Table of Contents. Page. Page

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1 POWERHEAD 4

2 Tle of Contents Pge Powerhed Specifictions Specil Tools Powerhed Repir Stnd Crnkshft - Pistons - nd Connecting Rods Crnkshft - Pistons - nd Connecting Rods Cylinder Block nd End Cp Powerhed Torque Sequence nd Torque Specifictions Powerhed Torque Sequence Notes: Generl Informtion Powerhed Removl from Driveshft Housing Powerhed Disssemly Clening nd Inspection Cylinder Block nd Crnkcse Cover Specil Service Informtion Cylinder Bores Pistons nd Piston Rings Cylinder Heds Crnkshft Crnkshft (nd End Cp) Berings Reed Block Assemly Reed Block Connecting Rods Thermostts Powerhed Ressemly nd Instlltion Generl Crnkshft Instlltion Piston nd Connecting Rod Ressemly Piston nd Piston Ring Comintion Piston Instlltion Crnkcse Cover Instlltion Assemly of Reed Blocks to Intke Mnifold Pge Exhust Plte w/wter Pressure Relief Vlve Components Liter Work/ Cr/ EFI/0 EFI Bleed Routing 4// Models ( Models DO NOT hve Front Mounted Bleed Check Vlves) Liter Work/ Cruretor Bleed Routing for / Models (SN 0G to 0G4). 4- EFI/0 EFI Bleed Routing for / Models (SN 0G to 0G4) Liter Work nd Cruretor Models (SN 0G4000 to 0G4) /0 EFI Models (SN 0G4000 to 0G4) ( EFI w/fuel ECM nd 0 EFI w/fuel ECM 004-) nd Newer Liter Work nd Cruretor Models (SN 04 nd ABOVE) nd Newer /0 EFI Models (SN 0G4 nd ABOVE) ( EFI w/fuel ECM 004- nd 0 EFI w/fuel ECM 004-) Reinstlling Engine Components Anchor Brcket/Throttle Linkge SEAPRO/MARATHON (S/N-0G004 & BELOW) 4- Anchor Brcket/Throttle Linkge Cr (S/N-0G004 & BELOW) Anchor Brcket/Throttle Linkge (Cr Models) (S/N-0G004 & Up) Anchor Brcket/Throttle Linkge (EFI Models) Powerhed Instlltion on Driveshft Housing Brek-ln Procedure POWERHEAD 0-00R DECEMBER

3 Powerhed Specifictions Block Type V, Cycle Displcement cu. in. (04cc) Reed Vlve Opening Opening (Mx.) in. (0.0mm) Stroke Length in. (.mm) Cylinder Bore Di. Stndrd in. (.mm) 0.0 Oversize in. (.mm) 0.00 Oversize in. (.mm) Tper/Out of Round Mx in. (0.0mm) Piston Di. Stndrd in..000 in. (.mm.0mm) 0.0 Oversize in..000 in. (.mm.0mm) 0.00 Oversize in..000 in.) (.mm.0mm) Piston Ring End Gp Specil Tools Lifting Eye -04 Flywheel Holder in. to 0.0 in. (0.mm to 0.4mm) Compression All Models - Using fully chrged ttery, throttle shutters wide open nd cylinder lock wrm psi (. --. kp) Vrince etween cylinders should not exceed psi (0. kp) IMPORTANT: Using micrometer, mesure dimension A t loction shown. Dimension A should e.0 in..000 for STANDARD size piston. Protector Cp -4 Flywheel Puller -A 44 Dimension A t Right Angle (0 ) to Piston Pin in. (.4mm) 0-00R DECEMBER POWERHEAD - 4-

4 Powerhed Stnd -0A Snp Ring Pliers -4 Piston Ring Expnder -4 Lockring Instlltion Tool --004A Lockring Removl Tool -A *Note: If.4 Liter Piston Lock Ring Instller (-004A) is ville, then only Guide (-00-) is required to instll Litre piston lock rings. Piston Ring Compressor - Piston Pin Tool -A Driver Hed - Compression Tester - Universl Puller Plte POWERHEAD 0-00R DECEMBER

5 Driver Hed - Powerhed Repir Stnd A powerhed repir stnd my e purchsed from: Bo Kerr s Mrine Tool Co. P.O. Box Winter Grden, FL Telephone: (0) -0 Universl Puller Plte -4 Snp Ring Pliers -4 Lockring Instlltion Tool --0A 0-00R DECEMBER POWERHEAD - 4-

6 Crnkshft - Pistons - nd Connecting Rods Cycle Outord Oil (-A4) -4-C With Teflon (-40A) POWERHEAD 0-00R DECEMBER

7 Crnkshft - Pistons - nd Connecting Rods TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m CRANKSHAFT ( TOOTH SPLINES) CRANKSHAFT ( TOOTH SPLINES) CRANKSHAFT BALL BEARING (LOWER) RETAINING RING 4 DRIVER GEAR SEAL RING WOODRUFF KEY O RING BEARING RACE PISTON (STBD-STANDARD) PISTON (PORT-STANDARD) AR PISTON (STBD-.0 O/S) AR PISTON (PORT-.0 O/S) AR PISTON (STBD-.00 O/S) AR PISTON (PORT-.00 O/S) 0 LOCK RING PISTON RING (STANDARD) AR PISTON RING (.0 O/S) AR PISTON RING (.00 O/S) CONNECTING ROD ASSEMBLY SCREW (-/4 ) Importnt: It is recommended tht connecting rod olts e discrded fter removl nd new olts e instlled. Apply Light Oil to Threds nd Bolt Fce: st Torque - l. in. (. N m) nd Torque - 0 l. ft. (4.0 N m) Turn Bolt n Additionl 0 fter nd Torque is Attined. 4 BEARING CAGE THRUST WASHER 04 ROLLER BEARING MAIN BEARING (UPPER) OIL SEAL O RING 0 WASHER NUT (M x.) 0.0 S/N -0G & BELOW ( TOOTH SPLINES) S/N -0G THRU 0G004 ( TOOTH SPLINES) NOTE: WHEN ORDERING REPLACEMENT POWERHEAD FOR ENGINES WITH S/N -0G4 & BELOW, REFER TO SERVICE BULLETIN #4- AND ORDER EXHAUST PLATE KIT 40A, IF NECESSARY. 0-00R DECEMBER POWERHEAD - 4-

8 Cylinder Block nd End Cp Loctite Mster Gsket (-4-) 4 Cycle Outord Oil (-A4) Loctite 0 (-0) -4-C With Teflon (-40A) 4- - POWERHEAD 0-00R DECEMBER

9 Cylinder Block nd End Cp TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m CYLINDER BLOCK (S/N -0G & BELOW) CYLINDER BLOCK (S/N-0G thru 0G4) CYLINDER BLOCK (S/N-0G4000 & UP) 4 STUD (M0 x. x 4) STUD (M0 x. x ) 4 PIPE PLUG (/ IN.) PIPE PLUG (/4 IN.-)(SEAPRO/MARATHON) 4 WATER DEFLECTOR (S/N-0G4000 & UP) CHECK VALVE FITTING PIN 0 DOWEL PIN FITTING (S/N-0G4 & BELOW) FITTING (S/N-0G4000 thru 0G4) CHECK VALVE T-FITTING S/N-0G4 & UP CHECK VALVE 4 CHECK VALVE 4 SCREW (M x ).0 CHECK VALVE SCREW (M0 x.) Note CENTER MAIN PIN CARRIER ASSEMBLY (Includes Crriers) 0 CHECK VALVE STOP PLUG (S/N-0G4000 & UP) ELBOW (W/Ref.#4)(S/N -0G &UP) ELBOW (4 degrees)(s/n -0G & BELOW) TIMING POINTER 4 SCREW (M x ) 00. AR STA-STRAP TUBING-MOLDED(S/N -0G & UP) TUBING (-/4 IN.)(S/N -0G & BELOW) TUBING (-/ IN.) 0 WASHER 0 0 NUT 0.0 TUBING (4 IN.)(S/N-0G4 & BELOW) TUBING (-/4 IN.)(S/N-0G4000 & UP) RETAINER-- check vlve. = S/N -0G & UP ( TOOTH SPLINES), = S/N -0G & BELOW ( TOOTH SPLINES),. = S/N -0G THRU 0G4 ( TOOTH SPLINES) : = NOTE: WHEN ORDERING REPLACEMENT POWERHEAD FOR ENGINES WITH S/N -0G4 & BELOW, RE- FER TO SERVICE BULLETIN #4-, AND ORDER EXHAUST PLATE KIT 40A IF NECESSARY. Note: Torque olt to 0 l. ft. (4.0 N m) nd rotte 0 degrees 0-00R DECEMBER POWERHEAD - 4-

