Ages 8 and up SMITHSONIAN

THE SMITHSONIAN INSTITUTION
FACT SHEET
The Sntilhxonian
Inntitutioll
is a nluse.um, education and research complex of 17 muse[1111~ alld gallerie~, and the National Zoological Park. Fifteen museums and galleries are
located in Washington, I).(’.,
Iwo are in New York City, and the National Zoo is in Washhl~tofi. "l~l] o1 the IIILI~eLIIIIS [tlld galleries arc nilualcd on the National Mall between the
[ J.%. (’al]ilol
and Washington Monument.One of the world’s leading scientific
research
centers, the Institution has facilities
in eight stales filial
the Republic of Panama.Research
prqjecls in Ihc arts, history, and science arc carried out hy the Smilhxonian all over
world. The new Nalional Museumof the American Indian is scheduled Io open on
National Mall in 2002. The centerpiece of the museumis the priccluxx collection of Native American allJl~~cls transl~rrud to the SnlJthsollJan I’ronl the Museumof the American
Indian, tteyc I:oundafi-n (New York). The NewYork exhibition lhdlily
- Ihc Heyc Center
of Ihe Nalinnal Museumof the American Indian opened ()ch~ber 30, 1994 in lower Manhatlan. Anod~er new museum,the National Po~~al Museum,is localcd near Union Station
on Capih~l Hill. I)cvoled Io Ihe history of Ihe [I.S. mail service, lhc muneumhouses
~orld’s largest and mo~l comprehensivecolleclion of ils kind, wilh more fl~an Ifl million
shlnll~S, covers, alld al-tJl’acls.
Item #90804
Ages8 andup
SMITHSONIAN
H ISTORY
,fairies
Smith.,,on (I 765-1829). a British scientist,
drew up his will in 1~26 naming his
nephew, flenry James thmEerl’ord, an beneficiary.
SInidl~On sfipuhncd thai ~hould
nephew die wittloUl heirs (as he did in 1835), the estate ~ould go to the United Slates
found "’at Washinghm, under the name of the Smithsonian Institution,
an establishmenl
for Ihe increase and ditlusion ~I" knowk’d~c...’"
On July I, 1836, Congress accepted the legacy hcqucalbcd to the na6on hy James Smithson.
and pledged lhc Ik61h of the United Slates to the charitable trust. In 1~3S, following approval of Ihc bequest by Ihe British courls, lhc United Shllus received Smilhson’s estate ha~ of ~old ~ovcrei~n~ - lhen ll~e equJvalenl of $515~ 169. Eight ~ar~ lal~r, on Au~u~l I 0,
1846, an Ac~ ol’Con~ress si~n~d by Pr~sid~m James K. Polk~ established th~ Smithsonian
InMiIL~llO~l HI ~I~ pl~h~lll h)rnl alld provided lor the admJlll~Ira[ion ol lhc IrL~l, md~pendenl of the ~overnmenl Jlsell,
by a Board o1 Re~enl~ and Secrelary of lhe SmJlhsonJan.
BAI-rERY SAFETYINFORMATION:
¯ Non-rechargeable
batteries are not to berecharged;
¯ Rechargeable
batteries are to be removed
fromthe Joybefore beingcharged;
¯ Rechargeable
batteries are only to be chargedunderadult supervision;
¯ Differenttypesof battenesor newandusedbatteries are not to bemixed;
¯ unly galleries oi lr~e sameor equivalenttype as recomrnerloea
are to ueuseu,
¯ Batteriesare to beinseded
withthe correctpolarity;
¯ Exhausted
batteries are to beremoved
fromthe toy;
¯ Thesupplyterminalsare not to beshort-circuited;
¯ Keeppackaging
for references~nceit containsimportantinformation;
¯ Thistoy not intended
for childrenunder3 yearsold;
¯ This toy mustbeusedwith the recommended
transformer;Thetransformeris not a toy;
¯ Toysliable to becleaned
with liquid are to bedisconnecled
fromthe transformerbeforecleaning,
DEAR CUSTOMER,
If we madean error and left something
out of this set, or if something
is damaged,
we are sorry
andwishto correct our error. Pleasedo not return the set to the store whereyoupurchased
it,
or to the Smithsonian,
as they donot havereplacement
parts. Instead, write us a letter giving
us:
1. Date of Purchase
4. Nameof Set
2. WherePurchased
5. Brief Descriptionof Problem
3. Model Number
6. SalesSlip
Wewill doour best to satisfy you. Quality ControlDepartment,
Natural ScienceIndustries, Ltd.
910 OrlandoAvenue,WestHempstead,
NY 11552-3942.(888) 425-9113.
NOTICE
Theengine
youaregoing
to buildis a greatlysimplifiedversionof a real engine.
Thiswillmake
it easier
for youto understand
theoperation
of a four-stroke,
internal
combustion
engine.
Consequently,
the following
components
arenotincluded:
oil
filter, liquidcooling
system,
air filter, connecting
rodbearings,
rings,oil pump,
fuel
pump,
alternator
anda starter.
Onthe otherhand,
thefollowing
components,
which
areincluded
soyoucanidentify
theirlocation
ontheengine,
arenotintended
to function:
waterpump,
carburetor,
dipstick(withoutoil), flywheelclutch.drive mo
dule, po
weredaby
sma
ll electric
motor,
replaces
thestarter.
HEAT
Mostof the energyproduced
by the gasconsumed
in an internal combustion
engineis
converted
into power
to dowork.Buta significantamount
of energy
in theformof heatis
also produced.
