Table of Contents. Powerhead Specifications Special Tools Crankshaft, Pistons And

Transcription

1 POWERHEAD

2 Tle of Contents Pge Powerhed Specifictions Specil Tools Crnkshft, Pistons And Connecting Rods Cylinder Block Assemly Reed Block And Cylinder Hed Mnifold Assemly And Adpter Plte Throttle Lever And Shift Shft Bleed System Bleed System Bleed Line Routing Torque Sequence Generl Informtion Powerhed Removl from Pump Unit Removing Engine Components Powerhed Disssemly Upper End Cp Lower End Cp Crnkcse Cover Removed Clening nd Inspection Cylinder Block nd Crnkcse Cover Specil Service Informtion Cylinder Bores Honing Procedure Pge Pistons nd Piston Rings Clening Piston Ring Grooves Mesuring Piston Roundness Cylinder Heds nd Exhust Divider Plte Crnkshft Crnkshft (nd End Cp) Berings Reed Block Assemly Reed Block Housing Connecting Rods Powerhed Ressemly nd Instlltion Generl Crnkshft Instlltion Piston nd Connecting Rod Ressemly Piston nd Piston Ring Comintions Piston Instlltion Crnkcse Cover Instlltion Assemly of Reed Blocks to Intke Mnifold Assemly of Exhust Mnifold to Block Clening nd Inspection Cylinder Block nd Crnkcse Cover Cylinder Hed Instlltion Adptor Plte Instlltion Reinstlling Engine Components Powerhed Instlltion On Pump Unit Brek-ln Procedure Brek-in Fuel Mixture POWERHEAD MAY 1996

3 Powerhed Specifictions Block Type V, 2 Cycle Displcement cu. in. (2.5 Litre) Reed Vlve Opening Reed Stnd Open (Mx.) in. (0.50 mm) Cylinder Bore Piston Di. Stndrd Di..015 in. Oversize in. ±.001 in. ( mm ±.025 mm) in. ±.001 in. ( mm ±.025 mm) IMPORTANT: Using micrometer, mesure dimension B t loction shown. Dimension B should e.008 in. or less thn dimension A. Specil Tools Lifting Eye Flywheel Holder Dimension A t Right Angle (90 ) to Piston Pin 1/2 in. (12.7mm) Protector Cp Flywheel Puller A Dimension B ( in line with Piston Pin) MAY 1996 POWERHEAD - 4-1

4 Powerhed Stnd A1 Snp Ring Pliers Piston Ring Expnder Lockring Instlltion Tool A3 Piston Ring Compressor Lockring Removl Tool A1 Piston Pin Tool A3 Universl Puller Plte Compression Tester Powerhed Repir Stnd A powerhed repir stnd my e purchsed from: Bo Kerr s Mrine Tool Co. P.O. Box 1135 Winter Grden, FL Telephone: (305) POWERHEAD MAY 1996

5 Notes: MAY 1996 POWERHEAD - 4-3

6 CRANKSHAFT, PISTONS AND CONNECTING RODS Loctite 271 ( ) 14 2 Cycle Outord Oil ( A24) 92 Loctite 7649 Primer ( ) C w/teflon ( A12) POWERHEAD MAY 1996

7 CRANKSHAFT, PISTONS AND CONNECTING RODS TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 CRANKSHAFT ASSEMBLY 2 1 BEARING-Bll (LOWER) 3 1 RING-Retining 4 2 GEAR KIT-Drive 5 2 SCREW (#6-32 x.620) NUT-Specil (#6-32) 7 7 RING-Seling-Crnkshft 8 2 BEARING KIT-Crnkshft 9 3 PISTON ASSEMBLY (STARBOARD) (STANDARD) OPT PISTON ASSEMBLY (STARBOARD) (.015 O.S.) 10 3 PISTON ASSEMBLY (PORT) (STANDARD) OPT PISTON ASSEMBLY (PORT) (.015 O.S.) 11 1 RING KIT (12 Rings) (STANDARD) 12 OPT RING KIT (8 Rings) (.015 O.S.) RING-Lock 14 6 PIN-Piston 15 6 CONNECTING ROD KIT SCREW-Connecting Rod 1st Torque - 15 l. in. (1.5 N m) 2nd Torque - 30 l. ft. (40.5 N m) Turn olt dditionl 90 fter 2nd torque WASHER-Needle Locting 18 6 BEARING KIT-Roller BEARING-Needle-Piston End MAY 1996 POWERHEAD - 4-5

8 CYLINDER BLOCK ASSEMBLY Loctite 271 ( ) 12 Loctite Mster Gsket ( ) 14 2 Cycle Outord Oil ( A24) C w/teflon ( A12) POWERHEAD MAY 1996

9 CYLINDER BLOCK ASSEMBLY TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 POWERHEAD ASSEMBLY 1 1 CYLINDER BLOCK ASSEMBLY 2 2 PIN-Dowel-Locting 3 2 PIN-Dowel (Center Min) 4 2 GASKET-Crnkcse Seling 5 1 COVER-Strter Motor (UPPER) 6 2 SCREW ( x 1.500) COVER-Strter Motor (LOWER) 8 2 SCREW ( x 2.00) BUSHING 10 2 SCREW ( x 3.250) NUT-Wing (#10-32) 12 3 WASHER 13 1 SPACER 14 1 J CLIP 15 1 FITTING ( ) 16 1 STUD ( x 1.870) 17 1 SCREW, Ground 18 2 CABLE TIE (8.00 in.) 19 1 HOSE (57.00 in. Bulk) (Cut in.) 20 1 END CAP ASSEMBLY-Upper 21 1 O RING 22 1 BEARING KIT (Top Min) 23 1 SEAL-Oil 24 4 SCREW ( x 1.00) STUD (#10-32 x 1.00) 26 1 BRACKET-Flywheel Cover 27 2 SCREW ( x.750) SCREW ( x 1.250) 29 1 CAP-Nylon 30 1 NUT ( ) 31 1 SCREW-Specil ( x 2.125) 32 6 SCREW ( x 3.250) 33 1 END CAP ASSEMBLY-Lower 34 1 O RING (3.250 I.D.) 35 2 SEAL-Oil 36 4 LOCKWASHER (.250) 37 4 SCREW ( x.750) FITTING 39 1 COVER 40 1 GASKET-Cover 41 4 SCREW ( x.875) 42 1 SCREW (#6-32 x.250) MAY 1996 POWERHEAD - 4-7