10 Cylinder Block nd End Cp Loctite Mster Gsket (-4-) 4 Cycle Outord Oil (-A4) Loctite 0 (-0) -4-C With Teflon (-40A) 4- - POWERHEAD 0-00R DECEMBER

11 Cylinder Block nd End Cp TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m SCREW (#0- x / IN.) Drive Tight 4 FITTING BRACKET (S/N -0G & UP)(SEAPRO/MARATHON) BRACKET (S/N -0G & BELOW) SCREW (M x ) 00. BRACKET-- lterntor SCREW (M x 0).0 BRACKET 40 SCREW (M x ) GUIDE BRACKET 4 SENSOR 4 SCREW (M x 0) SEAL-- cylinder hed 4 O RING CYLINDER HEAD (SEAPRO/MARATHON) 4 CYLINDER HEAD (S/N -0G004 & BELOW) CYLINDER HEAD (S/N -0G004 & UP) THERMOSTAT (4 degrees)(s/#-0g4000 & UP) 4 THERMOSTAT (4 degrees)(s/#-0g4 & BELOW) 4 GASKET-- thermostt 4 COVER-- thermostt 0 ELBOW (4 Degrees) USE WITH 4 DEGREE ELBOW TUBING ( IN.)(0-/ IN.) 4 COVER-- thermostt 4 ELBOW (0 Degrees) USE WITH 0 DEGREE ELBOW 4 TUBING (0 IN.)(-/ IN.) 0 l. ft. (4.0 N m) 4 SCREW (M x 0) nd Rotte 0 deg. 0 l. ft. (.0 N m) SCREW (M x 0) nd Rotte 0 deg.. = S/N -0G & UP ( TOOTH SPLINES), = S/N -0G & BELOW ( TOOTH SPLINES) : = NOTE: WHEN ORDERING REPLACEMENT POWERHEAD FOR ENGINES WITH S/N -0G4 & BELOW, RE- FER TO SERVICE BULLETIN #4-, AND ORDER EXHAUST PLATE KIT 40A IF NECESSARY. 0-00R DECEMBER POWERHEAD - 4-

12 Cylinder Block nd End Cp Loctite Mster Gsket (-4-) 4 Cycle Outord Oil (-A4) Loctite 0 (-0) -4-C With Teflon (-40A) POWERHEAD 0-00R DECEMBER

13 Cylinder Block nd End Cp TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 4 TEMPERATURE SENSOR S/N -0G40 & UP & CABLE (Use where pplicle) SEAPRO/MARATHON TEMPERATURE SENSOR S/N -0G4 & BELOW CABLE SENSOR RETAINER DESIGN I SCREW (.- x /) SENSOR RETAINER DESIGN II SCREW (M x ) LOWER END CAP O RING (S/N -0G004 & BELOW) OIL SEAL See Service Bulletin -4 OIL SEAL LOWER END CAP O RING S/N -0G004 & UP OIL SEAL 4 4 SCREW (M x ). PLUG O RING SEAPRO/MARATHON SCREW (M x 0) BRACKET SCREW 0 SCREW (M x ) 00. CLAMP. = S/N -0G & UP ( TOOTH SPLINES), = S/N -0G & BELOW ( TOOTH SPLINES) : = NOTE: WHEN ORDERING REPLACEMENT POWERHEAD FOR ENGINES WITH S/N -0G4 & BELOW, REFER TO SERVICE BULLETIN #4-, AND ORDER EXHAUST PLATE KIT 40A IF NECESSARY. 0-00R DECEMBER POWERHEAD - 4-

14 Powerhed Torque Sequence nd Torque Specifictions CRANKCASE COVER BOLTS (AND TORQUE SEQUENCE) Add light oil to threds nd olt fce: Bolts (M0 x. x 0) 0 l. ft. (40. N m) nd rotte 0 CYLINDER HEAD BOLTS (AND TORQUE SEQUENCE) IMPORTANT Add light oil to threds nd olt fce: Bolts nd 0 - Torque to 0 l. ft. (40. N m) nd rotte 0 All other olts - Torque to 0 l. ft. (. N m) nd rotte Bolts (M x. x ).0 l. ft. (. N m) PISTON ROD BOLTS IMPORTANT: IT IS RECOMMENDED THAT ROD BOLTS BE DISCARDED AFTER REMOVAL AND REPLACED WITH NEW BOLTS. Apply light oil to threds nd olt fce: st Torque - l. in. (. N m.) nd Torque - 0 l. ft. (40. N m.) Turn olt n dditionl 0 fter nd Torque is Attined. RELIEF VALVE COVER BOLTS 0.0 l. ft. (. N m) POWERHEAD 0-00R DECEMBER

15 Powerhed Torque Sequence Intke Mnifold 00 l. in. (. N m) R DECEMBER POWERHEAD - 4-

16 Notes: POWERHEAD 0-00R DECEMBER

17 Generl Informtion Powerhed Disssemly nd Ressemly instructions re printed in sequence tht should e followed to ssure est results when removing orreplcing powerhed components. If complete disssemly is not necessry, strt ressemly t point disssemly ws stopped. (Refer to Tle of Contents, preceding.) If mjor powerhed repirs re to e performed, remove powerhed from drive shft housing. Removl of powerhed is not required for ) inspection of cylinder wlls nd ) minor repirs on components such s ignition system, cruretors, reed locks, cylinder heds nd checking opertion of thermostts. Powerhed Removl from Driveshft Housing. Disconnect ttery cles from ttery terminls.. Disconnect fuel tnk hose from outord.. Remove top cowling. 4. Remove two screws which secure remote control hrness retiner nd remove retiner. - Screws - Retiner. Disconnect remote oil tnk hose from pulse fitting. - Oil Hose 0-00R DECEMBER POWERHEAD - 4-

18 . Disconnect remote control hrness from powerhed hrness connector nd wires s shown.. Disconnect cowl mounted tilt switch hrness.. MODELS WITH TRIM SOLENOIDS - Remove BLUE, GREEN nd BLACK trim hrness leds from trim solenoids. h e d c f - Remote Wiring Hrness - Engine Wiring Hrness Connector c - Led From Trim Solenoid (Down Solenoid) d - Led From Trim Solenoid (Up Solenoid) e - Led From Trim Sender f - Led From Temperture Sender g - Hrness Holder (Locted in Cowl) h - Tilt Switch g - BLUE Trim Led - BLACK Trim Led c - GREEN Trim Led c MODELS WITH TRIM RELAYS - Remove rely ground hrness from lower electricl plte mounting olt (). Remove rely positive leds () (RED) from BAT- TERY SIDE of strter solenoid. Disconnect trim rely hrness from ech rely (c). Disconnect BLUE/WHITE nd GREEN/WHITE trim leds from lower cowl trim switch hrness (d). Disconnect BLUE (sleeve) nd GREEN power trim leds from trim motor hrness (e). c e d POWERHEAD 0-00R DECEMBER