Temperatures
inside modern
automobile
enginescaneasily reach1700
degrees
Celsiusandengines
mustbe cooled,evenin the winter. Four-cycle
engines
usually usetwomethods
to remove
this heat.
CONVECTION
Asthe Motorworks
model
shows,a fan is often attachedto the front of the engineand
blowsair overit to helpkeepit cool. Some
engines,
like thoseonlawnmowers
alsohave
metalfins to increase
the surface
areaof theengine
andmake
it easierfor heatto escape.
Whatis this kit all about?
First,you’llidentifyandassemble
thevarious
parts,module
bymodule,
withthehelpof
theexplanations
provided
in this manual.
Once
you’ve
done
this, you’llhavethe
pleasure
of seeing
thefour-stroke,
internalcombustion
engine
you’ve
just builtin
operation.
You’llalsoseethespark
plugs
"fire"in thecorrect
sequencejustlike a real
engine!
Most
engines
used
in today’s
carsandtrucks
are4-stroke
cycleengines,
justlike this
one.
Theexplanations
in this manual
will helpyouunderstand
how
theengine
in your
parents’
caroperates.
Lateronyou’llbeableto expand
yourknowledge
andbecome
a "whiz"oninternal
combustion
engines.
RADIATORS
Forlargeandpowerful
engines
like thosein carsandtrucks,mostof thecoolingis doneby
circulatingfluids that passthrough
channels
in the engine.Thisfluid is keptmoving
by a
"water"pump
whichis powered
by the engine.Thecoolantabsorbsheatas it passes
through
the engine
andthenreleases
theheatto theair as it passes
through
the Radiator.
Aradiatoris just a seriesof narrow
tubeswithfins that allowair to flow overthemand
remove
the heat.Radiators
arealmostalways
locatedat thefront of thevehicleto make
it
easyfor the air to passoverthem.Many
modern
carshaveanelectric fan that continues
to cooltheengine
after it is turnedoff. Sometimes
youcanhearthesefansrunning
asyou
walkawayfromthe car on a hot summer
day.
LUBRICATION
Themoving
parts in anenginemustbepreciselymade
to workproperly.Toreducethe
friction between
thesepartsastheymove,
it is necessary
to lubricatethemwithoil. Car
andtruckmotors
useseveralquartsof oil to keepeverything
lubricatedandthis is stored
in the Oil Panat thebottom
of the engine.Everyengine
hasa DipStickthat reaches
down
into this oil andlets youmake
surethat the engine
hasenough.
AnOil Pump,
mechanically
connected
to the engine,circulatesoil throughout
engine.The
cylinderwallsarelubricated
by oil that is splashed
by themoving
crankshaft.
Asit circulates, the oil alsocarriesaway
dirt andchemicals
left overfromcombustion.
These
are
removed
by theOil Filter.
Further Reading
Tolearn moreaboutinternal combustion
engines
andhowtheywork,checkwith the pub-
FUELANDAIR- THEEXPLOSIVE
MIXTURE
As wesaid earlier, the powerin a gasolineenginecomes
fromcarefully burninga mixture
of gasolineandair. Thepart of the Motorworks
enginethat mixesgasandair is called a
Carburetor.
A carburetoraddsgasto the air as it flowsinto the engine.It takesa surprisinglysmall
amountof gasolineto providethe pushneeded
in eachpowerstroke. Onaverage,it only
takesabout10milligramsper stroke, but the mixtureis verysensitive. If too much
gasis
put in the cylinder, the engine"runsrich." Notonly will the enginewastefuel, but it will
producesmokyexhaust,run poorly (stall easily andhesitate on acceleration)andit may
not evenrun at all. If not enough
gasis put in the cylinder,the engine"runslean." A lean
mixturecan keepthe enginefromstarting and canevendamage
it.
To providea moreprecise mixtureandto reduceexhaustpollution, the carburetor has
nowbeenreplacedon automobilesby a systemcalled fuel injection. Since1991every
newcar sold in the UnitedStateshasusedfuel injection, but smallerengineslike thoseon
lawn mowersand chainsawscontinueto use carburetors becausethey are simple and
inexpensive.
Severalother systemshavebeendeveloped
to control the mixtureof fuel andair that
goesinto an engine.Superchargers
andTurbochargers
both usea pressurizedmixtureof
air andgasto increasethe powerthat canbe produced
by a gasolineengine.
STARTINGTHE CAR
Thepowerthat starts a car comes
fromthe battery. Onceit is running,anelectric generator (called an Alternator)that is connected
to the motorby a pulleyproduces
all the e~ectricity the engineneedsto run. Indeed,althoughit is not recommended,
a car’s batterycan
actually be removed
onceit is running.
When
youturn the key on an automobileto "Start", powerfrom the battery goesto the
Starter Motor,whichturns the crankshaftandmoves
the pistons. At the sametime, electricity goesto the Ignition Coil, where
the voltageis increased
to 15,000volts. Thishigh
voltageelectricity, whichis needed
to produce
a strongspark,is sentto the sparkplugsto
ignite the gas/air mixture.Assoonas the gasin the cylindersbeginsto explode,the enginecanrun on its ownandthe key canbe turnedbackto the "On"position.
Thefirst gasolineengineshadno battery. To start them,the crankshafthadto be turned
mechanicallyanda devicecalled a "magneto"
wouldprovidethe electricity to fire the
sparkplugs.Thisis whyearly carslike the FordModel
"T" hada crankin the front that had
to beturnedto start them.Later this wasreplacedby batteries andmechanical
ignitions.
