POWERHEAD 4 54727
Tle of Contents Pge Speifitions............................. 4-1 Speil Tools............................. 4-1 Generl Informtion....................... 4-1 Throttle Control Linkge.................... 4-2 Cylinder Blok nd Crnkse Assemly..... 4-4 End Cps nd Exhust Cover............... 4-6 Crnkshft, Pistons nd Conneting Rods.... 4-8 Powerhed Torque Sequene nd Torque Speifitions................... 4-10 Powerhed Removl from Driveshft Housing............................... 4-11 Eletri Strt Model.................... 4-11 Mnul Strt Model.................... 4-14 Powerhed Disssemly.................. 4-16 End Cp Disssemly.................... 4-21 Crnkshft Disssemly.................. 4-22 Clening nd Inspetion................... 4-25 Cylinder Blok nd Crnkse Cover..... 4-25 Cylinder Bore (Clening nd Inspetion).......................... 4-25 Honing Proedure................... 4-25 Cylinder Bore Size..................... 4-26 Pistons............................... 4-26 Mesuring Piston Roundness........... 4-27 Reed Bloks.......................... 4-27 Conneting Rods...................... 4-28 Clening Conneting Rods.............. 4-30 Crnkshft............................ 4-30 Bll Bering........................... 4-31 Powerhed Ressemly.................. 4-31 Generl.............................. 4-31 Crnkshft Ressemly................... 4-32 Piston Instlltion...................... 4-35 Crnkshft Sel Instlltion............. 4-37 End Cp Ressemly.................. 4-38 Lower End Cp..................... 4-38 Upper End Cp.................... 4-39 Cylinder Blok Ressemly................ 4-39 Instlling Powerhed on Driveshft Housing............................... 4-48 4-0 - POWERHEAD 90-814676R1 DECEMBER 1996
Speifitions Blok Type................. 4 Cylinder, 2 Cyle Displement.......... 44.0 u in. (721 ) Cylinder Bore Di. Stndrd......... 2.565 in. (65.15 mm) Di..015 in. Oversize... 2.580 in. (65.32 mm) Di..030 in. Oversize... 2.595 in. (65.91 mm) Out of Round (Mx.).... 0.004 in. (0.10 mm) Tper (Mx.).......... 0.004 in. (0.10 mm) Piston Di. Stndrd......... 2.558 in. (64.97 mm) Di..015 in. Oversize... 2.573 in. (65.35 mm) Di..030 in. Oversize... 2.588 in. (65.73 mm) Piston Clerne....... 0.007 in. to 0.011 in. (0.17 mm to 0.27 mm) Piston Ring End Gp... 0.0015 in. to 0.014 in. (0.038 mm to 0.35 mm) Reed Blok Reed Stop Opening (Mx.) Crnkshft Runout (Mx.)........... Tper (Mx.)............ 0.020 in. (0.50 mm) 0.003 in. (0.08 mm) 0.003 in. (0.08 mm) Firing Order.......................... 1-3-2-4 Speil Tools Desription Prt Numer Flywheel Holder 91-52344 Flywheel Holder Strp 91-24937A1 Wrenh Protetor Cp 91-24161 Flywheel Puller 91-73687A1 Lifting Eye 91-90455 Piston Ring Expnder 91-24697 Piston Pin Tool 91-76160A2 Piston Ring Compressor 91-31461A2 Bering Puller 91-24100A1 Powerhed Stnd 91-25821A1 Torque Wrenh (0-200 *91-32610 l. ft.) Torque Wrenh (0-150 *91-66274 l. in.) Compression Tester 91-29287 *My e Otined Lolly Generl Informtion Powerhed Disssemly nd Ressemly instrutions re printed in sequene tht should e followed to ssure est results when removing or repling powerhed omponents. If omplete disssemly is not neessry, strt ressemly t point where disssemly ws stopped. (Refer to Tle of Contents, preeding.) Usully, omplete 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 minor repirs on omponents, suh s ignition system, ruretors, et. 90-814676R1 DECEMBER 1996 POWERHEAD - 4-1
Throttle Control Linkge 30 29 31 32 9 95 10 11 26 27 28 2 3 1 20 95 95 25 24 23 35 95 4 10 8 16 7 6 95 5 33 34 4 35 95 22 21 15 14 12 13 6 7 33 34 19 18 36 17 95 2-4-C With Teflon (92-825407A12) 4-2 - POWERHEAD 90-814676R1 DECEMBER 1996
Throttle Control Linkge REF. TORQUE NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 BRACKET 2 3 SCREW (1-1/8 IN.) 150 17.0 3 3 LOCKWASHER 4 1 THROTTLE ACTUATOR 5 1 LINK ROD 6 2 SWIVEL BALL 7 2 SWIVEL BASE 8 1 NUT 9 1 SCREW (2 IN.) Drive Tight; ut tutor must e free to pivot 10 2 WASHER 11 1 WAVE WASHER 12 1 PLATE 13 2 SCREW (1/2 IN.) 14 1 SCREW (1 IN.) 15 1 NUT 16 1 CAP 17 1 SCREW (7/8 IN.) 18 1 SPRING 19 1 NUT 20 1 SPARK ADVANCE LEVER 21 1 SCREW (1-3/4 IN.) Drive Tight 22 1 BUSHING 23 1 BUSHING 24 1 SPRING 25 1 WASHER 26 1 SCREW (1-3/4 IN.) 27 1 NUT 28 1 CAP 29 1 LINK ROD 30 1 PIVOT 31 1 SWIVEL BALL 32 1 SWIVEL BASE 33 1 SCREW (2-1/4 IN.) 33 1 SCREW (1-3/4 IN.) 34 2 NUT 35 2 CAP 36 1 LATCH 90-814676R1 DECEMBER 1996 POWERHEAD - 4-3
Cylinder Blok nd Crnkse Assemly 22 11 23 15 16 75 16 15 24 1 21 20 25 20 21 19 7 14 13 12 19 33 19 2 18 9 19 17 4 8 7 3 10 33 30 31 27 28 6 4 5 29 26 19 Perfet Sel (92-34227-1) 33 Lotite 680 (Otin Lolly) 75 Lotite Mster Gsket (92-12564-1) 4-4 - POWERHEAD 90-814676R1 DECEMBER 1996
Cylinder Blok nd Crnkse Assemly REF. TORQUE NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 CYLINDER BLOCK/CRANKCASE ASSEMBLY 2 1 BRACKET strter motor (UPPER) 3 2 SCREW rket to rnkse (1-7/8 ) 180 15 20.3 4 4 LOCKWASHER rket srew 5 1 COVER strter motor (LOWER) 6 2 SCREW over to rnkse (1-7/8 ) 180 15 20.3 7 1 PLUG 8 2 DOWEL PIN 9 4 STUD ruretor (1-1/4 ) 10 2 STUD rnkse to drive shft housing (1-5/8 ) 11 2 DOWEL PIN rnkse to ylinder lok 12 2 STUD (4 ) 13 2 STUD (2-1/8 ) 14 2 STUD (2-1/2 ) 15 13 SCREW rnkse to ylinder lok (1-1/2 ) 210 17.5 23.7 15 3 SCREW rnkse to ylinder lok (1-3/8 ) 210 17.5 23.7 15 2 SCREW rnkse to ylinder lok (2-7/8 ) 210 17.5 23.7 16 17 WASHER rnkse srew 17 1 SCREW enter min ering loking (1 ) 75 8.5 18 2 SCREW (3/4 ) DESIGN II 75 8.5 19 3 LOCKWASHER w/lockwasher 18 2 SCREW (5/8 ) DESIGN I 75 8.5 19 3 TAB WASHER w/tab WASHER 20 1 TUBE lne min ering 21 2 ELBOW lne tue to ylinder lok 22 1 CONNECTOR leed hose (UPPER) 23 1 HOSE ylinder leed (11 ) 24 1 CHECK VALVE leed hose (LOWER) 25 1 PRIMER TEE (OLD DESIGN) 26 1 COVER 27 1 O-RING NON OIL 28 2 SCREW 29 2 WASHER 30 1 TEMPERATURE SENDER POWERBOAT 31 1 CABLE ASSEMBLY 90-814676R1 DECEMBER 1996 POWERHEAD - 4-5
End Cps nd Exhust Cover 95 7 3 2 17 18 9 8 95 10 14 5 4 6 15 16 25 1 11 7 12 13 22 21 14 20 95 23 14 24 19 A B C 7 Lotite 271 (Otin Lolly) 14 2 Cyle Outord Oil (92-13249A24) 95 2-4-C With Teflon (92-825407A12) A=DESIGN I B=DESIGN II C=DESIGN III 4-6 - POWERHEAD 90-814676R1 DECEMBER 1996