19 . Remove st-strps securing tell-tle hose nd flush hose to powerhed.. Remove locknut nd flt wsher securing throttle shift cles nd remove cles. - Tell-Tle Hose - Flush Hose 0. Disconnect ypss hoses etween thermostts nd exhust dptor plte. c - Cle Retiner - Throttle Cle c - Shift Cle d - Locknut nd Flt Wsher 4. Disconnect inlet fuel line. d - Inlet Fuel Line - Bypss Hose. Shift outord into NEUTRAL position.. Unltch throttle nd shift cle retiner R DECEMBER POWERHEAD - 4-

20 . Remove 4 olts securing ottom cowl hlves nd remove ottom cowling.. Remove 0 nuts nd wshers ( ech side) from powerhed se. - Bolt 4 - Nuts nd Wshers ( ech side). Remove plstic cp from center of flywheel nd instll Lifting Eye (-04) into flywheel t lest full turns. Using hoist, lift powerhed ssemly from drive shft housing. - Bolt - Bolt 4- - POWERHEAD 0-00R DECEMBER

21 REMOVING ENGINE COMPONENTS Remove the following engine components: Section Strter Motor Alterntor Sttor Ignition Modules Electronic Control Unit Solenoids Crnk Position Sensor Throttle Position Sensor Temperture Sensor Section Air Silencer Cruretors nd Linkge Fuel Pump Fuel Enrichment Section On-Bord Oil Tnk Oil Pump Section EFI Removl Powerhed Disssemly. Plce powerhed in repir stnd or on ench.. Remove thermostt covers, thermostts nd gskets. - Thermostt Cover 0 c - Thermostt c - Gsket 0-00R DECEMBER POWERHEAD - 4-

22 . Remove cylinder heds from engine lock.. Inspect reeds s outlined in Clening nd Inspection. - Cylinder Hed - Engine Block 4 4. Remove reed lock housing from cylinder lock.. Remove olts from end cp. LOWER END CAP - Reed Block Housing - Crnkcse Attching End Cp Bolts POWERHEAD 0-00R DECEMBER

23 . Remove olts which secure crnkcse cover to cylinder lock. 0. Using n wl or electric pencil, scrie the cylinder identifiction numer on ech connecting rod s shown. Ressemle connecting rods in sme cylinder. - Crnkcse Cover. Remove crnkcse end cp. CRANKCASE COVER REMOVED 0 4. Use / in. point socket to remove connecting rod olts, then remove rod cp, roller erings nd ering cge from connecting rod.. Use Powerhed Stnd (-4) for rotting crnkshft to desired position for removl of connecting rods. - Connecting Rod Bolts. Push piston out of cylinder lock.. After removl, ressemle ech piston nd connecting rod ssemly. 0-00R DECEMBER POWERHEAD - 4-

24 ! CAUTION Echconnectingrodndendcpre mtched mchined set nd must never e mismtched.. Using n wl, scrie identifiction numer of connecting rod on inside of piston (). Ressemle piston on sme connecting rod Inspect pistons s outlined in Clening nd Inspection, following.. Use Piston Ring Expnder (-4) to remove piston rings. Alwys instll new piston rings.. Using tool (-A), remove piston pin lockrings from oth ends of piston pin. Never re-use piston pin lockrings. - Lockring 4- - POWERHEAD 0-00R DECEMBER

25 IMPORTANT: Wrming the piston dome using torch lmp will ese removl nd instlltion of piston pin.. Support piston nd tp out piston pin using service tool (-A) s shown. 0. Remove nd discrd O-ring sel from end cp.. Remove oil sels from end cp y driving sels out with punch nd hmmer. - Piston Pin - Piston Pin Tool (-A). Remove piston pin needle erings (4 per piston) nd locting wshers ( 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. - O-ring - Sels () 4. Inspect roller ering in upper ering crrier s outlined in Clening nd Inspection. NOTE: If roller ering is dmged, replce ering crrier ssemly. c - O-Ring - Sel c - Crrier 4 - Needle Bering Locting Wshers 0-00R DECEMBER POWERHEAD - 4-

26 . Remove crnkshft nd plce in powerhed stnd s shown. IMPORTANT: DO NOT remove crnkshftseling rings from crnkshft, unless replcement of seling ring(s) is necessry. Usully, crnkshft seling rings do not require replcement, unless roken.! 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, orexcessive looseness. Refer to Section for proper oil drive ger instlltion procedures.. Remove ering rce hlves nd roller erings from crnkshft. IMPORTANT: Keep sme ering rces nd roller erings together. - Seling Rings () - Oil Pump Drive Ger 4. Remove retining ring s shown. - 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.. Remove lower ll ering from crnkshft s follows:. Remove retining ring using pir of snp ring pliers. - Retining Ring - Crnkshft Bll Bering - Pliers c - Retining Ring c POWERHEAD 0-00R DECEMBER

27 . Press crnkshft out of lower ll ering s shown.. Remove nd inspect wter pressure relief vlve components for deris or dmge. Replce components s required. c d - Press - Powerhed Stnd (-4) c - Crnkshft Bll Bering d - Universl Puller Plte (-4) Exhust Plte - Crrier - Grommet 4 - Poppet/Relief Vlve - Spring - Gsket - Inner Plte 0-00R DECEMBER - Diphrgm - Wsher 0- Screw - Gsket - Outer Cover - Bolts [Torque olts to 0 l. ft. (. N m)] POWERHEAD - 4-

28 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. 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 crnkshft 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. 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.! 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.. 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 exhustports.. Inspect cylinder lock nd crnkcse cover for crcks or frctures.. 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. 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. 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 POWERHEAD 0-00R DECEMBER

29 Stroke t rte of 0 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.. Hone ll cylinder wlls just enough to de-glze wlls.. 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. 4. If cylinder ore is tpered, out-of-round or worn more thn 0.00 in. (0.0mm) from stndrd Cylinder Block Finish Hone dimeter (refer to chrt, preceding), it will e necessry to re-ore tht cylinder(s) to 0.0 in. (0.mm) oversize or 0.00 in. (0.mm) oversize 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.. After honing nd thoroughly clening cylinder ores, pply light oil to cylinder wlls to prevent rusting. 4 Litre Work/ Cr/ EFI/0 EFI Models Model Litre Work/ Cr EFI/0 EFI Cylinder Block Finish Hone. (.mm) 0.0 in. Oversize.4 (.44mm) 0.00 in. Oversize. (.mm) 0-00R DECEMBER POWERHEAD - 4-

30 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).. Inspect pistons for scoring nd excessive piston skirt wer.. Check tightness of piston ring locting pins. Locting pins must e tight.. 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 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.. Use ristle rush nd cron remover solution to remove cron from side surfces.. 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 MEASURING PISTON ROUNDNESS Piston hs rrel profile shpe nd is not true dimeter.. Using micrometer, mesure dimension A t loction shown. Dimension A should e s indicted in chrt following. Piston Stndrd Piston Dimension A.0 in..000 in..0 in. Oversize Piston. in..000 in..00 in. Oversize Piston 4. in..000 in.. Using micrometer, mesure dimension A t loction shown. Dimension A should e.0 in in. for STANDARD size piston. - Dimension A t Right Angle (0 ) to Piston Pin Cylinder Heds in. (.4mm). 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 0.00 in. (0.mm) over the ENTIRE length of the cylinder hed. If mesured wrpge, s determined on surfce lock, exceeds 0.00 in. (0.mm) or discontinuity of up to 0.00 in. (0.0mm) exists in.0 in. (.4mm) length of the cylinder hed s surfce, then the cylinder hed must e replced.. Replce cylinder hed(s) s necessry. - Ring Grooves 4- - POWERHEAD 0-00R DECEMBER

