POWERHEAD R1 JUNE 1996 POWERHEAD

Transcription

1 POWERHEAD R1 JUNE 1996 POWERHEAD 4-1

2 Tle Of Contents Pge Powerhed Specifictions BOTTOM GUIDED PISTON Specil Tools Finished Hone Bore Size Piston Ring Powerhed Specifictions TOP GUIDED PISTON Specil Tools Specifictions Finished Hone Bore Size Piston Piston Ring Powerhed Removl Powerhed Disssemly Removing Crnkshft Disssemling Crnkshft Disssemling Piston Disssemling Cylinder Hed Inspecting nd Repiring Crnkshft Pge Connecting Rods Bottom/Top Guided Pistons Bottom Guided Piston Top Guided Piston Cylinder Block nd Crnkcse Cover Powerhed Ressemly Assemling Bottom Guided Piston /2 Model Yer S/N 0E nd Below Assemling Top Guided Piston Model Yer S/N 0E nd Aove Assemling Crnkshft Instlling Pistons Into Cylinder Block Assemling Cylinder Hed Completing Assemly Instlling Powerhed Powerhed Components 90/95 HP Crnkshft Components 90/95/120 HP Powerhed Components 120 HP POWERHEAD R1 JUNE 1996

3 Powerhed Specifictions BOTTOM GUIDED PISTON Specil Tools Description Prt No. 12-point Socket FT 2953 Piston Tool FT Ring Remover/Instller FT 8926 Ring Compressor FT 2996 Lockring Instller FT Compression Tester *Torque Wrench (0 200 l. ft.) *Torque Wrench (0 150 l. in.) Flywheel Puller FT Lifting Hook FT 8933 *My Be Otined Loclly Finished Hone Bore Size Stndrd Size Frction in. (mm) 3-3/ (85.725).010 Oversize in. (mm) (85.979).030 Oversize in. (mm) (86.487) IMPORTANT: Mesure piston skirt t right ngle (90 ) to piston pin center-line, 2.0 in. (50.8 mm) up from ottom edge of skirt. 2.0 in. (50.8 mm) 2.0 in. (50.8 mm) Piston Ring Mjor Dimeter mesured 90 to piston pin center line Minor Dimeter mesured prllel to piston pin center line 90/120 HP End Gp Top Piston Ring Bottom Piston Ring in. ( mm) in. ( mm) TOP CENTER BOTTOM NOTE: Mesure cylinder ore t Top, Center nd Bottom R1 JUNE 1996 POWERHEAD 4-1

4 Powerhed Specifictions TOP GUIDED PISTON Specil Tools Description Prt No. 12-point Socket FT2953 Piston Tool A3 Ring Remover/Instller Ring Compressor FT2996 Lockring Removl Tool A1 Lockring Instlltion Tool A2 Flywheel Puller A1 Powerhed Lifting Ring Specifictions Finished Hone Bore Size PISTON IMPORTANT: A zero minus tolernce nd plus.001 tolernce is cceptle. IMPORTANT: Mesure piston skirt t right ngle (90 ) to piston pin center-line,.15 in. (3.81 mm) up from ottom edge of skirt in. (3.81 mm) PISTON RING Mesured 90 to piston pin center line 95/120 HP End Gp Top Piston Ring in. ( mm) Stndrd Size Frction in. (mm) 3-3/ (85.725).015 Oversize in. (mm) (86.10).030 Oversize in. (mm) (86.487) 4-2 POWERHEAD R1 JUNE 1996

5 Powerhed Removl 1. Disconnect ttery led form ttery. 2. Remove sprk leds from sprk plugs. 3. Disconnect remote control hrness from engine. 4. Disconnect fuel line to fuel pump. 5. Remove throttle nd shift cles. 6. Disconnect wter inlet hose from pump cover. 7. Loosen top exhust oot clmp. 10. Instll lifting ring on end of crnkshft. If lifting hook hs less thn five turns of enggement remove flywheel nut. - Lifting Ring 11. Lift powerhed off pump cover. - Exhust Boot Clmp - Wter Inlet Hose 8. Remove four 13-mm nuts from studs tht hold powerhed dpter plte to pump cover. 9. Remove four 15-mm nut from studs tht hold dpter plte to pump cover. WARNING DO NOT leve powerhed suspended from hoist. Powerhed should e instlled on suitle stnd or lowered to the floor upon removl from pump cover. NOTE: Refer to pproprite sections in service mnul for removl of individul fuel nd electricl sussemlies from powerhed. Component/Assemly Section Strter Motor 2C Flywheel 2A/2B* Ignition Components 2A/2B* (Switch Box, Sttor, Trigger) Cruretor nd Linkge 3A Fuel Pump 3B *1996 Models, CDM Ignition NOTE: All ignition nd electricl components cn e removed nd instlled s n ssemly R1 JUNE 1996 POWERHEAD 4-3