10 REED BLOCK AND CYLINDER HEAD To Bottom Adpter Plte POWERHEAD MAY 1996

11 REED BLOCK AND CYLINDER HEAD TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 4 SCREW ( x 1.00) 2 1 ELBOW-90 Brss ( ) 3 4 CABLE TIE (8.00 in.) 4 1 HOSE ( in. Bulk) (Cut in.) 5 2 COVER KIT-Thermostt 6 2 GASKET-Thermostt 7 1 Sender, Temperture 8 24 SCREW ( x 2.30) Apply light oil to screw hed nd threds HEAD-Cylinder 10 4 PIN-Dowel (.250 x.625) 11 2 GASKET-Cylinder Hed 12 1 FITTING 13 1 HOSE ( in. Bulk) (Cut in.) 14 1 SENSOR ASSEMBLY-Temperture (PORT) 15 1 RETAINER-Sensor 16 2 SCREW ( x.500) 17 6 REED BLOCK ASSEMBLY 18 1 GASKET-Adptor Plte 19 1 PLATE ASSEMBLY-Adptor 20 6 STUD (.250 x 1.125) NS 2 FITTING-Bred NS 1 CHECK VALVE 21 1 CLIP 22 8 SCREW ( x.875) 23 6 SCREW ( x 2.00) Plte to Crnkcse 24 6 SCREW ( x.875) Cr Mounting 25 2 WASHER MAY 1996 POWERHEAD - 4-9

12 MANIFOLD ASSEMBLY AND ADAPTER PLATE POWERHEAD MAY 1996

13 MANIFOLD ASSEMBLY AND ADAPTER PLATE TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 ADAPTER ASSEMBLY-Flushing 2 1 PLUG-Top 3 1 WASHER 4 1 O RING 5 1 VALVE-Check 6 1 CONNECTOR 7 1 CLAMP 8 1 HOSE (49.00 in. Bulk) (Cut in.) 9 1 CLAMP 10 1 FITTING (90) 11 2 SCREW With WASHER ( x 1.500) J CLIP 13 1 SCREW ( x.500) WASHER SCREW ( x 5.250) DECAL-Flushing Adpter 17 2 SCREW (#10-32 x.620) 18 1 CLIP-Flushing Assemly Holder 19 1 COVER-Exhust Mnifold 20 2 TUBE-Striner 21 1 GASKET-Exhust Mnifold Cover 22 1 MANIFOLD-Exhust 23 1 GASKET-Exhust Mnifold 24 1 SEAL-Exhust Mnifold ( in.) 25 1 GASKET-Adpter To Block 26 1 HOSE ASSEMBLY-Wter Inlet 27 1 FITTING-Wter Inlet Hose 28 1 ADAPTER-Engine To Pump WASHER 30 4 SCREW ( x 2.250) PIN-Dowel 32 8 SCREW ( x 1.620) FITTING (45) 34 1 ELBOW (90) 35 3 CABLE TIE (8.00 in.) 36 1 HOSE-Syphon (9.00 ft. Bulk) (Cut in.) 37 1 SYPHON BREAK 38 1 HOSE-Syphon (9.00 ft. Bulk) (Cut in.) 39 1 CLAMP 40 1 FILTER-Syphon Hose MAY 1996 POWERHEAD

14 THROTTLE LEVER AND SHIFT SHAFT POWERHEAD MAY 1996

15 THROTTLE LEVER AND SHIFT SHAFT TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 LEVER ASSEMBLY-Sprk Advnce 2 1 SCREW ( x 2.125) 3 1 NUT ( ) 4 1 CAP 5 1 SCREW ( x 1.250) 6 1 NUT (#10-32) 7 1 CAP 8 1 WASHER 9 1 NUT (#10-32) 10 1 ROD-Link 11 1 NUT (#10-32)-Brss 12 1 BALL JOINT ASSEMBLY 13 1 PIVOT 14 1 SPRING 15 1 BUSHING 16 1 LEVER-Throttle Control 17 1 SCREW ( x 1.750) 18 1 BUSHING 19 1 SCREW ( x 2.125) 20 1 NUT ( ) 21 1 CAP 22 1 LATCH-Cle End 23 1 SCREW ( x.880) 24 1 SPRING 25 1 NUT ( ) 26 1 BARREL 27 1 ROD-Throttle Control 28 1 BUSHING-Swivel 29 1 CAM-Throttle 30 1 STUD ( x 1.750) 31 1 NUT ( ) 32 1 BRACKET ASSEMBLY-Cle Anchor 33 1 LATCH-Control Cle 34 1 NUT (#12-24) (Service Replcement Brkt) 35 1 WASHER (Service Replcement Brcket) 36 1 STUD (Service Replcement Brcket) 37 2 SCREW (Specil)-(Originl Brcket) 38 1 CUP-Brrel Retiner 39 3 SCREW ( x.880) MAY 1996 POWERHEAD

16 Bleed System Bleed System TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 2 TUBING (9 in.) 2 2 TUBING (12-1/2 in.) 3 1 TUBING (14 in.) 4 2 TUBING (19 in.) 5 1 TUBING (24 in.) 6 1 TUBING (26 in.) 7 7 CHECK VALVE 8 6 ELBOW 9 4 FITTING Bred 10 1 CHECK VALVE POWERHEAD MAY 1996

17 Bleed Line Routing STARBOARD SIDE VIEW FRONT VIEW PORT SIDE VIEW MAY 1996 POWERHEAD

18 Torque Sequence CRANKCASE COVER BOLTS (AND TORQUE SEQUENCE) 8 7 CYLINDER HEAD BOLTS Retorque hed olts fter outord hs een run for pproximtely 1/2-1 hour Apply light oil to threds nd olt fce: 40 l. ft. (54 N m) Apply light oil to threds nd olt fce: 8 Bolts (3/8 in in. 38 l. ft. (51.5 N m) Bolts (5/16 in. - 18) 180 l. in. (20.3 N m) EXHAUST COVER/MANIFOLD BOLTS 180 l. in. (20 N m) Apply light oil to threds nd olt fce POWERHEAD MAY 1996

