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O.S. 1.60 Gemini Disassembly

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Old 01-02-2012, 05:21 PM
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retransit
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Default O.S. 1.60 Gemini Disassembly

I have a 1.60 Gemini in need of con rod replacement. The lower half of one was destroyed and I want to remove the crank to thoroughly clean the case out and check the condition of the forward bearing. The only thing left to do is remove the thrust washer positioned over the woodruff key and remove the crankshaft. What is the best procedure to remove the washer? Do I then tap the crank through the rear of the case with a plastic head hammer?

This is an answer you gave in a post about the timing:
"The hole in one gear and the dot on the other must line up in the center on a straight line between the centers of the crankshaft and camshaft."

Is this with both marks at 12 o'clock?

Bob
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Old 01-03-2012, 08:14 AM
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Default RE: O.S. 1.60 Gemini Disassembly

The drive washer usually pulls right off by hand. The crankshaft can then be pushed out by hand. No pounding needed. However, a light tap with a plastic-head mallet may help, if it's a tight fit.

The timing marks are in the center, between the centers of the crankshaft and camshaft.
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Old 01-03-2012, 11:33 AM
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Default RE: O.S. 1.60 Gemini Disassembly

I removed the drive washer. It needed a bit of coaxing with a puller.

I know where the timing marks are, but not the position in relation to each other. Is this drawing correct with both marks at 12 o'clock?

Bob
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Old 01-04-2012, 06:51 AM
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Default RE: O.S. 1.60 Gemini Disassembly

No. When setting the timing, the two dots are next to each other. From top-to-bottom, you have: shaft center, dot, dot, shaft center. The dots are in the center where the gears touch.
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