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OS FS91 Surpass Four Stroke
Once the rod is connected lubricate everything again. Notice the rod is at Top Dead Center, this is where is needs to be to install the cylinder.
Lubricate the cylinder inside & outside. While keeping the piston on TDC gently rotate the cylinder back & fourth while inserting it into the jug. The tapered edge in the cylinder will compress the piston ring and the cylinder will slide in smoothly. When it's installed, rotate the crankshaft to be sure it's smooth.
Rotate the piston to EXACTLY Top Dead Center. This is where it needs to be to install the camshaft. Of all the work done so far, this will make or break your overhaul. So double-check your TDC position BEFORE you set the camshaft.
Here is what the TIMING MARK on the camshaft looks like. When inserting the camshaft, it will rotate slightly because it's a wormgear. It will likely take you a few tries to set it. Again, I must stress that the TDC position on the piston must be correct. Here is how to TIME the CAMSHAFT: With the Piston at TOP DEAD CENTER, insert the CAMSHAFT where the TIMING MARK is in the Centerline of the tappet guide. It's that SIMPLE!
Confirm your timing is correct, generously lubricate everything and install the cam bearing support with two screws. Rotate your crankshaft several times and check for binding or un-usual roughness.
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