6 Powerhed Disssemly 1. Remove intke mnifold nd reed ssemlies. See Section 3B. 2. Remove exhust mnifold. Discrd gsket. Clen ll gsket surfces. 3. Remove cylinder hed. Discrd gsket. Clen ll gsket surfces. 4. Remove trnsfer port covers. Discrd gsket. Clen ll gsket surfces. d e 6. Remove oil injection pump nd driven ger. - Oil Injection pump - Driven Ger 7. Remove crnkcse cover screws. c - Cylinder Block (120 HP Shown) - Trnsfer Port Cover (4 on the 120 HP) c - Cylinder Hed d - Exhust Mnifold e - Bering Cge 5. Remove ering cge. - Cover Screws (120 HP) - Cover Screws (90/95 HP) 4-4 POWERHEAD R1 JUNE 1996

7 8. Instll four olts in cylinder lock to protect gsket surfce on cylinder lock. 9. Remove olts securing dpter plte to ottom of cylinder lock. Remove dpter plte. Remove nd discrd gsket. Clen ll gsket surfces. 10. With ll cover screws removed, pry crnkcse prt strting t corner loctions. 2. Remove ering cge hlf. Rotte crnkshft nd remove remining ering cge hlf. IMPORTANT: DO NOT use mgnet to retrieve erings. 3. Push connecting rod down to cler crnkshft. 4. Repet steps 1 through 3 for ech cylinder. 5. Lift crnkshft out of cylinder lock. Disssemling Crnkshft 1. Remove snp rings from center min erings. Remove ering rces nd cged rollers. IMPORTANT: Keep erings seprted, do not intermix components. 2. Remove nd discrd crnkcse sels. Removing Crnkshft IMPORTANT: Mrk rod cps nd pistons s to the cylinder they re removed from. 1. Remove connecting rod screws with 12-point socket. - Crnkshft Sels 3. If replcement of the upper ll ering is necessry, remove using univerl ering puller Specil Tool Press new ering onto crnkshft R1 JUNE 1996 POWERHEAD 4-5

8 4. Remove lower crnkcse sel.. Slide lower min ering to end of crnkshft.. Pry sel out. AS NEEDED WARNING Eye protection MUST e worn when removing piston pin lockrings. 1. Snp out nd discrd piston lockring from oth ends of piston pin. - Sel 5. If replcement of the oil injection drive ger is necessry, the ger cn e remove using universl ering puller Specil Tool The new ger must e pressed on the crnkshft. Disssemling Piston 2. Press piston pin out using Specil Tool FT on Bottom Guided piston. Use Specil Tool A3 on Top Guided piston. 1. Hold connecting rod so tht it does not scrtch cylinder ore. Push piston out of cylinder lock. Disssemling Cylinder Hed 2. Remove piston ring using ring expnder. 1. Remove thermostt housing nd components. c d e f g - Screw (4) - Housing c - Gsket d - Spring e - Thermostt f - Retiner g - Sel 4-6 POWERHEAD R1 JUNE 1996

