Complete Rebuild - EC250

[RockefellerGG]

Cleaning up parts.



Primary shaft seal, spacer, and o-rings replaced:

[Zrt1200]

Very Nice Job. Thank you for taking the time to do this.

[RockefellerGG]

Re-Assembling this is a lot of the same thing, but in reverse. I took some pictures which may be redundant.

Ignition Reassembly. Line up the marks to put it back close to how it came out. Made sure the rubber seals are nice and tight and back in their homes:

8 Nm Torgue


Threadlocker on the crank and 40 Nm on the nut:


I'm leaving the cover off for now, so that I can use the nut to turn the engine over during squish measurements.

[RockefellerGG]

Reed block was cleaned up and treated to new gaskets:


10 Nm torque on the reed block bolts:

[RockefellerGG]

Used heat to release the bearings in the cover. Same technique used in the engine case, but it took less heat. Laid it flat and gave it a little tap. Both fell right out.



Waterpump shaft seals removed:




New seals, bearing and bushing:


New kickstart seal:

[RockefellerGG]

BTW - I like to oil the seals when putting them in. Helps them stay in shape and not tear.

[RockefellerGG]

Don't forget the crankshaft o-ring: I forgot this and had to crack the cover back off take it apart and add mine:


Crank spacer installed carefully so as not to damage the seal. Machined flat side up:


Put the key lock back in:


Flywheel:


Add the crank gear,washer and nut. I used the rubber side of a pair of needle nose to block the flywheel from turning. This is Lefty-Tighty. 40 Nm:

[RockefellerGG]

Install the shift selector. There's a trick to this. 1. Release the tension from the spring, so that the hook is on the left side of the plate. 2. Very loosely install the bolt. 3) Lift the spring hooked side over the plate and hook it over the right side. Then tighten the bolt. 15 Nm


See how the hook is on the left side:


Lift the spring up and over and hook it over the right side:


Slide the shift selector shaft back through the engine case. Remember to add the white plastic bushing. Curved side up:


Add the spring:


Lift the curved end of the spring up and over the post to pre-load the spring.

[RockefellerGG]

Place the starter gears into the case:



Re-tension the spring by placing the end back into the hole:


Add the washer and c-clip on the counter gear:


Lubricated the new bearings:


Reinstall the centrifugal assembly:



Put the alignment pins back in:


Re-install the support block back into the engine. Making sure to put the pin in the slot between the shims. Bolts tightened to 10 Nm:

[RockefellerGG]

Water pump gear and shaft assembly reinstalled: