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7. Stand the assembly on a table with the Front End
Plate Assembly upward.
8. Using an induction coil or oven, heat the Motor
Housing until the motor opening is large enough to be
placed over the Cylinder. At that time, install the
Housing over the Cylinder and Front End Plate
making sure the radial End Plate Alignment Pin (24)
in the Rear End Plate enters the notch in the Motor
Housing.
Take all precautions necessary to prevent being
burned by handling warm or hot parts.
9. Allow the assembly to cool and install the Rear End
Plate Gasket (36) (for 1100P or 1100P–EU models),
the Motor Case Cover Gasket (35) and Motor Case
Cover (33).
10. Secure the Cover to the Housing by installing the
three Motor Case Cover Screws (37) and Lock
Washers (38). Tighten each Screw between 45 and 50
in–lb (5.1 and 5.6 Nm) torque.
11. Install the Exhaust Deflector (22) in the bottom of the
handle of the Motor Housing and tighten it between
20 and 25 ft–lb (27 and 34 Nm) torque.
12. Thread the Inlet Bushing (21) into the bottom of the
handle of the Motor Housing (1) and tighten it
between 30 and 35 ft–lb (40 and 47 Nm) torque.
13. Install the Throttle Rod Seal (17) in the groove on the
large hub of the Throttle Rod (16).
14. Install the Throttle Valve Seal (14) in the groove on
the large hub of the Throttle Valve (13).
15. Slide the Throttle Valve, Valve Seal end first, onto the
Throttle Valve Rod.
16. Secure the Throttle Valve Assembly by installing the
Valve Retaining Ring (15) in the small groove on the
Throttle Valve Rod.
17. Install the three Throttle Bushing Seals (12) in the
grooves on the Throttle Bushing (11).
18. Slide the Throttle Bushing Assembly onto the shaft of
the Throttle Valve Rod and position the Trigger (18)
on the same shaft. Install the Trigger Pin (19).
19. Insert the assembled Trigger into the Housing. Make
certain the widest end of the Trigger is nearest the
motor bore and the narrowest portion of the Throttle
Valve aligns with the hole for the Throttle Retaining
Pin (20). Install the Pin making certain it captures the
Throttle Valve and secures the assembled Trigger.
20. Align the detent hole in the Reverse Valve (6) with
the hole inside the Reverse Valve Bushing (5) and
slide the Valve into the Bushing until almost reaching
the detent hole. Insert the Reverse Valve Detent
Spring (8) and Reverse Valve Detent Ball (7) into the
MAINTENANCE SECTION
21. Using snap ring pliers, install the Reverse Valve
22. Slide the Reverse Lever (2) onto the Reverse Valve,
Assembly of the Impulse Mechanism
1. Insert the long shaft of the Piston Stop (71) into the
2. When looking inside the central opening of the Liner
3. Insert the Piston Stop Assist Spring (73) into hole in
4. Thread the Threaded Tee Wrench furnished with the
5. Unscrew the Wrench and in the same manner, install
6. Install the Rear Liner Cover Seal (74) in the annular
7. Install the two Front Liner Cover Piston Seals (61) in
8. Install the Seal Back–Up Ring (60) followed by the
9. Insert the short round hub of the Drive Shaft (63) into
10. Insert a Blade (66) into one slot in the Drive Shaft.
20
hole and while compressing the Spring with the Ball,
slide the Valve completely into the Bushing.
Retainer (9).
making certain the Reverse Lever Alignment Pin (3)
or cast lug on 1900P models enters the notch on the
face of the Reverse Valve Bushing. Secure the Lever
to the Valve by inserting the Reverse Lever Retaining
Pin (4).
central opening of the O–ring Installer furnished
with the Tool Kit (Part No. 700A–99 or Part
No. 1900P–99). Place the Piston Stop Seal (72) on
the tapered end of the Installer and roll the Seal up the
taper and into the groove on the large body of the
Piston Stop. Repeat the procedure with the other
Piston Stop and Seal.
Assembly (68), the internal wall has three holes on
one side which do not extend through the wall. The
opening on the end face of that wall is for the Torque
Valve Piston (70). Install the Torque Valve Piston,
large end trailing, into that opening.
the end face of the opposite wall.
Tool Kit into one of the Piston Stop Assemblies and
using the Wrench to hold the Assembly, insert the
Assembly into the opening against Piston. Mark this
opening with a felt marker to indicate that it contains
the Torque Valve Piston.
the other Piston Stop Assembly in the hole with the
Spring.
groove on the face of the Rear Liner Cover (75).
the openings on the face of the Front Liner Cover.
Drive Shaft O–ring (59) in the central opening in the
face of the Front Liner Cover.
the central opening of the Rear Liner Cover.
Install the Blade Springs (67) through the Drive Shaft
and into the holes in the Blade. Place the remaining
Blade on the Springs making certain the Springs enter
the holes in that Blade.
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