High Performance Models) Assembly of Reed Blocks to Intake Manifold (Standard and High Performance

Transcription

1 POWERHEAD 4 A 51804

2 Tle of Contents Pge Powerhed Specifictions Specil Tools Powerhed Repir Stnd Cylinder Block nd End Cps Exhust Mnifold nd Exhust Plte Reed Block nd Cylinder Hed Crnkshft, Pistons nd Connecting Rods Torque Sequence Generl Informtion Powerhed Removl from Driveshft Housing Removing Engine Components Powerhed Disssemly Wter Pressure Relief Vlve Components Torque Specifictions Clening nd Inspection Cylinder Block nd Crnkcse Cover Specil Service Informtion Cylinder Bores Honing Procedure Pistons nd Piston Rings Clening Piston Ring Grooves Mesuring Piston Roundness Cylinder Heds nd Exhust Divider Plte Crnkshft Crnkshft (nd End Cp) Berings Reed Block Assemly Reed Block Housing Connecting Rods Thermostts Powerhed Ressemly nd Instlltion Generl Crnkshft Instlltion Specil Informtion Pge Piston nd Connecting Rod Ressemly Piston nd Piston Ring Comintions Piston Instlltion (Stndrd nd High Performnce Models) Crnkcse Cover Instlltion (Stndrd nd High Performnce Models) Assemly of Reed Blocks to Intke Mnifold (Stndrd nd High Performnce Models) Assemly of Exhust Divider Plte to Block (Stndrd nd High Performnce Models) Cylinder Hed Instlltion (Stndrd nd High Performnce Models) Bleed Line Routing (Crureted Models) Front View Port Side View Strord Side View Bleed Line Routing (Fuel Injected Models) Front View Port Side View Strord Side View Reinstlling Engine Components Notes: Throttle Lever nd Shift Shft Powerhed Instlltion on Driveshft Housing Brek-ln Procedure Brek-in Fuel Mixture Gsoline/Oil Mixing Rtio Chrt Engine Brek-in Procedure (All Models) A-0 - POWERHEAD R3 JUNE 2002

3 Powerhed Specifictions Block Type V, 2 Cycle Displcement 135 nd cu. in. (2.0 Litre) 175, XR6/Mg III, cu. in. (2.5 Litre) Reed Vlve Opening Reed Stnd Open (Mx.) in. (0.50 mm) Cylinder Bore (105 Jet, 135, 150) Di. Stndrd in. ( mm) Di..015 in. Oversize in. ( mm) Di..030 in. Oversize in. ( mm) (140 Jet, 175, XR6/Mg III, 200, 150XRI, 175XRI, 200XRI, Pro Mx/Super Mgnum 150, 200, 225) Di. Stndrd in. ( mm) Di..015 in. Oversize in. ( mm) Tper/Out of Round Mx in. (0.152 mm) Piston (105 Jet, 135, 150) Di. Stndrd Di..015 in. Oversize. Di..030 in. Oversize in. ±.002 in. ( mm ±.051 mm) in. ±.002 in. ( mm ±.051 mm) in. ±.002 in. ( mm ±.051 mm) IMPORTANT: Using micrometer, mesure dimension B t loction shown. Dimension B should e.008 in. or less thn dimension A. Dimension A t Right Angle (90 ) to Piston Pin Dimension B ( in line with Piston Pin) 1/2 in. (12.7mm) (140 Jet, 175, XR6/Mg III, 200, 150XRI, 175XRI, 200XRI, Pro Mx/Super Mgnum 150, 200, 225) Di. Stndrd in. ±.001 in. ( mm ±.025 mm) Di..015 in. Oversize in. ±.001 in. ( mm ±.025 mm) Compression All Models Using fully chrged ttery, throttle shutters wide open nd cylinder lock wrm psi ( kp) Vrince etween cylinders should not exceed 15 psi (102.7 kp) R3 JUNE 2002 POWERHEAD - 4A-1

4 Specil Tools Lifting Eye Powerhed Stnd A1 Flywheel Holder Piston Ring Expnder Lockring Removl Tool A1 Protector Cp Piston Pin Tool A1 Flywheel Puller T1 4A-2 - POWERHEAD R3 JUNE 2002

5 Driver Hed Piston Ring Compressor for 2 Litre (122 cu. in.) Universl Puller Plte Piston Ring Compressor for 2.5 Litre (153 cu. in.) Snp Ring Pliers Compression Tester Lockring Instlltion Tool A 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) R3 JUNE 2002 POWERHEAD - 4A-3

6 Cylinder Block nd End Cps Loctite 271 ( ) 12 Loctite Mster Gsket ( ) Cycle Outord Oil ( A24) 51 Loctite 222 (FT2962-2) 33 Loctite 680 ( ) C With Teflon ( A12) 4A-4 - POWERHEAD R3 JUNE 2002

7 Cylinder Block nd End Cps TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 CYLINDER BLOCK (135/150) 1 CYLINDER BLOCK (XR6/MAG. IlI ) 1 1 CYLINDER BLOCK (175) 1 CYLINDER BLOCK (200) 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 COVER strter motor (UPPER) 8 2 SCREW (1-1/2 IN.) (HEX FLANGE) COVER (LOWER) 10 2 SCREW (2 IN.)(HEX HEAD FLANGE) BUSHING UPPER END CAP ASSEMBLY 14 1 O-RING 15 1 ROLLER BEARING 16 1 OIL SEAL 17 4 SCREW (1 IN.) STUD (1-7/8 IN.) 19 1 J-CLIP 20 1 PLUG Seril Numer 21 1 SPACER 22 3 WASHER 23 3 NUT IDLE CONTROL 25 3 SCREW WASHER 27 1 BRACKET 28 2 SCREW (3/4 IN.) STUD (1 IN.) 30 1 CAP 31 1 ADJUSTING SCREW 32 1 JAM NUT 33 1 LOWER END CAP 34 1 O-RING (3-1/4 IN. I.D.) 35 2 OIL SEAL 36 4 SCREW (3/4 IN.) LOCKWASHER 8 SCREW (3-1/4 IN.) SCREW (1-1/4 IN.) R3 JUNE 2002 POWERHEAD - 4A-5

8 Exhust Mnifold nd Exhust Plte A Loctite 271 ( ) 9 Loctite PST Pipe Selnt ( ) 51 Loctite 222 (FT2962-2) 86 Loctite 262 (Otin Loclly) A = TO BLOCK 4A-6 - POWERHEAD R3 JUNE 2002

9 Exhust Mnifold nd Exhust Plte TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 GASKET 1 DIVIDER PLATE (S/N-0G & BELOW) 2 1 DIVIDER PLATE (S/N-0G & UP) 3 1 SEAL 4 4 J-CLAMP 5 20 SCREW FITTING 7 1 FITTING (90 ) 8 1 HOSE (23-1/2 IN.) 9 2 STA-STRAP 10 1 COVER relief vlve 11 4 SCREW (1-1/4 IN.) GASKET 13 1 SCREW (3/4 IN.) WASHER 15 1 DIAPHRAGM 16 1 WATER DEFLECTOR 17 1 PLATE 18 1 SPRING 19 1 WASHER 20 1 POPPET 21 1 GROMMET 22 1 CARRIER 23 1 GASKET 24 1 EXHAUST PLATE 25 1 CONNECTOR (STRAIGHT) 26 2 DOWEL PIN 27 1 SEAL 28 1 BRACKET 29 8 SCREW (1/2 IN.) 30 6 WASHER 31 6 NUT BUSHING 33 1 GROMMET 34 1 GROMMET 35 1 SCREW (1-1/4 IN.) SCREW (2-1/2 IN.) SCREW (3-1/2 IN.) FRONT BRACKET ASSEMBLY WASHER (Use with 5/8 IN. ref. #39) 41 4 WASHER 42 4 GROMMET 43 1 REAR BRACKET ASSEMBLY 4 SCREW (1/2 IN.) 4 SCREW (5/8 IN.) R3 JUNE 2002 POWERHEAD - 4A-7

10 Reed Block nd Cylinder Hed Dielectric Grese ( ) Loctite PST Pipe Selnt ( ) 14 2 Cycle Outord Oil ( A24) A = TO TELL-TALE HOSE B = TO ADAPTOR PLATE 4A-8 - POWERHEAD R3 JUNE 2002

11 Reed Block nd Cylinder Hed TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 2 CYLINDER HEAD 135/ GASKET 1 2 CYLINDER HEAD XR6/ Mgnum III 2 2 GASKET CYLINDER HEAD GASKET 3 24 SCREW (2 IN.) 30 l. ft. (40.5 N m); Then Turn Additionl DOWEL PIN 5 2 GASKET 6 2 COVER 7 2 THERMOSTAT 8 4 SCREW (1 IN.) ELBOW 10 1 TEMPERATURE SENDER (STBD.) 11 1 THERMAL AIR VALVE 12 1 HOSE (12-3/4 IN.) 13 1 FITTING STA-STRAP 15 1 HOSE (11-1/2 IN.) 16 1 T-FITTING 17 1 TEMPERATURE SENSOR (PORT) (2-WIRE) 18 2 RETAINER 19 2 SCREW HOSE (7-1/2 IN.) 21 1 ADAPTOR PLATE 22 8 SCREW GASKET 24 6 REED BLOCK 25 1 J-CLAMP 26 1 CLIP 27 1 C-WASHER 28 1 SCREW SCREW (7/8 IN.) SCREW (1-1/8 IN.) R3 JUNE 2002 POWERHEAD - 4A-9

12 Crnkshft, Pistons nd Connecting Rods Loctite 271 ( ) 14 2 Cycle Outord Oil ( A24) 92 Loctite 7649 Primer ( ) C With Teflon ( A12) 4A-10 - POWERHEAD R3 JUNE 2002

13 Crnkshft, Pistons nd Connecting Rods TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 CRANKSHAFT ASSEMBLY 2 1 BALL BEARING (LOWER) 3 1 RETAINING RING 4 1 DRIVE GEAR 5 2 SCREW NUT 7 1 CARRIER ASSEMBLY 8 1 SEAL 9 7 RING seling - crnkshft 10 2 ROLLER BEARING crnkshft 11 3 PISTON (STARBOARD-STANDARD) AR AR PISTON (STARBOARD-.015 O.S.) PISTON (STARBOARD-.030 OS.) 3 PISTON (PORT-STANDARD) AR PISTON (PORT-.015 O.S.) 135/150 AR PISTON (PORT-.030 O.S.) 1 PISTON RING (STANDARD) 12 AR PISTON RING (.015 O.S.) AR PISTON RING (.030 O.S.) LOCK RING 14 6 PISTON PIN PISTON (STARBOARD-STANDARD) AR PISTON (STARBOARD-.015 O.S.) XR6 3 PISTON (PORT-STANDARD) Mgnum III AR PISTON (PORT-.015 O.S.) 175/200 1 PISTON RING (STD.) 2 PISTON RING (.015 O.S.) LOCK RING 14 6 PISTON PIN 15 6 CONNECTING ROD ASSEMBLY SCREW connecting rod WASHER needle locting 18 6 ROLLER BEARING ASSEMBLY NEEDLE BEARING piston end 1st Torque - 15 l. in. (1.5 N m) 2nd Torque - 30 l. ft. (40.5 N m) Turn olt dditionl 90 fter 2nd torque R3 JUNE 2002 POWERHEAD - 4A-11

14 Torque Sequence CRANKCASE COVER BOLTS (AND TORQUE SEQUENCE) 8 7 CYLINDER HEAD BOLTS Add light oil to threds nd olt fce: 30 l. ft. (40.5 N m) then turn n dditionl 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. (20.3 N m) EXHAUST DIVIDER PLATE BOLTS 200 l. in. (22.6 N m) Apply Loctite 271 to threds A-12 - POWERHEAD R3 JUNE 2002

15 Generl Informtion NOTE: Throughout this section, STANDARD MODELS will refer to 135/150/175/200 crureted nd EFI outords. HIGH PERFORMANCE MODELS will refer to PRO MAX nd SUPER MAGNUM 150/200/225 outords. 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, cruretors, reed locks nd cylinder heds nd checking opertion of thermostts Stndrd Models - Screws - Retiner 5. Disconnect remote oil tnk hose connector Disconnect remote control hrness from powerhed hrness connector nd wires s shown. 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 Stndrd Models f d c e Control Hrness - Powerhed Hrness c - Trim 12 Volt Power Supply (RED) d - Trim Up Led (BLUE/WHITE) e - Trim Down Led (GREEN/WHITE) f - Overhet Led (TAN) 7. Remove st-strp which secures TELL-TALE hose to fitting on lower cowl nd remove hose from fitting Screws - Retiner R3 JUNE 2002 POWERHEAD - 4A-13

16 Stndrd Models Remove BLUE, GREEN nd BLACK trim hrness leds from trim solenoids. Remove trim hrness from J-clip on exhust cover High Performnce Models c c - Blue Trim Led - Green Trim Led c - Blck Trim Led Stndrd Models Disconnect trim rely hrnesses from ech rely Blue Trim Led - Green Trim Led c - Blck Trim Led (Hidden Attches to rely mounting plte) 1996 High Performnce Models - UP Trim Rely - DOWN Trim Rely UP Trim Rely - DOWN Trim Rely Slide outord shift lever into neutrl position. 10. Remove throttle cle. 4A-14 - POWERHEAD R3 JUNE 2002

17 11. 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. Remove four olts which secure ottom cowl hlves together nd remove ottom cowling Stndrd Models h c f g - Lock Nut - Shift Cle Ltch c - Flt Wsher (Hidden) d - Nylon Wer Plte e - Spring (Hidden) f - Shift Cle g - Anchor Brcket h - Throttle Cle d e Bolts Disconnect input fuel line. - Bolts St-Strp - Fuel Line R3 JUNE 2002 POWERHEAD - 4A-15

18 1996 Stndrd Models All High Performnce Models c - Bolts Bottom Pn (The ottom pn does not hve to e removed to remove the powerhed) - Skirt c - Bolts, Wshers, Nuts (8 ech) - Bolts All Stndrd Models Remove wter hose from fitting on exhust dptor plte Wter Hose - Fitting Bolts 4A-16 - POWERHEAD R3 JUNE 2002

19 15. All High Performnce Models Remove wter hose from fitting on exhust dptor plte nd pull hose through ottom pn. 17. 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 Hose - Fittings Fittings must e turned to llow clernce for ottom pn 16. All Models Remove 10 nuts nd 10 wshers (5 ech side) from powerhed se. - Nuts nd Wshers (5 Ech Side) REMOVING ENGINE COMPONENTS Remove the following engine components: Section 2 Strter Motor Strter Motor *Ignition Switch Boxes *Ignition Coil *Strter Solenoid Voltge regultor/rectifier Flywheel *Sttor Assemly *Trigger Assemly *Low speed/high speed sprk dvnce module *Idle Stilizer Section 3 Air Silencer Cruretors nd Linkge Fuel Pump *Fuel Enrichment Vlve Fuel Injection Assemly *Wrning Module 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 R3 JUNE 2002 POWERHEAD - 4A-17

20 Powerhed Disssemly 1. Plce powerhed in repir stnd or on ench. 2. Remove thermostt covers, thermostts nd gskets. 4. Remove exhust mnifold cover nd sel. c c - Thermostt Cover - Thermostt c - Gsket 3. Remove cylinder heds from engine lock Exhust Mnifold Cover - Sel c - Gsket Remove reed lock housing from cylinder lock. c - Cylinder Hed - Gsket c - Engine Block Reed Block Housing A-18 - POWERHEAD R3 JUNE 2002

21 6. Inspect reeds s outlined in Clening nd Inspection. LOWER END CAP - Crnkcse Attching End Cp Bolts Remove olts from end cps. UPPER END CAP 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 Crnkcse Attching End Cp Bolts R3 JUNE 2002 POWERHEAD - 4A-19