9 NOTE: Test the thermostt y removing the ruer grommet nd plcing the thermostt in hot wter. The thermostt should open t the temperture stmped on it. AS NEEDED 2. Remove thermoswitch y removing snp ring retiner nd pry/pull thermoswitch from cvity. 3. Remove olts from cylinder hed cover. Remove cover. Discrd gsket. Clen ll gsket surfces. Inspecting nd Repiring Crnkshft 1. Inspect crnkshft to drive shft splines for wer. Replce crnkshft if necessry. 2. Inspect upper nd lower crnkshft erings for roughness nd excessive looseness. Replce s necessry. 3. Check ll crnkshft ering surfces for rust, wter mrks, chtter mrks, uneven wer nd/or overheting. If necessry clen surfces with crocus cloth s shown. 4. Thoroughly clen (with solvent) nd dry crnkshft nd crnkshft ll erings. Recheck surfces of crnkshft. Replce crnkshft if surfces cnnot e properly clened up. If crnkshft will e reused luricte surfces with 2 cycle oil to prevent rust. 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 R1 JUNE 1996 POWERHEAD 4-7

10 4. Wter Mrks: When ering surfces re sujected to wter contmintion, ering surfce etching occurs. This etching resemles the size of the ering. 5. 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. 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). - Splling - Chtter Mrks Between Arrows 7. Uneven Wer: Uneven wer could e cused y ent connecting rod. - Uneven Wer 4-8 POWERHEAD R1 JUNE 1996

11 CAUTION Crocus cloth MUST BE USED to clen ering surfce t CRANKSHAFT END OF CONNECTING ROD. 320 grit Crorundum cloth MUST BE USED to clen ering surfce t PISTON PIN END OF CONNECTING ROD. VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS. DO NOT continue to clen connecting rod ering surfces fter mrks hve een removed. 8. Clen connecting rods s necessry. d - Attched to Drill Motor - Crocus Cloth c - Torque to 16 l. ft. (21.7 N m) d - Use 320 Crorundum Cloth c R1 JUNE 1996 POWERHEAD 4-9

12 Bottom/Top Guided Pistons IMPORTANT: There re two types of piston/rod ssemlies ville: Bottom Guided (centered in ore y crnkshft) /2 Model Yer S/N 0E nd Below Bottom Guided Piston Top Guided (centered in ore y piston) /2 Model Yer S/N 0E nd Aove Top Guided Piston c c - Ridged Wsher - Smooth c - Sclloped Flt Wsher - Sclloped c - Smooth POWERHEAD R1 JUNE 1996

13 Cylinder Block nd Crnkcse Cover 1. Inspect cylinder hed gsket surfce for erosion cross gsket surfce. Excessive erosion requires cylinder hed replcement. 2. Inspect cylinder hed for wrpge. 4. Mesure piston ring end gp. A cylinder hed with in. (0.305 mm) or less cn e resurfced. If wrped more thn in. (0.305 mm) replce cylinder hed. 3. Mesure cylinder ore dimeter t top, middle nd ottom of ech cylinder s shown. Check for tpered, out-of-round nd oversized ore. NOTE: Refer to Specifictions for dimensions. If gp is too smll widened with file. If gp is too wide recheck ore mesurements. Powerhed Ressemly Assemling Bottom Guided Piston /2 Model Yer S/N 0E nd Below 1. Instll piston pin needle erings in pin ore of connecting rod using. Luricte needle erings with Quicksilver Needle Bering Luricnt. - Berings (26 per set) Refer to Specifictions for Finished Hone Bore Size for Bottom Guided pistons nd Top Guided pistons R1 JUNE 1996 POWERHEAD 4-11

14 CAUTION DO NOT intermix new needle erings with used needle erings. Needle erings MUST BE REPLACED AS A SET. DO NOT intermix needle erings from one connecting rod with those of nother connecting rod. 2. Instll lignment pin (Specil Tool No. FT-2990B) through one side of piston. 6. Instll piston pin. - Block (Specil Tool FT 2990D) - Spcer - Alignment Pin 3. Instll first spcer with smll end towrd the inside of piston. 4. Instll connecting rod in piston. Slide connecting rod with erings over lignment tool. Instll second spcer with smll end towrd inside of piston. Push lignment pin through second spcer nd through piston ore. WARNING Eye protection must e worn while instlling piston pin lockrings. IMPORTANT: Use only new piston pin lockrings. 7. Instll NEW piston lockrings (one t ech end of piston pin) with lockring instlltion tool (Specil Tool No. FT 11291) s shown. 5. Plce piston on pillow lock (Specil Tool No. FT-2990D). - Lockring - Specil Tool FT IMPORTANT: Be sure piston pin lockrings re properly seted in piston grooves POWERHEAD R1 JUNE 1996

