Complete Rebuild - EC250

[RockefellerGG]

Replace the alignment dowels. The manual tells you to put them in the left side case. Not sure it matters.





Place the gasket on the engine case:


Time to replace the other crank seal. The manual says to position it with the lip facing out. I used a 1" socket to carefully get it seated. Be careful not to damage the lip. Others have chimed in with the observation that this seal should probably face with the lip inward. I'll report back if I have any problems with this orientation.


I am waiting on a new primary seal... it hasn't arrived yet. I'll add it later, but this is the logical time to put it in.

[RockefellerGG]

Place the left side over the right side and carefully align the shafts. Check that the alignment pins and gaskets are all aligned. A gentle tap with the rubber hammer and it all fell into place:

[RockefellerGG]

Oops!!! Where was this supposed to go? It looks like an alignment dowel but it is solid. Time to split the cases back open.

[pscook]

Originally Posted by RockefellerGG

Replace the alignment dowels. The manual tells you to put them in the left side case. Not sure it matters.

I like to put the alignment dowels in the same side with the gasket, as when I put the gasket on one side and the dowels on the other side, I get the inevitable gasket slide/alignment pin "hole punch" effect. Being careful helps, but sometimes my thumbs outnumber my fingers.

[barossi73]

I agree,except when dowels are stubborn and theres a risk of burring them on removal.as long as theres 2 locating gasket im happy.that said a quick buff cleans burrs up quick.great thread

[RockefellerGG]

Anyone know where the solid alignment pin goes? I've looked through all of my pictures and can't determine which one is supposed to be solid.

I assume this is an alignment pin, anyway. I don't recall this part anywhere in my disassembly and do not see it in the parts breakdown.

[RockefellerGG]

Well, I officially feel like an idiot. This isn't an alignment pin. It was an old crank roller bearing. It must have hit the floor when I was removing them and I picked it up inadvertently.

The alignment pins ARE all hollow. They have to be, since they have a bolt that must go through them.

[RockefellerGG]

I'll save some time for others, trying to remember which bolt length goes where. Remember to alternate around diagonally when tightening the case bolts. I started in the middle.

[Rick]

You sir!! Are going a fine job! Really liking this thread! Great detail! Thanks

[RockefellerGG]

Trimmed the gasket with a razor blade:


It might be a day or two before the next update. I'm waiting for the primary shaft seal and will be media blasting a number of parts before installing them.