22 CRANKCASE COVER REMOVED 3. Use 5/16 in. 12 point socket to remove connecting rod olts, then remove rod cp, roller erings nd ering cge from connecting rod Use Powerhed Stnd ( A1) for rotting crnkshft to desired position for removl of connecting rods. 2. Using n wl or electric pencil, scrie the cylinder identifiction numer on ech connecting rod s shown. Ressemle connecting rods in sme cylinder. - Connecting Rod Bolts Ä Ä 4. Push piston out of cylinder lock. 5. After removl, ressemle ech piston nd connecting rod ssemly. CAUTION Ech connecting rod nd end cp re mtched mchined set nd must never e mismtched Inspect pistons s outlined in Clening nd Inspection, following. 4A-20 - POWERHEAD R3 JUNE 2002

23 7. Use Piston Ring Expnder ( ) to remove piston rings. Alwys instll new piston rings. 9. Using tool ( A1), remove piston pin lockrings from oth ends of piston pin. Never re-use piston pin lockrings Using n wl, scrie identifiction numer of connecting rod on inside of piston (1). Ressemle piston on sme connecting rod. 1 - Lockring IMPORTANT: Wrming the piston dome using torch lmp will ese removl nd instlltion of piston pin. 10. Support piston nd tp out piston pin using service tool ( A1) s shown Piston Pin - Piston Pin Tool ( A1) Remove piston pin needle erings (29 per piston) nd locting wshers (2 per piston) s shown R3 JUNE 2002 POWERHEAD - 4A-21

24 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. NOTE: If roller ering is dmged, replce upper end cp nd roller erings s n ssemly. - Needle Bering Locting Wshers Remove upper end cp nd lower end cp from crnkshft. - O-Ring - Sel 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. IMPORTANT: DO NOT remove oil pump drive ger on crnkshft unless ger is dmged; i.e. crcked, ger teeth chipped or fretting, or excessive looseness. Refer to Section 3E for proper oil drive ger instlltion procedures. - Upper End Cp - Lower End Cp 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. - Seling Rings - Oil Pump Drive Ger A-22 - POWERHEAD R3 JUNE 2002

25 17. Remove retining ring s shown. 19. Remove lower ll ering from crnkshft s follows:. Remove retining ring using pir of snp ring pliers. c - Retining Ring Remove ering rce hlves nd roller erings from crnkshft. IMPORTANT: Keep sme ering rces nd roller erings together. - Crnkshft Bll Bering - Pliers c - Retining Ring Press crnkshft out of lower ll ering s shown. c - Bering Rce Hlves - Roller Berings d Inspect crnkshft ll ering s outlined in Clening nd Inspection, following. IMPORTANT: DO NOT remove crnkshft ll ering, unless replcement is required. - Press - Powerhed Stnd ( A1) c - Crnkshft Bll Bering d - Universl Puller Plte ( ) R3 JUNE 2002 POWERHEAD - 4A-23

26 Wter Pressure Relief Vlve Components If necessry, remove wter pressure relief vlve components s shown Torque Specifictions l. in. (17.0 N m) - 25 l. in. (3.0 N m) 1 - Cover 2 - Bolt 3 - Gsket 4 - Relief Vlve Plte 5 - Diphrgm 6 - Wter Deflector 7 - Wsher 8 - Screw 9 - Spring 10- Poppet Vlve 11- Crrier 12- Grommet 13- Wsher 4A-24 - POWERHEAD R3 JUNE 2002

27 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 crnk- shft nd the new seling rings on crnkshft do not line up with existing grooves in cylinder lock. If instlling new crnkshft, refer to crnkshft instlltion, Powerhed Ressemly section to determine if powerhed cn e used. Cylinder Bores 1. Inspect cylinder ores for scoring, scuffing or trnsfer of luminum from piston to cylinder wll. Scoring or scuffing, if NOT TOO SEVERE, cn normlly e removed y honing. If trnsfer of luminum hs occurred, n cidic solution such s TIDY BOWL CLEANER should e pplied to the res of the cylinder ore where trnsfer of luminum hs occurred. After the cidic solution hs removed the trnsferred luminum, thoroughly flush the cylinder ore(s) to remove ny remining cid. Cylinder wlls my now e honed to remove ny glze nd to id in the seting of new piston rings. CAUTION It crnkcse cover or cylinder lock is to e sumerged in very strong clening solution, it will e necessry to remove the crnkcse cover/cylinder lock leed system from crnkcse cover/cylinder lock to prevent dmge to hoses nd check vlves. 1. Thoroughly clen cylinder lock nd crnkcse cover. Be sure tht ll selnt nd old gskets re removed from mtching surfces. Be sure tht cron deposits re removed from exhust ports. 2. Inspect cylinder lock nd crnkcse cover for crcks or frctures. 3. Check gsket surfces for nicks, deep grooves, crcks nd distortion tht could cuse compression lekges. 4. Check ll wter nd oil pssges in cylinder lock nd crnkcse cover to e sure tht they re not ostructed nd tht plugs re in plce nd tight. 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 R3 JUNE 2002 POWERHEAD - 4A-25

28 d. Loclize stroking in the smllest dimeter until drill speed is constnt throughout length of ore. Expnd stones, s necessry, to compenste for stock removl nd stone wer. Stroke t rte of 30 complete cycles per minute to produce est cross-htch pttern. Use honing oil generously. e. Thoroughly clen cylinder ores with hot wter nd detergent. Scru well with stiff ristle rush nd rinse thoroughly with hot wter. A good clening is essentil. If ny of the rsive mteril is llowed to remin in the cylinder ore, it will cuse rpid wer of new piston rings nd cylinder ore in ddition to erings. After clening, ores should e swed severl times with engine oil nd clen cloth, then wiped with clen, dry cloth. Cylinders should not e clened with kerosene or gsoline. Clen reminder of cylinder lock to remove excess mteril spred during honing opertion. 2. Hone ll cylinder wlls just enough to de-glze wlls. 3. Mesure cylinder ore dimeter (with snp guge micrometer) of ech cylinder, s shown elow. Check for tpered, out-of-round (eggshped) nd oversize ore. 135 nd 150 (crureted) Models Models 135 nd 150 with Stndrd Piston 135 nd 150 with.015 in. (0.381mm) Oversize Piston 135 nd 150 with.030 in. (0.762mm) Oversize Piston Cylinder Block Finish Hone in. (79.375mm) in. (79.756mm) in. (80.137mm) 175, XR6, Mgnum III, 150 EFI nd 200 Models Models 175, XR6, Mg. III, 150 EFI nd 200 with Stndrd Piston 175, XR6, Mg. III, 150 EFI nd 200 with.015 in. (0.381mm) Oversize Piston Cylinder Block Finish Hone in. (88.93mm) in. (89.31mm) 4. If cylinder ore is tpered, out-of-round or worn more thn.003 in. (0.076 mm) from stndrd Cylinder Block Finish Hone dimeter (refer to chrt, preceding), it will e necessry to re-ore tht cylinder(s) to.015 in. (0.381mm) or.030 in. (0.762mm) 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 A-26 - POWERHEAD R3 JUNE 2002

29 Pistons nd Piston Rings IMPORTANT: If engine ws sumerged while engine ws running, piston pin nd/or connecting rod my e ent. If piston pin is ent, piston must e replced. (Piston pins re not sold seprtely ecuse of mtched fit into piston.) If piston pin is ent, connecting rod must e checked for strightness (refer to Connecting Rods, following, for checking strightness). 1. Inspect pistons for scoring nd excessive piston skirt wer. 2. Check tightness of piston ring locting pins. Locting pins must e tight. 3. Thoroughly clen pistons. Crefully remove cron deposits from pistons, with soft wire rush or cron remove solution. Do not urr or round off mchined edges. Inspect piston ring grooves for wer nd cron ccumultion. If necessry, scrpe cron from piston ring grooves eing creful not to scrtch sides of grooves. Refer to procedure following for clening piston ring grooves. CLEANING PISTON RING GROOVES NOTE: Clening instructions differ etween the rectngulr ring groove nd keystone (tpered) ring groove. Pistons my hve two keystone ring grooves or one keystone ring groove nd one rectngulr ring groove s shown. Rectngulr ring grooves A roken rectngulr piston ring cn e used s tool for scrping cron from ring grooves. Crefully scrpe cron from ring grooves without scrtching the side surfces of grooves. Keystone (tpered) ring grooves 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 one keystone (tpered) ring on top nd one rectngulr ring on ottom (135 & 150 crureted Models) Enlrged View of Piston Ring Grooves Piston with two hlf keystone (hlf tpered) rings (XR6, Mg III,175, 200 nd ll EFI Models) Enlrged View of Piston 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 R3 JUNE 2002 POWERHEAD - 4A-27

30 MEASURING PISTON ROUNDNESS Piston hs rrel profile shpe nd is not true dimeter. Stndrd 135 nd 150 (crureted) Models cu. in. (1999cc) 1. Using micrometer, mesure dimension A t loction shown. Dimension A should e s indicted in chrt following. Piston Stndrd Piston Dimension A in. ±.002 in..015 in. Oversize Piston in. ±.002 in..030 in. Oversize Piston in. ±.002 in. 2. Using micrometer, mesure dimension B t loction shown. Dimension B should e within.008 in. of dimension A. Stndrd 175, XR6, Mgnum III, 150 EFI, 200 EFI Models nd High Performnce Pro Mx/Super Mgnum 150, 200, 225 Models cu. in. (2508 cc) 1. Using micrometer, mesure dimension A t loction shown. Dimension A should e s indicted in chrt following. Piston Stndrd Piston Dimension A in. ± in..015 in. Oversize Piston in. ± in. 2. Using micrometer, mesure dimension B t loction shown. Dimension B should e within in. of dimension A. 29/32 in. (23mm) 1/2 in. (12.7mm) - Dimension A t RIGHT Angle (90 ) to Piston Pin - Dimension B (in line with Piston Pin) - Dimension A t Right Angle (90 ) to Piston Pin - Dimension B (in line with Piston Pin) Cylinder Heds nd Exhust Divider Plte 1. Inspect internl surfce of cylinder heds for possile dmge (s result of piston or foreign mteril striking cylinder heds). IMPORTANT: Cylinder hed wrpge should not exceed in. (0.1mm) over the ENTIRE length of the cylinder hed. If mesured wrpge, s determined on surfce lock, exceeds in. (0.1mm) 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. (0.25mm). 2. Replce cylinder hed(s) s necessry. 3. Thoroughly clen gsket surfces of exhust divider plte. 4. Inspect exhust divider plte for deep grooves, crcks or distortion tht could cuse lekge. Replce prts s necessry. 4A-28 - POWERHEAD R3 JUNE 2002