19 Generl Informtion Powerhed Disssemly nd Ressemly instructions re printed in sequence tht should e followed to ssure est results when removing or replcing powerhed components. If complete disssemly is not necessry, strt ressemly t point disssemly ws stopped. (Refer to Tle of Contents, preceding.) Usully, complete disssemly of powerhed will e required. If mjor powerhed repirs re to e performed, remove powerhed from the pump unit. Powerhed Removl from Pump Unit 1. Disconnect ttery cles from ttery terminls. Remove positive ttery cle from strter solenoid. Remove negtive ttery cle from lower front strter mounting olt. 2. Disconnect remote oil tnk hose connector. 3. Disconnect remote control hrness from powerhed hrness connector nd wires. 4. Remove throttle cle. 5. Remove fuel inlet line Fuel Inlet - Throttle Cle 6. Remove eight (8) nuts (four on ech side) securing powerhed to housing cover Positive Bttery Cle Attching Loction - Boot Protector for Positive Bttery Cle - M10 x 1.5 Nuts Forwrd Strter Bolt (Engine Ground) MAY 1996 POWERHEAD

20 7. Remove plstic cp from center of flywheel nd instll LIFTING EYE ( ) into flywheel t lest five full turns. Using hoist, lift powerhed ssemly from pump unit. Powerhed Disssemly 1. Plce powerhed in repir stnd or on ench. 2. Remove thermostt covers nd wshers REMOVING ENGINE COMPONENTS Remove the following engine components: Section 2 Strter Motor *Ignition Switch Boxes *Ignition Coil *Strter Solenoid *Voltge regultor/rectifier Flywheel *Sttor Assemly *Trigger Assemly *Turn Key Strt Module Section 3 Air Silencer Cruretors nd Linkge Fuel Pump Fuel Primer Fuel Enrichment Vlve Engine Mounted Oil Tnk Oil Pump * All ignition nd electricl components should remin ttched to electricl plte. Plte with components cn e removed s n ssemly. - Thermostt Cover - Wsher 3. Remove cylinder heds from engine lock c - Cylinder Hed - Gsket c - Engine Block POWERHEAD MAY 1996

21 4. Remove exhust mnifold nd sel. c 7. Remove olts from end cps. UPPER END CAP Exhust Mnifold - Sel c - Gsket 5. Remove reed lock housing from cylinder lock. - Crnkcse Attching End Cp Bolts LOWER END CAP Reed Block Housing Inspect reeds s outlined in Clening nd Inspection Crnkcse Attching End Cp Bolts 8. Remove olts which secure crnkcse cover to cylinder lock MAY 1996 POWERHEAD

22 9. Pry crnkcse cover off cylinder lock using pry rs in loctions shown. 11. Using n wl or electric pencil, scrie the cylinder identifiction numer on ech connecting rod s shown. Ressemle connecting rods in sme cylinder. Ä Ä - Pry Points - Crnkcse Cover CRANKCASE COVER REMOVED Use 5/16 in. 12 point socket to remove connecting rod olts, then remove rod cp, roller erings nd ering cge from connecting rod Use Powerhed Stnd ( A1) for rotting crnkshft to desired position for removl of connecting rods. - Connecting Rod Bolts 13. Push piston out of cylinder lock POWERHEAD MAY 1996

23 14. After removl, ressemle ech piston nd connecting rod ssemly. CAUTION Ech connecting rod nd end cp re mtched mchined set nd must never e mismtched. 17. Using n wl, scrie identifiction numer of connecting rod on inside of piston (1). Ressemle pis- ton on sme connecting rod Inspect pistons s outlined in Clening nd Inspection following. 16. Use Piston Ring Expnder ( ) to remove piston rings. Alwys instll new piston rings Using tool ( A1), remove piston pin lockrings from oth ends of piston pin. Never re-use piston pin lockrings Lockring IMPORTANT: Wrming the piston dome using torch lmp will ese removl nd instlltion of piston pin MAY 1996 POWERHEAD

24 19. Support piston nd tp out piston pin using service tool ( A1) s shown. 21. Remove upper end cp nd lower end cp from crnkshft Piston Pin - Piston Pin Tool ( A1) 20. Remove piston pin needle erings (29 per piston) nd locting wshers (2 per piston) s shown. IMPORTANT: We recommend tht you use new needle erings t ressemly for lsting repir. However, if needle erings must e re-used, keep ech set of erings identified for ressemly on sme connecting rod Upper End Cp - Lower End Cp 22. Remove nd discrd O-ring sels from ech end cp. 23. Remove oil sel(s) from end of ech end cp y driving sel out with punch nd hmmer. 24. Inspect roller ering in upper end cp s outlined in Clening nd Inspection. NOTE: If roller ering is dmged, replce upper end cp nd roller erings s n ssemly Needle Bering Locting Wshers - O-Ring - Sel POWERHEAD MAY 1996

25 25. Remove crnkshft nd plce in powerhed stnd s shown. IMPORTANT: DO NOT remove crnkshft seling rings from crnkshft, unless replcement of seling ring(s) is necessry. Usully, crnkshft seling rings do not require replcement, unless roken. 27. Remove ering rce hlves nd roller erings from crnkshft. IMPORTANT: Keep sme ering rces nd roller erings together. CAUTION Sfety glsses should e worn when removing or instlling crnkshft seling rings. IMPORTANT: DO NOT remove oil pump drive ger on crnkshft unless ger is dmged; i.e. crcked, ger teeth chipped or fretting, or excessive looseness. Refer to Section 8 for proper oil drive ger instlltion procedures Bering Rce Hlves - Roller Berings Inspect crnkshft ll ering s outlined in Clening nd Inspection, following. IMPORTANT: DO NOT remove crnkshft ll ering, unless replcement is required. 28. Remove lower ll ering from crnkshft s follows:. Remove retining ring using pir of snp ring pliers. - Seling Rings - Oil Pump Drive Ger Remove retining ring s shown. c - Retining Ring Crnkshft Bll Bering - Pliers c - Retining Ring MAY 1996 POWERHEAD

26 . Press crnkshft out of lower ll ering s shown. Clening nd Inspection Cylinder Block nd Crnkcse Cover IMPORTANT: Crnkcse cover nd cylinder lock re mtched, line-ored ssemly nd never should e mismtched y using different crnkcse cover or cylinder lock. c d Press - Powerhed Stnd ( A1) c - Crnkshft Bll Bering d - Universl Puller Plte ( ) 29. If necessry, remove wter pressure relief vlve cover s shown CAUTION It crnkcse cover or cylinder lock is to e sumerged in very strong clening solution, it will e necessry to remove the crnkcse cover/cylinder lock leed system from crnkcse cover/ cylinder lock to prevent dmge to hoses nd check vlves. 1. Thoroughly clen cylinder lock nd crnkcse cover. Be sure tht ll selnt nd old gskets re removed from mtching surfces. Be sure tht cron deposits re removed from exhust ports. 2. Inspect cylinder lock nd crnkcse cover for crcks or frctures. 3. Check gsket surfces for nicks, deep grooves, crcks nd distortion tht could cuse compression lekges. 4. Check ll wter nd oil pssges in cylinder lock nd crnkcse cover to e sure tht they re not ostructed nd tht plugs re in plce nd tight. - Bolt - Cover c - Gsket POWERHEAD MAY 1996

27 Specil Service Informtion Grooves in Cylinder Block Cused By Crnkshft Seling Rings Grooves in cylinder lock cused y crnkshft seling rings re not prolem, except if instlling new crnk- shft nd the new seling rings on crnkshft do not line up with existing grooves in cylinder lock. If instlling new crnkshft, refer to crnkshft instlltion, Powerhed Ressemly section to determine if powerhed cn e used. Cylinder Bores 1. Inspect cylinder ores for scoring, scuffing or trnsfer of luminum from piston to cylinder wll. Scoring or scuffing, if NOT TOO SEVERE, cn normlly e removed y honing. If trnsfer of luminum hs occurred, n cidic solution such s TIDY BOWL CLEANER should e pplied to the res of the cylinder ore where trnsfer of luminum hs occurred. After the cidic solution hs removed the trnsferred luminum, thoroughly flush the cylinder ore(s) to remove ny remining cid. Cylinder wlls my now e honed to remove ny glze nd to id in the seting of new piston rings. d. Loclize stroking in the smllest dimeter until drill speed is constnt throughout length of ore. Expnd stones, s necessry, to compenste for stock removl nd stone wer. Stroke t rte of 30 complete cycles per minute to produce est cross-htch pttern. Use honing oil generously. e. Thoroughly clen cylinder ores with hot wter nd detergent. Scru well with stiff ristle rush nd rinse thoroughly with hot wter. A good clening is essentil. If ny of the rsive mteril is llowed to remin in the cylinder ore, it will cuse rpid wer of new piston rings nd cylinder ore in ddition to erings. After clening, ores should e swed severl times with engine oil nd clen cloth, then wiped with clen, dry cloth. Cylinders should not e clened with kerosene or gsoline. Clen reminder of cylinder lock to remove excess mteril spred during honing opertion. 2. Hone ll cylinder wlls just enough to de-glze wlls. 3. Mesure cylinder ore dimeter (with snp guge micrometer) of ech cylinder, s shown elow. Check for tpered, out-of-round (egg-shped) nd oversize ore. HONING PROCEDURE. When cylinders re to e honed, follow the hone mnufcturer s recommendtions for use of the hone nd clening nd luriction during honing.. For est results, continuous flow of honing oil should e pumped into the work re. If pumping oil is not prcticl, use n oil cn. Apply oil generously nd frequently on oth stones nd work re. CAUTION When honing cylinder lock, remove hone frequently nd check condition of cylinder wlls. DO NOT hone ny more thn solutely necessry, s hone cn remove cylinder wll mteril rpidly. c. Strt stroking t smllest dimeter. Mintin firm stone pressure ginst cylinder wll to ssure fst stock removl nd ccurte results MAY 1996 POWERHEAD

28 175 Models Models Cylinder Block Finish Hone 175 with Stndrd Piston in. (88.93 mm) 175 with.015 in. (0.381mm) Oversize Piston in. (89.31 mm) 4. If cylinder ore is tpered, out-of-round or worn more thn.006 in. (0.152 mm) from stndrd Cylinder Block Finish Hone dimeter (refer to chrt, preceding), it will e necessry to re-ore tht cylinder(s) to.015 in. (0.381 mm) or.030 in. (0.762 mm) oversize or re-sleeve nd instll oversize piston(s) nd piston rings during ressemly. NOTE: The weight of n oversize piston is pproximtely the sme s stndrd size piston; therefore, it is not necessry to re-ore ll cylinders in lock just ecuse one cylinder requires re-oring. 5. After honing nd thoroughly clening cylinder ores, pply light oil to cylinder wlls to prevent rusting. Pistons nd Piston Rings IMPORTANT: If engine ws sumerged while engine ws running, piston pin nd/or connecting rod my e ent. If piston pin is ent, piston must e replced. (Piston pins re not sold seprtely ecuse of mtched fit into piston.) If piston pin is ent, connecting rod must e checked for strightness (refer to Connecting Rods, following, for checking strightness). 1. Inspect pistons for scoring nd excessive piston skirt wer. 2. Check tightness of piston ring locting pins. Locting pins must e tight. 3. Thoroughly clen pistons. Crefully remove cron deposits from pistons, with soft wire rush or cron remove solution. Do not urr or round off mchined edges. Inspect piston ring grooves for wer nd cron ccumultion. If necessry, scrpe cron from piston ring grooves eing creful not to scrtch sides of grooves. Refer to procedure following for clening piston ring grooves. CLEANING PISTON RING GROOVES NOTE: Clening instructions differ etween the rectngulr ring groove nd keystone (tpered) ring groove. Pistons my hve two keystone ring grooves or one keystone ring groove nd one rectngulr ring groove s shown. Rectngulr ring grooves 1. A roken rectngulr piston ring cn e used s tool for scrping cron from ring grooves. Crefully scrpe cron from ring grooves without scrtching the side surfces of grooves. Keystone (tpered) ring grooves CAUTION Cre must e tken not to scrtch the side surfces of the ring groove. Scrtching the side surfce of the ring groove will dmge the ring groove. 1. Use ristle rush nd cron remover solution to remove cron from side surfces. 2. A tool cn e mde for clening the inner dimeter of the tpered ring grooves. The tool cn e mde from roken tpered piston ring with the side tper removed to enle the inside edge of the ring to rech the inner dimeter of the groove. Crefully scrpe cron from inner dimeter of ring grooves. Cre must e tken not to dmge the grooves y scrtching the side surfces of the grooves. Piston with two hlf keystone (hlf tpered) rings (175 Models) Enlrged View of Piston Ring Grooves POWERHEAD MAY 1996

29 MEASURING PISTON ROUNDNESS Piston hs rrel profile shpe nd is not true dimeter cu. in. (2508 cc) 1. Using micrometer, mesure dimension A t loction shown. Dimension A should e s indicted in chrt following. Piston Stndrd Piston Dimension A in. ±.001 in..015 in. Oversize Piston in. ±.001 in. 2. Using micrometer, mesure dimension B t loction shown. Dimension B should e within.008 in. of dimension A. Crnkshft 1. Inspect crnkshft to drive shft splines for wer. (Replce crnkshft, if necessry.) 2. Check crnkshft for strightness. (Replce s necessry.) 3. Inspect crnkshft oil sel surfces. Seling surfces must not e grooved, pitted or scrtched. (Replce s necessry.) 4. Check ll crnkshft ering surfces for rust, wter mrks, chtter mrks, uneven wer nd/or overhet-ing. (Refer to Connecting Rods.) 5. If necessry, clen crnkshft surfces with crocus cloth. Dimension A t Right Angle (90 ) to Piston Pin c c 1/2 in. (12.7mm) Dimension B ( in line with Piston Pin) Cylinder Heds nd Exhust Divider Plte 1. Inspect internl surfce of cylinder heds for possile dmge (s result of piston or foreign mteril striking cylinder heds). IMPORTANT: Cylinder hed wrpge should not exceed.004 in. (.1mm) over the ENTIRE length of the cylinder hed. If mesured wrpge, s determined on surfce lock, exceeds.004 in. (.1mm) or discontinuity of up to.004 in. (.1 mm) exists in nrrow portion of the cylinder hed s surfce length, then the cylinder hed my e resurfced up to.010 in. (.25mm). 2. Replce cylinder hed(s) s necessry. 3. Thoroughly clen gsket surfces of exhust divider plte. 4. Inspect exhust divider plte for deep grooves, crcks or distortion tht could cuse lekge. Replce prts s necessry. - Crnkshft Journls - Crocus Cloth c - Work Cloth Bck-nd-Forth WARNING DO NOT spin-dry crnkshft ll ering with compressed ir. 6. Thoroughly clen (with solvent) nd dry crnkshft nd crnkshft ll ering. Recheck surfces of crnkshft. Replce crnkshft, if surfces cnnot e properly clened up. If crnkshft will e re-used, luricte surfces of crnkshft with light oil to prevent rust. DO NOT luricte crnkshft ll ering t this time MAY 1996 POWERHEAD

30 Crnkshft (nd End Cp) Berings 1. After clening crnkshft, grsp outer rce of crnkshft ll ering (instlled on lower end of crnkshft) nd ttempt to work rce ck-ndforth. There should not e excessive ply. 2. Luricte ll ering with light oil. Rotte outer ering rce. Bering should hve smooth ction nd no rust stins. If ll ering sounds or feels rough or hs ctches, remove nd discrd ering. (Refer to Powerhed Removl nd Disssemly - Crnkshft Removl nd Disssemly.) Reed Block Assemly IMPORTANT: Reed lock ssemly is not servicele. If reeds re dmged replce reed lock ssemly. 1. Thoroughly clen gsket surfces of reed locks nd reed lock housing. Check for deep grooves, crcks nd distortion tht could cuse lekge. Replce prts s necessry. 2. Check for wer (indenttions) on fce of ech reed lock. Replce reed lock ssemly if reeds hve mde indenttions. 3. Check for chipped nd roken reeds. Lower Bll Bering 3. Thoroughly clen (with solvent) nd dry crnkshft center min roller erings. Luricte erings with 2-Cycle Outord Oil. CAUTION DO NOT intermix hlves of upper nd lower crnk- shft center min roller erings. Replce erings in pirs only. 4. Thoroughly inspect center min roller erings. Replce erings if they re rusted, frctured, worn, glled or dly discolored. Center min Roller Bering 5. Clen (with solvent) nd dry crnkshft roller ering tht is instlled in upper end cp. Luricte ering with light oil. 6. Thoroughly inspect upper end cp roller ering. If roller ering is rusted, frctured, worn, glled, dly discolored or loose inside of end cp replce end cp nd roller ering s n ssemly Allowle reed opening is.020 in. (.51 mm) or less. Replce reed lock ssemly if ny reed is stnding open more thn.020 in. (.51 mm). Reed Block Housing 1. Check ruer leed hoses. Replce ny hose tht is crcked, cut or deteriorting. 2. Check opertion of leed system check vlves in reed lock housing. If vlves re working properly, ir cn e drwn thru check vlves one wy only. If ir cn pss thru check vlve oth wys, vlve is not working properly nd must e replced. Upper Roller Bering POWERHEAD MAY 1996

31 3. Check tht leed system check vlves re pressed tight into reed housing. 4. Inspect pssges in reed lock housing to e sure tht they re not ostructed. 4. Wter Mrks: When ering surfces re sujected to wter contmintion, ering surfce etching occurs. This etching resemles the size of the ering Splling: Splling is the loss of ering surfce, nd it resemles flking or chipping. Splling will e most evident on the thrust portion of the connecting rod in line with the I em. Generl ering surfce deteriortion could e cused y or ccelerted y improper luriction. Connecting Rods 1. Check connecting rods for lignment y plcing rods on surfce plte. If light cn e seen under ny portion of mchined surfces, if rod hs slight wole on plte, or if.002 in. (0.051mm) feeler guge cn e inserted etween ny mchined surfce nd surfce plte, rod is ent nd must e discrded. 2. Overheting: Overheting is visile s luish ering surfce color tht is cused y indequte luriction or excessive RPM. 3. Rust: Rust formtion on ering surfces cuses uneven pitting of surfce(s). - Splling Pitting MAY 1996 POWERHEAD

32 6. Chtter Mrks: Chtter mrks re the result of comintion of low speed - low lod - cold wter temperture opertion, ggrvted y indequte luriction nd/or improper fuel. Under these conditions, the crnkshft journl is hmmered y the connecting rod. As ignition occurs in the cylinder, the piston pushes the connecting rod with tremendous force, nd this force is trnsferred to the connecting rod journl. Since there is little or no lod on the crnkshft, it ounces wy from the connecting rod. The crnkshft then remins immoile for split second until the piston trvel cuses the connecting rod to ctch up to the witing crnkshft journl, then hmmers it. The repetition of this ction cuses rough ering surfce(s) which resemles tiny wshord. In some instnces, the connecting rod crnk pin ore ecomes highly polished. During opertion, the engine will emit whirr nd/or chirp sound when it is ccelerted rpidly from idle speed to pproximtely 1500 RPM, then quickly returned to idle. If the preceding conditions re found, replce oth the crnkshft nd connecting rod(s). 8. If necessry, clen connecting rod ering surfces, s follows:. Be sure tht etched mrks on connecting rod (crnkshft end) re perfectly ligned with etched mrks on connecting rod cp. Tighten connecting rod cp ttching olts securely. CAUTION Crocus cloth MUST BE USED to clen ering surfce t crnkshft end of connecting rod. DO NOT use ny other type of rsive cloth.. Clen CRANKSHAFT END of connecting rod y using CROCUS CLOTH plced in slotted 3/8 in. (9.5 mm) dimeter shft, s shown. Chuck shft in drill press nd opertion press t high speed while keeping connecting rod t 90 ngle to slotted shft. IMPORTANT: Clen connecting rod just enough to clen up ering surfces. DO NOT continue to clen fter mrks re removed from ering surfces Chtter Mrks Between Arrows 7. Uneven Wer: Uneven wer could e cused y ent connecting rod c. Clen PISTON PIN END of connecting rod, using sme method s in Step, preceding, ut using 320 grit crorundum cloth insted of crocus cloth. d. Thoroughly wsh connecting rods to remove rsive grit. Recheck ering surfces of connecting rods. Replce ny connecting rod(s) tht cnnot e properly clened up. Luricte ering surfces of connecting rods (which will e re-used) with light oil to prevent rust. - Uneven Wer Between Arrows POWERHEAD MAY 1996

33 Powerhed Ressemly nd Instlltion Generl Before proceeding with powerhed ressemly, e sure tht ll prts to e re-used hve een crefully clened nd thoroughly inspected, s outlined in Clening nd Inspection, preceding. Prts, which hve not een properly clened (or which re questionle), cn severely dmge n otherwise perfectly good powerhed within the first few minutes of opertion. All new powerhed gskets MUST BE instlled during ressemly. During ressemly, luricte prts with Quicksilver 2-Cycle Outord Luricnt whenever light oil is specified. Quicksilver prt numers of luricnts, selers nd locking compounds nd tools re listed in Powerhed Generl Informtion, preceding. A torque wrench is essentil for correct ressemly of powerhed. DO NOT ttempt to ressemle powerhed without using torque wrench. Attching olts for covers, housings nd cylinder heds MUST BE torqued y tightening olts in 3 progressive steps (following specified torque sequence) until specified torque is reched (see Exmple, following). EXAMPLE: If cylinder hed ttching olts require torque of 40 I. ft. (54 N m), ) tighten ll olts to 10 I. ft. (13.5 N m), following specified torque sequence, ) tighten ll olts to 20 I. ft. (27 N m), following torque sequence, then finlly c) tighten ll olts to 40 I. ft. (54 N m), following torque sequence. 1. If removed, press lower crnkshft ll ering onto crnkshft s shown. Be sure ering is pressed firmly ginst counterweight Crnkshft - Crnkshft Bll Bering c - Suitle Mndrel d - Press 2. Reinstll retining ring using suitle pir of Snp Ring Pliers. d c - Retining Ring MAY 1996 POWERHEAD

34 3. If removed, spred new crnkshft seling rings just enough to slide over crnkshft journl. 5. Luricte center min crnkshft roller erings nd rces with light oil. Instll so Lrger of the 3 Holes is towrd ottom End of Crnkshft Mke Sure Retining Ring Bridges the Seprting Lines of the Bering Rce Crnkshft Seling Rings 4. Use Piston Ring Expnder ( ) nd instll crnkshft seling rings into groove. 6. Plce center min crnkshft roller erings on upper nd lower min ering journls s shown. 7. Instll center min ering rces s shown. FLYWHEEL END BOTTOM END POWERHEAD MAY 1996

35 8. Secure center min ering rces together with retining rings. Mke sure retining ring ridges the seprting lines of the ering rce Center min Bering Rces Instll oil sels into lower end cp s follows:. Apply thin ed of Loctite Type A ( ) to outer dimeter on 2 lower end cp oil sels ().. Using driver hed ( ) press one oil sel (lip fcing down) into lower end cp until firmly seted. Remove ny excess Loctite. c. Press second oil sel (lip fcing down) until firmly seted on first oil sel. Remove ny excess Loctite. d. Luricte oil sel lips with Quicksilver Needle Bering Assemly Luricnt ( A1). e. Apply light cot of Perfect Sel ( ) to end cp flnge. f. Luricte O-ring sel with Quicksilver Needle Bering Assemly Luricnt ( A1) nd instll over lower end cp. - O-ring 10. Instll oil sel into upper end cp s follows:. Apply thin ed of Loctite 271 ( ) to outer dimeter of upper end cp oil sel.. Use suitle mndrel, press oil sel into upper end cp (lip fcing down) until ottomed out on lip of end cp. Remove ny excess Loctite. c. Luricte oil sel lip with Quicksilver Needle Bering Assemly Luricnt ( A1). d. Luricte O-ring with Quicksilver Needle Bering Assemly Luricnt ( A1) nd instll on end cp. - Oil Sel - Lip of End Cp - Oil Sel - O-ring MAY 1996 POWERHEAD

36 Crnkshft Instlltion SPECIAL INFORMATION Instlling A New Crnkshft Assemly Into Cylinder Block Check the crnkshft seling ring mting surfces in the cylinder lock nd crnkcse cover for wer grooves tht were cused y the crnkshft seling rings from the previous crnkshft. If wer grooves re present, the seling rings on the new crnkshft will hve to fit into the grooves without inding the crnkshft. Before instlling crnkshft, remove ny urrs tht my exist on groove edges. Luricte seling rings with light oil nd instll new crnkshft s instructed. Instll upper nd lower end cps nd then inspect fit etween seling rings nd grooves. Temporrily instll crnkcse cover nd rotte crnkshft severl times to check if seling rings re inding ginst crnkshft. (You will feel drg on the crnkshft.) If seling rings re inding, recheck grooves for urrs. If this does not correct the prolem, it is recommended tht the cylinder lock e replced. Instll crnkshft s follows: 1. Luricte crnkshft seling rings with light oil. 2. Check cylinder lock to e sure tht dowel pins re in plce. 5. Gently push crnkshft down into position mking sure tht the dowel pins re lined up with the holes in center min erings nd crnkshft sel rings re in plce Dowel Pin 6. Luricte crnkshft ends (oil sel res) with light oil, then instll upper nd lower end cps ( nd ). Secure end cps to cylinder lock with ttching olts. DO NOT tighten end cp olts t this time. - Upper End Cp - Lower End Cp Dowel Pins 3. Position ll crnkshft sel ring gps stright up. 4. Align hole in ech center min ering rce with dowel pin POWERHEAD MAY 1996