TABLE OF CONTENTS
BEFORE
ASSEMBLING
........................................................................................................ 4
BASIC
ENGINE
TERMS
................................................................................................... 5-12
LIST
OFPARTS
INCLUDED
INTHIS
KIT.............................................................................
ASSEMBLING
YOUR
MOTOR
WORKS
ENGINE
................................................................
HOW
AGAS
ENGINE
WORKS
............................................................................................
13
14-34
35
THE
FOUR
CYCLES
...................................................................................................... 36-37
FUELING
AND
AIR- THE
EXPLOSIVE
MIXTURE
...................................................................
38
STARTING
THE
CAR
..........................................................................................................38
HEAT/LUBRICATION/RADIATION/CONVECTION
.................................................................
39
SMITHSONIAN
INSTITUTION
FACT
SHEET
..........................................................................
40
BEFORE ASSEMBLING YOUR
ENGINE WE SUGGEST:
In thePower
stroke,thepistonhasjustreached
thehighest
pointit cantravelwhen
thespark
plug
ignitesthefuel. Thegasliterally explodes
andpushes
thepistonrapidlydown.
Thisprovides
the
engine’s
power.
1.
First, thoroughlyidentify the variouscomponents
by trying to learn the
name
of eachpart. In so doing, makegooduseof the drawingsincludedin this
manual.
2.Removethe parts from the plastic moldingas youneedthem,andstrictly
follow the order of assembly
indicatedon the following pages.Otherwise,you
will run into problemsbecauseyouwon’t knowwhichnumbergoeswith which
part (there are no numbers
on the parts themselves).In anycase, the drawings
on the following pagesare intendedto help you. Referto themanytime you
havea questiononthe identity of a part.
3.After separationfrom the plastic mold, small burrs mayremainon some
parts. Remove
theseburrs by means
of a knife or other cutting implement.
Otherwise,they couldhinder properoperationof the engine.(Havean adult
helpwith this step.)
4. If severalscrewsare to be mounted
on the samepart, first place all the
screwsin position andtighten themlightly by hand.
5. Thinkcarefully aboutthe position of eachpart beforeattachingit permanently(be awareof the possibility of installing it upside-down,
backwards,
etc.).
In this regard, note the referencenumbers
indicated on the assembly
drawings
shownon the following pages.Otherwise,youmayhaveto start over.
6,Youshouldlightly oil
all of the bearingsso the variousparts of your Motor
WorksEnginewill operatesmoothly.Usevegetableoil; there shouldbe some
in your kitchen.(Note:A "bearing"is anypart of a machine
that supports
rotatingshaft.)
YOURGOAL should be to assemble your engine properly
on the first try, andto haveit operateright away.Beingable to do
this will give you enormous
satisfaction. If youfollow these recommendationsfor assemblingyour engine, you will accomplishthis
goal.
in theExhaust
stroke,thepistonhasagaingone
asfar down
asit canandis now
moving
backup.
Theexhaust
valveis open
andthepistonpushes
the"exhaust"
gases
outof thecylinder
asit rises.As
soon
asthepistonreaches
thetopof thecylinder,theexhaust
valvecloses,
theintakevalveopens
andthecycles
begin
again.
THEFOURCYCLES
Thefour cycles- or "strokes"- of anengineare"Intake","Compression",
"Power"
and"Exhaust".
These
repeatagainandagainin thesame
orderas the pistonmoves
upanddownin the cylinder.
Sincemostengines
havemore
thanonecylinder,thesecyclesarealternated
in thedifferentcylinders
to reduce
vibrationandmake
theengine
runsmoother.
In theIntakestroke,thepistonis descending
andtheIntakeValve
is open.
Since
thepistonis tightlysealed
against
thewallsof thecylinder,it pulls
thegas/airmixture
intothecylinderbehind
it.
LIST OF PARTS
DESCRIPTION
Number
Number
2 washers, 9.5 mme
1 timing belt (green)
1 shaft, 3 mmo, 156 mmlong
1 timing wheel
28
1 shaft, 3 mme, 206 mmlong
1 timing gear
27
(half round)
1 belt tensioning pulley
30
4 exhaust valves
13
1 lower cylinder head
11
4 intake valves
14
1 lower cylinder block
9
8 valve stems
12
1 dipstick
43
4 piston pins
1
1 positioningjig
29
8 pistons
3
1 timing belt cover
31
1 intake manifold
40
42
4 connecting rod keepers
In theCompression
stroke,the pistonhasgonedown
as far as it canandis nowmoving
backup.
Bothvalvesareclosed,sothegashasnoplaceto goandis "compressed"
by thepiston.
DESCRIPTION
(big end)
5
1 exhaust manifold
4 connecting rods
2
1 aluminumcarburetor
8 timings cams
A-H
cover
41
8 rocker arms
24
1 carburetor bowl
39
1 crankshaft
4
1 front half of water pump
33
36
1 rear half of water pump
32
1 fan pulley
34
1 aluminumflywheel clutch
37
1 fan
35
1 fan belt
~r~nl~qh:~ft nl dl~v
1 engine mounting stand
8
1 head gasket
5 bearings
25
8 valve springs
1 clutch housing
38
1 distributor assembly
1 oil-pan
6
1 drive module
1 lower crankcase
7
1 battery box
1 cylinder block
9
67 screws
1 rocker arm cover
26
1 upper cylinder head
23
screwdriver
10
A B C D E F GH
How A GAS ENGINE WORKS
Internal Combustion
TheMotorworks
modelshows
the basicparts of a four cycleinternal combustion
gasoline
engine.Thisis the mostcommon
typeof gasoline
engineandis the kindusedin mostcars
andtrucks.