31 Crnkshft 1. Inspect crnkshft to drive shft splines for wer. (Replce crnkshft, if necessry.) 2. Check crnkshft for strightness. (Replce s necessry.) 3. Inspect crnkshft oil sel surfces. Seling surfces must not e grooved, pitted or scrtched. (Replce s necessry.) 4. Check ll crnkshft ering surfces for rust, wter mrks, chtter mrks, uneven wer nd/or overheting. (Refer to Connecting Rods.) 5. If necessry, clen crnkshft surfces with crocus cloth. Crnkshft (nd End Cp) Berings 1. After clening crnkshft, grsp outer rce of crnkshft ll ering (instlled on lower end of crnkshft) nd ttempt to work rce ck-ndforth. There should not e excessive ply. 2. Luricte ll ering with light oil. Rotte outer ering rce. Bering should hve smooth ction nd no rust stins. If ll ering sounds or feels rough or hs ctches, remove nd discrd ering. (Refer to Powerhed Removl nd Disssemly - Crnkshft Removl nd Disssemly ). Lower Bll Bering c c 3. Thoroughly clen (with solvent) nd dry crnk-shft center min roller erings. Luricte erings with 2-Cycle Outord Oil. - 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. CAUTION DO NOT intermix hlves of upper nd lower crnk- shft center min roller erings. Replce erings in pirs only. 4. Thoroughly inspect center min roller erings. Replce erings if they re rusted, frctured, worn, glled or dly discolored. Center min Roller Bering 5. Clen (with solvent) nd dry crnkshft roller ering tht is instlled in upper end cp. Luricte ering with light oil. 6. Thoroughly inspect upper end cp roller ering. If roller ering is rusted, frctured, worn, glled, dly discolored or loose inside of end cp replce end cp nd roller ering s n ssemly. Upper Roller Bering R3 JUNE 2002 POWERHEAD - 4A-29

32 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. 1. Thoroughly clen gsket surfces of reed locks nd reed lock housing. Check for deep grooves, crcks nd distortion tht could cuse lekge. Replce prts s necessry. 2. Check for wer (indenttions) on fce of ech reed lock. Replce lock(s), if reeds hve mde indenttions. 3. Check for chipped nd roken reeds. 3. Check tht leed system check vlves re pressed tight into reed housing. 4. Inspect pssges in reed lock housing to e sure tht they re not ostructed Allowle reed opening is in. (0.51mm) or less. Replce reeds if either reed is stnding open more thn in. (0.51mm). Reed Block Housing 1. Check ruer leed hoses. Replce ny hose tht is crcked, cut or deteriorting. 2. Check opertion of leed system check vlves in reed lock housing. If vlves re working properly, ir cn e drwn thru check vlves one wy only. If ir cn pss thru check vlve oth wys, vlve is not working properly nd must e replced. Connecting Rods 1. Check connecting rods for lignment y plcing rods on surfce plte. If light cn e seen under ny portion of mchined surfces, if rod hs slight wole on plte, or if in. (0.051mm) feeler guge cn e inserted etween ny mchined surfce nd surfce plte, rod is ent nd must e discrded. 2. Overheting: Overheting is visile s luish ering surfce color tht is cused y indequte luriction or excessive RPM. 3. Rust: Rust formtion on ering surfces cuses uneven pitting of surfce(s). - Pitting A-30 - POWERHEAD R3 JUNE 2002

33 4. Wter Mrks: When ering surfces re sujected to wter contmintion, ering surfce etching occurs. This etching resemles the size of the ering. 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) 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. - Chtter Mrks Between Arrows Uneven Wer: Uneven wer could e cused y ent connecting rod. - 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 wshord. In some instnces, the connecting rod crnk pin ore ecomes highly polished. During opertion, - 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. (9.5mm) 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 R3 JUNE 2002 POWERHEAD - 4A-31

34 IMPORTANT: Clen connecting rod just enough to clen up ering surfces. DO NOT continue to clen fter mrks re removed from ering surfces 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. 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. NOTE: BE SURE tht wter in thermostt tester is llowed to cool sufficiently [elow 130 F (56 C)] efore testing the other thermostt. Thermostts 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 A-32 - POWERHEAD R3 JUNE 2002

35 Powerhed Ressemly nd Instlltion Generl Before proceeding with powerhed ressemly, e sure tht ll prts to e re-used hve een crefully clened nd thoroughly inspected, s outlined in Clening nd Inspection, preceding. Prts, which hve not een properly clened (or which re questionle), cn severely dmge n otherwise perfectly good powerhed within the first few minutes of opertion. All new powerhed gskets MUST BE instlled during ressemly. During ressemly, luricte prts with Quicksilver 2-Cycle Outord Luricnt whenever light oil is specified. Quicksilver prt numers of luricnts, selers nd locking compounds nd tools re listed in Powerhed Generl Informtion, preceding. A torque wrench is essentil for correct ressemly of powerhed. DO NOT ttempt to ressemle powerhed without using torque wrench. Attching olts for covers, housings nd cylinder heds MUST BE torqued y tightening olts in 3 progressive steps (following specified torque sequence) until specified torque is reched (see Exmple, following). EXAMPLE: If cylinder hed ttching olts require torque of 40 I. ft. (54.0 N m), ) tighten ll olts to 10 I. ft. (13.5 N m), following specified torque sequence, ) tighten ll olts to 20 I. ft. (27.0 N m), following torque sequence, then finlly c) tighten ll olts to 40 I. ft. (54.0 N m), following torque sequence. 1. If removed, press lower crnkshft ll ering onto crnkshft s shown. Be sure ering is pressed firmly ginst counterweight. - Crnkshft - Crnkshft Bll Bering c - Suitle Mndrel d - Press d c Reinstll retining ring using suitle pir of Snp Ring Pliers. - Retining Ring R3 JUNE 2002 POWERHEAD - 4A-33

