0433989 JOHNSON CARBURETOR ASSEMBLY

3. Remove air inlet line (2) from air compressor. Remove air outlet line (3) from air compressor.4. Remove water lines (1) and (4). Remove line (6) from air compressor governor.5. Remove lubrication line (7) from air compressor.6. Remove bolts (5) and then pull air compressor off bearing.Install Air Compressor
1. Put the air compressor (1) in position on the engine and install the bolts that fasten it to the engine.2. Connect lubrication line to air compressor.3. Connect line to air compressor governor.4. Install water lines on air compressor.5. Connect air outlet line to the air compressor.6. Connect air inlet line to compressor.7. Start the engine and check for air and water leaks.8. Fill the cooling system with coolant to the correct level.Disassemble Air Compressor
start by: a) remove air compressor 1. Loosen two setscrews (1) and cover (2).2. Put alignment marks on head assembly (3) and on liner (5) and also on the liner and on crankcase (7) so parts can be put in correct location when they are assembled. 3. Disconnect air line (4) and remove two bolts (8) and governor assembly (6).4. Remove four nuts (9) and remove head assembly (3). 5. Remove cover (16), unloader valve (10) and spring (11) from top half of head and clean the unloader valve.6. Remove two setscrews from top half (12) and hit either top half (12) or bottom half (13) with a soft hammer to make a separation of the head.7. Remove and clean exhaust valve (14) and spring (15).8. Remove and clean inlet valve (17) and spring (18).9. Clean all of the passages in both top half (12) and bottom half (13). 10. Remove cylinder (19) and gasket.11. Remove bolts (20) and end cover (21). 12. Remove four bolts and cover (23). 13. Put marks on rod cap (26) and connecting rod (27) so rod and rod cap can be installed on crankshaft (28) in the same location from which they were removed.14. Bend lock (24) and remove bolts (25) and rod cap (26). Remove connecting rod (27) and piston (29) from crankcase (22). 15. Put a mark on piston (29) so it can be installed on connecting rod (27) in the same location from which it was removed.16. Remove pin lock (30) and push piston pin (31) out of piston (29) and connecting rod (27).17. Clean all parts.18. Remove piston rings and clean the ring grooves in piston (29) with a piece of hard wood. 19. A press (32) can be used to remove crankshaft (28) from crankcase (22). 20. Put a pipe (33) with a bore larger than 1.03 in. (26.2 mm) and a diameter of approximately 2 in. (50.8 mm) with an approximate length of 6 in. (152.4 mm) over the end of crankshaft (28) and on bearing (34).21. Push crankshaft (28) and bearing (34) out of crankcase as a unit. Remove bearing (34). 22. Put a mark on cover (35) and body (42) of the air compressor governor so the cover can be installed on the body in the correct location.23. Measure the distance from cover (35) to the top of screw (36) and make a record of the measurement. Loosen the locknut and remove screw (36).24. Remove four screws, identification tag, cover (35), spring (37) and spring seat (38).25. Remove nut (39), plunger (41) and diaphragm (40) as a unit.26. A rod with a diameter of .12 in. (3.05 mm) put in the hole in plunger (41) is used to hold the plunger when nut (39) is removed.27. Remove screw (48) and exhaust diaphragm (47).28. Remove exhaust nut (45), spring (46), exhaust valve (43) and spring retainer (44).29. Clean all of the parts and the passages in body (42) and plunger (41).Assemble Air Compressor
1. Install seal (12) on plunger (11).2. Put new soft washer (10), follower (9), new diaphragm (8), follower (7), spring guide (5) and new nut (6) on plunger (11). The diaphragm is between the chamfered sides of followers (7) and (9).3. A rod with a diameter of .12 in. (3.05 mm) put in the hole in plunger (11) is used to hold the plunger when nut (6) is tightened.4. Put lubricant on plunger (11) and in body (13). Install plunger in body.5. Install spring seat (3) in spring (4) and put them on spring guide (5).6. Install cover (2) over spring seat (3) and spring (4). Mark (A) on cover (2) must be in alignment with mark (A) on body (11) when the four lockwashers and screws in the cover are tightened. The governor identification tag is under of the four screws.7. Install screw and nut (1) in cover (2). Make an adjustment for the length of the screw to get the same measurement as before the screw was removed from the cover.8. Install screw and diaphragm washer (20) and new exhaust diaphragm (19) on exhaust nut (18).9. Install spring (17), spring retainer (16) and new exhaust valve (15) in exhaust nut (18).10. Install washer (14) and exhaust nut (18), spring retainer and spring in body (13). 11. Heat the crankshaft ball bearing in oil to a temperature of not over 350°F (175°C) and put the bearing on crankshaft (23).12. Put the bearing and crankshaft (23) into crankcase (21) with the crankcase in a vertical position on the large flange end.13. The outer race of the bearing (22) is pushed into the crankcase with a soft metal rod put at many locations on outer race of the bearing while the rod is hit with a hammer. 14. The gap for oil ring (24) and the gap for compression rings (25) is measured with the rings near the bottom in the cylinder. The gap for each ring is .003 to .009 in. (0.08 to .023 mm).15. Install rings (24) and (25) on piston (26). The gap for each ring must not be near the piston pin bore and each gap must be approximately 120° from the gap in the next ring.16. Install pin (27) in piston (26) and connecting rod (29). Install