Table of contents 1

I. Introduction *

II. Engine Operation *

A. Engine Components *

1. Engine Block *

2. Cylinder Head *

3. Crankshaft *

4. Piston and Piston Rings *

5. Piston Design *

6. Ring Grooves *

7. Piston Dynamics *

8. Connecting Rod *

9. Bearings *

10. Flywheel *

11. Valve Train *

12. Valve Dynamics *

13. Valve Seats *

B. Four Stroke Cycle Engines *

1. Intake Event *

2. Compression Event *

3. Ignition Event *

4. Power Event *

5. Exhaust Event *

C. Additional Engine Considerations *

1. Valve Overlap *

2. Compression System *

3. Changes in the Charge *

4. Piston Ring Break-In *

III. Tools *

A. Ratchet & Sockets *

B. Spark Plug Socket *

C. Torque Wrench *

D. Standard Screw Driver *

E. Mallet *

F. Box and Open Ended Wrenches *

G. Pliers *

H. Piston Ring Compressor *

III. Safety Precautions *

IV. Engine Disassembly *

A. Guarding and Cover Removal *

B. Cylinder Head Removal *

C. Fuel System Removal *

D. Crankcase Cover Removal *

E. Camshaft and Push-Rods Removal *

F. Piston and Connecting Rod Removal *

G. Flywheel and Crankshaft Removal *

V. ENGINE ASSEMBLY *

H. Flywheel and Crankshaft Assembly *

I. Piston and Connecting Rod Assembly *

J. Camshaft and Push-Rods Assembly *

IV. Crankcase Assembly *

K. Cylinder Head Assembly *

L. Fuel System Assembly *

M. Guarding and Cover Assembly *

V. References *

List of Figures

Figure 1- Cylinder Head *

Figure 2 - Crankshaft *

Figure 3- Crankshaft-Camshaft Synchronization *

Figure 4 - Piston Rings *

Figure 5 - Piston Ring Gap *

Figure 6- Piston Assembly *

Figure 7- Intake & Exhaust Valves *

Figure 8 - Ratchet, Socket, Nut Driver, and Socket Adapter *

Figure 9 - Torque Wrench *

Figure 10 - Standard Screwdriver *

Figure 11 - Box End Wrench *

Figure 12 - Open End Wrench *

Figure 13 - Combination Wrench *

Figure 14 - Needle Nose Pliers *

Figure 15 - Adjustable Pliers *