Thepowerof aninternal combustion
enginecomes
fromthe carefullycontrolledburning
of fuelinsidethecylinder.That’swhyit’s calledan"internalcombustion"
engine
- it literally
means
"burning
inside."Internalcombustion
engines
aregenerallyabouttwiceas efficient
as "externalcombustion"
engines,
like the old steam
engines.
Internalcombustion
engines
wereinvented
in the 1860s,but it wasthe German
engineer
Nikolaus
August
Ottowhoin 1867patented
the four-stroke"Otto"cycleenginethat weuse
today.Thisis the kindof engine
shown
in the Motorworks
model.All "four-stroke"engines
workin the samewayandhavethe samebasicparts inside. Theseare shown
in the
drawing.
Spark Plug
Intake Valve
!
Exhaust Valve
ombustion
’Chamber
M)
Cy.n,~er
.......
.~.//
_ li"
/ /./-...
0=1
"Piston
~ Piston
~Crankshaft
5
Understanding
howtheseparts workwill let youunderstand
the basicprinciplesof all
engines.
Tobeginwith, gasolinemixedwith air is burnedin the Combustion
Chamber
abovethe
Piston.Thegas/airmixturecomes
into the chamber
throughthe IntakeValveandis ignited by a sparkfromthe SparkPlug.Thewastegasesthat remainafter the gasoline
burnsare pushed
out of the enginethroughthe Exhaust
Valve.TheroundPistonthat
moves
upanddownin the Cylinderis connected
to the Crankshaft
by the PistonRod.As
the piston moves
up anddown,the "rod" turns the Crankshaft
andchanges
the up/down
CONGRATULATIONS!
Please
observe
your
You
have
successfully
builtyour
own
model
engine.
engine.
It should
looklikethedrawing.
7
INSTALLING
THEEXHAUST
MANIFOLD
Onthe sparkplug side of the
engine,install the exhaust
manifold(part 42) in the lower
cylinder head.
I
|
I
__~25
manifold
OPERATING
THEENGINE
12
12
The long-awaited momenthas
ardved!Youwill nowhavethe
opportunityto run your engine
for thefirst time.First, plugthe
cablesfromthe distributor and
the drive module
into the battery
box. When
the latter cable is
connected,the engineshould
start to turn. Notethe direction
in whichthe fan bladesturn.
Theoretically,the fan bladesof
all automotive
engines
turn in
the samedirection.
Did you knowthis?
Removing
the drive moduleplug
fromthe battery boxstopsthe
engine. By successively
connectinganddisconnecting
"-...
this plug, youcanstart andstop
the enginejust as if youwere
turningit onandoff with a
switch. Note,in eachinstance,
the position of the pistonsand
the sequence
in whichthe spark
plugsare "firing". Thiswill helpyouunderstand
the operatingprinciplefor a 4-strokeinternal combustion
engine.You’ll find moreaboutthis principle onthe followingpages.
MOUNTING
THE CARBURETOR
AND THE
INTAKE MANIFOLD
Placethe carburetorbowl(part 39)
onthe intake manifold(part 40).
Attach
the
carburetor
41) by means
of a screwinto the
intake manifold/carburetor
bowl
assembly.
Nowinstall the intake manifol,/
carburetor assembly
you havejust
,,nishedonthe engine.Notethat ,t
goesonthe side oppositethe spark
Carburetor
,,
~
vv
cover
(part
....
~
" ~’~- -~~’~
~
.....
¯ "--.-~ _-- - ’~ -.
’~ /,.~
-.,L.~I,
....~:
~.~-~-~’_
-~
’~
~.’~;~,~
~ ....
.~
~:~
~_ ~-~
,__’"
/~’~,
.~--~,~
"~ 2
]
’~h~:"
~_~,- ~
~~~.. ~/ --.~
~.’
~ ~".
I ~ ~ ~ ~ ~ ~,}~ =.: Intake ~nifold
I ~ ~ ~ ~)~ ~ ~ (pa.
40)
~
I
. "-. ¯ :
42
INSTALLING
THEDIPSTICK
Insertthe dipstick (part 43) in the
cylinder block. Thehole for the
dipstick is also onthe side
oppositethe sparkplugs.
36
30
34
ATTACHING
THE DRIVE MODULE
fan belt (black)
Position the drive module
by
meshing
its gearteeth with those
onthe flywheelclutch.
Attach the moduleto the engine
with three screws.
timing belt (green)
8
ATTACHING
THE CLUTCHCONE
Feedthe wire fromthe drive
modulethroughthe openingin
theclutch cone(part 38).
Line upthe three holesin the
clutch conewith the three studs
onthe engine.
Altach the clutch conewith three
screws.
Clutch cone
(part
ADJUSTING
THEIGNITION
Carefully identify lampNumber
1
by followingthe red wire fromthe
"1" markon the distributor. (Lamp
Nr. 1 is the "sparkplug"for
cylinderNr. 1)
Adjustthe ignition systemas
follows:
¯ Gentlyrotatethe distributor
housing
until lampNr. 1 lights.
¯ WithlampNr. 1 lit. tightenthe
three distributor screws.
¯ Remove
the distributor plug from
the battery boxsocket.
Theignition systemis nowfully
adjusted. Youcan nowcontinue
with the nextstep or repeatthis
step; take all the time youneed.
11
INSTALLING
THESPARK
PLUGS
Insert the four sparkplugsin their
respectivereceptacles~n the
lowercylinder head.
NOTE!