End Cps nd Exhust Cover REF. TORQUE NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 TEMPERATURE SWITCH (ELECTRIC) 2 1 END CAP ASSEMBLY upper 3 1 OIL SEAL upper end p 4 1 O-RING upper end p 5 1 BALL BEARING upper end p 6 AR SHIM upper end p (.005-10) 7 4 SCREW upper end p (3/4 ) 200 16.6 22.5 8 1 COVER ASSEMBLY ylinder lok 9 1 PIPE PLUG ylinder lok over 10 1 GASKET ylinder lok over 11 10 SCREW ylinder lok over (1 ) 100 11.3 12 1 COVER ASSEMBLY trnsfer port 13 2 GASKET trnsfer port over 14 6 SCREW trnsfer port over (5/8 ) 65 7.3 15 1 GASKET ylinder lok to ffle plte 16 1 PLATE ffle exhust mnifold 17 1 GASKET ffle plte to exhust over 18 1 COVER exhust mnifold 19 1 END CAP ASSEMBLY lower DESIGN I/II 20 1 O-RING lower end p END CAP 21 2 OIL SEAL (Design I End Cp) SEE 21 1 OIL SEAL (Design II End Cp) BELOW 21 1 OIL SEAL (Design II End Cp) FOR S/N 22 1 BALL BEARING lower end p 19 1 END CAP ASSEMBLY lower DESIGN III 20 1 O-RING lower end p END CAP 21 2 OIL SEAL SEE BELOW 22 1 BALL BEARING lower end p FOR S/N 23 AR SHIM lower end p (.005-10) 24 3 SCREW lower end p 200 16.6 22.5 25 15 SCREW mnifold over to ylinder lok (1 ) 200 16.6 22.5 DESIGN I/II S/N USA-D279349 & BELOW BEL-9793444 & BELOW DESIGN III S/N USA-D279350 & UP BEL-9793445 & UP 90-814676R1 DECEMBER 1996 POWERHEAD - 4-7
Crnkshft, Pistons, nd Conneting Rods 15 14 14 13 19 16 20 95 3 11 10 14 14 14 95 18 19 1 9 6 8 4 12 5 26 16 17 7 25 23 24 95 7 4 27 29 21 28 2 95 22 23 21 30 7 Lotite 271 (Otin Lolly) 14 2 Cyle Outord Oil (92-13249A24) 95 2-4-C With Teflon (92-825407A12) 4-8 - POWERHEAD 90-814676R1 DECEMBER 1996
Crnkshft, Pistons nd Conneting Rods REF. TORQUE NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 CRANKSHAFT 2 1 O-RING 3 1 KEY rnkshft 4 2 MAIN BEARING ASSEMBLY (VALVE TYPE) 5 4 DOWEL PIN min ering 6 16 DOWEL PIN reed loting 7 4 SCREW min ering 55 6.2 8 4 NUT min ering srew 9 2 REED SET mthed 10 8 REED STOP 11 8 SCREW reed stop (9/16 ) 40 4.5 12 8 NUT reed stop srew 13 4 PISTON/PISTON PIN (STANDARD) 13 AR PISTON/PISTON PIN (.015 O.S) DESIGN II 13 AR PISTON/PISTON PIN (.030 O.S.) 13 4 PISTON/PISTON PIN (STANDARD) 13 AR PISTON/PISTON PIN (.015 O.S.) DESIGN I 13 AR PISTON/PISTON PIN (.030 O.S.) 14 8 LOCK RING piston pin 15 1 PISTON RING (STANDARD) 15 AR PISTON RING (.015 O.S.) DESIGN II 15 AR PISTON RING (.030 O.S.) 15 1 PISTON RING (STANDARD) 15 1 PISTON RING (.015 O.S.) DESIGN I 15 1 PISTON RING (.030 O.S.) 16 4 CONNECTING ROD AND CAP ASSEMBLY 17 8 SCREW p to rod 200 16.6 22.5 18 108 NEEDLE BEARING piston pin 19 8 WASHER needle loting 20 1 NEEDLE BEARING rnk pin 21 1 CENTER MAIN BEARING ASSEMBLY 22 2 DOWEL PIN enter min ering 23 56 NEEDLE BEARING 24 1 RACE outer 25 1 SNAP RING outer re 26 2 SCREW enter min ering (1 ) 80 9.0 27 1 DRIVER GEAR 28 1 KEY driver ger 29 1 CARRIER ASSEMBLY DESIGN I/II 30 1 SEAL Design 1 Design 2 90-814676R1 DECEMBER 1996 POWERHEAD - 4-9
Powerhed Torque Sequene nd Torque Speifitions CRANKCASE COVER BOLTS 17.5 l. ft. (23.5 N m) 16 17 CYLINDER BLOCK COVER BOLTS 100 l. in. (11.5 N m) 12 13 9 10 8 9 4 5 1 2 5 6 3 7 6 1 2 11 10 15 14 4 3 EXHAUST COVER 16.5 l. ft. (22.5 N m) 11 10 8 7 12 POWERHEAD TO DRIVESHAFT HOUSING 12.5 l. ft. (17.0 N m) 7 6 4 3 1 1 2 5 8 9 13 15 4-10 - POWERHEAD 90-814676R1 DECEMBER 1996 14
Powerhed Removl from Driveshft Housing 5. Remove shift nd throttle les from engine. Eletri Strt Model 1. Disonnet powerhed ttery les from ttery. 2. Remove top owling. 3. Remove Sprk Plug leds from sprk plugs. 4. Disonnet powerhed nd remote ontrol eletril hrness onnetor. Disonnet remote ontrol trim ontrol leds (BLUE/ WHITE nd GREEN/WHITE), if pplile. - Throttle Cle - Shift Cle 50564C 6. Remove POSITIVE LEAD from strter motor. 7. Remove four olts seuring strter motor nd remove retining lmps nd strter motor from powerhed. d d - Hrness Connetor - Trim Control Leds 26835 54652 - Positive Led - Strter Motor - Bolts d - Retining Clmps 90-814676R1 DECEMBER 1996 POWERHEAD - 4-11
8. Disonnet two lue low oil level leds t their ullet onnetors. 9. Disonnet lue/white nd green/white power trim swith leds t their ullet onnetors. 11. Remove inlet hose from oil pump. NOTE: If oil tnk ontins oil, inlet hose to oil pump must e plugged when disonneted to prevent oil lekge. d - Blue Leds - Blue/White Led - Green/White Led d - Trim Swith 54668 10. Remove olt seuring fuel line onnetor to ottom owl. - Inlet Hose - Oil Pump 53119 12. Remove lk led from grounding olt t ft strord orner of ottom owl. 13. Remove tell-tle hose from ottom owl. 54669 - Bolt - Fuel Line Connetor 54670 - Blk Led - Grounding Bolt - Tell-Tle Hose 4-12 - POWERHEAD 90-814676R1 DECEMBER 1996
14. Remove three olts seuring flywheel over to powerhed nd remove over nd oil tnk ssemly. NOTE: Hold oil tnk seurely when removing from powerhed s oil tnk my deth from flywheel over ssemly. 16. Remove eight nuts seuring powerhed to driveshft housing. - Nuts (4 Eh Side) 54672 17. Remove plsti p from enter of flywheel nd thred Lifting Eye (91-75132) into flywheel. Using hoist, lift powerhed from driveshft housing nd instll on Powerhed Stnd (91-25821A1) or work enh. 54640 - Bolts - Flywheel Cover 15. Remove four olts seuring trim over to ottom owl nd remove over. 54673 54671 - Lifting Eye (91-75132) - Bolts (2 Eh Side) - Trim Cover 90-814676R1 DECEMBER 1996 POWERHEAD - 4-13
Mnul Strt Model 1. Disonnet ny lterntor hrging leds from ttery. 2. Remove top owl. 3. Remove sprk plug leds from sprk plugs. 4. Unlth le retiner nd remove throttle le from throttle/sprk rm nd shift le from shift rket. 6. Disonnet BLACK/YELLOW stop leds t oth ullet onnetors. 7. Remove three lk leds from grounding olt t ft strord orner of ottom owl. 8. Remove tell-tle hose from ottom owl. d e 54675 - Blk/Yellow Leds - Bullet Connetors - Blk Leds d - Bolt e - Tell-Tle Hose 9. Remove olt nd retining lip from nti-strt-inger linkge. - Throttle Cle - Throttle Cle Lth 26830 5. Remove olt seuring fuel onnetor to ottom owl. 54676 - Bolt - Retining Clip 10. Remove two fuel hoses from enrihener vlve. - Bolt - Fuel Connetor 54674 - Fuel Hoses - Enrihener Vlve 54677 4-14 - POWERHEAD 90-814676R1 DECEMBER 1996