37 Piston nd Connecting Rod Ressemly 1. Plce needle erings on clen piece of pper nd luricte with Quicksilver Needle Bering Assemly Luricnt ( A1). NOTE: There re 29 needle erings per piston. 2. Plce sleeve which is prt of piston pin tool ( A3) into connecting rod nd instll needle erings round sleeve s shown. 4. Insert piston pin tool ( A3) nd push sleeve out of piston. Keep piston pin tool in piston Sleeve (Prt of Tool Assy A3) 3. Plce locting wshers on connecting rod. IMPORTANT: Position connecting rod prt numer fcing towrds flywheel. Crefully position piston over end of rod. Mke sure locting wshers remin in plce Piston Pin Tool ( A3) - Sleeve 5. Use mllet nd tp piston pin into piston nd push piston pin tool out. - Piston Pin - Piston Pin Tool Locting Wshers Instll new piston pin lockrings (one ech end of piston pin) with Lockring Instlltion Tool ( A3) MAY 1996 POWERHEAD

38 7. Mke sure lockrings re properly seted in piston grooves Lockring Instlltion Tool - Lockring Instlltion Tool ( A3) - Lockring Piston nd Piston Ring Comintions.056 in. Hlf Keystone (tpered) Piston Ring Enlrged View of Piston Ring Grooves.056 in. All 153 cu. in. (2508 cc) models hve two hlf keystone (hlf tpered) rings POWERHEAD MAY 1996

39 Piston Instlltion 1. Before instlling new piston rings, check gp etween ring ends y plcing ech ring in its respective cylinder, then pushing ring out 1/2 in. (12.7mm) into cylinder using piston to ssure proper position. 2. Check end gp of ech new piston ring with feeler guge. End gp must e within.018 in. to.025 in. (0.45mm to 0.64mm). If end gp is greter, check other piston rings in cylinder ore, until rings (within tolernce) re found. 5. Luricte piston, rings nd cylinder wll with 2-Cycle Outord Oil c Piston Ring - Dots (Fces Up) c - Feeler Guge d - Ring End Gp IMPORTANT: Piston ring side with dot or letter must e fcing up. d - Piston Ring Expnder - Dot Side Up on Piston Ring 6. Rotte ech piston ring so end of ring is ligned with locting pin s shown. 7. Instll Piston Ring Compressor. 8. Remove screws nd connecting rod cp from piston rod ssemly eing instlled. IMPORTANT: Piston must e correctly instlled nd positioned s shown. Pistons mrked with the word UP nd with the letter P or S on top of piston. Pistons with the letter P must e instlled in the port side of engine nd the word UP fcing towrd top of engine. Pistons with the letter S must e instlled in the strord side of engine nd the word UP towrd top of engine. CYL 2 UP P CYL 1 UP S Dot or Letter CYL 4 UP P CYL 3 UP S Piston Ring 3. Use Piston Ring Expnder ( ) nd instll piston rings (dot side up) on ech piston. Spred rings just enough to slip over piston. CYL 6 UP P CYL 5 UP S 4. Check piston rings to e sure tht they fit freely in ring groove MAY 1996 POWERHEAD

40 9. Cot cylinder ore with 2-cycle oil. Mtch piston ssemly with cylinder it ws removed from, nd position piston s descried elow. Push piston into cylinder. 12. Tighten connecting rod olts (using 5/16 in point socket) First torque to 15 l. in. (1.7 N m) then 30 l. ft. (40.6 N m). Turn ech olt n dditionl 90 fter 2 nd torque is ttined. Recheck lignment etween rod cp nd rod s shown Apply Quicksilver Needle Bering Assemly Luricnt to ering surfce of connecting rod nd instll ering ssemly, s shown. 11. Plce connecting rod cp on connecting rod. Apply light oil to threds nd fce of connecting rod olts. Thred connecting rod olts finger-tight while checking for correct lignment of the rod cp s shown. IMPORTANT: Connecting rod nd connecting rod cps re mtched hlves. Do not torque screws efore completing the following procedure. Run pencil lightly over ground re. If pencil stops t frcture point, loosen olts, retighten, nd check gin Connecting Rod Screws 13. Rotte crnkshft severl times (using powerhed stnd) to ssure free opertion (no inds nd ctching). Connecting Rod Cp Alignment Check ech connecting rod cp for correct lignment. If not ligned, ridge cn e seen or felt t the seprting line s shown elow. Correct ny mislignment. Side View Correct Side View Incorrect-Cp on Bckwrds NOTE: If you still feel the frcture point, discrd the rod. End View Correct End View Incorrect- Not Aligned End View Incorrect-Cp on Bckwrds ÄÄ ÄÄ ÄÄ ÄÄ Ä POWERHEAD MAY 1996

41 14. Verify tht no piston rings were roken during instlltion y pressing in on ech piston ring thru exhust port using screwdriver. If no spring tension exists (ring fils to return to position), it s likely ring is roken nd must e replced Screwdriver Crnkcse Cover Instlltion Thoroughly remove ll oil from mting surfces of crnkcse cover nd cylinder lock with Loctite Primer T ( ). 2. Instll gsket strips into grooves in crnkcse cover. Trim end of ech gsket strip flush with edge of cover s shown. - Loctite Mster Gsket ( ) 4. Plce crnkcse cover in position on cylinder lock. Turn the 8 center min olts in LITTLE t time, (following torque sequence) compressing crnkshft sel rings until crnkshft cover hs een drwn down to cylinder lock. Tighten eight olts () evenly in three progressive steps (following torque sequence). 5. Instll remining crnkcse cover flnge olts. 6. Tighten end cp olts to specified torque. Upper End Cp Bolts 150 l. in. (17 N m) Add light oil to threds nd olt fce: 8 Bolts (3/8 in in. 38 l. ft. (51.5 N m) Gsket Strips - Edge of Cover 3. Apply thin, even cot of Loctite Mster Gsket #203 on mting surfces of crnkcse cover nd cylinder lock. Bolts (5/16 in. - 18) 180 l. in. (20.3 N m) Lower End Cp Bolts 80 l. in. (9 N m) MAY 1996 POWERHEAD

