BLUE DIAMOND ASSEMBLY PROCEDURE 1593 Ref Dwg 1584

1. Install flat thrust bearing race with largest O.D. in bottom of bearing housing. Should be light press fit. If loose, use Loc-Tite bearing mount. If there are factory numbers stamped in the race, be sure this side is down. Check with .002 feeler gage to be sure this race is fully seated. 2. Assemble motor on a horizontal pipe fixture if available. Motor should have been match-marked before disassembly, but otherwise, carefully mark top dead center of cam bearing on outside of motor housing. Then install internal motor parts, and finally, when installing port end cover, orient TDC of cam bearing exactly between two main ports. Failure to orient exactly will scrap the motor soon after startup! 3. Install bearing housing to motor, taking care to insure clean, square seating. 4. Install thrust bearing races with smallest O.D. on thrust nut. Should be light press fit. If loose, use Loc-Tite bearing mount. Check bearing races to be sure bevels in their I.D. clear any corner radius. 5. Pack the lower thrust bearing with grease and put it in the housing on the bottom race. 6. Screw left hand thrust nut and races on shaft until it contacts bearing, then back off three turns to be sure it is well away from bearing face. 7. Using a two-bolt puller bar across the end of the shaft, pull the shaft dawn as far as it will go. 8. Screw thrust nut down until it contacts race positively. Repeat to be sure this is a solid stop indicating everything is fully seated and squarely made up. 9. Mark the shaft with a felt tip pen in line with any slot and mark the thrust nut in line with this mark. 10. Remove puller without turning shaft. Now rotate the thrust nut down until the mark on the thrust nut aligns with the next slot. Then continue to rotate slightly to align the closest two opposite setscrew holes with two of the slots in the shaft. 11. Install two half dog point self-locking setscrews into full engagement in the slots. If being reused in the field, these must be thoroughly cleaned and Loc-Tited. 12. This procedure provides the required floating clearance (appx .045) between the rotor and the valve plate. 13. Install upper thrust bearing spacer ring. Pack housing loosely with grease. The spacer ring thickness should result in approx .004-.008 shaft end play. Otherwise weld and/or machine spacer ring.