11. Remove three olts seuring reoil strter to powerhed nd remove reoil ssemly. 13. Remove eight nuts seuring powerhed to driveshft housing. - Nuts (4 Eh Side) 26815 14. Remove plsti p from enter of flywheel nd thred lifting eye (91-75132) into flywheel. Using hoist, lift powerhed from driveshft housing nd instll on powerhed stnd (91-25821A1) or work enh. - Reoil Strter 26817 12. Remove four olts seuring trim over to ottom owl nd remove over. 54671 - Bolts (2 Eh Side) - Trim Cover - Lifting Eye (91-75132) 54678 90-814676R1 DECEMBER 1996 POWERHEAD - 4-15
Powerhed Disssemly 1. Remove the following omponents/ssemlies referring to the listed servie mnul setions. 3. Remove three olts tthing throttle tutor ssemly to rnkse over. Component/Assemly Rewind Strter Flywheel Ignition Components Strter Motor Cruretors, Fuel Pump nd Fuel Enrihment Vlve Setion 2A 2A 2A 2B 3A 2. Remove two llen srews seuring oil pump to rnkse over. Remove oil pump nd driven ger. NOTE: If driven ger remins in rnkse over, it n e removed when rnkse over is removed from ylinder lok. 54680 - Bolts - Throttle Atutor Assemly 4. Remove olt seuring throttle/sprk rm to exhust mnifold over nd remove rm ssemly. 54679 - Allen Srews - Oil Pump - Driven Ger (Hidden) - Bolt - Throttle/Sprk Arm 54681 4-16 - POWERHEAD 90-814676R1 DECEMBER 1996
5. Remove olts seuring upper nd lower end ps to ylinder lok nd rnkse over. 6. Bend k lok ts on reed ge olts nd enter min olt. - Bolts - Upper End Cp 54682 54684 - Loking T Wsher - Reed Cge Bolt - Center Min Bolt 7. Remove 17 olts seuring rnkse over to lok. 54683 - Bolts - Lower End Cp 54685 - Crnkse Cover 90-814676R1 DECEMBER 1996 POWERHEAD - 4-17
8. Using pry points to id in removl, lift rnkse over from ylinder lok. - Pry Points - Crnkse Cover 54686 9. Gently tp upper nd lower end ps from rnkshft with rwhide mllet. - Lower End Cp 54688 10. Remove oil pump drive ger (eletri strt models only) from rnkshft. Ger slides off rnkshft. 54689 - Oil Pump Drive Ger - Upper End Cp 54687 4-18 - POWERHEAD 90-814676R1 DECEMBER 1996
11. Remove rnkshft ssemly from ylinder lok. If pry r is used to id in removl of rnkshft ssemly, pd surfe of lok where pry r ontts. 12. Remove 6 srews seuring trnsfer over to ylinder lok nd remove over. 13. Remove lne tue nd fittings from ylinder lok. 14. Remove leed hose nd leed hek vlve from ylinder lok. 15. Remove tell-tle hose nd fitting from ylinder lok. NOTE: Mnul Strt Models nd some erly Eletri Strt Models hve fuel enrihment fitting in the lne tue. d - Crnkshft Assemly - Pry Br - Pd 54690 f e - Srews - Trnsfer Cover - Blne Tue d - Bleed Hose e - Bleed Chek Vlve f - T-Fitting (Fuel Enrihment) 54691 90-814676R1 DECEMBER 1996 POWERHEAD - 4-19
16. Remove 10 olts from ylinder lok over nd remove over. Remove temperture swith from ylinder lok. 17. Remove 15 olts from exhust mnifold over nd remove mnifold over nd ffle plte from ylinder lok. Exhust Mnifold Cover 50532 - Cylinder Blok Cover - Temperture Swith 54692 - Exhust Mnifold Cover - Bffle Plte - Gskets 4-20 - POWERHEAD 90-814676R1 DECEMBER 1996
End Cp Disssemly IMPORTANT: It is reommended tht new oil sels e instlled in end ps, regrdless of pperne, to ensure lsting repir. UPPER END CAP 1. Drive oil sel from end p with suitle punh. Disrd oil sel. 2. Remove nd disrd O-ring from end p. 3. Inspet ll ering loted in the end p s outlined in Clening nd Inspetion, following. IMPORTANT: DO NOT remove ll ering from end p unless replement is required. IMPORTANT: It is reommended tht het e pplied refully to end p housing to id in removl of ll ering. 4. If inspetion determines tht replement of ll ering is required, use Bll Bering Puller (91-24100A1) nd press ll ering from end p. d - Sel (Hidden) - Upper End Cp - O-Ring d - Punh 54693 LOWER END CAP 1. Remove nd disrd O-ring from end p. 55432 90-814676R1 DECEMBER 1996 POWERHEAD - 4-21
2. Use Bll Bering Puller (91-24100A1) nd press ll ering from end p. Inspet ll ering s outlined in Clening nd Inspetion, following. IMPORTANT: It is reommended tht het e pplied refully to end p housing to id in removl of ll ering. Crnkshft Disssemly WARNING Eye Protetion must e worn while removing piston rings nd piston pin lok rings from pistons. 1. Remove piston rings from pistons with Piston Ring Expnder (91-24697). Disrd piston rings. 54695 - Lower End Cp - Bll Bering Puller (91-24100A1) 3. Drive oil sels from end p with suitle punh. Disrd oil sels. Design 1 End Cp - Oil Sels Design 2 End Cp - Piston Ring Expnder (91-24697) 54696 - Oil Sels Design 3 End Cp - Oil Sels 4-22 - POWERHEAD 90-814676R1 DECEMBER 1996
2. Remove piston pin lok rings from oth ends of piston pin ores. Disrd lok rings. DO NOT reuse piston pin lok rings. 4. Ple Piston Pin Tool (91-76160A2) into top of piston pin. Support ottom of piston with hnd nd tp on end of piston pin tool with mllet, pushing piston pin out of piston. Remove piston from onneting rods. - Piston Pin Lok Ring (One Eh Side) - Needle Nose Pliers 54697 3. Use n wl nd mrk eh onneting rod nd piston with the sme numer s the ylinder to whih it is instlled. Mrk onneting rods on the I em nd piston on inside of skirt. 54699 - Piston Pin Tool (91-76160A2) - Piston Pin - Support Piston (Up) While Foring Piston Pin Out 5. Remove piston pin needle erings nd loting wshers from onneting rod. 54698 - Srie Identifition No. on Conneting Rod nd Inside of Piston Skirt - Needle Berings (27 Required) - Loting Wshers 54700 90-814676R1 DECEMBER 1996 POWERHEAD - 4-23
