Engine Assembly; Install Crankshaft; Install Piston And Connecting Rod; Install Camshaft - Vanguard OHV V-Twin User Manual

ENGINE ASSEMBLY

Install Crankshaft

Lubricate mag bearing and lips of oil seal with engine
oil. Install crankshaft, Fig. 1.
Fig. 1
Install Piston and Connecting Rods
NOTE: Install #1 piston and connecting rod first.
1. Oil piston rings and piston skirt. Compress rings
with Piston Ring Compressor #19070 (2), Fig. 2.
a. Place piston and ring compressor upside
down on bench with projections (1) on
compressor facing up.
b. Tighten ring compressor until rings are fully
compressed.
c. Loosen ring compressor slightly so the
compressor can be rotated on the piston
skirt while holding connecting rod.
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Fig. 2
2. Lubricate cylinder bores and crankpin. Rotate
crankshaft until it is at bottom of stroke.
3. Install #1 piston with notch or offset casting mark
(3) toward the FLYWHEEL SIDE of the engine
(4), Fig. 3. Push piston down by hand until
connecting rod is seated on crankpin.
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NOTE: The words "OUT-1" (5) on #1 connecting rod
must be facing PTO side of engine (6).
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Fig. 3
4. Assemble connecting rod cap to rod with match
marks aligned, Fig. 4. Torque screws to 115 in.
lbs. (13 Nm).
NOTE: Models 540000, 610000 – 125 in. lbs.
(14 Nm).
Fig. 4
5. Rotate crankshaft two revolutions to check for
binding. Connecting rod should also be free to
move sideways on crankpin.
6. Repeat for #2 cylinder.
NOTE: The words "OUT-2" on #2 connecting rod
must face PTO side.
CAUTION: Failure to use a torque wrench can
result in loose connecting rod screws causing
breakage, or overtightened connecting rod
screws, causing scoring.

Install Camshaft

1. Lubricate tappets, camshaft journals and lobes
with engine oil. Assemble timing gear to
crankshaft.
2. Install tappets.
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