36 3. If removed, spred new crnkshft seling rings just enough to slide over crnkshft journl. 5. Luricte center min crnkshft roller erings nd rces with light oil. - Crnkshft Seling Rings Use Piston Ring Expnder ( ) nd instll crnkshft seling rings into groove 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 6. Plce center min crnkshft roller erings on upper nd lower min ering journls s shown. 7. Instll center min ering rces s shown. FLYWHEEL END DRIVE SHAFT END A-34 - POWERHEAD R3 JUNE 2002

37 8. Secure center min ering rces together with retining rings. Mke sure retining ring ridges the seprting lines of the ering rce. - Center min Bering Rces Instll oil sels into lower end cp s follows:. Apply thin ed of Loctite 271 (otin loclly) 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. - O-ring 10. Instll oil sel into upper end cp s follows: Apply thin ed of Loctite 271 (otin loclly) 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. - Oil Sel - Lip of End Cp - Oil Sel - O-ring R3 JUNE 2002 POWERHEAD - 4A-35

38 Crnkshft Instlltion SPECIAL INFORMATION Instlling A New Crnkshft Assemly Into Cylinder Block Check the crnkshft seling ring mting surfces in the cylinder lock nd crnkcse cover for wer grooves tht were cused y the crnkshft seling rings from the previous crnkshft. If wer grooves re present, the seling rings on the new crnkshft will hve to fit into the grooves without inding the crnkshft. Before instlling crnkshft, remove ny urrs tht my exist on groove edges. Luricte seling rings with light oil nd instll new crnkshft s instructed. Instll upper nd lower end cps nd then inspect fit etween seling rings nd grooves. Temporrily instll crnkcse cover nd rotte crnkshft severl times to check if seling rings re inding ginst crnkshft. (You will feel drg on the crnkshft.) If seling rings re inding, recheck grooves for urrs. If this does not correct the prolem, it is recommended tht the cylinder lock e replced. Instll crnkshft s follows: 1. Luricte crnkshft seling rings with light oil. 2. Check cylinder lock to e sure tht dowel pins re in plce. 5. Gently push crnkshft down into position mking sure tht the dowel pins re lined up with the holes in center min erings nd crnkshft sel rings re in plce. - Dowel Pin Luricte crnkshft ends (oil sel res) with light oil, then instll upper nd lower end cps ( nd ). Secure end cps to cylinder lock with ttching olts. DO NOT tighten end cp olts t this time. - Upper End Cp - Lower End Cp Dowel Pins Position ll crnkshft sel ring gps stright up. 4. Align hole in ech center min ering rce with dowel pin. 4A-36 - POWERHEAD R3 JUNE 2002

39 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 ( A12). 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. 4. Insert piston pin tool ( A1) nd push sleeve out of piston. Keep piston pin tool in piston. - Piston Pin Tool ( A1) - Sleeve Sleeve (Prt of Tool Assy A1) Use mllet nd tp piston pin into piston nd push piston pin tool out. 3. Plce locting wshers on connecting rod. IMPORTANT: Position connecting rod prt numer fcing towrds flywheel. Crefully position piston over end of rod. Mke sure locting wshers remin in plce. - Piston Pin - Piston Pin Tool Locting Wshers Instll new piston pin lockrings (one ech end of piston pin) with Lockring Instlltion Tool ( A1) R3 JUNE 2002 POWERHEAD - 4A-37

40 7. Mke sure lockrings re properly seted in piston grooves Lockring Instlltion Tool ( A1) - Lockring Lockring Instlltion Tool 4A-38 - POWERHEAD R3 JUNE 2002

41 Piston nd Piston Ring Comintions 122 CU. IN. (1999cc) MODELS All 122 cu in. (1999cc) models hve one keystone (tpered) ring on top nd one rectngulr ring on ottom. Piston with one keystone (tpered) ring on top nd one rectngulr ring on ottom.093 in. c.063 in. - Keystone (tpered) Piston Ring - Rectngulr Piston Ring c - Enlrged View of Piston Ring Grooves 153 CU. IN. (2508cc) MODELS All 153 cu. in. (2508cc) models hve two hlf keystone (hlf tpered) rings. Pistons with two hlf keystone (hlf tpered) rings.056 in..056 in. - Hlf Keystone (hlf tpered) Piston Ring - Enlrged View of Piston Ring Grooves R3 JUNE 2002 POWERHEAD - 4A-39

42 Piston Instlltion (Stndrd nd High Performnce Models) 1. Before instlling new piston rings, check gp etween ring ends y plcing ech ring in its respective cylinder, then pushing ring out 1/2 in. (12.7mm) into cylinder using piston to ssure proper position. 2. Check end gp of ech new piston ring with feeler guge. End gp must e within.018 in. to.025 in. (0.45mm to 0.64mm). If end gp is greter, check other piston rings in cylinder ore, until rings (within tolernce) re found. 5. Luricte piston, rings nd cylinder wll with 2-Cycle Outord Oil Piston Ring Expnder - Dot Side Up on Piston Ring 6. Rotte ech piston ring so end of ring is ligned with locting pin s shown. 7. Instll Piston Ring Compressor. c d 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. - Piston Ring - Dots (Fces Up) c - Feeler Guge d - Ring End Gp 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. IMPORTANT: Piston ring side with dot or letter must e fcing up. CYL 2 UP P CYL 1 UP S - Dot or Letter - Piston Ring CYL 4 UP P CYL 3 UP S 3. Use Piston Ring Expnder ( ) nd instll piston rings (dot side up) on ech piston. Spred rings just enough to slip over piston. CYL 6 UP P CYL 5 UP S 4. Check piston rings to e sure tht they fit freely in ring groove. 4A-40 - POWERHEAD R3 JUNE 2002