IMPORTANT: It is reommended tht new needle erings e instlled in onneting rod to ensure lsting repir. NOTE: If needle erings must e reused, store them in numered ontiner so they n e reinstlled with sme onneting rod. DO NOT intermix needle erings from one onneting rod with those from nother onneting rod. Keep needle erings len. 6. Remove nd disrd onneting rod olts. Seprte onneting rod from rod p. Remove onneting rod, p nd needle erings from rnk pin throw. Keep onneting rod, p nd needle erings together, if they re to e reused. d 54702 - Srew nd Nut (One Eh Side) - Reed Blok 8. Ressemle eh reed lok s it is removed to ssure orret remth of eh ssemly. 9. Inspet reed loks s outlined in Clening nd Inspetion, following. If inspetion indites tht replement of prt is neessry, remove prt from reed lok. 10. Remove two olts whih seure oth hlves of the enter min ering support together. Remove enter min ering support from rnkshft. 54701 - Conneting Rod - Conneting Rod Cp - Conneting Rod Bolts d - Needle Bering (25 Required) 7. Remove two srews nd loknuts whih seure oth hlves of reed lok together. Remove reed lok from rnkshft. 54703 - Center Min Bering Support - Bolts - Loting Pin 4-24 - POWERHEAD 90-814676R1 DECEMBER 1996
Clening nd Inspetion Cylinder Blok nd Crnkse Cover IMPORTANT: Crnkse over nd ylinder lok re mthed, line-ored ssemly nd never should e mismthed y using different rnkse over or ylinder lok. CAUTION While honing nd lening proedures re eing performed on ylinder lok, ll leed system omponents hoses, fittings nd hek vlve MUST BE REMOVED from ylinder lok to prevent dmge from rsive mterils. Cylinder Bore (Clening nd Inspetion) 1. Inspet ylinder ores for soring, suffing or trnsfer of luminum from piston to ylinder wll. Soring or suffing, if NOT TOO SEVERE, n normlly e removed y honing. If trnsfer of luminum hs ourred, n idi solution suh s Tidy Bowl Clener should e pplied to the res of the ylinder ore where trnsfer of luminum hs ourred. After the idi solution hs removed the trnsferred luminum, thoroughly flush the ylinder ore(s) to remove ny remining id. Cylinder wlls my now e honed to remove ny glze nd to id in the seting of new piston rings. HONING PROCEDURE. When ylinders re to e honed, follow the hone mnufturer s reommendtions for use of the hone, lening nd lurition during honing.. For est results, ontinuous flow of honing oil should e pumped into the work re. If pumping oil is not prtil, use n oil n. Apply oil generously nd frequently on oth stones nd work.. Lolize stroking in the smllest dimeter until drill speed is onstnt throughout length of ore. Mintin firm stone pressure ginst ylinder wll to ssure fst stok removl nd urte results. Expnd stones, s neessry, to ompenste for stok removl nd stone wer. Stroke t rte of 30 omplete yles per minute to produe est rosshth pttern. Use honing oil generously. d. Thoroughly len ylinder ores with hot wter nd detergent. Sru well with stiff ristle rush nd rinse thoroughly with hot wter. A good lening is essentil. If ny of the rsive mteril is llowed to remin in the ylinder ore, it will use rpid wer of new piston rings, ylinder ore nd erings. After lening, ores should e swed severl times with engine oil nd len loth, then wiped with len, dry loth. Cylinders SHOULD NOT e lened with kerosene or gsoline. Clen reminder of ylinder lok to remove exess mteril spred during honing operting. 2. Hone ll ylinder wlls JUST ENOUGH to deglze wlls. 3. Mesure ylinder ore dimeter (with n inside mirometer) of eh ylinder. Chek for tpered, out-of-round ( egg-shped ) nd oversized ore. CAUTION When honing ylinder lok, remove hone frequently nd hek ondition of ylinder wlls. DO NOT hone ny more thn solutely neessry, s hone n remove ylinder wll mteril rpidly. - Inside Mirometer 54704 90-814676R1 DECEMBER 1996 POWERHEAD - 4-25
Cylinder Bore Size Piston Size With Stndrd Size Piston With.015 Oversize Piston With.030 Oversize Piston Cylinder Bore Finish Hone 2.565 (65.15mm) 2.580 (65.53mm) 2.595 (65.91mm) 2. Inspet piston ring grooves for wer, urns, distortion or loose piston ring loting pins. 3. Clen piston dome, ring grooves nd piston skirt. Use reessed end of roken piston ring to len ron deposits from ring grooves. DO NOT use n utomotive type ring groove lener, s this type tool ould loosen piston ring loting pins. 1. If ylinder ore is tpered, out-of-round or worn more thn.004 (0.10mm) from STANDARD PISTON DIAMETERS nd CYLINDER BLOCK FINISH HONE (refer to hrt, preeding), it will e neessry to re-ore ylinders) to.015 (0.38mm) or.030 (0.762mm) oversize nd instll oversize piston(s) nd piston rings during ressemly. If.030 oversize ylinder lok finish hone dimeter is tpered, out-of-round or worn more thn.004, ylinder lok must e repled. NOTE: The weight of n oversize piston is pproximtely the sme s stndrd size piston, therefore, it is not neessry to re-ore ll ylinders in lok just euse one ylinder requires re-oring. 2. After honing nd thoroughly lening ylinder ores, pply light oil to ylinder wlls to prevent rusting. Pistons NOTE: To ssure lsting repirs nd proper engine opertion fter repirs, it is importnt tht piston rings e repled. IMPORTANT: If engine ws sumerged while engine ws running, piston pin nd/or onneting rod my e ent. If piston pin is ent, piston must e repled. (Piston pins re not sold seprtely euse of mthed fit into piston.) If piston pin is ent, onneting rod must e heked for strightness (refer to Conneting Rods, following, on how to hek strightness). 1. Chek pistons for soring, rks, metl dmge nd rked or worn piston pin osses. If ny of these onditions re found, reple piston(s). 54705 4. Clen ron deposits from top of pistons with soft wire rush, ron removl solution or snd lsting. When wire rushing top of piston, DO NOT urr or round mhined edges. Clen (polish) piston skirt with rous loth. 5. After thoroughly lening pistons, hek eh piston size nd roundness, using mirometer. Piston must e mesured s desried, following. 4-26 - POWERHEAD 90-814676R1 DECEMBER 1996