31 Crnkshft. Inspect crnkshft to drive shftsplines forwer. (Replce crnkshft, if necessry).. Check crnkshft for strightness. Mximum runout in. (0.00mm) Check runout t center min ering surfces with ends of crnkshft supported in v-locks. (Replce s necessry).. 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 wernd/or overhet- ing. (Refer to Connecting Rods ).. If necessry, clen crnkshft surfces with crocus cloth. Crnkshft (nd End Cp) Berings IMPORTANT: When overhuling powerhed ssemly, it is recommended tht ll crnkshft erings - upper/lower, center min, connecting rod nd wrist pin erings - e replced to ensure optimum powerhed performnce nd longevity.. 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.. 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 ). 4 c c - Crnkshft Journls - Crocus Cloth c - Work Cloth Bck-nd-Forth 4 Cycle Outord Oil (-A4) - Lower Bll Bering. Thoroughly clen (with solvent) nd dry crnkshft center min roller erings. Luricte erings with -Cycle Outord Oil.! WARNING DO NOT spin-dry crnkshft ll ering with compressed ir.. 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. 0-00R DECEMBER POWERHEAD - 4-

32 ! CAUTION DO NOT intermix hlves of upper nd lower crnkshft 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. Reed Block Assemly IMPORTANT: DO NOT remove reeds from reed locks, unless replcement is necessry. DO NOT turn used reeds over for re-use. Replce reeds in sets only.. Thoroughly clen gsket surfces of reed locks nd reed lock housing. Check for grooves, crcks nd distortion tht could cuse lekge. Replce prts s necessry.. Check for wer (indenttions) on fce of ech reed lock. Replce lock(s), if reeds hve mde indenttions.. Check for chipped nd roken reeds. - Center Min Roller Bering. Clen (with solvent) nd dry crnkshft roller ering tht is instlled in upper end cp. Luricte ering with light oil.. Thoroughly inspect upper crnk shft roller ering. If roller ering is rusted, frctured, worn, glled or dly discolored, replce roller ering. - Upper Roller Bering 4 0 Allowle reed opening is 0.00 in. (0.mm) or less. Replce reeds if either reed is stnding open more thn 0.00 in. (0.mm) POWERHEAD 0-00R DECEMBER

33 Reed Block Inspect pssges in reed lock 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. Connecting Rods. 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 0.00 in. (0.0mm) feeler guge cn e inserted etween ny mchined surfce nd surfce plte, rod is ent nd must e discrded.. Overheting: Overheting is visile s luish ering surfce color tht is cused y indequte luriction or excessive RPM.. Rust: Rust formtion on ering surfces cuses uneven pitting of surfce(s). - Pitting. 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. - Splling. 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 0-00R DECEMBER POWERHEAD - 4-

34 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 00 RPM, then quickly returned to idle. If the preceding conditions re found, replce oth the crnkshft nd connecting rod(s). 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. 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 0 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. 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 ofconnecting rod. DO NOT use ny other type of rsive cloth.. Clen CRANKSHAFT END of connecting rod y using CROCUS CLOTH plced in slotted / in. (.mm) dimeter shft, s shown. Chuck shft in drill press nd opertion press t high speed while keeping connecting rod t 0 ngle to slotted shft. Thermostts. Inspect thermostt covers nd cylinder hed covers (thermostt opening) for crcks nd corrosion dmge tht could cuse lekge. Replce prts s necessry.. Remove nd discrd gsket from ech thermostt.. Wsh thermostts with clen wter. 4. Using thermostt tester, similr to the one shown, test ech thermostt s follows:. Open thermostt vlve, then insert thred etween vlve nd thermostt ody. Allow vlve to close ginst thred.. Suspend thermostt (from thred) nd thermometer inside tester so tht neither touches the continer. Bottom of thermometer must e even with ottom of thermostt to otin correct temperture of thermostt opening. c. Fill thermostt tester with wter to cover thermostt POWERHEAD 0-00R DECEMBER

35 d. Plug tester into electricl outlet. e. Oserve temperture t which thermostt egins to open. (Thermostt will drop off thred, tht ws instlled in Step, when it strts to open.) Thermostt must egin to open when temperture reches 40-4 F (0 - C). f. Continue to het wter until thermostt is completely open. g. Unplug thermostt tester. h. Replce thermostt, if it fils to open t the specified temperture, or if it does not fully open. NOTE: BE SURE tht wter in thermostt tester is llowed to cool sufficiently [elow 0 F ( C)] efore testing the other thermostt. 0 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 -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 progressive steps (following specified torque sequence) until specified torque is reched (see Exmple, following). EXAMPLE: If cylinder hed ttching olts require torque of 0 I. ft. (.0 N m), ) tighten ll olts to I. ft. (.0 N m), following specified torque sequence, ) tighten ll olts to 0 I. ft. (. N m), following torque sequence, then finlly c) tighten ll olts to 0 I. ft. (.0 N m), following torque sequence. IMPORTANT: If oil pump drive ger hs een removed from crnkshft, GEAR MUST BE REIN- STALLED WITH GEAR FLANGE FACING DOWN TOWARDS BALL BEARING. IMPORTANT: DO NOT operte engine without thermostts instlled. 0-00R DECEMBER POWERHEAD - 4-

36 . Slide oil pump drive ger (flnge fcing down) onto crnkshft. Align slot in ger with keywy on crnkshft. Set ger ginst counter weight shoulder. IMPORTANT: If lower drive shft ll ering hs een removed, it is recommended tht new ering e instlled s the removl process will dmge the ering.. If removed, press new lower crnkshft ll ering onto crnkshft s shown. Be sure ering is pressed firmly ginst shoulder. d c c - Flnge (Fces Down Towrds Bll Bering) - Keywy c - Shoulder - Crnkshft - Crnkshft Bll Bering c - Suitle Mndrel d - Press. Reinstll retining ring using suitle pir of Snp Ring Pliers. - Retining Ring POWERHEAD 0-00R DECEMBER

37 . If removed, spred new crnkshft seling rings just enough to slide over crnkshft journl.. Luricte center min crnkshft roller erings nd rces with light oil. 4 - Crnkshft Seling Rings 4. Use Piston Ring Expnder (-4) nd instll crnkshft seling rings into groove. 4 4 Cycle Outord Oil (-A4) - Instll so Hole is Towrd Drive Shft End of Crnkshft - Verify Retining Ring Bridges the Seprting Lines of the Bering Rce. Plce center min crnkshft roller erings on upper nd lower min ering journls s shown.. Instll center min ering rces s shown. - Piston Ring Expnder (-4) - Crnkshft Seling Rings ( Ech) 0 - Flywheel End - Drive Shft End 0-00R DECEMBER POWERHEAD - 4-

38 . 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 NOTE: Four styles of end cps hve een used on liter powerheds - -A; -A; -A4 nd -A. If not previously instlled, it is recommended tht end cp -A e instlled. - -A - Crnkshft Sel (Fces UP) c - Drive Shft Sel (Fces DOWN) c - -A - Crnkshft Sels (Both Fce DOWN) c - Drive Shft O-Ring w/sleeve tht slides over Crnkshft. Instll oil sels into typicl lower end cp s follows:. Apply thin ed of Loctite Type (- 0-) to outer dimeter of lower end cp oil sels.. Using driver hed (-) or suitle mndrel, 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 UP or DOWN, s required y specific end cp) until firmly seted on first oil sel. Remove ny excess Loctite. d. Luricte oil sel lips with -4-C w/teflon (-40A). e. Apply light cot of Perfect Sel (-4-) to end cp flnge. f. Luricte O-ring sel with -4-C w/teflon (-40A) nd instll over lower end cp. c c - -A - Crnkshft Sel (Fces UP) c - Drive Shft Sels (Both Fce DOWN) - -A4 - Crnkshft Sels (Both Fce DOWN) 4 Loctite (-00) Perfect Sel (-4-) -4-C With Teflon (-40A) - O-ring 4- - POWERHEAD 0-00R DECEMBER

