at a slight angle, the fan hub and clutch Delrin ball be aligned at the point of contact. This
Apoint of contact@ is approximately 3.75 to 4.0mm below the top surface of the fan hub. After alignment,
tighten all related bolts with moderate torque. Note: future removal of the engine will not require loosening
the motor mounts at the frames so the process will be much simpler.