Mesuring Piston Roundness Piston hs tpered m profile shpe nd is not true dimeter. Using mirometer, mesure dimension A t lotion shown. Dimension should e s indited in hrt following. Dimensions t Right Angle (90 ) to Piston Pin 54706 - Feeler Guge - Reed 6. Reple reeds s neessry. IMPORTANT: Reple reeds in sets only. DO NOT turn used reed over for re-use. Piston Size Stndrd Piston.015 Oversize Piston.030 Oversize Piston Reed Bloks Piston Mesurements Dimension A 2.558 (64.97mm) 2.573 (65.35mm) 2.588 (65.74mm) Cyl. Blok Finish Hone 2.565 (65.15mm) 2.580 (65.53mm) 2.595 (65.91mm) IMPORTANT: DO NOT remove reeds from reed lok, unless replement is neessry. DO NOT turn used reeds over for re-use. 1. Thoroughly len reeds nd reed lok. 2. Ple reed lok hlves together nd seure with srews nd nuts. 3. Chek for wer (indenttion) on fe of eh reed lok. If reeds hve mde indenttions, reple lok. 4. Chek for hipped or roken reeds. 5. Chek reeds to e sure tht they re not preloded (dhere tightly to reed lok) nd tht they re not stnding open n exessive mount [greter thn.007 (0.78mm)]. 7. Mesuring from top of losed reed to inside of reed stop, hek reed stop opening of eh reed stop. Speified reed stop opening is 5/32 (3.97mm). If reed stop opening is not orret, refully end reed stop to hieve speified opening. 8. After instlling ny new reeds [nd hving torqued reed retining srews to 30 l. in. (3.3 N m)], hek new reeds s outlined in Step 5, preeding. IMPORTANT: If engine shows inditions of hving een overheted, hek ondition of nylon loting pins. Dmged (melted) loting pins will ffet engine opertion (poor idle, hrd strting, et.). d e e d - Top of Closed Reed - Inside of Reed Stop - Reed Stop Opening 5/32 (3.97mm) d - Loting Pins e - Reed Retining Srews [Torque to 30 l. in. (3.3 N m)] 90-814676R1 DECEMBER 1996 POWERHEAD - 4-27 54707
Conneting Rods 1. Chek onneting rod for lignment y pling rods on surfe plte. If light n e seen under ny portion of mhined surfes, if rod hs slight wole on plte or, if.002 feeler guge n e inserted etween ny mhined surfe nd surfe plte, rod is ent nd must e disrded.. Wter Mrks: When ering surfes re sujeted to wter ontmintion, ering surfe ething ours. This ething resemles the size of the ering. 51853 Conneting Rod with Wter Mrks. Splling: Splling is the loss of ering surfe; it resemles flking or hipping. Splling will e most evident on the thrust portion of the onneting rod in line with the I em. The generl deteriortion of the ering surfe ould e used y, or elerted y, improper lurition. - Feeler Guge - Surfe Plte - Even Downwrd Pressure 54708 2. Crefully inspet onneting rod erings for rust or signs of ering filure. Reple erings s neessry. CAUTION DO NOT intermix new nd used needle erings. If replement of some erings is required, reple ll erings t tht lotion. 3. Inspet rnkshft end nd piston pin end ering surfes of onneting rod for the following:. Rust: Rust formtion on ering surfes uses uneven pitting of surfe(s). - Splling 51853 51853 - Pitting 4-28 - POWERHEAD 90-814676R1 DECEMBER 1996
d. Chtter Mrks: Chtter mrks re the result of omintion of low speed-low lod-old wter temperture opertion tht is ggrvted y indequte lurition nd/or improper fuel. Under these onditions, the rnkshft journl is hmmered y the onneting rod. As ignition ours in the ylinder, the piston pushes the onneting rod with tremendous fore, nd this fore is trnsferred to the onneting rod journl. Sine there is little or no lod on the rnkshft, it ounes wy from the onneting rod. The rnkshft then remins immoile for split seond, until the piston trvel uses the onneting rod to th up to the witing rnkshft journl, then hmmers it. The repetition of this tion uses rough ering surfe(s) tht resemles tiny wshord. In some instnes, the onneting rod rnk pin ore eomes highly polished. During opertion, the engine will emit whirr nd/or hirp sound when it is elerted rpidly from idle speed to pproximtely 1500 RPM, then quikly returned to idle. If the preeding onditions re found, reple oth the rnkshft nd onneting rod. e. Uneven Wer: Uneven wer ould e used y ent onneting rod or improper shimming of rnkshft end ply [filure to mintin pproximtely the sme mount of shim(s) under end p, therey using the rnkshft journl not to e entered over the ylinder ore]. - Uneven Wer etween Arrows 51853 f. Overheting: Overheting is visile s luish ering surfe olor used y indequte lurition or exessive RPM. 51853 - Chtter Mrks etween Arrows 90-814676R1 DECEMBER 1996 POWERHEAD - 4-29
Clening Conneting Rods 1. If neessry, len onneting rod ering surfes, s follows:. Instll onneting rod p nd olts (using 1/4-12 point soket). Be sure tht p is ligned with rod orretly. Refer to onneting rod p lignment, following.. Clen PISTON PIN END of onneting rod, using sme method s in Step, preeding, using 320 grit rorundum loth. d. Thoroughly wsh onneting rods to remove rsive grit. Rehek ering surfes of onneting rods. Reple ny onneting rod(s) tht nnot e properly lened up. Lurite ering surfes of onneting rods (whih will e re-used) with light oil to prevent rust.. Clen CRANKSHAFT END of onneting rod y using 320 CLOTH pled in slotted 3/8 (9.5mm) dimeter shft, s shown. Chuk shft in drill press nd operting press t high speed while keeping onneting rod t 900 ngle to slotted shft. IMPORTANT: Clen onneting rod just enough to len up ering surfes. DO NOT ontinue to len fter mrks re removed from ering surfes. Crnkshft 1. Inspet rnkshft to drive shft splines for wer. (Reple rnkshft, if neessry.) 2. Chek rnkshft for strightness. Reple s neessry. 3. Inspet rnkshft oil sel surfes. Seling surfes must not e grooved, pitted or srthed. Reple s neessry. 4. Chek ll rnkshft ering surfes for rust, wter mrks, htter mrks, uneven wer nd/or overheting. (Refer to Conneting Rod, Step 3, preeding.) 5. If neessry, len rnkshft surfes with 320 loth. 51083-320 Cloth 54709 4-30 - POWERHEAD 90-814676R1 DECEMBER 1996