39 0. Instll oil sel into upper ering crrier ssemly s follows:. Apply light film of -4-C w/teflon (-40A) to outer dimeter of oil sel; this will ese sel instlltion into crrier.. Luricte oil sel lip with -4-C w/teflon. c. Use suitle mndrel, press oil sel into crrier (lip fcing DOWN) until ottomed out on shoulder of crrier. d. Luricte O-ring with -4-C w/teflon nd instll on crrier. 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:. Luricte crnkshft seling rings with light oil.. Check cylinder lock to e sure tht dowel pins re in plce. - O-ring - Sel -4-C With Teflon (-40A) Crnkshft Instlltion SPECIAL INFORMATION 4 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. - Dowel Pins 4. Position ll crnkshft sel ring gps stright up. 4. Align hole in ech center min ering rce with dowel pin.. 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 R DECEMBER POWERHEAD - 4-

40 . Luricte lower crnkshft end (oil sel re) with light oil, then instll lower end cp. Secure end cp to cylinder lock with ttching olts. DO NOT tighten end cp olts t this time. Position piston over end of rod. Verify locting wshers remin in plce. - Lower End Cp - Locting Wshers 0 4. Insert piston pin tool (-A) nd push sleeve out of piston. Keep piston pin tool in piston. Piston nd Connecting Rod Ressemly. Plce needle erings on clen piece of pper nd luricte with -4-C w/teflon (-40A). NOTE: There re 4 needle erings per piston.. Plce sleeve which is prt of piston pin tool (-A) into connecting rod nd instll needle erings round sleeve s shown. - Piston Pin Tool (-A) - Sleeve 4. Use mllet nd tp piston pin into piston nd push piston pin tool out. -4-C With Teflon (-40A) - Sleeve (Prt of Tool Assy. -A). Plce locting wshers on connecting rod. IMPORTANT: Position connecting rod prt numer fcing towrds flywheel POWERHEAD 0-00R DECEMBER

41 - Piston Pin - Piston Pin Tool. Instll new piston pin lockrings (one ech end of piston pin) with Lockring Instlltion Tool (-004A).. Mke sure lockrings re properly seted in piston grooves. - Lockring Instlltion Tool - Lockring Instlltion Tool (-004A) - Lockring R DECEMBER POWERHEAD - 4-

42 Piston nd Piston Ring Comintion.0 in. (.mm).0 in. (.mm) - Hlf Keystone (tpered) Piston Ring Piston Instlltion. Before instlling new piston rings, check gp etween ring ends y plcing ech ring in its respective cylinder, then pushing ring out / in. (.mm) into cylinder using piston to ssure proper position.. Check end gp of ech new piston ring with feeler guge. End gp must e within 0.00 in. to 0.0 in. (0.mm to 0.4mm). If end gp is greter, check other piston rings in cylinder ore, until rings (within tolernce) re found. c IMPORTANT: Piston ring side with dot or letter must e fcing up. - Piston Ring - Dot. Use Piston Ring Expnder (-4) nd instll piston rings (dot side up) on ech piston. Spred rings just enough to slip over piston. 4. Check piston rings to e sure tht they fit freely in ring groove.. Luricte piston, rings nd cylinder wll with -Cycle Outord Oil. d - Piston Ring - Dots (Fces Up) c - Feeler Guge d - Ring End Gp 4 4 Cycle Outord Oil (-A4) - Piston Ring Expnder - Dot Side UP on Piston Ring POWERHEAD 0-00R DECEMBER

43 . Rotte ech piston ring so end of ring is ligned with locting pin s shown.. Instll Piston Ring Compressor.. 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.. Cot cylinder ore with -cycle oil. Mtch piston ssemly with cylinder it ws removed from, nd position piston s descried elow. Push piston into cylinder. 4 CYL CYL 4 CYL UP P UP P UP P CYL CYL CYL UP S UP S UP S 4 Cycle Outord Oil (-A4) - Piston Ring Compressor (-) 0. Apply -4-C w/teflon to ering surfce of connecting rod nd instll ering ssemly, s shown.. 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. NOTE: If you still feel the frcture point, discrd the rod. 0-00R DECEMBER POWERHEAD - 4-4

44 . Tighten connecting rod olts (using / in. - point socket) First torque to l. in. (. N m) then 0 l. ft. (4.0 N m). Turn ech olt n dditionl 0 fter nd torque is ttined. Recheck lignment etween rod cp nd rod s shown. Crnkcse Cover Instlltion. Thoroughly remove ll oil from mting surfces of crnkcse cover nd cylinder lock with Loctite Primer 0 included in Mster Gsket Kit (-4-). -4-C With Teflon (-40A) - Connecting Rod Screws. 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 tthe seprting line s shown elow. Correct ny mislignment. - Crnkcse Cover - Remove All Oil. Apply thin, even cot of Loctite Mster Gsket on mting surfce of cylinder lock. c d - Side View Incorrect -- Cp on Bckwrds - End View Incorrect -- Cp on Bckwrds c - Side View Correct d - End View Correct Loctite Mster Gsket (-4-) - Loctite Mster Gsket (-4-) POWERHEAD 0-00R DECEMBER

45 . Plce crnkcse cover in position on cylinder lock. Turn the 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). 4. Instll remining crnkcse cover flnge olts (following torque sequence). 4. Tighten end cp olts to specified torque. - Torque Bolts to l. in. (. N m) 4 Assemly of Reed Blocks to Intke Mnifold Cycle Outord Oil (-A4) - Add Smll Amount of Light Oil to Threds nd Bolt Fce; Bolts (M0 x. x 0); 0 l. ft. (40. N m) nd Rotte 0-4 Bolts (M x. x ) l. ft. (. N m) - Intke Mnifold Bolts [Torque to 00 l. in. (. N m)] - Reed Block Mounting Bolts [Torque to 0 l. in. (0. N m)] c - Reed Attching Screws [Torque to l. in. (. N m)] 0-00R DECEMBER POWERHEAD - 4-4

46 Exhust Plte w/wter Pressure Relief Vlve Components M Permond #MO (Otin Loclly) -4-C With Teflon (-40A) POWERHEAD 0-00R DECEMBER

47 Exhust Plte w/wter Pressure Relief Vlve Components TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m EXHAUST PLATE (W/O REF #) EXHAUST PLATE (WITH REF #) STRAINER S/N-0G4 & BELOW GASKET 4 GASKET (Refer to Service Bulletin #4 -) GASKET (LOWER) SPRING SPRING EXHAUST PLATE S/N-0G4000 & UP GASKET GASKET (LOWER) SEAL SCREW (M x ) COVER RELIEF VALVE PLATE ASSEMBLY GASKET SCREW Drive Tight 4 WASHER DIAPHRAGM POPPET GROMMET CARRIER 4 SCREW (M x ) CONNECTOR ELBOW (4 degrees) ELBOW (4 degrees). = S/N -0G & UP ( TOOTH SPLINES), = S/N -0G & BELOW ( TOOTH SPLINES) : = NOTE: WHEN ORDERING REPLACEMENT POWERHEAD FOR ENGINES WITH S/N -0G4 & BELOW, REFER TO SERVICE BULLETIN #4-, AND ORDER EXHAUST PLATE KIT 40A IF NECESSARY. 0-00R DECEMBER POWERHEAD - 4-4