15 8. Instll piston rings (Specil Tool No. FT-8926). 2. Plce flt wshers on connecting rod; keeping wshers in plce, crefully plce piston over end of rod. Use disssemly mrks for mtching rod to piston nd direction of insertion (which side of rod is UP ). 1 - Upper Piston Ring - Lower Piston Ring IMPORTANT: Gps in piston rings must fit over pins in ring grooves. Assemling Top Guided Piston Model Yer S/N 0E nd Aove Plce clen needle erings on clen sheet of pper nd luricte with Quicksilver Needle Bering Luricnt ( A1). NOTE: There re 29 needle erings per piston Scried Identifiction Numer - Locting Wsher 3. Insert piston pin tool through piston in the direction shown, pushing out sleeve. CAUTION Never intermix new needle erings with used needle erings t the sme connecting rod end. Never intermix needle erings on one connecting rod with those of nother connecting rod. Should one (or more) piston pin needle ering of connecting rod require replcement (or should one or more e lost), replce ll of tht connecting rod s piston pin needle erings. 1. Plce sleeve, which is prt of Piston Pin Tool ( A3), into connecting rod nd instll needle ering round sleeve, s shown. - Sleeve - Piston Pin Tool ( A3) Needle Berings (29) - Sleeve [From Piston Pin Tool ( A3)] R1 JUNE 1996 POWERHEAD 4-13

16 4. Plce piston pin over end of tool, nd tp into position (driving tool out other side). - Piston Pin - Piston Pin Tool Instll piston rings. Top piston ring hs one dot: instll fcing up. Bottom piston ring hs two dots nd white stripe: instll with dots fcing up. Assemling Crnkshft WARNING Eye protection must e worn while instlling piston pin lockrings. 5. Instll new piston pin lockrings (ech side of piston) using Lockring Tool ( A2). Mke sure lockrings re properly seted in piston grooves. CAUTION Do not reuse piston pin lockrings. Use only new lockrings nd mke sure they re properly seted in piston grooves. 1. Instll new sel into lower min ering. Press sel into ering with grter spring fcing up. Use Specil Tool FT Apply Needle Bering Luricnt A1 etween lis of sel nd slide ering on crnkshft. - Grter Spring (Fces Up Towrd Flywheel When Instlled) Lockring Instlltion Tool ( A2) - Lockring (2) 4-14 POWERHEAD R1 JUNE 1996

17 3. Scrpe old Loctite off upper ering. Clen ering surfces with Locquic Primer Instll lower ering on crnkshft with sel. 4. Instll new crnkshft sels on crnkshft. - Crnkcse Sels 5. Instll center min erings on crnkshft with lignment holes of ering rce etween snp ring groove nd crnkcse sel. - Lower Bering - Sel Instlling Pistons Into Cylinder Block 1. Cot pistons, rings, nd cylinder ores with 2-cycle oil. 2. Instll piston in ring compressor, Specil Tool FT IMPORTANT: Be sure to position end gp of rings t the ring lignment pin. NOTE: Pins re 180 prt on piston. c - Alignment Pin - Snp Ring Groove - Alignment Hole c - Crnkcse Sel NOTE: Position snp ring on center min erings so tht the gp is not over the frcture re of the erings R1 JUNE 1996 POWERHEAD 4-15

18 3. Instll piston in cylinder ore. Position piston so tht piston dome fces intke port of cylinder lock. Align holes in center min erings with loction pins in cylinder lock. - Intke Ports - Piston Dome 4. Push piston into cylinder ore. NOTE: Be sure piston is instlled in the sme ore it ws removed from. 5. Instll cylinder hed to prevent pistons from flling out. Do Not torque the cylinder hed olts t this time. 6. Clen cylinder lock upper ering ore with Locquic Primer Apply Loctite to upper min ering ore. - Center Min Bering Hole - Locting Pin IMPORTANT: Instll crnkshft with seling ring gps fcing up. When the crnkshft is seted the ends of the seling rings must e le to touch. IMPORTANT: Mke sure crnkshft is fully seted y pushing ends of crnkshft: there should e no rocking. 9. Spin crnkshft sels so tht openings fce down. IMPORTANT: Sel rings rek esily; hndle crefully when turning. IMPORTANT: Mke sure upper crnkshft ering is fully seted ginst the flnge in the cylinder lock. Tp on end of crnkshft to ensure seting. 8. Instll crnkshft in cylinder lock. - Bering Seted Aginst Cylinder Block Flnge 10. Instll one hlf of ering cge in connecting rod. Apply Needle Bering Luricnt A1 to cge hlf to hold needle erings in plce (Bottom Guided rods, not necessry on Top Guided rods). NOTE: Bottom Guided rods use loose needle ering with cge. Top Guided rods use cge tht contins the needle erings. Instll nine rollers (Bottom Guided rods) POWERHEAD R1 JUNE 1996

