Fitting Rod Bearings

Oversize rollers are available in .0002, .0006, .0008 and .0010 in.

There are three ways to determine oversize rollers to use. All will result in properly fitted bearings if applied correctly.

1. Use a micrometer to measure the outside diameter of the crank pin at its center. Use an inside micrometer or telescoping hole gauge to measure the inside diameter of the rod races. Subtract the diameter of the crank pin from the inside diameter of the bearing race. Subtract from this figure the standard allowance for bearing running fit size. This answer, divided by two will give proper roller size. To find oversize amount of bearing, subtract from this figure the diameter of a standard roller.

Example:

The rod bearing race measure 1.6263 in. after lapping and truing. The crank pin is slightly worn and measures 1.2485 in. Subtract 1.2485 in from 1.6263 in. The answer, .3778 in., represents the diameters of both rollers (one on each side) plus clearance for running fit. Subtract minimum clearance for running fit (.001 in.). The answer (.3768 in.) is then divided by two to get the diameter of each oversize roller. In this case it would be .1884 in. To find how much oversize each roller must be, subtract from this figure the diameter of a standard roller, or .1875 in. Rollers must be .0009 in. oversize.

2. Install any new set of oversize rollers to bearing races and position on crank pin. Slip rods over bearings. If they will not fit, it is obvious rollers are too large and a smaller size must be tried. If they fit and spin freely, install a larger set of rollers. Try various roller sizes until the rods will turn with a very slight drag. This is a plug fit. Determining running fit is merely a matter of subtracting one half the desired running fit clearance (.0005 in.) from the roller size to find the running fit roller size.

It may be easier to gauge a plug fit as follows:

3. Fit any size rollers into races. Position bearings in rods. Support rods and bearings with left hand. Drop crank pin (not attached to flywheel) through crank pin hole. Plug fit has been achieved when crank pin will slide slowly through hole from its own weight. Running fit is then determined by subtracting one half running clearance from oversize of rollers used to make plug fit.

Example:

Plug fit is achieved with .0009 in. oversize rollers. By subtracting from this one half the minimum clearance (.0005 in.) it is determined that a .0004 in. oversize roller set will give desired running fit.

If lower end race of one rod is found to be slightly larger than the other, select rollers to fit the larger rod race and lap smaller rod race to same size as larger race rather than fitting rollers of two sizes.

When rods are correctly fitted with required bearing clearance, extreme upper end of female (forked) rod will have 1/64 in. side shake while the upper end of the male rod will have 3/64 in. side shake. All fitting and checking must be made with bearings, rods and crank pin clean and free of oil.

Fitting bearings tighter than described may result in seizing and bearing damage when heat expands parts.

Check overall width of roller retainer assembly. It must be less than width of female rod end.

ASSEMBLING FLYWHEELS (Figure 3-41)

1. After correct connecting rod bearing fit has been attained, clean and assemble parts as follows:

Wipe all tapers perfectly clean and free from oil. Install sprocket shaft (21) to left flywheel (4). For 1970 and 1971 models, make sure key (22) is in position. See "Engine Specifications" for proper torque. Assemble pinion shaft (11) and crank pin (16) to right flywheel making sure keys (12 and 17) are in proper position. Install lock plates (8 and 19). Tighten mounting screws (7 and 18) to 20-24 in-lbs torque. If corners of nuts do not align with notches in lock plate, tighten (do not loosen) shaft nuts to achieve alignment.

For 1972 and later models with 1 -5/8 in. sprocket shaft nut. Snap-on Socket, Part No. IM-522 with Handle, Part No. L-52BH and a pipe extension is recommended to obtain 400 ft-lbs torque (4 ft x 100 lbs) required. To obtain maximum nut engagement, end of socket should be forced off in a lathe. Check to make sure oil passages through pinion shaft, right flywheel and crank pin are clear by blowing compressed air into hole near end of pinion shaft.

2. Position right flywheel assembly in vise, crank pin up. Wipe crank pin taper clean. Slip bearings and connecting rods over crank pin with forked rod to rear cylinder. Wipe crank pin hole in left flywheel clean and dry. Install left flywheel and tighten nut lightly. Hold steel straightedge along outer face of wheel rims at 90 degrees from crank pin as shown in Figure 3-43. Tap outer rim of top wheel until wheels are concentric. Tighten nut, recheck with straightedge at frequent intervals. Use soft metal hammer to realign wheels. To prevent flywheel assembly from turning in vise while tightening nut, insert a rod 5 in. long and about 1/2 in. in diameter through holes in flywheels and between vise jaws so that rod bears against some part of the vise.

Figure 3-43. Squaring Flywheel Faces

3. When nut is fairly tight, install flywheel assembly in Flywheel Truing Device, Part No. 96650-30. Adjust so centers are snug. Wheels must turn freely but shafts may not be loose in centers. If flywheel assembly is either loose or squeezed, indicators will not indicate accurately. Adjust indicators to take reading as near to flywheels as possible, so pointers read at about the middle of the scales.

4. Turn flywheels slowly and observe the movement of indicator pointers. Movement toward flywheels indicate high points of shafts. Find highest point of each shaft and chalk-mark flywheel rims at those points. Loosen centers slightly, just enough so looseness may be detected, and make corrections as follows:

5. Flywheels may be out of true three ways. A, B and C, Figure 3-44 or a combination of two of the three ways.

Figure 3-44. Correcting Flywheel Alignment

6. When wheels are both out of true as indicated in "A," tighten a C-clamp on rims of wheels opposite crank pin and lightly tap the rim at the crank pin with lead or copper mallet.

7. When wheels are both out of true as indicated in "B," drive a hardwood wedge between the wheels opposite the crank pin and lightly tap the rims near the crank pins with a mallet.

8. When wheels are out of true as indicated in "C," strike the rim of the wheel a firm blow at about 90 degrees from crank pin on high side (see Figure 3-45).

9. When wheels are out of true in a combination of any of conditions shown, correct C first, and then correct condition A and B.

10. The number of blows required and how hard they should be struck depends on how far shafts are out of true and how tight nuts are drawn. Remember that centers must be loosened slightly before striking flywheels. Making them too loose may result in damaged centers. Never strike wheels a hard blow near crank pin. This could result in a broken crank pin.

11. Readjust centers, revolve wheels and take reading from indicator. Repeat truing operation until indicated run out does not exceed .001 in. (each graduation on indicator is .002 in.).

Figure 3-45. Truing Flywheels on Truing Stand

12. If it is impossible to true wheels, check for a cracked flywheel, damaged or enlarged tapered hole, or a sprocket or pinion shaft worn out-of-round at surface where indicator reading is being taken. When wheels are true, position in vise and draw crank pin nuts very tight using Crank Pin and Flywheel Nut Wrench, Part No. 94546-41, or use torque wrench and tighten to foot-pound reading given in "Engine Specifications." Check connecting rod side play with thickness gauge as shown in Figure 3-46. If it is greater than tolerance shown in "Engine Specifications," draw up crank pin nuts until within tolerance. Insufficient play between rods and flywheel face is caused by one of the following conditions:

a. Flywheels and crank pin assembled with oil on tapers and nuts over-tightened. Disassemble, clean, reassemble.

b. New flywheel washers installed and not fully seated. Disassemble, inspect, replace deepest seating flywheel or exchange crank pin. As last resort, grind down width of forked rod.

c. Taper holes enlarged as a result of having been taken apart several times. Replace wheel seating deepest.

d. Cracked flywheel at tapered hole. Replace flywheel.

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