Paycareful attention to the
orderin whichthe four spark
plugsare installed. Trace
eachred wire to ensure that
plugNr. 1 goesto the "1"
hole in the lower cylinder
head,Nr. 2 goesto the "2"
hole, etc.
9
INSTALLING
THEBATTERIES
distributor assembly
drive module
In the MotorWorks
kit, electric
poweris providedby two 1.5 volt
batteries(typeAA).
Takea look at the battery box:
inside the boxyouwill seethe
outline of two batteries showing
the polarity (+ and-) of each
battery. Install thebatteriesas
follows;
¯ Pushthe + endof the battery
againstthe spring.
¯ Pressthe - endof the battery
downwards
until it is firmly seated
in its compartment.
Anytypeof 1.5 volt batterywill
work AA, SP7, LR6, MN! 500
alkaline),etc.
CAUTION
Neverattemptto connectthe
kit to anyACsupply(110o220
volts). Neverconnectthe
circuitsof thekit to anyunit
poweredby the main power
supply,evenif the unit is
switched
off.
BA-I TERYSAF L I Y INFORMATION:
¯ Only ba[teries of the sameor equivalent type as re~:ommendedare to be used,
¯ Do not m~x old and fleW batteries.
¯ Do not mix alkaline, standard {carbon-zinc) or rechargeable (nickel-cadrnium) batteries.
¯ Do not attempt to burn batteries.
¯ Dispose of batteries safely and correctly.
ba~ew box
iNSTALLING
THEDISTRIBUTOR
ASSEMBLY
2 washers(9,5mmin
7 screws
~8 valve springs
1 shaft, 3 mm~, 206 mmlong (half-round)
1 shaft, 3 mmE/, 156 mmlong
Mount
the distributor on the
camshaft
suchthat the identification marks1,2, 3, and4 are at
the top, Attachthe distributor with
three screws,but donot tighten
themyet. Makesure that the
position of the piston and
camshaft
(establishedin step31
donot shift, Thedistributor has
aninner socketthat spins. Turn
this socketusingthe screwdriver
until theflat sideis facingup.
Twoof the wires fromthe
distributor havea phonejack on
oneend. Plugthis jack into the
socketonthe battery box.
INSTALLINGTHE FLYWHEEL
CLUTCH
Mountthe flywheelclutch (part
37) on the oppos~Ie
endof the
crankshaft.
Next,we’ll checkthe entire
engineby rotating the crankshaft
by hand.Notice carefully what
happens.
POSITIONINGTHE PISTONS
AND CAMSHAFT
Preliminaryadjustment:
Gentlyrotate the crankshaftby
handuntil piston Number
1 is at
thetopof its verticaltravel.
(Thispositionis called"dead
center").Theflat portionof the
half-round camshaftshouldbe
horizontal,withthe flat portion
facing upwards.
Onceyouhaveverified that the
piston andthe camshaftare in
the correct position,continue
with the nextstep.
I
BASIC
ENGINE
¯ ALTERNATOR
A devicefor generatingelectrical current. An
alternatorgenerates
A.C,(alternatingcurrent),but
is rectifiedinlo D,C.(direcl current)for char.oingthe
battery.
¯ BATrERY
A devicefor sloring electrical energy.Its [unclionis
to activate the starter molorandaccessones
when
the engineis first started. Thebatteryis automatically re-chargedas long as the engineis running.
¯ BOX, CASE
Thena~negiven to anycomponent
~n the shapeof a
boxor casingthat housesmovingmechanical
parts.
Examples:
crankcase,gearbox,differential gear
casing.
¯ CAMSHAFT
A shall w~thlumps,or lobesonit that forceseachof
the intake andexhaustvalves to openin the proper
sequence.
¯ CARBURETOR
A dewcefor mixing~ncoming
air w~tha measured
amount
of gasolineto producea gas-a~rmixturethat
the enginecanrun on.
¯ CONNECTING
ROD
A metalarmthat attachesthe piston to the
crankshaftandallows the piston to go upanddown
in the cylinder as the crankshaftrotates.
¯ CRANKSHAFT
A metal shaft that takesthe up anddownaction of
the pistonsandconvertsit into a rotating motionto
drive the vehicle,
¯ CYLINDER
Thechamber
in whichthe piston moves,It is
hollowedout of the engineblock.
¯ CYLINDERHEAD
Theupperpart of the engine(attachedto the top of
the cylinder block) wherethe explosionsoccur.It
containsthe valves,spark plugs, andthe camshaft.
This hart of the eneineheatsup considerablyand
mustbe constantlycooled.
¯ DISPLACEMENT
Thesize of the engine,expressed
as cubic inches,
cubic centimeters
or liters (1000cubiccentimeters).
This is the volume
of the spaceinsideall of the
cylinders that the pistonsactually goup anddown
in.
¯ EXHAUSTSYSTEM
Thesystemthat carries the burnedgasesor
exhaustawayfromthe engineafter combustion.
Thesystemconsistsof exhaustvalves, ports or
openingsin the engine,exhaustmanifold, andpipes
that lead to Ihe muffler whichquiets the soundof
the engine’sexhaust.
¯ FUELINJECTION
A systemthat measures
anddelivers the correct
amount
of fuel to the cylinders.Eachinjector.
whether
mechanical
or electrical, squirts a tiny
amount
of fuel into the engine’sintake like a
doctor’ssyringeinjects medicine.Usedinsteadof a
carburetor,a fuel injection systemis moreaccurate
than a carburetorandallowsfor better performance,
TERMS
I
¯ FUELSYSTEM
Thegroupof components
that feeds gasanda~r to
thecarburetor.It includes:thetuel tank,gasfilters,
the gaspump.
fuel supplylines, andthe air filter.
