460cc Do-It-Yourself Assembly Guide

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2995 Coleman St North Las Vegas, NV 89032 702-530-7753 702-643-7517 FAX VegasCarts.

1 2995 Coleman St North Las Vegas, NV FAX VegasCarts.com 460cc Do-It-Yourself Assembly Guide *DIY Engines do not come with a warranty, these kits are intended for experienced engine builders, failure to properly assemble your engine, may directly result in premature engine failure. Proceed at your own risk! Revised 5/23/2015

2 Step 1: Thoroughly Clean your crankcase/engine block with soap & water. Dry well to avoid rusting the cylinder liner and bearings.

3 Step 2: Install Crankshaft, make sure to seat the bearing completely. Use a liberal amount of 30W oil to lubricate.

4 Step 3: Install Piston on to connecting rod (Dont Forget the wrist pin and locks). Make sure the arrow on the piston is facing down. Remove the rod bolts and install the first side of the rod bearing into the rod. Using a piston ring compressor, compress the rings tightly and push the piston into the cylinder bore. Ensure that the piston ring gaps are at least 90 degrees apart from each other. Use a liberal amount of 30W oil to lubricate. Follow instructions provided with your connecting rod to properly torque it onto your crankshaft journal.

5 Step 4: Install your valve tappets/lifters by drenching them in oil and sliding them into their lifter bores. Install your camshaft and then your balance shaft by simply turning the crankshaft by hand and aligning the timing dots on the crank gears with the timing dots on the cam and balance shaft. Use a liberal amount of 30W oil to lubricate. Turn the crankshaft multiple complete rotations back and forth to ensure that nothing is binding. If something is hitting, please call tech support before attempting to clearance the engine. All of our components are pre-clearanced and there should be no interference issues.

6 Step 5: Install your side cover by simply sliding it into place. Make sure it is seated fully before starting to tighten the 10-bolts. It may be tight and require some work to get it to line up correctly and seat. DO NOT FORCE IT WITH A HAMMER! Torque all 10 Bolts to 17 ft lbs, Loctite may be used but is not required. Lock Washers are required, make sure to use them!

7 Step 6: Install your flywheel onto the crankshaft making sure to align the keyway slot with the timing key. **If you are using a timing advance key, make sure the machined part of the key is facing the cylinder head side of the engine. It is imperative that all machined surfaces including the flywheel taper and the crankshaft are perfectly clean. There cannot be any oil or the flywheel will slip and break the timing key, potentially scoring the crank or flywheel. Set the plastic fan insert into the flywheel by matching the 3 pins with the 3 holes on the face of the flywheel. Slide the metal recoil catch onto the crankshaft and align the plastic pin with the hole in the recoil catch. Loosely Install the flywheel nut.

8 The flywheel nut must be torqued to 83ft lbs. If you are using a timing advance key, make sure the flywheel to seated fully into the machined portion of the key. Apply clockwise pressure to the flywheel while tightening the nut to prevent it from moving.

9 Step 7: Bolt on the ignition coil with the spark plug wire facing upwards. Use a feeler gauge to set the air gap to.010" while tightening the coil bolts. There is no specific torque value, however, its best to use loctite.

10 Step 8: Slide fan shroud & recoil cover onto the side of the engine and attach with the provided (4) 6mm bolts. Pull the recoil cord several times to make sure the engine is smooth and there is no binding or knocking.

11 Step 9: The cylinder head needs to be assembled before installation onto the shortblock. Starting with a bare cylinder head, we recommend lapping the valves to the seats with valve grinding compound (coarse then fine). Clean the head and valves thoroughly before assembly. Use 30W oil as pre-lubricant for the valve guides. Press the valve seal onto the intake valve guide. (This engine uses only 1 valve stem seal, do not install another onto the exhaust side, it will melt)

Step 10: Once the valves are in place, slide the valve springs over the stems and install the locks by pressing down over the valve stem and slipping them on.

12 Step 10: Once the valves are in place, slide the valve springs over the stems and install the locks by pressing down over the valve stem and slipping them on. Install the pushrod guide plate and rocker arm studs. Torque the studs to 17 ft lbs with loctite. Your cylinder head is now ready to install onto the shortblock.

13 Step 11: Before installing the cylinder head onto the shortblock, thoroughly clean the deck of the block. Press in both alignment dowels and slide the headgasket into place. Now you can install the cylinder head.

14 Step 12: Torque the (4) headbolts to 25 ft lbs. Insert the pushrods through the guideplate and into the lifter cups. Install the Lash Caps on the valves before proceeding with rocker arm setup.

Step 13: Rocker arms will drop directly onto the studs and the pushrods will sit in the rocker cups while the front of the rocker arm rests on the lash cap of the valve.

15 Step 13: Rocker arms will drop directly onto the studs and the pushrods will sit in the rocker cups while the front of the rocker arm rests on the lash cap of the valve. Install the rotator cup nuts loosely, followed by the stud girdle and then the hex nuts. The valve lash needs to be set to ". Keep in mind that the reading will change once everything is torqued down, it may take a few tries to get it right. Torque spec is 7ft lbs.

16 Step 14: At this point, the engine is 90% complete. Now is a good time to install the valve cover and spark plug. Spark plug gap should be set to.030"

17 Step 15: The last step to assembly is to install the carburetor and its supporting components. Tighten the long mounting studs into the cylinder head, then slide the port gasket on the studs making sure the gasket matches the intake port. Slide the Plastic Isolator onto the studs and then follow with the isolator gasket. Finally, slide the carburetor onto the studs and then follow with the carburetor gasket. Carburetor Linkage is shown in the picture below:

18 Electric Start (optional) If you purchased an electric starter with your engine, installation is very simple. Instead of using an aluminum starter blockoff plate, simply bolt the electric starter onto the rear of the block using the provided mounting hole and hardware.

19 Refer to the wiring diagram below to setup the starter wiring correctly:

4.510" Connecting Rod Instructions

4.510 Connecting Rod Instructions 2995 Coleman St North Las Vegas, NV 89032 702-530-7753 702-643-7517 FAX VegasCarts.com 4.510" Connecting Rod Instructions For use with: Honda GX390 420cc/440cc Clone Engines VRX460 Engines (The rods extended