19 IMPORTANT: Do Not intermix rollers. Rollers cn only e replced s set. Instll new rod cp screws nd thred until cp nd rod fit together. Inspect for lignment. c - Bering Cge Hlf - Roller (9) 11. Crefully lign connecting rod with crnkshft. 12. Instll second hlf of ering cge in connecting rod. Apply Needle Bering Luricnt A1 to cge hlf to hold needle erings in plce. Instll remining seven rollers (Bottom Guided). - Correct Fit - Incorrect Fit - Gp Present c - Incorrect Fit - Ridge Present Correct ny mislignment. 14. Remove cp screws nd pply Loctite FT to cp screw threds. Hnd tight cp screws nd check lignment. If lignment is good torque cp screws in increments of 50 l. in. (5.65 N m) until torque of 120 l. in. (13.55 N m) is reched, then turn n dditionl Repet procedure for the remining connecting rods. Rotte the crnkshft fter ech rod is instlled to check for inding. If ny inding is present remove rod cp nd check lignment. 16. Apply Loctite to the exposed portion of the upper ering. 13. Instll connecting rod cp. IMPORTANT: Connecting rods nd connecting rod cps re mtched hlves. Do not torque screws efore checking lignment. NOTE: Do Not re-use old rod cp screws, lwys use new rod cp screws R1 JUNE 1996 POWERHEAD 4-17

20 17. Apply Seler on sel surfce nd round min olt holes on lock. 19. Instll crnkcse olts. Following torque pttern torque olts to 270 l. in. (30.5 N m). 90/95 HP Check crnkshft for free rottion. - Seler ( ) 18. Instll crnkcse cover on cylinder lock, ligning corner dowel pins. 120 HP 20. Using new gsket, instll dpter plte on ottom of cylinder lock. Torque olts to 30 l. ft. (40.7 N m). - Dowel Pins 4-18 POWERHEAD R1 JUNE 1996

21 Assemling Cylinder Hed 1. Instll cylinder hed cover on cylinder hed. Torque center ttching screws to 70 l. in. (7.91 N m) /2 Model Yer S/N 0E nd elow: 4. Torque olts s shown to 75 l. in. (8.5 N m), then torque 50 l. in. (5.6 N m) t time until olts re torqued to 225 l. in. (29.14 N m). For S/N numers 0E nd ove pply light oil to threds nd olt hed. Torque in sequence to 120 l. in. (13.5 N m). Then turn n dditionl 90. c - Cylinder Hed Cover - Cylinder Hed NOTE: 90/95 HP Shown. c - Cylinder Hed Gsket 2. Apply selnt to cylinder hed cover on cylinder lock side of cover. 3. Using new gsket, instll cylinder hed. 90/95 HP 120 HP R1 JUNE 1996 POWERHEAD 4-19

