15.6. REPLACING THE DOUBLE JOINT SEALS

Tappet rubbers are used for the sealing of the pushrod pipes and are located underneath the cylinders and pressed against the engine Block by means of a spring. They are called tappet rubbers because of their shape; two circular rubbers attached together with a small connecting piece. These rubbers also harden after some time and may then show leakage.
Replacing the tappet rubbers is not very difficult but this does involve special tools (torque wrench) and takes quite some time:
- Remove the air filter and the fuel pipe connected with the carburettor.
- Remove the heat exchanger (heater pots) by unscrewing the exhaust clamps.
- Remove the complete manifold including carburettor. The throttle and choke cable do not need to be removed.
- Remove the cooling plates around the cylinder at the side where you want to replace the tappet rubber. It is recommended to replace both sides at the same time.
-remove the cylinder head cover and the oil pipe at the bottom of the cylinder head. Be prepared for leakage.
- Evenly unscrew the cap nuts of the cylinder head.
- Now you can remove the cylinder head by pulling it towards you. Ensure that the cylinder does not move! The push rods often come out with the cylinder head, so do not mutually exchange those.
- Now the tappet rubbers become visible. You can replace those after neatly cleaning the different parts. Different types of tappet rubbers exist, please mount the same type. Please make sure no dirt enters the motor via the feed-through holes of the valve tappets.
- Reinstall the cylinder head. Take very good care that the aluminium push rod pipes fit well in the engine block, otherwise they will bend when the cylinder head is tightened.
- Make sure that the valves are set as freely as possible and that the push rods are well fitted. In the meantime please fit the cylinder head finger tight and make sure that the two brass rings are located below the two cap nuts and the steel ring below the lowest cap nut.
- Install the oil pipe.
- Install the cooling plates.
- Install the manifold. If the holes do not properly match, this can be adapted by tightening or loosening the cylinder had nuts.
- Attach the manifold using 19 Nm.
- Permanently attach the cylinder head using 21 Nm. Please take care of the right order: The front nut First, then the rear and the lower one.
- Adjust the valves and install the cylinder head cover using the correct torque.
- Let the engine run for a while and check for leakage.

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