48 Exhust Plte w/wter Pressure Relief Vlve Components M Permond #MO (Otin Loclly) -4-C With Teflon (-40A) POWERHEAD 0-00R DECEMBER

49 Exhust Plte w/wter Pressure Relief Vlve Components TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m IDLE EXHAUST BOOT 4 AR STA STRAP HOSE-- telltle (-/ IN.) FITTING-- telltle PLUG WASHER CHECK VALVE 0 O RING FITTING HOSE DRAIN CHECK VALVE 4 4 DOWEL PIN NUT WASHER ROLLER NUT SHIFT LINK 40 BUSHING UPPER SHIFT SHAFT (LONG) 4 UPPER SHIFT SHAFT (X -LONG) UPPER SHIFT SHAFT (XX -LONG) 4 BUSHING 4 GROMMET 44 COUPLING 4 PLUG (S/N -0G4 & BELOW) 0-00R DECEMBER POWERHEAD - 4-4

50 Cylinder Hed Instlltion. Instll ech cylinder hed to engine lock with thermostt pocket UP. Apply light oil to cylinder hed olt threds nd olt fce. Torque olts nd 0 to 0 I. ft. (40. N m) nd rotte 0. Torque ll other olts to 0 l. ft. (. N m) nd rotte 0. NOTE: The Litre Work hs low compression cylinder heds which cn e identified from other CARB/ EFI/ 0 EFI cylinder heds y the csting #. - C4 0 4 Litre WORK C 4 Cycle Outord Oil (-A4) CARB/ EFI & 0 EFI POWERHEAD 0-00R DECEMBER

51 . Instll thermostt ssemly into ech cylinder hed.. Instll overhet temperture sensor into STARBOARD cylinder hed elow # sprk plug. f NOTE: During norml engine operting temperture, the sender electricl circuit is open nd will close if temperture reches 00 F F (. C. C) thus ctivting the overhet lrm. 4. Thermostt nd temperture sensor instlled. c d e - Thermostt (4 F -. C) - Bolt - Torque to 0 l. ft. (40. N m) nd rotte 0 c - Temperture Sensor d - Bolt - Torque to 00 l. in. (. N m) e - Bolt - Torque to 0 l. ft. (. N m) nd rotte 0 f - O-ring - Thermostt [4 F (. C)] - Overhet Temperture Sensor R DECEMBER POWERHEAD - 4-4

52 Liter Work/ Cr/ EFI/0 EFI Bleed Routing 4// Models ( Models DO NOT hve Front Mounted Bleed Check Vlves) Front View - Check Vlve ( Ech) (4// Models) - Crrier ( Ech) c - Crrier (No Check Vlve -- Models) POWERHEAD 0-00R DECEMBER

53 Liter Work/ Cruretor Bleed Routing for / Models (SN 0G to 0G4) Strord View in. (.cm) ( e.) -. in. (.cm) ( e.) - 4 in.(0.cm) 4 -. in. (.cm) - in. (.cm) - 4. in. (.4cm) - Check Vlve (-4--) ( e.) - Fitting (--4-) ( e.) - Fitting (Stright) (-40-) 0- Fitting (0 ) (-4) ( e.) - Check Vlve (-4-) ( e.) - Check Vlve (--4) ( e.) - Retiner () ( e.) 4- Pipe Plug (/) (-0) ( e.) 0-00R DECEMBER POWERHEAD - 4-

54 Liter Work/ Cruretor Bleed Routing for / Models (SN 0G to 0G4) Port View in. (.cm) ( e.) -. in. (.cm) ( e.) - in. (.cm) ( e.) 4-4. in. (.4cm) - Check Vlve (-4--) ( e.) - Fitting (-4) ( e.) - Fitting (Stright) (-40-) ( e.) - Fitting (0 ) (-4) - Retiner () 0- Pipe Plug (/) (-0) ( e.) 4- - POWERHEAD 0-00R DECEMBER

55 EFI/0 EFI Bleed Routing for / Models (SN 0G to 0G4) Strord View Continution of leed line from PORT side - 4 in. (0.cm) -. in. (.cm) 4 - Pipe Plug (/) ( e.) -. in. (.cm) ( e.) - in. (.cm) - -/ in. (.cm) - in. (.cm) - in. (4.cm) 0- Mnifold (0A) - Screw (0-x/4) (0-0) ( e.) - Pipe Plug (/) (-0) - Fitting (0 ) (-4) 4- Check Vlve (-4-) (e.) - Check Vlve (---4) (e.) - Pipe Plug (/) (-0) ( e.) 0-00R DECEMBER POWERHEAD - 4-

56 EFI/0 EFI Bleed Routing for / Models (SN 0G to 0G4) Port View Continution of Bleed Line from STARBOARD side. - To Vpor Seprtor - Pipe Plug (/) ( e.) 4 -. in. (.4cm) ( e.) - in. (.cm) - in. (.cm) ( e.) - in. (.cm) - in. (4.cm) -. in. (4.cm) ( e.) 0- Filter (-0) - Mnifold (0A) - Screw (0-x/4) (0-0) - Fitting (0 ) (-4) ( e.) 4- Fitting (Stright) (-40-) ( e.) - Pipe Plug (/) (-0) ( e.) POWERHEAD 0-00R DECEMBER

57 Liter Work nd Cruretor Models (SN 0G4000 to 0G4) Strord View in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) 0-00R DECEMBER POWERHEAD - 4-

58 Liter Work nd Cruretor Bleed Hose Flow Digrm (SN 0G4000 to 0G4) Strord View 4 A C 4 B E D in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - Fitting (-4-) ( e.) 0- Fitting (Stright) (-40-) ( e.) - Fitting (0 ) (-4) ( e.) - Check Vlve (--4) ( e.) - Check Vlve (-4-) ( e.) 4- T-Fitting (-) ( e.) F 4- - POWERHEAD 0-00R DECEMBER

59 Liter Work nd Cruretor Models (SN 0G4000 to 0G4) Front View 0-00R DECEMBER POWERHEAD - 4-

60 Liter Work nd Cruretor Models (SN 0G4000 to 0G4) Port View 4 -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) 4- - POWERHEAD 0-00R DECEMBER

61 Liter Work nd Cruretor Bleed Hose Flow Digrm (SN 0G4000 to 0G4) A 4 Port View Fuel Pump B C D E F -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - Fitting (-4-) ( e.) - Fitting (0 ) (-4) ( e.) 0- T-Fitting (-) ( e.) - Fitting (Stright) (-40-) ( e.) 0-00R DECEMBER POWERHEAD - 4-

62 /0 EFI Models (SN 0G4000 to 0G4) ( EFI w/fuel ECM nd 0 EFI w/fuel ECM 004-) Strord View 4 -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - 4 in. (.cm) ( e.) POWERHEAD 0-00R DECEMBER

63 /0 EFI Bleed Hose Flow Digrm (SN 0G4000 to 0G4) ( EFI w/fuel ECM nd 0 EFI w/fuel ECM 004-) Strord View 0 4 A B C D F E -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - 4 in. (.cm) ( e.) 0- Fitting (-4-) ( e.) - Fitting (Stright) (-40-) ( e.) - Check Vlve (-4-) ( e.) - Check Vlve (--4) ( e.) 4- Fitting (0 ) (-4) ( e.) - T-Fitting (-) ( e.) 0-00R DECEMBER POWERHEAD - 4-

64 nd Newer /0 EFI Models ( EFI w/fuel ECM nd 0 EFI w/fuel ECM 004-) Front View POWERHEAD 0-00R DECEMBER

65 /0 EFI Models (SN 0G4000 to 0G4) ( EFI w/fuel ECM nd 0 EFI w/fuel ECM 004-) Port View 4 -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) (4 e.) 4 -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - 4 in. (.cm) ( e.) 0-00R DECEMBER POWERHEAD - 4-