WARNING DO NOT spin-dry rnkshft ll erings with ompressed ir. 6. Thoroughly len (with solvent) nd dry rnkshft ll erings. Rehek surfes of rnkshft. Reple rnkshft, if surfes nnot e properly lened up. If rnkshft will e reused, lurite surfes of rnkshft with light oil to prevent rust. Bll Bering 1. Clen ll erings with solvent nd dry with ompressed ir. 2. Attempt to work inner ering re in-nd-out. There should not e exessive ply. 3. Lurite ll ering with light oil. Rotte outer ering re. Bering should hve smooth tion nd no rust stins. If ll ering sounds or feels rough or hs thes, remove nd disrd ering. (Refer to Powerhed Disssemly, preeding.) Powerhed Ressemly Generl Before proeeding with powerhed ressemly, e sure tht ll prts to e re-used hve een refully lened nd thoroughly inspeted, s outlined in Clening nd Inspetion, preeding. Prts, whih hve not een properly lened (or whih re questionle), n severely dmge n otherwise perfetly good powerhed within the first few minutes of opertion. All new powerhed gskets MUST BE instlled during ressemly. During ressemly, lurite prts with Quiksilver Formul 50-D 2-Cyle Outord Lurint when light oil is speified or with Quiksilver Needle Bering Assemly Lurint whenever grese is speified. Quiksilver prt numers of lurints, selers nd loking ompounds re listed in the Tool Ctlog nd in essories rohures. A torque wrenh is essentil for orret ressemly of powerhed. DO NOT ttempt to ressemle powerhed without using torque wrenh. Atthing olts for overs, housings nd ylinder heds MUST BE torqued y tightening olts in 3 progressive steps (following speified torque sequene) until speified torque is rehed (see Exmple, following). Exmple: If ylinder over tthing olts require torque of 70 l. in. (81 kg-m), ) tighten ll olts to 20 l. in. (2.2 N m), following speified torque sequene, ) tighten ll olts to 50 l. in. (5.5 N m), following torque sequene, then finlly ) tighten ll olts to 70 l. in. (7.7 N m) following torque sequene. Powerhed torques re listed in Generl Informtion Powerhed, preeding. 90-814676R1 DECEMBER 1996 POWERHEAD - 4-31
Crnkshft Ressemly 1. Lurite min ering outer re with Quiksilver Needle Bering Assemly Lurint nd ple needle erings on re. - Outer Re - Needle Bering Assemly Lurint - Needle Berings (56 Required) 54710 2. Instll ering re with needle erings in ple on rnkshft. Seure oth hlves of re together with snp ring. - Snp Ring - Outer re 54712 Min Bering Instlled 3. Instll min ering support onto min ering re. Loting pin must enter hole in min ering re. 54713 54711 - Loting Pin - Position in Min Bering Re - Alignment Pins (2 Required) Instlling Min Bering Re on Crnkshft 4-32 - POWERHEAD 90-814676R1 DECEMBER 1996
4. Seure oth hlves of eh min ering re together with two olts. Torque olts to 80 l. in. (9.0 N m). 6. Seure oth hlves of reed lok together with two srews nd nuts. Torque reed lok srews to 55 l. in. (6.2 N m). 54702 - Min Bering - Bolts [Torque to 80 l. in. (9.0 N m)] - Loting Pin 54703 IMPORTANT: Chek reed stop setting for proper opening. Lrger opening n use reed rekge; smller opening will not llow suffiient ir/ fuel mixture to enter t higher RPM. NOTE: Either side of reed lok n e fing up. 5. Lurite inner ore of reed loks with Light Oil nd instll onto rnkshft. - Torque Srews (One Eh Side) to 55 l. in. (6.2 N m) - Reed Blok CAUTION Clen onneting rod olts with solvent nd dry with ompressed ir to prevent dmge to threds while torquing. DO NOT lurite threds prior to instlltion.. Clen suffiient mount of new onneting rod olts with solvent nd dry with ompressed ir.. Apply thin ot of Quiksilver Needle Bering Assemly Lurint to rnk pin ering surfe of onneting rod nd rod p to hold needle erings in ple. 54714 - Lurite Inner Bore with Light Oil - Insert Loting Pins into Holes nd Press Together 90-814676R1 DECEMBER 1996 POWERHEAD - 4-33
CAUTION Never inter-mix new needle erings with used erings. If ny ering requires replement, reple ll needle erings.. Ple needle erings (25 required) round rnk pin ering surfe of onneting rod nd p. d 54715 - Conneting Rod - Rod Cp - Bolts d - Needle Berings d. Ple onneting rod nd p together on rnk pin. e. Apply Lotite Grde A (271) to rod olt threds. f. Thred onneting rod olts finger-tight while heking for orret lignment of the rod p. Corret Conneting Rod Cp Alignment g. Tighten onneting rod olts (using 1/4-12 point soket) evenly in three progressive steps until torqued to 200 l. in. (22.5 N m). h. Chek eh onneting rod p for orret lignment. If not ligned, ridge n e seen or felt t the seprting line s shown. Corret ny mislignment. 7. Use smll dimeter wire nd try to spred needle erings prt. If needle erings do not spred the width of single ering, the orret numer of erings hs een used. Rotte onneting rod (fter torquing), heking tht it rottes freely. If rough, remove nd hek re nd needle erings. 8. Repet preeding proedure for remining onneting rods. 4-34 - POWERHEAD 90-814676R1 DECEMBER 1996
Piston Instlltion 1. Ple piee of pper on enh nd line up piston pin needle erings. CAUTION Never inter-mix new needle erings with used erings t the sme piston pin end. If ny needle ering requires replement, reple ll erings. 2. Ple sleeve on Piston Pin Tool (91-76160A2) nd pply smll mount of Quiksilver Needle Bering Assemly Lurint round sleeve. Roll tool over lined-up erings. 4. Ple upper loting wsher over sleeve on piston pin tool, then slide piston pin tool out of sleeve (sleeve nd wshers will hold needle erings in position in onneting rod). 5. Ple piston on onneting rod. Position piston pin ore diretly over sleeve nd slide piston pin tool thru upper pin ore nd into sleeve. IMPORTANT: Intke side of piston defletor must fe towrds intke ports. 6. Lurite piston pin with light oil. Use mllet nd drive piston pin into piston while mintining the position of piston pin tool with other hnd. Continue to drive pin into piston s tool nd sleeve re driven out. 54716 - Piston Pin Tool (91-76160A2) - Sleeve - Needle Berings (27 Required) 3. Ple lower loting wsher on onneting rod nd slide sleeve (long with needle erings) thru wsher nd into onneting rod. Add needle erings until re will ept no more (27 required). 54718 - Instll Piston so tht Defletor will e Towrd Intke Ports - Piston Pin Tool - Piston Pin 54717 - Sleeve - Loting Wsher - Needle Berings (27 Required) 90-814676R1 DECEMBER 1996 POWERHEAD - 4-35
7. Seure piston pin in piston y instlling new G type piston lokrings into groove in eh end of piston pin ore. Mke sure tht lokrings re seted in grooves. 9. Lurite rings with light oil nd lign ring ends with loting pins in ring grooves. 54719 - Piston Ring Loting Pin - Piston Pin Lokring (One Eh Side) - Needle Nose Pliers 54697 8. Instll new piston rings on piston with Piston Ring Expnder Tool (91-24697). Spred eh ring just enough to slip over piston. Chek tht piston rings rotte freely in ring grooves. If ring does not rotte freely, ondition must e orreted. Design 1 Design 2 4-36 - POWERHEAD 90-814676R1 DECEMBER 1996
