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Kalamazoo, Michigan.
It
is recommended that this
tool only be used for these operations. Removing and
replacing bushings with makeshift tools and methods
can result in irreparable damage to the crankshaft
and/ or dampeners. Order tool direct from Borrough's
Tool and Equipment Corporation.
(5) Stone small nicks in connecting rods.
Replace
bolts if damaged in any way. Replace damaged nuts.
Press
out
excessively· worn
bushings;
smooth
bores; oil new bushings, and press in with split at
45
0
from axis toward big end.
(e) Pistons and Piston Pins.
(1) Remove small scores from piston skirts with a
hard A:r kansas stone and from pin bores with crocus
cloth. Polish old type pins to obtain correct clear-
ance and all pins to a smooth surface before Magna-
flux inspection.
Do
not reduce
original
piston surfaces.
Never use abrasive paste, wire brushes or
buffers on pistons. After repair, re-check
dimensions.
(2) Replace
cracked, burned or heavily scored
pistons with new parts of proper size for cylinder
barrels.
Maintain set within 1/4 oz. difference in
weight of any two pistons. Replace worn plugs in
C 125
piston pins of old type.
(3) Replace old piston rings with new standard rings
in standard barrels.
Use .005" O.S. rings
with
standard pistons in .005" O.S. barrels. Use .015"
O.S. pistons and rings in reground barrels.
(f) Crankcase Cover Assembly.
(1) Stone nicks and scores on finished surfaces, and
chase female threads, if necessary. Stone burrs on
oil screen and relief valve cap threads.
(2) Stone small scores and nicks on oil pump gear
teeth. Discard worn and deformed parts.
(3) Replace tachometer drive housing oil seal, and
stone burrs on housing thread.
(g) Camshaft and Hydraulic Valve Lifters.
(1) Stone light scores on cam lobes, journals and
valve lifter bodies.
(2) Replace camshaft
if
lobes are pitted or
if
lobes
or journals are excessively worn. Replace complete
hydraulic unit
if
any part is worn or damaged. (Re-
fer to Section 16.)
.
Do not drop valve lifters or allow them to be
damaged by contact with other objects.
(h) Gears.
Stone light scores and nicks on all gear teeth.
Replace any gear whose to.oth profiles show exces-
sive wear, heavy scoring or burrs.
(i) Intake Elbows and Manifolds.
Discard and replace cracked parts. Lap parting
flanges to true, flat surfaces.
(j)
Pushrod Housings, Flanges, Clamps.
(1) Lap
fla~ge
parting surfaces flat.
28
(2) Remove dents from housings by tapping with a
soft mallet while on a suitable mandrel.
(3) Replace cracked flanges, housings, or clamps.
(k) Ignition System.
Replace all ignition cable assemblies.
(1) PROTECTIVE COATING.
The manufacturer
protects all aluminum alloy castings, sheet metal and
tubing from corrosion by treating all surfaces of the
parts with "Alodine 1200" (American Paint and Chemi-
cal Company, Ambler, Pennsylvania).
(m) APPLICATION OF "ALODINE 1200".
In the
event the original finish of an aluminum part has de-
teriorated or has been removed, the part may be
"Alodized" as described in "Alodine Manufacturer's
Technical Service Data Sheet No.
AL-1200-D."
Wrought or die cast (smooth surface) parts, such as
valve rocker covers and intake tubes, are tumble
blasted prior to machining,
if
any, to roughen surface
before treatment.
Such treatment should not be em-
ployed in overhaul work shops on parts with machined
surfaces.
"Alodine " , unlike enamel or primer, will
not flake or peel off to contaminate engine lubricattng
oil. Corrosion protection can therefore be afforded
to all interior aluminum surfaces and parts.
If
enamel
coating is required for a part previously treated with
"Alodine", application of a primer before painting is
not necessary.
"Alodizing" will be performed after
all machining and/or repair operations have been
completed.
The surface color of an "Alodized" part
may vary from light gold to dark brown. When a part
is treated with "Alodine 1200", the thickness of the
film, or build-up, on the mating or bearing surfaces
is so small that the effect on dimensional tolerances
is negligible.
(n)
REPAIR OF "ALODIZED" SURFACES.
If
"Alodized" parts have been remachined, rubbed with
abrasives or scratched in handling so as to expose
areas of bare aluminum, the surface may be repaired
by local application of "Alodine" solution in the fol-
lowing steps:
(1) Clean bare area thoroughly with carbon tetrachlo-
ride. Do not, under any circumstances, use an oil
base solvent or strong alkaline cleaner.
(2) Mix a small quantity of hot water (180° F. ) with
1-1/2 to 2 ounces of "Alodine 1200" powder to form a
paste, then gradually dilute with hot water until one
gallon of solution is attained. This solution is to be
adjusted by addition of nitric acid to a PH value of
1.
5 to
1.
7.
(3)
Apply solution with rubber set paint brush in such
a manner that solution flows over bare area. Allow
solution to remain on area from one to five minutes,
or until color of new film is approximately that of the
original.
(4) Flush part with clear water and dry with warm
air current. Do not air blast or rub with cloth to dry
new film area.
If
color is too light, repeat step "3"
until desired color is attained.
NOTE
If
"Alodine" does not adhere to a metal, a
more severe cleaning method must be used,
A solution of 12 to 16 ounces of Oakite No.
61, or equal, per one gallon of water is
preferred. Apply and remove the solution
with caution, because an alkaline cleaner
ofthis type will remove any "Alodine" film
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