66 /0 EFI Bleed Hose Flow Digrm (SN 0G4000 to 0G4) ( EFI w/fuel ECM nd 0 EFI w/fuel ECM 004-) Port View A B C Fuel Pump D E F 0 -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) (4 e.) 4 -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - 4 in. (.cm) ( e.) - Fitting (0 ) (-4) ( e.) 0- Fitting (-4-) ( e.) - Fitting (Stright) (-40-) ( e.) - T-Fitting (-) ( e.) POWERHEAD 0-00R DECEMBER

67 nd Newer Liter Work nd Cruretor Models (SN 04 nd ABOVE) Strord View 4 -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - 0. in. (.0cm) ( e.) - in. (40.cm) ( e.) - Check Vlves (-4--) ( e.) 0-00R DECEMBER POWERHEAD - 4-

68 nd Newer Liter Work nd Cruretor Bleed Hose Flow Digrm (SN 0G4 nd ABOVE) Strord View A 0 B 0 C D E F -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm) ( e.) -. in. (.cm ( e.) -. in. (.cm) ( e.) - 0. in. (.0cm) ( e.) - in. (40.cm) ( e.) 4 - Check Vlves (-4--) ( e.) 0- Fitting (-4-) ( e.) - Fitting (Stright) (-40-) ( e.) - Check Vlve (0 ) (--) ( e.) - Check Vlve (T-Fitting) (-404-) ( e.) 4- Check Vlve (Stright) (-4-) ( e.) - Check Vlve (Stright) (--) ( e.) 4- - POWERHEAD 0-00R DECEMBER

69 nd Newer Liter Work nd Cruretor Models (SN 0G4 nd ABOVE) Front View 0-00R DECEMBER POWERHEAD - 4-

70 nd Newer Liter Work nd Cruretor Models (SN 0G4 nd ABOVE) Port View 4 -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm ( e.) -. in. (.cm) ( e.) - 0. in. (.0cm) ( e.) - Check Vlves (-4--) ( e.) 4- - POWERHEAD 0-00R DECEMBER

71 nd Newer Liter Work nd Cruretor Bleed Hose Flow Digrm (SN 0G4 nd ABOVE) A Port View 0 B C D E 0 0 F -. in. (4.cm) ( e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm ( e.) -. in. (.cm) ( e.) - 0. in. (.0cm) ( e.) - Check Vlves (-4--) ( e.) - Check Vlve (0 ) (--) ( e.) - Fitting (-4-) ( e.) 0- Fitting (Stright) (-40-) ( e.) - Clmp (4-) - Screw (0-440) - Check Vlve (T-Fitting) (-404-) ( e.) 0-00R DECEMBER POWERHEAD - 4-

72 nd Newer /0 EFI Models (SN 0G4 nd ABOVE) ( EFI w/fuel ECM 004- nd 0 EFI w/fuel ECM 004-) Strord View 4 -. in. (4.cm) (4 e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm ( e.) -. in. (.cm) ( e.) -. in. (.cm) ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) POWERHEAD 0-00R DECEMBER

73 /0 EFI Bleed Hose Flow Digrm (SN 0G4 nd ABOVE) ( EFI w/fuel ECM 004- nd 0 EFI w/fuel ECM 004-) Strord View A B 4 0 C 4 D 0 E F -. in. (4.cm) (4 e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm ( e.) -. in. (.cm) ( e.) -. in. (.cm) ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - Fitting (-4-) ( e.) 0- Fitting (Stright) (-40-) e.) - Check Vlve (Stright) (-4-) ( e.) - Check Vlve (Stright) (--4) ( e.) - Check Vlve (T-Fitting) (-404-) ( e.) 4- Check Vlve (0 ) (--) ( e.) 0-00R DECEMBER POWERHEAD - 4-

74 nd Newer /0 EFI Models (SN 0G4 nd ABOVE) ( EFI w/fuel ECM 004- nd 0 EFI w/fuel ECM 004-) Front View POWERHEAD 0-00R DECEMBER

75 nd Newer /0 EFI Models (SN 0G4 nd ABOVE) ( EFI w/fuel ECM 004- nd 0 EFI w/fuel ECM 004-) Port View in. (4.cm) (4 e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm ( e.) -. in. (.cm) ( e.) - in. (40.cm) ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) 0-00R DECEMBER POWERHEAD - 4-

76 nd Newer /0 EFI Models Bleed Hose Flow Digrm (SN 0G4 nd ABOVE) ( EFI w/fuel ECM 004- nd 0 EFI w/fuel ECM 004-) A Port View B 0 C D E 0 F 0 -. in. (4.cm) (4 e.) - in. (.cm) ( e.) - in. (.cm) ( e.) 4 -. in. (.cm ( e.) -. in. (.cm) ( e.) - in. (40.cm) ( e.) -. in. (.cm) ( e.) - Check Vlves (-4--) ( e.) - Fitting (-4-) ( e.) 0- Fitting (Stright) (40-) ( e.) - Check Vlve (0 ) (--) ( e.) - Check Vlve (T-Fitting) (-404-) ( e.) - Clmp (4-) 4- Screw (0-440) POWERHEAD 0-00R DECEMBER

77 Reinstlling Engine Components Reinstll the following components: Section Strter Motor Alterntor Sttor Ignition Modules Electronic Control Unit Solenoids Crnk Position Sensor Throttle Position Sensor Temperture Sensor Section Air Silencer Cruretors nd Linkge Fuel Pump Fuel Enrichment Oil Injection On-Bord Oil Tnk Oil Pump 0-00R DECEMBER POWERHEAD - 4-

78 Anchor Brcket/Throttle Linkge SEAPRO/MARATHON (S/N-0G004 & BELOW) 4 A 4 B Loctite (-00) -4-C With Teflon (-40A) A - l. ft. (. N m) B - 0 l. ft. (. N m) 4- - POWERHEAD 0-00R DECEMBER

79 Anchor Brcket/Throttle Linkge SEAPRO/MARATHON (S/N-0G004 & BELOW) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m ANCHOR BRACKET ROLLER GUIDE SPRING 4 BUSHING SCREW (M x ) BUSHING DRIVE SCREW LATCH CUP 0 STUD THROTTLE CAM WASHER NUT 4 SWIVEL BUSHING THROTTLE LINK BUSHING SCREW (M x x ) NUT CAP 0 THROTTLE LEVER WASHER SCREW (M x ) PIN INSERT 4 NUT WASHER THROTTLE LINK KIT LINK (Stu Shft) LINK (Bll Shft) ROLLER 0 SCREW (0- x / ) WASHER LOCKWASHER 0-00R DECEMBER POWERHEAD - 4-

80 Anchor Brcket/Throttle Linkge Cr (S/N-0G004 & BELOW) 0 A 4 B Loctite (-00) -4-C With Teflon (-40A) A - l. ft. (. N m) B - 0 l. ft. (. N m) 4- - POWERHEAD 0-00R DECEMBER

81 Anchor Brcket/Throttle Linkge Cr (S/N-0G004 & BELOW) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m SWITCH SCREW (M. x 0) 0. ANCHOR BRACKET 4 DRIVE SCREW LATCH CUP SCREW (M x ) BUSHING BUSHING 0 SPRING ROLLER GUIDE THROTTLE LINK Use With WMH- LINK (Stu Shft) Series Cruretors 4 THROTTLE LINK KIT Use With WMH-4/4 LINK (Stu Shft) Series Cruretors LINK (Bll Shft) ROLLER SCREW (0- x / ) WASHER 0 LOCKWASHER LINK SWIVEL BUSHING STUD 4 THROTTLE CAM WASHER NUT THROTTLE LINK BUSHING SCREW (M x x ) 0 NUT CAP THROTTLE LEVER WASHER 4 SCREW (M x ) PIN INSERT WASHER NUT 0-00R DECEMBER POWERHEAD - 4-