42 Assemly of Reed Blocks to Intke Mnifold 80 l. in. (9 N m) 105 l. in. (11.8 N m) Assemly of Exhust Mnifold to Block Plce exhust divider sel into slot in lock. 2. Instll exhust mnifold with gsket. 3. Instll gsket nd exhust mnifold cover. 4. Apply light oil to olt threds nd torque olts to 180 I. in. (20 N m). 5. Torque exhust mnifold cover olts in following sequence. EXHAUST MANIFOLD COVER BOLTS 180 l. in. (20 N m) Apply light oil to threds nd olt hed If removed, instll wter pressure relief vlve cover s shown. d c - Divider Sel - Exhust Mnifold c - Gsket d - Exhust Cover c - Bolt - Cover c - Gsket POWERHEAD MAY 1996

43 Clening nd Inspection Cylinder Block nd Crnkcse Cover IMPORTANT: Crnkcse cover nd cylinder lock is mtched, line-ored ssemly nd should never e mismtched y using different crnkcse cover or cylinder lock. CYLINDER HEAD INSTALLATION 1. Instll ech cylinder hed to engine lock with thermostt pocket UP. Apply light oil to cylinder hed olt threds nd torque olts to 40 I. ft. (54 N m). IMPORTANT: After first 1/2 to 1 hour of running time, ech cylinder hed olt should e loosened one t time, 1/4 turn, nd re-torqued in sequence shown. CAUTION It crnkcse cover or cylinder lock is to e sumerged in very strong clening solution, it will e necessry to remove the crnkcse cover/cylinder lock leed system from crnkcse cover/ cylinder lock to prevent dmge to hoses nd check vlves. 1. Thoroughly clen cylinder lock nd crnkcse cover. Be sure tht ll selnt nd old gskets re removed from mtching surfces. Be sure tht cron deposits re removed from exhust ports. 2. Inspect cylinder lock nd crnkcse cover for crcks or frctures. 3. Check gsket surfces for nicks, deep grooves, crcks nd distortion tht could cuse compression lekges. 4. Check ll wter nd oil pssges in cylinder lock nd crnkcse cover to e sure tht they re not ostructed nd tht plugs re in plce nd tight. 2. Instll thermostt wsher into ech cylinder hed. 3. Instll overhet temperture sensor into STAR- BOARD cylinder hed elow #1 sprk plug. d c e f g h j i - Wsher - Thermostt Cover c - Hose d - Clmp e - Bolt (Torque to 200 L. in N m) f -90 Elow g - Temperture Sensor h - Bolt (Torque to 200 L. in N m) i j - Retiner - Bolt [Apply Light Oil to Threds - Torque to 40 l. ft. (54.2 N m)] MAY 1996 POWERHEAD

44 Adptor Plte Instlltion 1. Using new gsket, instll dptor plte to ottom of powerhed. 2. Torque screws to 35 l. ft. (47 N m). Reinstlling Engine Components Reinstll the following engine components: Section 2 Strter Motor Ignition Switch Boxes Ignition Coils Strter Solenoid Voltge regultor/rectifier Flywheel Sttor Assemly Trigger Assemly Turn Key Strt Module Section 3 Air Silencer Cruretors nd Linkge Fuel Pump Fuel Primer Fuel Enrichment Vlve Engine Mounted Oil Tnk Oil Pump Powerhed Instlltion On Pump Unit 1. Instll Lifting Eye ( ) into flywheel. WARNING BE SURE tht Lifting Eye is threded into flywheel minimum of five (5) turns BEFORE lifting powerhed. 2. Using hoist, lift powerhed high enough to llow removl of powerhed from repir stnd. Remove powerhed from repir stnd, eing creful not to dmge gsket surfce of dptor plte. 3. Apply smll mount of Specil Lue 101 ( A1) onto driveshft splines. Refer to Section 1D, Sport Jet Instlltion to complete powerhed instlltion nd cle djustment. Following Timing, Synchronizing nd Adjusting s outlined in Section 2C. Brek-ln Procedure BREAK-IN FUEL MIXTURE During the rek-in period, operte the engine with the first 30 gllons of fuel y mixing gsoline- oil in the fuel tnk t 50:1 rtio s descried in chrt elow. NOTE: The 50:1 rtio gsoline - oil in the fuel tnk comined with the metered oil supplied y the oil injection system will supply the necessry gsoline-oil mixture required for rek-in luriction. Type of Oil Quicksilver 2-Cycle Outord Oil Other Acceptle BIA TC-W3 nd TC-W II Oils U.S. Mesure 16 U.S. oz. to ech 6 gllons of gsoline Imperil Mesure 15 Imp. oz. to ech 5 Imp. gllons of gsoline Metric Mesure 400cc to ech 20 liters of gsoline Use t Mnufcturer s Recommendtions. DO NOT EXCEED 50:1. Operte the engine t vried throttle settings - not to exceed 1/2 throttle ( RPM) during the first hour or the first ten gllons of rek-in fuel. Refer to Fuel Mixture nd Gsoline/Oil Recommendtions - Brek-ln Fuel Mixture. During the second hour of opertion, or the second 10 gllons of rek-in fuel, operte the engine t vried throttle settings not to exceed 4500 RPM. DO NOT OPERATE THE ENGINE AT FULL THROTTLE UNTIL THE SECOND HOUR OF BREAK-IN IS COMPLETED. This includes full throttle ccelertion, pulling wter skiers, or wide open throttle running. After the first two hours of running, pproximtely 20 gllons of fuel, full throttle opertion my e ttined, ut not sustined, for the remining rek-in fuel (pproximtely 10 gllons). After the 30 gllons of 50:1 rek-in fuel hs een consumed, it is no longer necessry to mix oil to the gsoline in the remote fuel tnk. For the next five hours of opertion, full throttle opertion my, gin, e ttined, ut it is strongly not recommended for sustined use. (Not more thn 5 minutes of continuous wide open throttle.) POWERHEAD MAY 1996