Before installing front cover I measured end play at .002" using the lift the flywheel by hand method. With a used crush washer on the e-shaft bolt and no assembly lube on the front stack. Then I Installed the front cover (with new gasket and silicone, new o-ring), put a new crush washer on the e-shaft bolt with some silicone infront and behind the crush washer, and assembly lube on the needle bearings + thrust plate and now I measure .0014" end play when lifting the flywheel.

If I put a long screwdriver under the front pulley, and lift it rather hard, I can get exactly .002" and absolutely no more. So should this motor be installed or should I redo the end float. ?????

 

ur end play is fine.

 

FWIW, I ruined the 2nd motor I built by having insufficient end-play; I was under the impression (based on the pic in the FSM) that you should pry at it to take the measurement. Engine ran great for about 6000 miles, then began progressively failing. Upon opening it, massive wear.

Guys at RB set me straight: end-play should be measured under hand-pressure only, and with the crank horizontal, so flywheel weight doesn't enter into it. Literally meant to be "free play."

Front stack is most sensibly assembled with the e-shaft vertical, but end-play should be measured with it horizontal.

 

I think the assembly lube on the torrington bearings & thrust washer changed the end play. We're talking 6 tenths of a thou difference.

 

I ended up removing the pulley and reinstalling. With much less silicone under the bolt and only torqued it to 80 ft lbs. Got .0019" wet when lifting the flywheel and .0025" wet when prying on the front pulley.

It was interesting to see the affect of e-shaft bolt torque vs. endplay. Also minimal effort to increase torque from 60 to 70, and 70 to 80. But to go from 80 to 90 ft lbs the bolt had to be turned 1/8 of a rotation.