82 Anchor Brcket/Throttle Linkge (Cr Models) (S/N-0G004 & Up) A 4 4 B -4-C With Teflon (-40A) A - l. ft. (. N m) B - 0 l. ft. (. N m) POWERHEAD 0-00R DECEMBER

83 Anchor Brcket/Throttle Linkge (Cr Models) (S/N-0G004 & Up) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m SWITCH NON SEAPRO/MARATHON SCREW (M. x 0) 0. ANCHOR BRACKET 4 DRIVE SCREW LATCH CUP SCREW (M x ) BUSHING BUSHING 0 SPRING ROLLER GUIDE THROTTLE LINK KIT THROTTLE LEVER 4 THROTTLE LEVER SCREW (0- x /4 ) WASHER LOCKWASHER THROTTLE LINK SWIVEL BUSHING 0 PIN INSERT WASHER NUT SCREW (M x x ) 4 NUT CAP THROTTLE LEVER BUSHING SCREW (M x ) NUT 0 BRACKET-Oil Link SCREW (M x ) WASHER LINK 0-00R DECEMBER POWERHEAD - 4-

84 Anchor Brcket/Throttle Linkge (EFI Models) A 4 A - l. ft. (. N m) B - 0 l. ft. (. N m) B -4-C With Teflon (-40A) 4- - POWERHEAD 0-00R DECEMBER

85 Anchor Brcket/Throttle Linkge (EFI Models) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m SWITCH SCREW (M. x 0) 0. ANCHOR BRACKET 4 DRIVE SCREW LATCH CUP SCREW (M x ) BUSHING BUSHING 0 SPRING ROLLER GUIDE THROTTLE CAM BUSHING 4 NUT THROTTLE LINK SWIVEL BUSHING BRACKET-Oil Link LINK SCREW (M x ) NUT THROTTLE LEVER SCREW (M x ) WASHER 4 PIN INSERT BUSHING NUT SCREW (M x x ) NUT CAP 0 WASHER 0-00R DECEMBER POWERHEAD - 4-

86 Powerhed Instlltion on Driveshft Housing. Instll Lifting Eye (-04) into flywheel.! WARNING BE SURE tht Lifting Eye is threded into flywheel s fr s possile BEFORE lifting powerhed.. Using hoist, lift powerhed high enough to llow removl of powerhed from repir stnd. Remove powerhed from repir stnd, eing creful not to dmge drive shft housing gsket surfce of powerhed.. Plce new gsket round powerhed studs nd into position on se of powerhed. IMPORTANT: DO NOT pply luricnt to top of drive- shft s this will prevent driveshft from fully engging into crnkshft. 4. Apply smll mount of -4-C w/teflon (-40A) onto driveshft splines.. Use hoist to lower powerhed onto driveshft housing. It my e necessry to turn flywheel (ligning crnkshft splines with drive shft splines) so tht powerhed will e fully instlled.. Instll 0 flt wshers nd 0 locknuts which secure powerhed to exhust extension plte/driveshft housing. Torque locknuts in progressive steps until secured.. Disconnect hoist from Lifting Eye nd remove Lifting Eye from flywheel.. Reinstll plstic cp into center of flywheel cover. - Locknuts nd Flt Wshers [Torque to 0 l. ft. (.0 N m)]. Connect ypss wter hoses to fittings on exhust dptor plte. c - Lifting Eye (-04) - Wter Hose - Fitting c - Wter Pressure Guge Fitting POWERHEAD 0-00R DECEMBER

87 0. Connect tell-tle hose nd flush hose to engine lock. - Tell-Tle Hose - Flush Hose. Instll four olts which secure ottom cowl hlves together. - Bolts [Torque to l. in. (. N m)]. Re-connect input fuel line. - Bolts [Torque to l. in. (. N m)] 4 - St-Strp - Fuel Line - Bolts [Torque to l. in. (. N m)] 0-00R DECEMBER POWERHEAD - 4-

88 . Connect remote oil tnk pressure hose to to crnkcse fitting. of strter solenoid with nut. Torque nut to 4 l. in. (. N m). f c - Remote Oil Tnk Pressure Hose 4. MODELS WITH TRIM SOLENOIDS - Connect BLUE, GREEN nd BLACK trim hrness leds to trim solenoids. Instll trim hrness to J-clip on exhust cover. e d 44 - Nut -- Attch RED Rely Leds -- Torque Nut to 4 l. in. (. N m) - Relys -- Secure with Retined Bolts nd Nuts c - Bolt -- Attch BLACK (ground) Rely leds -- Torque Bolt to. l. ft. (.4 N m). d - Connect BLUE/WHITE nd GREEN/WHITE Trim Leds to Lower Cowl Trim Switch Hrness. e - St-Strps f - Connect BLUE (sleeve) nd GREEN Power Trim Leds.. Re-connect remote control hrness to powerhed hrness connector nd wires s shown. c c - Blue Trim Led - Blck Trim Led c - Green Trim Led MODELS WITH TRIM RELAYS - Attch rely ground hrness to lower electricl plte mounting olt. Torque olt to. l. ft. (.4 N m). Attch rely positive leds (RED) to BATTERY SIDE - Engine Hrness Connector - Remote Wiring Hrness c - J Clmp 4- - POWERHEAD 0-00R DECEMBER

89 . Instll two screws which secure remote control hrness retiner. Brek-ln Procedure MODELS WITH OIL INJECTION Use 0: (%) gsoline/oil mixture in the first tnk of fuel. Follow the tle elow for mixing rtios. Use of this fuel mixture comined with oil from the oil injection system will supply dequte luriction during engine rek-in. After the rek-in fuel mixture is used up, it is no longer necessry to dd oil with the gsoline. NOTE: At the end of the rek-in period, visully check to see if the oil level in the oil injection tnk hs dropped. Oil usgeindictes theoil injectionsystem is functioning correctly. - Screws - Retiner. Slide outord shift lever into neutrl position.. Instll throttle cle.. Instll shift cle ssemly s shown Refer to Cle Adjustment Section A. GASOLINE/OIL MIXING RATIO CHART GAS/OIL RATIO 0: (%) GAL- LON GAS (. LI- TERS) FL. OZ. ( ML) OIL GAL- LONS GAS (. LITERS) FL. OZ. ( ML) OIL MODELS WITHOUT OIL INJECTION GAL- LONS GAS ( LITERS) FL. OZ. (4 ML) OIL Use : (4%) gsoline/oil mixture in the first tnk of fuel. After the rek-in fuel mixture is used up, use 0: (%) gsoline/oil mixture. Follow the tle elow for mixing rtios. GASOLINE/OIL MIXING RATIO CHART c - Throttle Cle - Shift Cle c - Cle Retiner Refer to Section of this Service Mnul Timing/ Synchronizing/Adjusting for engine set-up procedures. GAS/OIL RATIO : (4%) 0: (%) GAL- LON GAS (. LI- TERS) FL. OZ. (4 ML) OIL FL. OZ. ( ML) OIL GAL- LONS GAS (. LITERS) FL. OZ. (4 ML) OIL FL. OZ. ( ML) OIL ENGINE BREAK-IN PROCEDURE (ALL MODELS) GAL- LONS GAS ( LITERS) FL. OZ. (4 ML) OIL FL. OZ. (4 ML) OIL Vry the throttle setting during the first hour of opertion. Avoid remining t constnt speed for more thn two minutes nd void sustined wide open throttle. 0-00R DECEMBER POWERHEAD - 4-