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Zenith CruZer & Sonex Logs
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Date:  12-24-2017
Number of Hours:  2.00
Manual Reference:  na
Brief Description:  Removed Pistons, Valve Stuff, split case

Amazing what a good night of sleep will do. The piston pins were supposed to just slide right out with just finger pressure. Then I noted that "if they're varnished in-place, it may be necessary to tap or press them out."

I was a bit perplexed, but this AM I realized that I could use a big c-clamp I have and use sockets to press the pins out. Worked like a champ.

I then removed the lower baffle; had to drill-out some pop rivets to split it in two, and that came right off.

Still could not figure out how to remove the vacuum pump drive on the bottom of the crankcase. Tapped it forever with a plastic hammer. Used my HF heat gun; figured that might loosen-up whatever sealant was holding the gasket to the metal. No luck. Finally, I took a chance. I have a flat-on-one-side wood chisel. Since I'm not going to use the vacuum pump adapter anyway (will use a block-off plate), I kept the flat side against the engine case, and tapped real light. Hmm....looked like it budged a bit. Moved around the perimeter of the adapter, and it kept loosening. I was then able to pull it off with my hand. Seems the chisel blade went right thru the middle of the gasket (it was thick) such that the chisel never touched metal!

Lastly, I removed all case bolts and was able to split the case. First removed the cam gear; that came off with ligtht prying. Crank gear would not come off; I'll wait until I have the crank on a bench, since I didn't want to pry on the crankcase. Case is parted, but I did not pull the halves more than 1/8" until I have time and a helper to keep things like the cam from falling onto the floor.
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