TM 5-3805-255-14
0065
ASSEMBLY CONTINUED
19. Install plug (Figure 9, Item 2) in cylinder head (Figure 9, Item 3).
20. Install sleeves (Figure 9, Item 10) and plungers (Figure 9, Item 9) on crankcase (Figure 9, Item 8). Install
unloader pistons in their bores. Position unloader plungers in their guides and slip them in and over the piston
tops. Install unloader spring seat in the crankcase inlet cavity. Position the saddle between the unloader guide
piston guides so forks are centered on guides. Install unloader spring, making sure it seats both in crankcase
and on saddle.
21. If removed, install discharge valve seats (Figure 9, Item 6), discharge valves (Figure 9, Item 5), and discharge
valve springs (Figure 9, Item 4) on cylinder head (Figure 9, Item 3). After installing new discharge valves,
springs, and seats, the discharge valve travel should be between 0.041 and 0.057 in. (1.04 to 1.44 mm).
NOTE
The dimension from top of the cylinder block to the inlet valve seat should not exceed
0.113 in. (2.87 mm) or be less than 0.101 in. (2.56 mm). If inlet valves cannot be reclaimed
by lapping with crocus cloth, replace inlet valves.
22. Install two inlet valve seats (Figure 9, Item 11), inlet valve guides (Figure 9, Item 12), and inlet valves (Figure 9,
Item 13) in crankcase (Figure 9, Item 8).
23. Install two inlet valve springs (Figure 9, Item 14) on cylinder head (Figure 9, Item 3). Apply a turning motion to
the spring after it is in cylinder head. If spring does not stay, apply a small amount of grease to hold spring in
position.
24. Install new cylinder head gasket (Figure 9, Item 7) on cylinder head (Figure 9, Item 3).
25. Install cylinder head (Figure 9, Item 3) and six bolts (Figure 9, Item 1) on crankcase (Figure 9, Item 8). Torque
bolts to 25 to 30 lb-ft (34 to 41 Nm).
0065-12