43 9. Cot cylinder ore with 2-cycle oil. Mtch piston ssemly with cylinder it ws removed from, nd position piston s descried elow. Push piston into cylinder. 12. Tighten connecting rod olts (using 5/16 in point socket). First torque to 15 l. in. (1.5 N m) then 30 l. ft. (40.5 N m). Turn ech olt n dditionl 90 fter 2nd torque is ttined. Recheck lignment etween rod cp nd rod s shown Apply Quicksilver Needle Bering Assemly Luricnt to ering surfce of connecting rod nd instll ering ssemly, s shown. 11. Plce connecting rod cp on connecting rod. Apply light oil to threds nd fce of connecting rod olts. Thred connecting rod olts finger-tight while checking for correct lignment of the rod cp s shown. IMPORTANT: Connecting rod nd connecting rod cps re mtched hlves. Do not torque screws efore completing the following procedure. Run pencil lightly over ground re. If pencil stops t frcture point, loosen olts, retighten, nd check gin. NOTE: If you still feel the frcture point, discrd the rod. - 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 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 ÄÄ ÄÄ ÄÄ R3 JUNE 2002 POWERHEAD - 4A-41

44 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. - Loctite Mster Gsket ( ) - Screwdriver Crnkcse Cover Instlltion (Stndrd nd High Performnce Models) Thoroughly remove ll oil from mting surfces of crnkcse cover nd cylinder lock with Loctite Primer T ( ). 2. Instll gsket strips into grooves in crnkcse cover. Trim end of ech gsket strip flush with edge of cover s shown. 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 c d - Gsket Strips - Edge of Cover Apply thin, even cot of Loctite Mster Gsket #203 on mting surfces of crnkcse cover nd cylinder lock. 5 - Upper End Cp Bolts Torque to 150 l. in. (17.0 N m) - Lower End Cp Bolts Torque to 80 l. in. (9.0 N m) c - Add Light Oil to Threds nd Bolt Fce 8 Bolts (3/8 in.-18) Torque to 38 l. ft. (51.5 N m) d - Bolts (5/16 in.-18) Torque to 15 l. ft. (20.5 N m) 6 4A-42 - POWERHEAD R3 JUNE 2002

45 Assemly of Reed Blocks to Intke Mnifold (Stndrd nd High Performnce Models) - Torque to 25 l. in. (3.0 N m) - Torque to 105 l. in. (12.0 N m) c - Torque to 80 l. in. (9.0 N m) c Assemly of Exhust Divider Plte to Block (Stndrd nd High Performnce Models) 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 (otin loclly) to olt threds nd torque olts to 16.5 I. ft. (22.5 N m). 5. Torque exhust divider plte olts in following sequence. Torque olts to 16.5 l. ft. (22.5 N m). Add Loctite 271 to threds If removed, instll wter pressure relief vlve components s shown. Torque olts to specifictions d c - Divider Sel - Exhust Divider Plte c - Gsket d - Attching Bolt Cover 2 - Bolt l. in. (17.0 N m) 3 - Gsket 4 - Relief Vlve Plte 5 - Diphrgm 6 - Wter Deflector 7 - Wsher 8 - Screw - 25 l. in. (3.0 N m) 9 - Spring 10- Poppet Vlve 11- Grommet 12- Crrier 13- Wsher R3 JUNE 2002 POWERHEAD - 4A-43

46 CYLINDER HEAD INSTALLATION (STANDARD AND HIGH PERFORMANCE MODELS) 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. (40.5 N m) then turn n dditionl NOTE: During norml engine operting temperture, the sender electricl circuit is open nd will close if temperture reches 240 F ± 8 F (116.0 C ± 13.3 C) thus ctivting the overhet lrm. 4. Thermostt nd temperture sensor instlled Instll thermostt ssemly into ech cylinder hed. 3. Instll overhet temperture sensor into STAR- BOARD cylinder hed elow #1 sprk plug. g f c d e h - Thermostt (143 F) (16.7 C) j i k - Overhet Temperture Sensor Thermostt (143 F) (61.7 C) - Gsket c - Thermostt Cover d - Bolt (Torque to 16.5 l. ft N m) e - 90 Elow f - Hose g - St-Strp h - Temperture Sensor i - Retiner j - Bolt (Torque to 16.5 l. ft N m) k - Bolt [Apply Light Oil to Threds - Torque to 30 l. ft. (40.5 N m) nd turn dditionl 90 ] 4A-44 - POWERHEAD R3 JUNE 2002

47 Bleed Line Routing (Crureted Models) STARBOARD SIDE VIEW FRONT VIEW PORT SIDE VIEW Bleed Line Routing (Fuel Injected Models) FRONT VIEW To Vpor Seprtor Thru Bleed Shut-Off Vlve (0G nd Below) Direct to Vpor Seprtor (0G nd Aove) - To Bottom of EFI Mnifold if Equipped NOTE: Filter removed S/N 0G nd ove R3 JUNE 2002 POWERHEAD - 4A-45