¯ IGNITION SYSTEM
Thegroupof electrical circuits requiredto ignite the
gas-airmixturethat ~s drawninto the cylindersot the
engine.
¯ INTAKESYSTEM
Thesystemthal bnngsfresh a~r needed
for the
combustionprocessinto the engine. Thesystem
consistsot theair intakeduct,air cleaner,~ntake
manifold,intakeports or openings
in the engine,
andintake valves.A throttle controlsthe amount
of
air that entersthe intakemanifold.
¯ PISTON
]he cylindrically-shapedpieceol metalthat moves
upanddown
inside the cylinder.It is linked to the
crankshaftby the connectingrod. Themovement
of
the pistonsgovernsthe four strokesof the cycle
invented by BeauDeRochas.
¯ ROCKERARM
A series of small armsor levers that actually open
the valves whenthe lobesof the camshaflact on
the rockeror a rod, calleda pushrod, whichactually
pushesthe rocker arm.
¯ SPARKPLUGS
Thedevicethat triggers the explosion~n the
combustion
chamber.
It is part of the electrical
system.It hastwo electrodes,one(-) grounded
the engineblock andthe other (+) connected
to the
distributor. A small gapseparates
thesetwo poinls.
When
a high voltage(at least 14.000volts)
appliedto the + terminal,anelectric arc is formed
h~lw~nthis qaDionitinq the qas-air mixturein the
combustion
chamber.
Thesparkplug "’fires" 10, 25,
or even50 or moretimes per second,dependingon
the RPM
of the engine.
¯ STARTER
A small electric motorwhichis powered
by the
battery. When
the starter is engaged
by the ignition
switch, the motorspins anda small gearturns the
large gearattachedto the engine’sflywheel,forcing
the crankshaftto rotate andthe engineto operate.
Oncethe enginestarts andruns on its ownpower,
the starter automaticallydisengages.
¯ VALVE
Anydevicethat opensor closes an openingto allow
something
to passor not passthroughthat opening.
Enginesusespecialsteel valvesto control intake
andexhaustinto andout of the engine. These
valves are openedby the action of the camshaft
operating on pushrodsand/or rocker arms.They
are closedby their powerfulsprings.
ASSEMBLING
YOUR
MOTOR
WORKS
ENGINE
ASSEMBLING
THEPISTONS
Inserta pistonpin(part1)
through
the smallendof the
connecting
rod(part 2),
Piston pin
(part 1)
INSTALLING
THEFANBELTPULLEY
AND
FAN
Place
thefanbelt pulley(part34)
overtheshaftstickingoutfrom
the waterpump.
Make
sureit is
orientedasshown
in the drawing.
Attach
thepulleyto theshaft
usinga screwanda washer.
Identifythe outside
faceof the
fan(part35)(theoutsideface
hasribs- seedrawing!)
Hold
the
fan
against
pulleywiththeoutsideof thefan
facingtowards
you.Attachthe
fanwithtwoscrews.
Z(...... ._.-=-_.-~-~
the
fan
belt
~ !
~,
.~!.i_---
~
(part 35)
Fan\~~.’~l~
Connectingrod
(part2)
INSTALLING
THECRANKSHAFT
PULLEY
AND FAN BELT
Pistonhalf-head
(part3)
Fit twopistonhalf-heads
(part 3)
ontothepistonpin. Jointhe
pistonhalf-heads
bypressing
firmly againstthe sides.They
shouldbeso~idlyconnected,
and
thepistonshould
beableto
rotatefreelyaround
the piston
pin.
Repeat
operations
1 and2 to
assemble
the otherthree
pistons,
Placethecrankshaft
pulley(part
36)againstthecircularshoulder
at thebottom
of thetimingbelt
cover.Positionthepulleyas
shown
in the drawing.
Attachthe
pulleyusinga screwandwasher.
Crankshaftpulley
Thescrewpasses
throughthe
holein thetimingbelt coverand
screws
into the endof the
crankshaft.
Passthe fanbelt
(blackcolor)overthetopof the
fanblades
andinstall it onthefan
MOUNTING
THE PISTONSON
THE CRANKSHAFT
INSTALLING
THETIMINGBELTCOVER
Mountthe timing belt cover(part
31) as shown
~n the drawing.
Attachwith four screws.
.....
NOTE!
Breakoff the small tongue
(marked
with a ’4’) onthe
crankshaftprior to making
the following assembly.Any
remainingburrs could
subsequently
hinderrotation
of the crankshaft,so trim
themoff witha knife. Adult
participationis recommendedwhentrimming.
Timingbelt cover
(part
Onthe crankshaft(part 4) and
onthe drawing,~dentifythe four
locationsat whichthe piston/
connectingrod assembly
will
be mounted.At eachlocation.
attachthe big endof the
connectingrod to the crankshaft
by meansof two screwsthrough
the keeper(part 5).
INSTALLINGTHE WATER
PUMP
Pressthe rear half of the water
pump
(part 32) onto the three
~t~d~nnth~ timinqh~lt envy.r:
makesure it is orientedas shown
in the drawing.
Placethe front half of the water
pump
(part 33) againstthe rear
half. Join the two halvesby
means
of three screws.
Rearhaftof waterpump
~__
(part 32)
~ /~..~
Front half of ~ ~-~
water pump ~ ~
.."~’,.. ", "i ! -._.~
rods have beenmounted,check
the completeassemblyfor
properoperationas follows:
Graspthe endsof the crankshaft
betweenthe thumband
forefinger of eachhand.
