* REMOVE ENGINE COVER, FLYWHEEL, AND MAGNETO PLATE FROM
ENGINE. REMOVE POINT COLLAR AND SET ASIDE (THESE PARTS
WILL NOT GO BACK ON ENGINE).
* REMOVE TRANSMISSION, AND BRAKE BRACKETS FROM TRANSMISSION.
* REMOVE BLOWER HOUSING AND LOWER MOUNTING BRACKETS..
* BOLT ON SNUG, BUT NOT TIGHT, LOWER BLOWER HOUSING BRACKETS. USE RTV SEALANT ON THREADS. NOTE: FRONT BRACKET USUALLY USES UPPER MOUNTING HOLE.
* INSTALL NEW STATOR PLATE; BE SURE TO ROUTE WIRE FROM STATOR TO VOLTAGE REGULATOR, SO IT WON’T BE PINCHED WHEN TIGHTENING STATOR PLATE.
* INSTALL NEW FLYWHEEL, MAKING SURE KEY DOES NOT PUSH OUT WHEN INSTALLED. PUT 3/8 STUDS IN REAR OF ENGINE. COAT WITH RTV
SEALANT ON THREADS BEFORE INSTALLING. BOLT STARTER BY PUTTING NUTS ON TOGETHER AT SAME TIME. CHECK CLEARANCE ON STARTER BENDIX AND FLYWHEEL RING GEAR TO MAKE SURE IT IS NOT RUNNING TIGHT. SHIM IF NECESSARY.
* ENGINE TIMING:
1. SET IGNITION COIL AT .010 CLEARANCE BETWEEN COIL
LEGS AND ENGINE MAGNET.
2. TO SET CORRECT ENGINE TIMING, SET TIMING FOR
CUSHMAN AT .109 BEFORE TDC- I SUGGEST .120
BEFORE TDC.
3. TO ADJUST TIME-LOOSEN STATOR PLATE BOLTS THRU HOLE
IN FLYWHEEL WHICH WILL ALLOW THE STATOR PLATE AND COIL
TO ROTATE TO DESIRED TIMING. WHEN SETTING PISTON AT
TDC, IT SHOULD BE .930 FROM LEADING EDGE OF MAGNET
TO LEADING EDGE OF COIL LEG.
COIL LEG SHOULD BE IN RELATION TO SAFETY SCREW IN
MAGNET AS PICTURED (FIGURE 1) IT WILL BE AT 17
DEGREES OR .109 BEFORE TDC. IF YOU BACK UP COIL
TO BACK EDGE OF SCREW HEAD YOU WILL BE AT .120
BEFORE TDC.
* ROUTE WIRING HARNESS BEHIND STATOR PLATE AND ENGINE. CONNECT VOLTAGE WIRE TO SHORT RED WIRE ON WIRING HARNESS. CONNECT MAGNETO WIRE TO IGNITION COIL. CONNECT PURPLE WIRE TO STARTER SOLENOID TRIGGER. CONNECT RED WIRE WITH EYELET TO POSITIVE SIDE OF SOLENOID. CONNECT RED WIRE WITH BULLET END TO CUSHMAN LIGHTING WIRE.
* REMOVE TRANSMISSION SHIFT BRAKE FROM TRANSMISSION. USE RTV SEALANT ON THE BOLTS JUST TAKEN OUT AND REINSTALL IN TOP HOLE.
* TAKE OLD TENSION SPRING AND INSTALL ON NEW BRAKE ROD AS PICTURED. (FIGURE 2)
*ADD NEW SHIFT BRAKE LEVER. DOUBLE NUT 1/4 INCH BOLT AND USE RTV SEALANT ON THREADS. LEAVE BRAKE ARM FREE ON BOLT.
*INSTALL TRANSMISSION SET BACK BRACKETS ON OUTSIDE OF EXISTING TRANSMISSION BRACKET USING THE 2, 7/16X20X1-1/4 BOLTS PROVIDED.
*INSTALL TRANSMISSION IN NEW MOUNTS USING 1/4 INCH BUSHINGS BETWEEN TRANSMISSION AND SET BACK BRACKETS. 7/16X5 1/2 BOLT AND NUT PROVIDED.
* INSTALL NEW BELT. WHEN BELT ADJUSTED UP IT WILL BE NECESSARY TO READJUST GEAR SHIFT LINKAGE. BRING TRUNNION ON TRANSMISSION IN FROM BOTTOM SIDE.
* TO INSTALL BLOWER HOUSING, CUT TOP BRACE OUT OF BLOWER HOUSING. ADD 1/8 INCH SHIM WASHER TO BOTTOM OF SPACER FOR HEAD BOLT. (FIGURE 3) CAN BE GLUED TO SET IN PLACE, BUT I SUGGEST BOLT ON AND HOLD IN PLACE AND SPOT WITH WELDER SO IT WON’T FALL WHEN INSTALLING AND BE SUCKED INTO MAGNETS. NEED TO CUT BLOWER HOUSING FOR STARTER GEAR. (FIGURE 4) (TEMPLATE ENCLOSED) AFTER ALTERING BLOWER HOUSING, INSTALL IGNITION SWITCH AND WIRING HARNESS INTO BLOWER HOUSING. IGNITION SWITCH NEEDS 5/8 WASHER FOR IGNITION SWITCH ON BACK SIDE OF BLOWER HOUSING. (PROVIDED) REVERSE STAR WASHER AND NUT ON OUTSIDE OF BLOWER HOUSING. REINSTALL BLOWER HOUSING LOOSELY. TURN ENGINE OVER SLOWLY AND MAKE SURE FLYWHEEL AND MAGNET DO NOT RUB BLOWER HOUSING COVER. WHEN ALL BOLTS ARE IN AND READY TO TIGHTEN, LOCK DOWN THE 1/4” BOLTS ON LOWER BLOWER HOUSING.
* FIT STARTER NOSE COVER (PROVIDED). TRIM OFF FLANGE ON NOSE COVER. LOWER MOUNTING BRACKET NEEDS SOME TRIMMING TO CLEAR LOWER BLOWER HOUSING MOUNT BRACKET. (FIGURE 5) LOCATE NOSE ON BLOWER HOUSING AND MARK HOLES AND DRILL 1/16” HOLE TO START SCREWS (USE 2 SHEET METALS SCREWS PROVIDED).
Detailed step by step instructions to install and electric starter onto a Cushman Scooter. For more information visit www.philhumphreys.com