Crnkshft Sel Instlltion NOTE: Crnkshfts tht use Design 1 nd Design 3 lower end ps (shown) hve replele sel in the ottom of the rnkshft. This sel protets the drive shft splines. Design 2 type lower end ps hve the sel inorported in the end p. SEAL CARRIER REPLACEMENT (DESIGN 1) 1. Thoroughly len rnkshft splines with solvent nd dry with ompressed ir. 2. Drive sel rrier squrely into end of rnkshft, using lok of wood to protet sel rrier. Instll sel rrier to the dimension shown. CRANKSHAFTS USING DESIGN 1 LOWER END CAP 1. Instll new O-Ring sel into sel rrier on end of rnkshft. 2. Lurite sel with 2-4-C Mrine Lurint. 5/32 in. (4mm) - Sel Crrier CRANKSHAFTS USING DESIGN 3 LOWER END CAP 1. Instll new O-Ring sel into sel rrier on end of rnkshft. 2. Lurite sel with 2-4-C Mrine Lurint. - Design 1 Type Lower End Cp - O-Ring Sel - Sel Crrier d - Lurite with 2-4-C Mrine Lurint d - Design 3 Type Lower End Cp - O-Ring Sel - Lurite with 2-4-C Mrine Lurint 90-814676R1 DECEMBER 1996 POWERHEAD - 4-37
End Cp Ressemly LOWER END CAP 1. Instll O-Ring Sel into sel groove. 2. Apply Lotite Grde A (271) to outer dimeter oil sels nd press into end p using proper mndrel s shown. Wipe off exess Lotite. 3. Apply 2-4-C Mrine Lurint to lips of oil sels. 4. Press ll ering into lower end p with press lok. - Blok - Aror Press 54723 - O-Ring Sel - Mndrel Design 1 End Cp 54722 IMPORTANT: If instlling Design 1, 2 or 3 end p on engine S/N 0D040454 nd elow, remove nd disrd sel (if equipped) from end of drive shft. - 26-41953 Oil Sel (2) Design 2 End Cp - Sel 51188-26-41953 Oil Sel (1) - 26-63742 Oil Sel (1) Design 3 End Cp - 26-41953 Oil Sel (2) 4-38 - POWERHEAD 90-814676R1 DECEMBER 1996
UPPER END CAP 1. If removed, press ll ering into upper end p with press lok. Cylinder Blok Ressemly 1. Lurite piston rings, pistons nd ylinder wlls with light oil. 2. Rotte nd lign end of eh piston ring with loting pin in ring groove. CAUTION Piston rings MUST BE properly positioned with loting pin etween piston ring end gps. Improperly positioned piston rings my rek during instlltion. - Blok - Aror Press 54720 2. Apply Lotite Grde A (271) to outer dimeter on oil sel nd press into end p with lip of sel towrd ll ering, using proper mndrel. Remove exess Lotite from end p. 54719 - Oil Sel Lip Towrd Bll Bering 54721 - Piston Ring Loting Pin 3. Instll ring ompressors, s follows:. No. 1 piston must e stright out from rnk pin throw nd t ottom of stroke. Use stright ring ompressor.. No. 2 piston must e stright out from rnk pin throw nd t top of stroke. Use stright ompressor.. No. 3 nd No. 4 pistons must e diretly inline with upper pistons nd use offset ring ompressors. d. Chek piston ring end gp lignment (ll pistons) with loting pins. 90-814676R1 DECEMBER 1996 POWERHEAD - 4-39
54724 - Stright Compressors - Offset Compressors Ring Compressors Instlled on Pistons (Front View) 54725 - Stright Compressors - Offset Compressors Ring Compressors Instlled on Pistons (Rer View) 4-40 - POWERHEAD 90-814676R1 DECEMBER 1996
4. If removed, ple reed lok loting pins into ylinder lok. 6. Align entermin ering nd reed loks with loting pins nd push entermin ering nd reed loks downwrd to set them in ylinder lok. 54726 - Reed Blok Loting Pin - Min Bering Support Loting Pin (on Some Models, Pin is Loted in Bering Support) - Lurite Cylinder Wlls, Pistons nd Piston Rings with Light Oil 5. Instll rnkshft ssemly into ylinder lok. Remove ring ompressors s eh piston enters ylinder. Mke sure tht rnkshft is kept horizontl while instlling. 54728 - Align Centermin Bering Support nd Reed Bloks with Loting Pins nd Push Downwrd to Set 7. Chek eh piston ring for spring tension thru the exhust ports y pressing with srewdriver. If no spring tension exists (ring fils to return to position), it is likely tht the piston ring ws roken during ssemly [reple roken piston ring(s)]. Use ution not to urr piston or ring during inspetion. 54727 54729 - Keep Crnkshft Horizontl - Srewdriver - Piston Rings 90-814676R1 DECEMBER 1996 POWERHEAD - 4-41
8. Slide oil pump drive ger onto rnkshft. Chmfer side of ger goes towrds ottom rnkshft throw. Engge key with slot in ger. d. With rnkshft ginst lower end p, use feeler guge nd hek mesurement etween inner re of upper ll ering nd thrust fe of rnkshft. Corret end ply should e etween.008 to.012 (0.203mm to 0.305mm). 54730 - Oil Pump Drive Ger - Chmfer - Key d - Slot 9. Use powerhed stnd nd rotte rnkshft severl times to ssure free opertion (no inds nd/or thes). 10. Chek rnkshft end ply, s follows:. Temporrily instll upper nd lower end ps with originl shim(s). Seure eh end p to ylinder lok with end p olts.. Use mllet nd tp rnkshft towrd ottom (stud end) of ylinder lok. Hold rnkshft tight ginst lower end p while mking mesurement in Step C. 54731 - Top End Cp Bll Bering - Top Crnkshft Throw d. If neessry, dd or remove shim(s) to ttin orret end ply. Keep shim(s) thikness pproximtely the sme [within.005 (0.127mm)] etween upper nd lower end ps to ssure tht rnk pin throws re entered over ylinders. 11. Loosen end p olts severl turns nd slide end ps wy from ylinder lok to llow rnkse over to e instlled. 12. Thoroughly len mhined, mting surfe of rnkse over nd ylinder lok with solvent to remove ll oil. CAUTION Before pplying Lotite Mster Gsket (92-12564-1) to ylinder lok, mke sure tht mting surfes of rnkse over nd ylinder lok re len nd free of oil. Loqui Primer T n e used to len these surfe. Lotite must e pplied in ontinuous ed long the inside of mounting olt holes. If void should our when pplying ed of Lotite, either remove the entire ed with rg or pply with dditionl ed prllel to the void nd overlpping the previously pplied ed. Assemle rnkse over to ylinder lok without lterl movement. 4-42 - POWERHEAD 90-814676R1 DECEMBER 1996