Rotatethe crankshaft.
Thepistons should gle freely
withoutbindingonthe
crankshaft.
Cranksha
~
~
~
Connecting
rodkeeper
(part5)
INSTALLING
THEALIGNMENT
TOOL
MOUNTING
THE OIL PANON
THE LOWERHOUSING
Thealignment
tool is usedto lock
the positionof thetimingwheel
whilethetimingbelt is being
installed.Carefully
identifythe
reference
marks
andholesthatlet
youcorrectlypositionthe
alignment
tool (part 29)between
the timingwheelandthe
timinggear.
~
Installthe
/r~j/.~.~,,~
Alignmenttool
alignm
Settheoil pan(part6) onthe
fourlugsprotruding
fromthe
bottomof the lowercrankcase
(part7), asshown
in the
drawing.
Secure
the oil pan
ush~g
four screws.
(part6)
Lower
crankcase
(part7)
INSTALLING
THETIMINGBELTAND
TIMINGBELTPULLEY
Place
thetimingbelt (green
color)
overthe timinggearandtiming
wheel.Mount
thebelt pulley
(part 30)onthe upperpost
stickingoutfromthecylinder
block(thesmooth
sideof the
timingbelt restsagainst
the
pulley).
Once
thesetwostepshavebeen
performed,
remove
the
alignment
tool;
it must
notremain
attached
to
theengine.
Insertthe four mounting
studson
the bottom
of the lower
crankcase/oil
panassembly
into
the matching
receptacles
onthe
engine
stand(part 8).
stand
(part8)
Timingbelt
I1~ MOUNTINGTHE TIMING GEARON THE
i~ INSTALLING THE PISTON-CRANKSHAFT
CRANKSHAFT
ASSEMBLY IN THE CYLINDER BLOCK
Putthehmingendgearof
the(partcrank-27)
lined
t:hta~ p
POsitiOn
the
pistOn’crankshaft
~
N~E.-~
I
.........
--
’1
assembly
and the cylinder
as ,nthe
block (partY)
shown
- I
drawingOarefullylnsertthetour
p,stonheads,nto the,r respechve
(Paycloseattar, lion to
~
~ -rll~;~
~
./
/’~
---~1-’L-<"
"~---~-~"~JA~-----
~~
~
’
I~
~
I
I ,hereforencemarks On the ~
I drawing. Makesure the
~
I~ match
~r~.~,*,ont~s
those shownin the
~
~
I
~
~
[
ie sli. freelyontoth
I drawing. This gear must
SPECIAL
NOTE:
attentionto thethreescrew
pOStS.Theyneedto be
ontheleft side.
,
~~&%~l~l
~~~
¯ ¯
T~
I c,~n~s~.,.
~ou~,~oI I
Pay
;:~;;r
~’"
"~J~~"-~~-
~
close
..
~
N
~~~"
~~
~~
~///r
j
I
, isin~o~LI
f°rceit’thenthep°siti°ning
~~
~J
~
~ MOUNTING THE TIMING WHEELON THE
CAMSHAFT
Pressthe timing wheel(part 28)
onto lhe camshaft while
I .....
liming
w~eel
~,,ehin~ ~incf th¢~ n.~.nn~it~
(part 28)
endof the camshaftwith yourI
<
finger to preventthe camshaft
|
..~L
from moving. If the camshaft~x ~:~
moves,youwill haveto
¯ \ ’,1~1~’~
realign the cams.
~--1] :".~/
!
,
.......
0 MOUNTINGTHE CYLINDER BLOCK
ASSEMBLYON THE LOWERCRANKCASE
Pos=fio~
theoil paR/lower
cra~kc~se/
enginemountingstandassemblyas
shown
~nthe drawing.Graspthe
endsof the crankshafb’cylinder
block
assembly
with lhe fingersof each
n~uu.~ ~i,uw.by,;,~ ~.~,,i..~. T~.;.
the assembly
upsidedownso it is
positionedas shown
in the drawing.
Setthe cylinder blockassembly
on
the lowercrankcase
un,t. Makesure
theunits are alignedasshown
in the
drawing,andthat youhavenot
reversed
theorientationof eitherund
(lower crankcaseand cylinder block/
studss~o~d
~ckoutto ~o~~e~t.~
~
I
I
~,’~’x~
I
’
!
~
ATTACHING
THE UPPERCYLINDERHEAD
TO THE LOWER
CYLINDERHEAD
Fastenthe two units together
with six screws.Checkthe
overall assembly,
at this point,
1or properoperation:Rotatethe
crankshaftby hand. The
cylinders should move freely up ~
anddowninside their respective I i~1~
cylinders,
I
~ i~-.--~-!
" ...
°
~’
-
"
.....
~,a,,~
INSTALLING
THESPRINGS
ONTHEVALVE
STEMS
Beforeattaching the upper
cylinder headwith screws,
youshouldcheckthat the
rocker armsare correctly
positionedoverthe top of
the valve stems.The wayto
dothis is to actuateeach
rocker armwith your finger.
The arms shouldpush
againstthe valves. Take
care not to pull on the ends
of the camshaft.Otherwise,
the camsmayshift their
positionandyouwill haveto
realign themagain.
/
~
L
~.
--
f~
When
youare satisfied that everythingis properlypositioned,attachthe uppercylinder headto the lower
cylinder headby means
of four screws,as shownin the drawing.