22 Completing Assemly /2 Model Yer S/N 0E nd elow: 1. Instll exhust mnifold using new gsket. Torque olts in sequence from center out to 100 l. in. (11.3 N m). For S/N numers 0E nd ove pply light oil to threds nd olt hed. Torque olts in sequence to 115 l. in. (13 N m). Then re-torque # s 1-6. NOTE: Stinless steel olts re torqued to 100 l. in. (11.3 N m). Grde 8 olts re torqued to 115 l. in. (13 N m). Stinless steel olts re not mgnetic, grde 8 olts re mgnetic. 90/95 HP 120 HP NOTE: Refer to pproprite sections in service mnul for instlltion of individul fuel nd electricl sussemlies on powerhed. Component/Assemly Section Strter Motor 2C Flywheel 2A/2B* Ignition Components 2A/2B* (Switch Box, Sttor, Trigger) Cruretor nd Linkge 3A Fuel Pump, Reed Vlves 3B *1996/97 Models, CDM Ignition NOTE: All ignition nd electricl components cn e removed nd instlled s n ssemly. Instlling Powerhed 1. Instll top exhust oot nd clmp. Instll O-ring in counterore of drive housing cover. - Exhust Boot - O-Ring c c - Drive Housing Cover d - Lrge O-Ring 2. Luricnt driveshft splines with 2-4-C w/teflon Luricnt A12. NOTE: DO NOT pply luricnt to TOP of drive shft s grese my pre-lod drive shft/crnkshft resulting in dmge to powerhed nd/or pump housing. 3. Lower powerhed on drive housing cover. Align exhust oot with exhust elow, driveshft splines, nd mounting studs. 4. Torque exhust ellows clmp screws to 50 l. in. (5.6 N m). d 4-20 POWERHEAD R1 JUNE 1996

23 5. Connect wter inlet hose to fitting on drive housing cover. Snug nut with wrench, then tighten one dditionl flt (60 degrees). REFER TO SECTION 6 ENGINE INSTALLATION TO COMPLETE INSTALLATION OF WIRE HAR- NESS, CONTROL CABLES, SET-UP AND TIMING. IMPORTANT: Follow Brek-In procedure s out lined in Section 6: Engine Instlltion. CAUTION SEVERE DAMAGE to your engine cn result y not complying with the proper rek-in procedure. - Wter Inlet Hose 6. Secure powerhed to drive housing cover with nuts. 7. Torque nuts in sequence shown elow. The forwrd nd ft nuts (7,8 nd 5,6) re torqued to 35 l. ft. (47.5 N m). The left nd right nuts (1,2 nd 3,4) re torqued to 20 l. ft. (27.1 N m) R1 JUNE 1996 POWERHEAD 4-21

24 Powerhed Components 90/95 HP U Quicksilver Luriction/Selnt Appliction Points U RTV Selnt U U Item Qty. Description Torque L. In. L. Ft. 1* 21 Bolt (1/4-20x1-1/8) /2 Model Yer S/N 0E nd Below * 21 Bolt (1/4-20x1-1/8) S/N 0E nd Aove - Apply Light Oil to Bolt Hed & Threds 2 1 Mnifold 3 Delete 4 1 Bolt (5/16-18x3/4) Wsher 6 2 Clmp 7 1 Bellows 8 1 Cylinder Block * Refer to torque sequence listed on pge N m 4-22 POWERHEAD R1 JUNE 1996

25 Powerhed Components 90/95 HP (Continued) Item Qty. Description Torque 9 1 Stud 10 7 Wsher 11 1 Lock Wsher L. In. L. Ft. N m 12 1 Nut (3/8-16) Bolt (3/8-16x2-3/4) Bolt (3/8-16x3) Bolt (1/4-20x3/4) Bolt (3/8-16x1-3/ Wsher 18 2 Bolt (1/4-20x1-1/4) Gsket 21 2 Gsket 22 2 Bolt (1/4-20x5/8) Cover 24 2 Tue 25 2 Pin 26 1 Gsket 27 1 Hed 28 1 Cover Wsher - Only Used On /2 S/N 0E nd Below 30* 14 Bolt (5/16-18x2-3/8) /2 Model Yer S/N 0E nd Below * 14 Bolt (5/16-18x2-3/8) S/N 0E nd Aove - Apply Light Oil to Bolt Hed & Threds 120 l. in. (13.5 N m) Then Turn An Additionl Bolt (1/4-20x5/8) Bolt (1/4-20x3/4) Cover 34 1 Gsket 35 1 Spring, (Silver) 36 1 Thermostt (130 ) 37 1 Spcer 38 1 Sel 39 1 Plug 40 1 Pin 41 1 Bolt (1/4-20x3/4) Tue 43 1 Gsket 44 4 Plug (1/2-14) Wsher - Only Used On /2 S/N 0E nd Below * Refer to torque sequence listed on pge R1 JUNE 1996 POWERHEAD 4-23