13. Apply ontinuous ed of Lotite Mster gsket Selnt on ylinder lok. 15. Instll entermin ering nd reed lok mounting olts with loking ts. Torque olts to speified torque nd end loking ts up nd ginst flt of eh olt. - Cylinder Blok - Lotite Mster Gsket Selnt (92-12564-1); Apply in Continuous 1/16 (1.6mm) Bed 14. Ple rnkse over (without lterl movement) on ylinder lok nd seure with mounting olts nd lokwshers. Use torquing sequene shown. Torque olts evenly, to 210 l. in. (23.7 N m), in 3 progressive steps. - Reed Blok Mounting Bolts 5/8 (16mm) Long; Torque to 75 l. in. (8.5 N m) - Centermin Mounting Bolt 1 (25mm) Long; Torque to 75 l. in. (8.5 N m) - Loking T Wshers (Bend s Shown) 54732 16. Seure end ps to ylinder lok. Torque olts to speified torque. Rotte rnkshft severl times to ssure free opertion (no inds nd/or thes). 50545 54733 Torque Sequene Intke Mnifold - Torque Bolts to 200 l. in. (22.6 N m) - Upper End Cp 90-814676R1 DECEMBER 1996 POWERHEAD - 4-43
54683 - Torque Bolts to 200 l. in. (22.6 N m) - Bottom End Cp 17. Instll exhust over nd divider plte with new gskets. Apply Lotite Grde A (271) to olt threds. Torque olts evenly in three stges until torque of 200 l. in. (22.6 N m) is hieved. - Exhust Cover - Divider Plte - Gskets 50532 Torque Sequene Exhust Cover 18. Instll lne tue with fittings into ylinder lok. Apply pipe selnt (otin lolly) to fitting threds. NOTE: Mnul strt models nd some erly eletri models hve T-fitting for the fuel enrihment hose in the lne tue. Lter eletri strt models will not hve this T-fitting. 19. Apply pipe selnt (otin lolly) to leed hek vlve threds nd instll leed hose nd hek vlve on ylinder lok. NOTE: The leed hek vlve llows exess rnkse lurint to flow one wy, from the ottom of the rnkse to the top end p ering to provide dditionl lurition. Inspet hek vlve for proper opertion y pplying vuum to outlet side of hek vlve (red end). No restrition to flow should e felt. Apply vuum to threded side of hek vlve. A restrition to flow should e felt inditing hek ll is seting properly. If these test results re not otined, hek vlve must e repled. 4-44 - POWERHEAD 90-814676R1 DECEMBER 1996
21. Instll trnsfer port over nd new gsket. Apply Lotite Grde A to srew threds nd torque srews to 65 l. in. (7.3 N m). d - Blne Tue - Fittings - T-Fitting (Fuel Enrihment) d - Bleed Hose e - Bleed Chek Vlve e 54734 - Trnsfer Port Cover - Gskets - Srews (6 Eh) 22. Instll ylinder over nd new gsket. Torque olts eqully in three progressive steps to 100 l. in. (11.3 N m). 20. Apply pipe selnt (otin lolly) to threds of 45 tell-tle fitting nd instll fitting nd hose. - Cylinder Cover - Gsket - Bolt (10 Eh) 54735-45 Tell-Tle Fitting 90-814676R1 DECEMBER 1996 POWERHEAD - 4-45
23. Instll temperture swith in ylinder lok. NOTE: A plug is provided on ylinder over whih my e removed for instlling Wter Pressure Guge Kit or Wter Temperture Guge Kit. 50531 Cylinder Blok Cover Torque Sequene 54692 - Plug (Remove for Instlltion of Wter Pressure or Wter Temperture Guge Kit) - Temperture Swith 24. On Eletri Strt Models Only, refer to Setion 8, Oil Injetion, for proper instlltion proedure of oil pump. 4-46 - POWERHEAD 90-814676R1 DECEMBER 1996
25. Instll throttle/sprk ontrol rm ssemly. Seure ontrol to ylinder lok with olt. 26. Instll throttle tutor ssemly to rnkse over. Seure tutor with three olts. Torque olts to 150 l. in. (16.9 N m). - Bolt - Throttle/Sprk Control Arm 54681 - Bolts [Torque to 150 l. in. (16.9 N m)] - Throttle Atutor Assemly 54680 27. Referring to Setion 3, reinstll ruretors, fuel pump nd fuel enrihment omponents. 28. Referring to Setion 2A, reinstll ignition omponents nd flywheel. 29. On Eletri Strt Models, reinstll strter motor referring to Setion B. 90-814676R1 DECEMBER 1996 POWERHEAD - 4-47
Instlling Powerhed on Driveshft Housing 1. Verify gerse is in neutrl (propeller shft turns freely in oth diretions). Shift lever plte should e positioned s shown with gerse in neutrl. 2. Inspet powerhed se gsket surfe on oth driveshft housing nd ottom of powerhed for lenliness nd roughness. Both surfes MUST BE len nd smooth. 3. Instll new powerhed se gsket on driveshft housing. Apply 2-4-C Mrine Lurint to driveshft splines. DO NOT pply grese to the top of the driveshft s this will prevent driveshft from fully engging rnkshft. 5. Using suitle hoist, instll powerhed onto driveshft housing. NOTE: It my e neessry to rotte flywheel slightly to engge rnkshft splines into driveshft splines when lowering powerhed onto driveshft housing. IMPORTANT: The forwrd strord nd port powerhed tthing nuts MUST BE strted onto their respetive studs BEFORE powerhed is ompletely lowered onto driveshft housing. 54737 - Thred Atthing Nut Onto Forwrd Most Stud (One Eh Side) First Before Lowering Powerhed Assemly Completely Onto Driveshft Housing 6. Instll remining powerhed tthing nuts. Tighten nuts eqully in three progressive stges until torque of 150 l. in. (16.9 N m) is otined. 54736 - Shift Lever Plte - Gsket - Driveshft Splines 4. Thred LIFTING EYE (91-75132) into flywheel t lest 5 full turns. - Atthing Nuts (4 Eh Side) [Torque to 150 l. in. (16.9 N m)] 54672 4-48 - POWERHEAD 90-814676R1 DECEMBER 1996
7. Seure lower trim over to ottom owl with four olts nd self-loking nuts (2 eh side). - Bolts (2 Eh Side) - Trim Cover 54671 8. On ELECTRIC START MODELS, reinstll oil tnk referring to Setion 8. 9. Reinstll rewind strter or flywheel over, where pplile, referring to Setion 2A. 10. Reinstll sprk plugs. Torque sprk plugs to 20 l. ft. (27.1 N m). 11. On ELECTRIC START MODELS, reonnet remote ontrol hrness to engine hrness. 12. Refer to Setion 2C for TIMING/SYNCHRONIZ- ING/ADJUSTING proedure. 13. Atth throttle nd shift les. 14. Atth remote fuel hose to engine. NOTE: Ger Cse lurint level should e heked prior to operting outord. Refer to Setion 5A for orret inspetion nd filling proedures. If new erings nd piston rings were instlled in powerhed, rek-in proedures MUST BE followed. Refer to OWNERS MANUAL for speifi rek-in instrutions. When initilly priming ruretors with fuel using the fuel line primer ul, inspet ll fuel hose onnetions for signs of fuel lekge. 90-814676R1 DECEMBER 1996 POWERHEAD - 4-49