Crankcase Cover Installation; Flywheel Installation - Pioneer 1200 Maintenance Service Manual

13
FE400 ENGINE

CRANKCASE COVER INSTALLATION

CAUTION
• Before assembly, make sure parts are clean.
• Do not reuse the gasket. Install a new one.
• Install and tighten crankcase cover bolts as instructed. Failure to do so could cause the cover
to become warped.
1. Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the
oil seal for wear and damage.
2. Install crankcase cover. Using HANDS ONLY, seat cover completely against the crankcase.
3. Install and finger tighten evenly the eight cover mounting bolts (Figure 13-10, Page 13-9).
4. Tighten the cover mounting bolts in two steps. First, in the sequence shown, tighten all eight bolts to
approximately 130 in-lb (14 N·m). Then, repeating the sequence, tighten them to 250 in-lb (28.2 N·m).

FLYWHEEL INSTALLATION

See General Warning, Section 1, Page 1-1.
1. Connect the yellow jumper wire (11) to the cord connector (12) (Figure 13-2, Page 13-4).
CAUTION
• Before assembly, make sure parts are clean.
2. Insert the flywheel key into the keyway in the crankshaft and align the flywheel keyway. Push the flywheel
and fan onto the crankshaft until it seats. Install flat washer and nut finger-tight.
3. Use a strap wrench (3) to keep the flywheel and fan (1) from turning. Tighten the flywheel nut to 63 ft-lb
(85.4 N·n) (Figure 13-11, Page 13-9). See following CAUTION.
CAUTION
• The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to
loosen.
• Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place
screwdriver or pry bar between fan blades.
4. Install the fan housing and tighten the seven screws to 90 in-lb (10 N·m).
5. Install the fan shroud and tighten the four screws to 25 in-lb (2.8 N·m).
Page 13-8 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Flywheel Installation