Slide the spring over eachof the |
eight valvestems(part 12),
I
~’
carefully;the screwholesin the
twounits mustline up.
t/I I/i
t~
Placethe uppercylinder head/
rocker armunit (assembled
in
step 15) overthe lowercylinder
head/camshaft
unit
(assembled
ATTACHING
THE ROCKER
ARMCOVER
Placethe rocker armcover(part
26) over the uppercylinder
head.Attachthe coverto the
uppercylinder headby means
of
six screws.
ASSEMBLING
THE CAMSHAFT
Thereare two waysyou can
Camshaft
identify the cams:
¯ Eachcamis stampedwith a
(half-round rod, 3 mmL~, 206 mmlong)
letter (A-H)
Notches
should
always
faceto theleft
¯ Eachcamis markedwith a
line; the positionof eachline
mustcorrespond
to the drawing.
Now,slide the camson
the camshaft(half-round
ThenotchonCam
H~snol seen.It ~sonthebacks~de.
shaft).
Note:Strictly follow the mountingsequence
given belowbecauseeachcamhasa different orientation
angle.Slide the camsonto the camshaftin the following order: 1st=A;2rid=B; 3rd=C;4th=D;5th=E;6th=F;
7th=G; 8th=H.
INSTALLINGTHE CAMSHAFT
ONTHE
LOWERCYLINDERHEAD
First, make
sure the splined
(grooved)endof the crankshaft
is to yourleft. Withthe camshaft
oriented as ~hownin the drawing
(camHto yourlefl), placethe
camshaftonthe lower cylinder
head. Eachend of the camshaft
is supportedby grooves
(bearings)in the lowercylinder
head.
H
INSTALLING
THEVALVES
IN THE
CYLINDERHEAD
Positionthe lowercylinder
(part 11) as shown
in the
drawing.Locatethe small
holes. Theseare the holdsfor
the exhaust
valves.First, insert
the endsof four valve stemsin
theseholes, oneby one(the
springsaretoo largeto slip
throughthe holes).
Nowrepeat the following
operationsfor eachof the four
valve stems:
Usingyour finger, pressdownon
the upperendof the valve stem
to compress
the spring. The
otherendof the valvestemwill
nowbe exposedbelowthe
cylinder head.Pressthe
exhaustvalve (part 13-the small
ones)onto the lowerendof the
valve stem.Pressfirmly so the
twoparts will remainlocked
together.
.XExhaust valve
(part
Lowercylinder head
(part 11)
G
In the samemanner,
install the
other four valve stems(and
4)<,
Intake valve
(~rt 14)
Grooved
End
holes, Pressan intake valve
(part 14-thelargeones)onto
the lowerendof eachvalve
stem.Pressfirmly so the two
partswill remainlockedtogether.
Check
to seethat all eight of the
valvesyouhavejust installed
workproperly:
Pressonthe spring endof each
valve, oneby one.
Thevalves should openand
closetheir respectiveholesas
youpress andrelease each
valve stem. Theaction should
be smooth,somewhat
like the
keysof a piano¯
NOTE:Uppercylinder headhas
a smallcover.Make
sureit is in
nl~P.: otherwisethe valveswill
MOUNTING
THE ROCKER
ARMSON THE
ROCKERARMSHAFT
Collect the eight rockerarms
(part 24) andthe rocker arm
shaft (roundshaft. 3 mm
in o.
Rocker arms (part 24)
(each one in alternateposition).~
armonto the shaft, oneby one.
Rotateevery other rocker arm
180"so that the longandshort
segments
of eacharmalternate
(see diagram}.Asa check:the
first andthe last rockerarms
should not be orientedthe same
way,
~""~...----’-.,
, ,~-~T,-., "~ !~
" ..........~- ~"’~’~i
INSTALLINGTHEROCKER
ARMASSEMBLY
IN THEUPPERCYLINDER
HEAD
Holdthe rockerarmunit that you
havejust finished assembling
(step 13) over the uppercylinder
head(part 23).
Carefully lowerthe rockerarm
unit into position(seedrawing).
Tworocker armsgo into eachof
the four openings.Useyour
fingersto separate
the four pairs
of arms,Eacharmof these four
pairs shouldhavea different
orientation,
~\
"\
, ’ ~-~
,.
Uppercylinder head
(part23)
INSTALLING
THEHEADGASKET
ONTHE
CYLINDERBLOCK
Theheadgasket(part 10)
attachedby means
of six screws
passingthroughholesin the
gasket: two at eachend andtwo
in the middle.Thereare also
two holesusedfor alignment.
Usinga ballpoint pen, punchthe
cardboard
out of theseeight
holesin the headgasket.Place
the headgasketonthe upperlip
of the cylinder block. Notethe
twolugs protrudingfromthe
upperlip. Theykeepthe head
gasketin the correctposition
prior to final installationwiththe
six screws.Usetheselugs as a
guide.
MOUNTING
THE LOWER
CYLINDERHEAD
ONTHE CYLINDER
BLOCK
NOTE~
Beforestartingthis step,
carefullynotethe details
shown
in the drawing.This
will helpyouproperlyorient
, the cylinderhead.
Positionthe five bearings(part
25) as shownin the drawing.
Attachthemto the cylinder head
by meansof 10 screws.
When
finished, checkthat the
rocker armspivot freely around
their common
shaft.
Positionthe lowercylinder head
overthe cylinderblock, Prior to
joining the twounits make
a final
checkonthe orientationof the
cylinder headand block. Notehow
the screwsline up with the dashed
lines on the drawing. When
you
are satisfied that everythingis lined
upproperly,fastenthe lower
cylinderheadto the cylinder block
with six screws.