Model 12 Intek Horizontal OHV

1. Model 12 Intek Horizontal OHV Crankcase Disassembly and Assembly Lab #7

2. Model 12 Intek Horizontal OHV Stripping Engine to Bare Block Lab #7A

3. Required Tools • 7, 8, 10, 24 mm socket • ½” breaker bar • Ratchet wrench • Extension • 5/8” Combination wrench • 1/8” Allen wrench • Inch pound torque wrench • Foot pound torque wrench • Standard screwdriver • Pliers • Strap wrench • Feeler gauge set • .010 long flat gauge (Or 2 microfiche cards) • Spark tester • Optional T-30 Torx bit

4. Systematic Approach • Technicians need to take their time when disassembling an engine. This is not a race! • Listen for instruction when to remove the next piece. Do not work ahead! • Lay assemblies in order as they were removed. • Put fasteners with removed assemblies, or loosely back in bolt holes.

5. Let’s Begin • Close fuel shut-off valve • Disconnect spark plug ignition lead from spark plug • Move throttle to stop position

6. Remove Carburetor Per Lab#2 Instructions • Use written instructions

7. Remove Fuel Tank Per Lab#4 Instructions • Use written instructions

8. Remove Cylinder Head Assembly Per Lab#5 Instructions • Use written instructions

9. Remove Flywheel and Ignition Armature Per Lab#6 Instructions • Use written instructions

10. Bring Piston to TDC Compression • Valve tappets will be at the bottom of their travel

11. Model 12 Intek Horizontal OHV Crankcase Disassembly and Assembly Lab #7B

12. Bring Piston to TDC Compression • Valve tappets will be at the bottom of their travel

13. Remove Crankcase Cover • Use 10 mm socket • Case cover gasket will probably be damaged during removal • Do not pry off cover – It will come off by hand

14. Inspect Camshaft Gear • Timing marks of cam gear and crankshaft gear should align • Draw diagram

15. Remove Cam Gear and Tappets • Tilt block • Remove cam gear by hand • Remove tappets by hand

16. Remove Piston/Connecting Rod Assembly • Use 8 mm socket • Rod cap can only fit on one way • Long screw is closest to piston • Dipper held on by small screw • Piston and rod have orientation mark

17. Remove Crankshaft • Pull out crankshaft by hand • Use caution not to scratch bearing surface in case

18. Discuss Crankcase • Wipe up any remaining oil in case • Clean all gasket surfaces with gasket scrapper

19. Reassembly • Technicians need to take their time when reassembling an engine. This is not a race! • Listen for instruction when to add the next piece. Do not work ahead! • Fasteners will need the proper torque values. • Special procedures will be explained.

20. Install Crankshaft • Install crankshaft by hand into cylinder block • Be careful not to damage bearing • Position crankpin to 7 o-clock

21. Install Piston Assembly • Use ring compressor • Coat piston assembly and cylinder bore with oil • Check orientation marks • DO NOT hammer or force piston assembly into block!

22. Attach Rod to Crankshaft • Rod cap only goes on one way • Long screw goes closest to piston • Dipper attaches with short screw • Use 8 mm socket • Torque fasteners to 100 in. lbs • Rotate crankshaft and check for free movement

23. Install Tappets and Cam Gear • Install tappets first • Align timing marks of cam gear and crankshaft gear

24. Install Case Cover • New gasket? • Lubricate governor gears • Insure governor lever is laying flat • May need to rotate crankshaft for governor gears to mesh • Use 10 mm socket • Torque fasteners in sequence to 110 in. lbs

25. Install Cylinder Head Assembly Per Lab#5 Instructions • Use written instructions

26. Install Flywheel and Ignition Armature Per Lab#6 Instructions • Use written instructions

27. Install Carburetor Per Lab#2 Instructions • Use written instructions

28. Install Fuel Tank Per Lab#4 Instructions • Use written instructions

29. Test Ignition System • Use spark tester 19368 • Look for a spark in the run position • Look for no spark in the stop position

30. Install Spark Plug • Use 5/8" spark plug socket • Torque to 180 in. lbs • Attach ignition lead

31. Success! • Do you have any extra parts? • Do you have any questions?