POWERHEAD. Section 4A

Transcription

1 Tle of Contents Section 4A Powerhed Specifictions A-1 Specil Tools A-1 Powerhed Repir Stnd A-3 Cylinder Block nd End Cps A-4 Exhust Mnifold nd Exhust Plte A-6 Cylinder Hed A-8 Crnkshft, Pistons nd Connecting Rods A-10 Torque Sequence A-11 Generl Informtion A-13 Powerhed Removl from Driveshft Housing.. 4A-13 Powerhed Disssemly A-17 Wter Pressure Relief Vlve Components... 4A-25 Torque Specifictions A-25 Clening nd Inspection A-26 Cylinder Block nd Crnkcse Cover A-26 Specil Service Informtion A-26 Cylinder Bores A-27 Pistons nd Piston Rings A-28 Cylinder Heds nd Exhust Divider Plte... 4A-30 Crnkshft A-30 Powerhed Specifictions Crnkshft (nd End Cp) Berings A-31 Reed Block Assemly A-32 End Bering Bleed System A-33 Connecting Rods A-33 Thermostts A-35 Powerhed Ressemly nd Instlltion A-36 Generl A-36 Crnkshft Instlltion A-40 Piston nd Connecting Rod Ressemly.... 4A-42 Piston nd Piston Ring Comintions A-43 Piston Instlltion A-44 Crnkcse Cover Instlltion A-46 Assemly of Reed Blocks to Intke Mnifold. 4A-48 Assemly of Exhust Divider Plte to Block.. 4A-48 Reinstlling Engine Components A-51 Throttle Lever nd Shift Shft A-52 Throttle Lever nd Shift Shft A-53 Powerhed Instlltion on Driveshft Housing.. 4A-54 Brek-ln Procedure A-58 4 A CYLINDER BLOCK Type Displcement V-6 Cylinder, Two Cycle, Direct Injected 153 cu. in. (2508 cc) 60 Vee STROKE Length (All Models) 2.65 in. (67.3 mm) CYLINDER BORE PISTON Dimeter (Std) Dimeter in. Oversize Tper/Out of Round/Wer Mximum Bore Type Piston Type Dimeter Stndrd Dimeter in. Oversize in. ( mm) in. ( mm) in. (0.076 mm) Cst Iron Aluminum in. ±.0005 in. ( mm ± mm) in. ± in. ( mm ± mm) CRANKSHAFT Mximum Runout in. (0.152 mm) R1 JANUARY 1999 Pge 4A-1

2 PISTON DIAMETER Dimension A t Right Angle (90 ) to Piston Pin mm in. ±.0005 in. ( mm ±.0127 mm) Using micrometer, mesure dimension A t loction shown. Dimension A should e in. ±.0005 for STAN- DARD size piston (new) Dimension A will e less if coting is worn off piston (used) REEDS Reed Stnd 0pen (Mx.) in. (0.50 mm) Specil Tools 1. Lifting Eye Powerhed Stnd A1 3. Piston Ring Expnder Lockring Removl Tool A1 5. Piston Pin Tool A1 6. Driver Hed Pge 4A R1 JANUARY 1999

3 7. Universl Puller Plte Snp Ring Pliers Lockring Instlltion Tool A1 10. Piston Ring Compressor for 2.5 Litre (153 cu. in.) 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) R1 JANUARY 1999 Pge 4A-3

4 Cylinder Block nd End Cps 9 Loctite PST Pipe Selnt ( ) 12 Loctite 514 Mster Gsket ( ) 14 2 Cycle Outord Oil ( A24) PORT OIL FITTING ORIENTATION TOP OF BLOCK CRANK 2 o clock HEAD BOTTOM OF BLOCK A = TO AIR HANDLER B = TO ON BOARD OIL TANK 33 Loctite RCA/680 Retining Compound ( ) C w/teflon ( A12) Pge 4A R1 JANUARY 1999

5 Cylinder Block nd End Cps TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 CYLINDER BLOCK 2 6 STUD powerhed (1-3/4 IN.) 2 STUD powerhed (5-1/2 IN.) 3 2 STUD powerhed (6-3/4 IN.) 4 2 DOWEL PIN locting 5 2 DOWEL PIN (BEARING RACE) 6 2 GASKET seling 7 1 PIPE PLUG (1/2-14) Drive Tight 8 1 CHECK VALVE 9 1 CHECK VALVE 10 1 TUBING (19 IN.) STA STRAP 12 2 FITTING (STRAIGHT)(STARBOARD - TOP/BOTTOM) 13 1 FITTING (ELBOW) (STARBOARD - CENTER) 14 3 FITTING (ELBOW) (PORT) 2 TUBING (16 IN.) (TOP/BOTTOM) 15 1 TUBING (20 IN.) (CENTER) 16 3 TUBING (24-1/2 IN.) 17 1 CONDUIT (7 IN.) 18 1 FITTING 19 1 TUBING (11-1/2 IN.) 20 1 CONNECTOR 21 6 STA-STRAP 22 8 SCREW (3/8-16 x 3-1/4) SCREW ( x 1-1/4) CAP 25 1 ADJUSTING SCREW (1/4-20 x 1-3/4) 26 1 JAM NUT 27 1 UPPER END CAP 28 1 O-RING 29 1 ROLLER BEARING 30 1 BEARING RACE 31 1 OIL SEAL 32 4 SCREW (5/16-18 x 1) LOWER END CAP 34 1 O-RING (3-1/4 IN. I.D.) 35 2 OIL SEAL 36 4 SCREW (1/4-20 x 3/4) LOCKWASHER 38 1 BRACKET 39 1 TPI LEVER 40 3 SCREW -Brcket to crnkcse BUSHING 42 3 GROMMET 43 1 THROTTLE POSITION SENSOR (INSIDE) 44 1 SPACER 45 1 THROTTLE POSITION SENSOR (OUTSIDE) 46 3 SCREW -TPS to rcket (#10-32 x 2-3/4 IN.) THROTTLE LINK 48 1 PLUG-Seril Numer 49 1 STA-STRAP-Oil Lines R1 JANUARY 1999 Pge 4A-5

6 Exhust Mnifold nd Exhust Plte D A C 30 B Loctite 271 ( ) Loctite PST Pipe Selnt ( ) Loctite 222 ( ) Permond 105 Cyncrylte Adhesive (Purchse Loclly) C With Teflon ( A12) A = TO FUEL COOLER WATER IN B = TO FUEL COOLER WATER OUT FITTING C = TO LOWER PORT FUEL RAIL SIDE FITTING D = TO AIR COMPRESSOR LOWER WATER INLET FITTING Pge 4A R1 JANUARY 1999

7 Exhust Mnifold nd Exhust Plte REF. TORQUE NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 GASKET 2 1 DIVIDER PLATE 3 1 SEAL 4 17 SCREW (5/16-18 x 1-1/2 IN.) SCREW (5/16-18 x 1 IN.) STRAINER 7 1 HOSE (4-1/2 IN.) 8 1 ELBOW 9 1 HOSE (21-1/2 IN.) 10 5 STA-STRAP 11 1 COVER relief vlve 12 4 SCREW (5/16-18 x 1-1/4 IN.) SCREW (10-16 x 3/4 IN.) WASHER 15 1 DIAPHRAGM 16 1 WATER DEFLECTOR 17 1 PLATE 18 2 GASKET 19 1 SPRING 20 1 WASHER 21 1 POPPET 22 1 GROMMET 23 1 CARRIER 24 1 GASKET 25 1 EXHAUST PATE 26 2 DOWEL PIN 27 1 SEAL 28 1 BRACKET 29 8 SCREW (10-16 x 1/2 IN.) FITTING (STRAIGHT)(BACK) 31 1 ELBOW (STARBOARD-TOP HOLE) 32 1 FITTING (STRAIGHT)(STARBOARD-BOTTOM HOLE) 33 1 GROMMET 34 1 GROMMET 35 1 HOSE (25 IN.) 36 1 HOSE 37 4 WASHER 38 6 NUT BUSHING 40 1 SCREW (5/16-18 x 1-1/4 IN.) SCREW (5/16-18 x 2-1/2 IN.) SCREW (3/8-16 x 3-1/2 IN.) FRONT BRACKET ASSEMBLY 44 4 SCREW (5/16-18 x 1/2 IN.) WASHER 46 4 GROMMET 47 1 REAR BRACKET ASSEMBLY R1 JANUARY 1999 Pge 4A-7

8 Cylinder Hed 10 9 Wter Fitting Orienttion Looking Down t Top of Block Bck of Engine A Dielectric Grese ( ) Loctite PST Pipe Selnt ( ) 14 2 Cycle Outord Oil ( A24) A = TO STRAIGHT FITTING ON BACK OF EXHAUST PLATE 4 Pge 4A R1 JANUARY 1999

9 Cylinder Hed TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 CYLINDER HEAD (PORT) 1 1 CYLINDER HEAD (STARBOARD) 2 2 GASKET 30 l-ft 3 24 BOLT (2 IN.) (40.7 N m) then tighten dditionl DOWEL PIN 5 2 GASKET 6 2 COVER 7 2 THERMOSTAT (143 degrees) 8 4 SCREW (M6 x 25) ELBOW (STARBOARD) 10 1 ELBOW (PORT) 11 1 HOSE (21-1/2 IN.) 12 1 HOSE (11-1/2 IN.) 13 5 STA-STRAP 14 1 TEMPERATURE SENSOR (STARBOARD) 15 1 RETAINER 16 1 SCREW (M8 x 12) R1 JANUARY 1999 Pge 4A-9

10 Crnkshft, Pistons nd Connecting Rods Cycle Outord Oil ( A24) C w/teflon ( A12) Pge 4A R1 JANUARY 1999

11 Crnkshft, Pistons nd Connecting Rods TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 CRANKSHAFT ASSEMBLY 2 1 BALL BEARING (LOWER) 3 1 RETAINING RING 4 1 CARRIER ASSEMBLY 5 1 SEAL 6 7 RING seling 7 2 ROLLER BEARING 8 2 RACE 3 PISTON (STARBOARD) 9 3 PISTON (PORT) 10 1 PISTON RING LOCK RING 12 6 CONNECTING ROD ASSEMBLY 1st Torque: 15 l-in 2nd Torque: 30 l-ft SCREW Turn Screw dditionl 90 fter 2nd torque WASHER 15 6 ROLLER BEARING ASSEMBLY NEEDLE BEARING piston end Torque Sequence CRANKCASE COVER BOLTS (AND TORQUE SEQUENCE) Add 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 N m) R1 JANUARY 1999 Pge 4A-11

12 EXHAUST DIVIDER PLATE BOLTS 200 l. in. (22.5 N m) Apply Loctite 271 to threds CYLINDER HEAD BOLTS Add light oil to threds nd olt fce: 30 l. ft. (41 N m) then turn n dditionl Pge 4A R1 JANUARY 1999

13 AIR PLENUM/REED BLOCK ASSEMBLY PLATE BOLTS 100 l. in. (11.3 N m) 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 drive shft housing. Removl of powerhed is not required for 1) inspection of cylinder wlls nd pistons (refer to Powerhed Removl nd Disssemly, following, nd remove cylinder heds nd exhust cover), 2) minor repirs on components, such s ignition system, fuel injection, reed locks nd cylinder heds nd checking opertion of thermostts. Powerhed Removl from Driveshft Housing 1. Disconnect ttery cles from ttery terminls. 2. Disconnect fuel tnk hose from outord. 3. Remove top cowling. 4. Remove two screws which secure remote control hrness retiner nd remove retiner Screws -Retiner R1 JANUARY 1999 Pge 4A-13

14 5. Disconnect remote oil tnk hose connector. 6. Disconnect remote control hrness from powerhed hrness connector nd wires s shown. BLU/WHT GRN/WHT TAN BRN/WHT BLU/WHT GRN/WHT -Power Trim Connections 7. Remove st-strp which secures tell-tle hose to fitting on lower cowl nd remove hose from fitting. -Tell-tle Hose 8. Disconnect wrning guge hrness e c d c d -TAN/BLACK -TAN/WHITE c -PINK/LT. BLUE to PINK/LT. BLUE d-orange e -St-Strps Pge 4A R1 JANUARY 1999

15 9. Remove BLUE nd GREEN trim hrness leds from trim solenoids. -Trim Solenoids 10. Slide outord shift lever into neutrl position. 11. Remove throttle cle. 12. Remove locknut tht secures shift cle ltch ssemly nd remove ltch, flt wsher, nylon wer plte, spring nd shift cle from control cle nchor rcket. 13. Disconnect input fuel line. c -Throttle Cle -Shift Cle c -Hose Clmp d-fuel Line d 14. Remove 4 olts securing ottom cowl hlves nd remove ottom cowling Bolt R1 JANUARY 1999 Pge 4A-15

16 15. Remove fuel cooler inlet nd outlet wter hoses from fittings on exhust dptor plte nd poppet vlve cover. Remove excess ir hose (from port fuel ril) from fitting on exhust dptor plte. 16. Remove thermostt cover hose from exhust dptor plte. d c Fuel Cooler Outlet Wter Hose -Fuel Cooler Inlet Wter Hose c -Air Hose d-thermostt Cover Hose 17. Remove 10 nuts nd wshers (five ech side) from powerhed se. 18. Remove plstic cp from center of flywheel nd instll LIFTING EYE ( ) into flywheel t lest five full turns. Using hoist, lift powerhed ssemly from driveshft housing Nuts nd Wshers (5 Ech Side) -Lifting Eye Pge 4A R1 JANUARY 1999

17 REMOVING ENGINE COMPONENTS Remove the following engine components: Section 2 Strter Motor Strter Motor *Electronic Control Module *Ignition Coil *Strter Solenoid Alterntor Flywheel Section 3 Direct Fuel Injection Fuel Pump On-Bord Oil Tnk Oil Pump Section 7 Shift Cle Ltch Assemly Control Cle Anchor Brcket *All ignition nd electricl components should remin ttched to electricl plte. Plte with components cn e removed s n ssemly. Powerhed Disssemly 1. Plce powerhed in repir stnd or on ench. 2. Remove thermostt covers, thermostts nd gskets. 3. Remove cylinder heds from engine lock. c -Thermostt Cover -Thermostt c -Gsket d-cylinder Hed e -Gsket f -Engine Block f e d R1 JANUARY 1999 Pge 4A-17

18 c 4. Remove exhust mnifold cover nd sel. 5. Referring to Section 3B, remove ir plenum/reed lock/dptor plte ssemly from cylinder lock. d Exhust Mnifold Cover -Sel c -Gsket d-reed Block/Adptor Plte Assemly 6. Inspect reeds s outlined in Clening nd Inspection. 7. Remove olts from end cps Pge 4A R1 JANUARY 1999

19 UPPER END CAP -Crnkcse Attching End Cp Bolts LOWER END CAP -Crnkcse Attching End Cp Bolts Remove olts which secure crnkcse cover to cylinder lock. 2. Pry crnkcse cover off cylinder lock using pry rs in loctions shown. -Pry Points -Crnkcse Cover R1 JANUARY 1999 Pge 4A-19

20 CRANKCASE COVER REMOVED Use Powerhed Stnd ( A1) for rotting crnkshft to desired position for removl of connecting rods. 2. Using n wl or electric pencil, scrie the cylinder identifiction numer on ech connecting rod s shown. Ressemle connecting rods in sme cylinder. Ä Use 5/16 in. 12 point socket to remove connecting rod olts, then remove rod cp, roller erings nd ering cge from connecting rod. -Connecting Rod Bolts Push piston out of cylinder lock. 5. After removl, ressemle ech piston nd connecting rod ssemly. Pge 4A R1 JANUARY 1999

21 CAUTION Ech connecting rod nd end cp re mtched mchined set nd must never e mismtched. 6. Inspect pistons s outlined in Clening nd Inspection, following. 7. Use Piston Ring Expnder ( ) to remove piston rings. Alwys instll new piston rings Using n wl, scrie identifiction numer of connecting rod on inside of piston (). Ressemle piston on sme connecting rod. 9. Using tool ( A1), remove piston pin lockrings from oth ends of piston pin. Never re-use piston pin lockrings Scrie Identifiction Numer -Lockring IMPORTANT: Wrming the piston dome using torch lmp will ese removl nd instlltion of piston pin R1 JANUARY 1999 Pge 4A-21

22 10. Support piston nd tp out piston pin using service tool ( A1) s shown. 11. 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 Piston Pin -Piston Pin Tool ( A1) c -Needle Bering Locting Wshers c Remove upper end cp nd lower end cp from crnkshft. 13. Remove nd discrd O-ring sels from ech end cp. 14. Remove oil sel(s) from end of ech end cp y driving sel out with punch nd hmmer. 15. 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. d -Upper End Cp -Lower End Cp c -O-Ring d-sel c Pge 4A R1 JANUARY 1999

23 16. 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. CAUTION Sfety glsses should e worn when removing or instlling crnkshft seling rings. 17. Remove retining ring s shown Seling Rings -Retining Ring 18. Remove ering rce hlves nd roller erings from crnkshft. IMPORTANT: Keep sme ering rces nd roller erings together. -Bering Rce Hlves -Roller Berings R1 JANUARY 1999 Pge 4A-23

24 Inspect crnkshft ll ering s outlined in Clening nd Inspection, following. IMPORTANT: DO NOT remove crnkshft ll ering, unless replcement is required. 19. Remove lower ll ering from crnkshft s follows:. Remove retining ring using pir of snp ring pliers. c -Crnkshft Bll Bering -Pliers c -Retining Ring Press crnkshft out of lower ll ering s shown. c d -Press -Powerhed Stnd ( A1) c -Crnkshft Bll Bering d-universl Puller Plte ( ) Pge 4A R1 JANUARY 1999

25 Wter Pressure Relief Vlve Components 1. If necessry, remove wter pressure relief vlve components s shown Cover 2 -Bolt 3 -Gsket 4 -Relief Vlve Plte 5 -Diphrgm 6 -Wter Deflector 7 -Wsher 8 -Screw 9 -Spring 10 - Poppet Vlve 11 - Grommet 12 - Crrier 13 - Wsher Torque Specifictions 150 l. in. (17 N m) 25 l. in. (3 N m) R1 JANUARY 1999 Pge 4A-25

26 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. CAUTION If 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. 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. Pge 4A R1 JANUARY 1999

27 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. 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. 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 R1 JANUARY 1999 Pge 4A-27

28 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. 135/150 Models Pistons nd Piston Rings Models Cylinder Block Finish Hone Stndrd Piston Bore in. (88.93mm).015 in. (0.381mm) Oversize Piston Bore in. (89.31mm) 4. If cylinder ore is tpered, out-of-round or worn more thn in. (0.076mm) from stndrd Cylinder Block Finish Hone dimeter (refer to chrt, preceding), it will e necessry to re-ore tht cylinder(s) to in. (0.381mm) 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. 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. Pge 4A R1 JANUARY 1999

29 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. 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 (135/150 Models) Enlrged View of Piston Ring Grooves R1 JANUARY 1999 Pge 4A-29

30 MEASURING PISTON ROUNDNESS Piston hs rrel profile shpe nd is not true dimeter. Stndrd 135/150 Models cu. in. (2508 cc) 1. Using micrometer, mesure dimension A t loction shown. Dimension A should e s indicted in chrt following. Stndrd Piston Piston Dimension A in. ± in in. Oversize Piston in. ± in. 2. Using micrometer, mesure dimension B t loction shown. Dimension B should e within in. of dimension A in. (17.78mm) -Dimension A t RIGHT Angle (90 ) to Piston Pin -Dimension B (in line with Piston Pin) Cylinder Heds nd Exhust Divider Plte Crnkshft 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 in. (0.1 mm) over the ENTIRE length of the cylinder hed. If mesured wrpge, s determined on surfce lock, exceeds in. (0.1 mm) or discontinuity of up to in. (0.1 mm) exists in nrrow portion of the cylinder hed s surfce length, then the cylinder hed my e re-surfced up to in. (0.25 mm). 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. 1. Inspect crnkshft to drive shft splines for wer. (Replce crnkshft, if necessry.) 2. Check crnkshft for strightness. Mximum runout is in. (0.152 mm). (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 overheting. (Refer to Connecting Rods.) Pge 4A R1 JANUARY 1999

31 5. If necessry, clen crnkshft surfces with crocus cloth. c c -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. 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-nd-forth. 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.) 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 crnkshft center min roller erings. Replce erings in pirs only R1 JANUARY 1999 Pge 4A-31

32 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. Reed Block Assemly Upper Roller Bering 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. 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. Inspect reed lock neoprene surfce for wer, cuts or rsions. Replce reed lock(s) s required. 3. Check for chipped nd roken reeds Allowle reed opening is in. (0.51 mm) or less. Replce reeds if either reed is stnding open more thn in. (0.51 mm). Pge 4A R1 JANUARY 1999

33 End Bering Bleed System Connecting Rods 1. Check ruer leed hoses. Replce ny hose tht is crcked, cut or deteriorting. 2. Check opertion of lower end cp check vlve. If vlve is working properly, ir cn e drwn thru check vlve one wy only. If ir cn pss thru check vlve oth wys, vlve is not working properly nd must e replced. 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 in. (0.051 mm) 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). -Pitting 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. -Splling R1 JANUARY 1999 Pge 4A-33

34 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) Chtter Mrks Between Arrows 7. Uneven Wer: Uneven wer could e cused y ent connecting rod. -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 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. Pge 4A R1 JANUARY 1999

35 IMPORTANT: Clen connecting rod just enough to clen up ering surfces. DO NOT continue to clen fter mrks re removed from ering surfces. Thermostts 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. 1. Inspect thermostt covers nd cylinder hed covers (thermostt opening) for crcks nd corrosion dmge tht could cuse lekge. Replce prts s necessry. 2. Remove nd discrd gsket from ech thermostt. 3. 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. 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 F (60-63 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 R1 JANUARY 1999 Pge 4A-35

36 NOTE: BE SURE tht wter in thermostt tester is llowed to cool sufficiently [elow 130 F (56 C)] efore testing the other thermostt 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 30 I. ft. (41 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 30 I. ft. (41 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. Pge 4A R1 JANUARY 1999

37 2. Reinstll retining ring using suitle pir of Snp Ring Pliers. d e c Crnkshft -Crnkshft Bll Bering c -Suitle Mndrel d-press e -Retining Ring R1 JANUARY 1999 Pge 4A-37

38 3. If removed, spred new crnkshft seling rings just enough to slide over crnkshft journl. 4. Use Piston Ring Expnder ( ) nd instll crnkshft seling rings into groove Crnkshft Seling Rings Luricte center min crnkshft roller erings nd rces with light oil Cycle Outord Oil ( A24) Instll so LARGER of the 3 holes is towrd DRIVE SHAFT end of crnkshft -Verify retining ring ridges the seprting lines of the ering rce Pge 4A R1 JANUARY 1999

39 6. Plce center min crnkshft roller erings on upper nd lower min ering journls s shown. 7. Instll center min ering rces s shown. 8. Secure center min ering rces together with retining rings. Mke sure retining ring ridges the seprting lines of the ering rce. FLYWHEEL END DRIVE SHAFT END Center Min Bering Rces Instll oil sels into lower end cp s follows:. Apply thin ed of Loctite 271 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 2-4-C w/teflon ( A12). e. Luricte O-ring sel surfce on end cp with 2 cycle oil. Instll O-ring over lower end cp. 7 Loctite 271 ( ) 14 2 Cycle Outord Oil ( A24) C With Teflon ( A12) -Oil Sel -O-ring R1 JANUARY 1999 Pge 4A-39

40 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 2-4-C w/teflon ( A12). d. Luricte O-ring sel surfce on end cp with Quicksilver 2-4-C w/teflon ( A12). Instll O-ring on end cp Loctite 271 ( ) C With Teflon ( A12) c Crnkshft Instlltion SPECIAL INFORMATION -Oil Sel -Lip of End Cp c -O-ring 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. Pge 4A R1 JANUARY 1999

41 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. -Dowel Pins Position ll crnkshft sel ring gps stright up. 4. Align hole in ech center min ering rce with dowel pin. 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. 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 c 14 2 Cycle Outord Oil ( A24) -Dowel Pin -Upper End Cp c -Lower End Cp R1 JANUARY 1999 Pge 4A-41

42 Piston nd Connecting Rod Ressemly 1. Plce needle erings on clen piece of pper nd luricte with Quicksilver 2-4-C w/teflon Mrine Luricnt. NOTE: There re 29 needle erings per piston. 2. Plce sleeve which is prt of piston pin tool ( A1) into connecting rod nd instll needle erings round sleeve s shown. 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 Sleeve (Prt of Tool Assy A1) -Locting Wshers Insert piston pin tool ( A1) nd push sleeve out of piston. Keep piston pin tool in piston. 5. Use mllet nd tp piston pin into piston nd push piston pin tool out. c d Piston Pin Tool ( A1) -Sleeve c -Piston Pin d-piston Pin Tool Pge 4A R1 JANUARY 1999

43 6. Instll new piston pin lockrings (one ech end of piston pin) with Lockring Instlltion Tool ( A1). 7. Mke sure lockrings re properly seted in piston grooves Lockring Instlltion Tool ( A1) -Lockring Piston nd Piston Ring Comintions 153 CU. IN. (2508 cc) MODELS All 153 cu. in. (2508 cc) models hve two hlf keystone (hlf tpered) rings. Pistons with two hlf keystone (hlf tpered) rings in. (1.4 mm) in. (1.4 mm) -Hlf Keystone (hlf tpered) Piston Ring -Enlrged View of Piston Ring Grooves R1 JANUARY 1999 Pge 4A-43

44 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. (12.7 mm) 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 in. to in. (0.25 mm to 0.45 mm). If end gp is greter, check other piston rings in cylinder ore, until rings (within tolernce) re found. IMPORTANT: Piston ring side with dot or letter must e fcing up. e c d f -Piston Ring -Dots (Fces Up) c -Feeler Guge d-ring End Gp e -Dot or Letter f -Piston Ring Use Piston Ring Expnder ( ) 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. 5. Luricte piston, rings nd cylinder wll with 2-Cycle Outord Oil. -Piston Ring Expnder -Dot Side Up on Piston Ring Rotte ech piston ring so end of ring is ligned with locting pin s shown. 7. Instll Piston Ring Compressor. Pge 4A R1 JANUARY 1999

45 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 str- ord side of engine nd the word UP towrd top of engine. 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. CYL 2 UP P CYL 1 UP S 14 CYL 4 UP P CYL 3 UP S CYL 6 UP P CYL 5 UP S Cycle Outord Oil ( A24) 10. Apply Quicksilver 2-4-C w/teflon 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. NOTE: If you still feel the frcture point, discrd the rod. 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. (41 N m). Turn ech olt n dditionl 90 fter 2nd torque is ttined. Recheck lignment etween rod cp nd rod s shown C With Teflon ( A12) -Connecting Rod Screws R1 JANUARY 1999 Pge 4A-45

46 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 End View Correct End View Incorrect- Not Aligned End View Incorrect-Cp on Bckwrds Ä Ä Ä ÄÄ ÄÄ ÄÄ ÄÄ ÄÄ 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 1. Thoroughly remove ll oil from mting surfces of crnkcse cover nd cylinder lock with Loctite 7649 Primer ( ). 2. Instll gsket strips into grooves in crnkcse cover. Trim end of ech gsket strip flush with edge of cover s shown. -Gsket Strips -Edge of Cover Pge 4A R1 JANUARY 1999

47 3. Apply thin, even cot of Loctite Mster Gsket #203 on mting surfces of crnkcse cover nd cylinder lock. 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. 8 7 d 1 4 e Loctite Mster Gsket ( ) -Loctite Mster Gsket ( ) -Upper End Cp Bolts Torque to 150 l. in. (17 N m) c -Lower End Cp Bolts Torque to 80 l. in. (9 N m) d-add Light Oil to Threds nd Bolt Fce 8 Bolts (3/8 in.-18) Torque to 38 l. ft. (51.5 N m) e -Bolts (5/16 in.-18) Torque to 180 l. in. (20 N m) c R1 JANUARY 1999 Pge 4A-47

48 Assemly of Reed Blocks to Intke Mnifold -Torque to 105 l. in. (12 N m) Assemly of Exhust Divider Plte to Block 1. Plce exhust divider sel into slot in lock. 2. Instll exhust divider plte with gsket. 3. Clen olt threds with Loctite 7649 Primer ( ). 4. Apply Loctite 271 to olt threds nd torque olts to 16.5 I. ft. (22 Nm). 5. Torque exhust divider plte olts in following sequence. Torque olts to 16.5 l. ft. (22 N m). Add Loctite 271 to threds d c -Divider Sel -Exhust Divider Plte c -Gsket d-attching Bolt Pge 4A R1 JANUARY 1999

49 6. If removed, instll wter pressure relief vlve components s shown. Torque olts to specifictions Cover 2 -Bolt l. in. (17 N m) 3 -Gsket 4 -Relief Vlve Plte 5 -Diphrgm 6 -Wter Deflector 7 -Wsher 8 -Screw - 25 l. in. (3 N m) 9 -Spring 10 - Poppet Vlve 11 - Grommet 12 - Crrier 13 - Wsher R1 JANUARY 1999 Pge 4A-49

50 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 30 I. ft. (41 N m) then turn n dditionl Instll thermostt ssemly into ech cylinder hed. 3. Instll overhet temperture sensor into STARBOARD cylinder hed elow #1 sprk plug c f d c e g h i j Elow (Strord) -St-strp c -Hose d-elow (Port) e -Bolt [Torque to 30 l. ft. (41 N m) nd then turn 90 ] f -Bolt [Torque to 17 l. ft. (23.0 N m)] g-cover h-gsket i -Thermostt (143 ) j -Temperture Sensor (Strord) k -Bolt [Torque to 17 l. ft. (23.0 N m)] l -Retiner k l NOTE: The temperture sender provides continuous temperture informtion to the ECU while the engine is running. Should temperture rech pproximtely 221 F (104.5 C), the ECU will ctivte wrning horn nd wrning light. Pge 4A R1 JANUARY 1999

51 4. Thermostt nd temperture sensor instlled Thermostt (143 F 61.7 C) -Overhet Temperture Sensor NOTE: When instlling thermostt hoses, secure strord to port thermostt hose () with st-strps () to prevent hose from eing cut y lterntor/ir compressor elt. Reinstlling Engine Components Reinstll the following engine components: Section 2 Strter Motor Electronic Control Module Ignition Coil Strter Solenoid Alterntor Flywheel Section 3 Direct Fuel Injection Fuel Pump On-Bord Oil Tnk Oil Pump Section 7 Shift Cle Ltch Assemly Control Cle Anchor Brcket R1 JANUARY 1999 Pge 4A-51

52 Throttle Lever nd Shift Shft A C w/teflon ( A12) A Tighten nd ck off 1/2 turn Pge 4A R1 JANUARY 1999

53 Throttle Lever nd Shift Shft REF. TORQUE NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 THROTTLE CONTROL LEVER 2 1 SCREW ( x 1-3/4 IN.) BUSHING 4 1 WASHER 5 1 WASHER 6 1 SCREW (2-1/8 IN.) 7 1 NUT (1/4-20) 8 1 CAP 9 1 INSERT 10 1 WASHER 11 1 NUT CAM 13 1 BUSHING 14 1 SCREW (M6 x 40) SWIVEL BUSHING 16 1 THREADED BALL Drive Tight 17 1 LINK 18 1 ROLLER 19 1 THROTTLE ROLLER 20 1 SCREW (M5 x 16) Drive Tight 21 1 WASHER 22 1 STAR WASHER 23 1 ANCHOR BRACKET 24 1 LATCH 25 2 SCREW-Drive 26 1 CAP 27 1 WEAR PLATE 28 1 LATCH 29 1 WASHER 30 1 NUT 31 3 SCREW ( x 7/8) GUIDE BLOCK 33 1 SPRING 34 1 LINK ROD ASSEMBLY 35 1 SHIFT SHAFT ASSEMBLY 36 1 ROLL PIN 37 1 SHIFT SHAFT LEVER UPPER 38 1 BUSHING 39 1 WAVE WASHER 40 1 WASHER 41 1 NUT 42 1 IDLE STABILIZING SHIFT KIT 43 2 SCREW (6-32) WASHER R1 JANUARY 1999 Pge 4A-53

54 Powerhed Instlltion on Driveshft Housing 1. Instll Lifting Eye ( ) into flywheel. WARNING BE SURE tht Lifting Eye is threded into flywheel s fr s possile 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 drive shft housing gsket surfce of powerhed. 3. Plce new gsket round powerhed studs nd into position on se of powerhed. IMPORTANT: DO NOT pply luricnt to top of driveshft s this will prevent driveshft from fully engging into crnkshft. 4. Apply smll mount of 2-4-Cw/Teflon Mrine Luricnt ( A12) onto driveshft splines. 5. Use hoist to lower powerhed onto driveshft housing. It my e necessry to turn flywheel (ligning crnkshft splines with driveshft splines) so tht powerhed will e fully instlled. 6. Instll 10 flt wshers nd10 locknuts which secure powerhed to exhust extension plte/driveshft housing. Torque locknuts in 3 progressive steps until secured. 7. Disconnect hoist from Lifting Eye nd remove Lifting Eye from flywheel. 8. Reinstll plstic cp into center of flywheel cover Lifting Eye ( ) -Powerhed Attching Locknuts nd Flt Wshers Torque Nuts to 20 l. ft. (27 N m) 9. Instll fuel cooler inlet nd outlet wter hoses to fittings on exhust dptor plte nd poppet vlve cover. Instll ir hose from port fuel ril to fitting on exhust dptor plte. Secure ll hoses with st-strps. Pge 4A R1 JANUARY 1999

55 10. Instll thermostt cover hose to exhust dptor plte. c d Fuel Cooler Outlet Wter Hose -Fuel Cooler Inlet Wter Hose c -Air Hose d-thermostt Cover Hose 11. Instll 4 olts securing ottom cowl hlves nd instll ottom cowling Bolt R1 JANUARY 1999 Pge 4A-55

56 12. Reconnect input fuel line. 13. Reconnect BLUE nd GREEN trim hrness leds to trim solenoids. -Hose Clmp -Fuel Line c -Trim Solenoids c 14. Reconnect remote control hrness to powerhed hrness connector nd wires s shown. BLU/WHT GRN/WHT TAN BRN/WHT BLU/WHT GRN/WHT -Power Trim Connections Pge 4A R1 JANUARY 1999

57 15. Reconnect wrning guge hrness e c d c d f -TAN/BLACK -TAN/WHITE c -PINK/LT. BLUE to PINK/LT. BLUE d-orange e -St-Strps f -Connect PURPLE to 12 Volt Source or Adjcent Guge IMPORTANT: Sufficient slck must exist in engine wiring hrness, ttery cles, fuel hose, nd oil hoses routed etween clmp nd engine ttchment point, to relieve stress nd prevent hoses from eing kinked or pinched. 1. Plce the clmp over the wiring, hoses, nd control cles s shown. ÇÇ ÇÇ ÇÇ ÇÇ ÇÇÇ ÇÇÇÇ ÉÉÉ ÉÉÉ c ÇÇ ÉÉ e d g f -Bttery Cles -Remote Wiring Hrness c -Wrning Guge Wiring Hrness d-control Cles e -Oil Hose with Blue Stripe f -Fuel Hose g-oil Hose R1 JANUARY 1999 Pge 4A-57

58 2. Fsten clmp together with two screws. 3. Slide outord shift lever into neutrl position. 4. Instll shift cle nd secure with spring, nylon wer plte, flt wsher, ltch nd lock nut. Instll throttle cle nd secure with ltch. -Shift Cle -Throttle Cle Brek-ln Procedure FUEL REQUIREMENTS Refer to Section 2 of this Service Mnul Timing/ Synchronizing/Adjusting for engine set-up procedures. CAUTION Severe dmge to the engine cn result y not complying with the Engine Brekin Procedure. Do not use pre-mixed gs nd oil in this engine. Use stright gsoline during engine rek-in nd fter engine rek-in. The ECM is progrmmed to signl the oil pump to provide dditionl oil (50:1 rtio) during the first 120 minutes of opertion. The ECM will monitor this period through its own internl clock. At the end of this period, the ECM will signl the oil pump to go to stndrd rtio of 300 idle nd W.O.T. INITIATING ENGINE BREAK-IN SEQUENCE Refer to Section 3C for proper procedures. ENGINE BREAK-IN PROCEDURE (ALL MODELS) 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. Pge 4A R1 JANUARY 1999