26 Crnkshft Components 90/95/120 HP 90/95 3-CYLINDER SHOWN CYLINDER NOT SHOWN One Circle Mrk - Fces Up Two Circle Mrks - Fce Up V C V E V 90/120 HP /2 S/N 0E nd Below V E C Quicksilver Luriction/Selnt Appliction Points Direction of mjor seling lip UP or DOWN C V E Needle Bering Assy. Lu. ( A1) Loctite #601 (FT ) 2 Cycle Outord Oil ( A24) 4-24 POWERHEAD R1 JUNE 1996

27 Item Qty. Description Torque 1 1 Cp 2 1 Sel L. In. L. Ft. N m 3 5 Screw (1/4-20x3/4) Cge Assemly 5 1 Key 6 1 Crnk Shft (90/95 HP Shown) 7 1 Bering 8 3 Cge/Roller 9 3 Rod Cp 10 6 Bolt - Apply Light Oil to Bolt Hed & Threds 120 l. in. (13.5 N m) Then Turn An Additionl Cge/Roller 12 2 Min Bering Rce 13 3 Locting Pin 14 1 Bering 15 1 Sel 16 2 Crnk Cse Sel 17 2 Snp Ring 18 6 Flt Wsher (2 Ech) S/N 0E nd Aove 18 6 Spcer (2 Ech) S/N 0E nd Below 19 3 Piston 20 3 Piston Ring (2 Ech) 21 6 Retiner (2 Ech) 22 3 Piston Pin 23 3 Needle Bering (29 Ech) S/N 0E nd Aove 23 3 Needle Bering (26 Ech) S/N 0E nd Below 24 3 Connecting Rod 25 1 Nut, Flywheel Wsher - Only Used On S/N 0E nd Aove R1 JUNE 1996 POWERHEAD 4-25

28 Powerhed Components 120 HP U U U Quicksilver Luriction/Selnt Appliction Points U RTV Selnt POWERHEAD R1 JUNE 1996

29 Item Qty. Description Torque 1 1 Cylinder Block L. In. L. Ft. 2 1 Bolt (3/8-16x3-1/8) Bolt (3/8-16x2-3/4) Bolt (3/8-16x3) Bolt (3/8-16x2) Wsher 7 2 Bolt (3/8-16x1-3/4) Bolt (1/4-20x1-1/4) Dowel Pin (3/8x5/8) 10 3 Tue 11 1 Tue 12 1 Pin 13 3 Pin 14 1 Gsket Set 15 1 Gsket 16 1 Bolt (5/16-18x3/4) Lock Wsher (5/16) 18 1 Gsket 19 1 Cylinder Hed 20 1 Cover 21 4 Bolt (1/4-20x5/8) * 18 Bolt (5/16-18x2-3/8) /2 Model Yer S/N 0E nd Below * 18 Bolt (5/16-18x2-3/8) S/N 0E nd Aove - Apply Light Oil to Bolt Hed & Threds Wsher - Only Used On /2 S/N 0E nd Below 24 3 Cover Kit 25 1 Plug N m 120 l. in. (13.5 N m) Then Turn An Additionl Bolt (1/4-20x5/8) Gsket Bolt (1/4-20x7/8) Cover 30 4 Bolt (1/4-20x3/4) Gsket 32 1 Spring (RED) 33 1 Thermostt (130 ) 34 1 Spcer 35 1 Sel * Refer to torque sequence listed on pge R1 JUNE 1996 POWERHEAD 4-27

30 Powerhed Components (Continued) Exhust Mnifold 120 HP Not Used on 1996 Models Item Qty Description Torque 1 1 Mnifold 2 1 Gsket 3 1 Striner Tue 4 4 Plug (3/4-14) 5 25 Wsher Only Used On /2 S/N 0E nd Below L. In. L. Ft. 6* 21 Bolt (1/4-20x3) /2 Model Yer S/N 0E nd Below * 21 Bolt (1/4-20x3) - S/N 0E nd Aove - Apply Light Oil to Bolt Hed & Threds 7 4 Bolt (1/4-20x4) Retiner 9 2 Clip 10 2 Clmp 11 1 Bellows * Refer to torque sequence listed on pge N m 4-28 POWERHEAD R1 JUNE 1996