Tle of Contents POWERHEAD Setion 4B - Cylinder Blok/Crnkse CYLINDER BLOCK/CRANKCASE Speifitions........................... 4B-2 Speil Tools........................... 4B-3 Crnkshft............................. 4B-4 Cylinder Blok And Crnkse............ 4B-6 Torque Sequene....................... 4B-8 Powerhed Removl.................... 4B-9 Removing Powerhed Components....... 4B-12 Cylinder Blok Disssemly.............. 4B-13 Crnkse nd Crnkshft Removl.... 4B-14 Inspetion.............................. 4B-17 Cylinder Bore........................ 4B-17 Piston............................... 4B-18 Piston Pin........................... 4B-19 Piston Rings......................... 4B-19 Crnkshft.......................... 4B-20 Cheking Min Bering Clerne...... 4B-21 Cheking Conneting Rod Bering Clerne.......................... 4B-23 Thermostt.......................... 4B-24 Oil Pressure Swith................... 4B-24 Cylinder Blok Ressemly............... 4B-25 Seleting New Min Berings.......... 4B-25 Min Bering Instlltion.............. 4B-26 Seleting New Conneting Rod Berings 4B-27 Instlling Conneting Rod Berings..... 4B-27 Conneting Rod Instlltion............ 4B-28 Piston Ring Instlltion................ 4B-29 Piston Instlltion.................... 4B-30 Crnkshft Instlltion................ 4B-30 Crnkse Cover Instlltion........... 4B-32 Thermostt nd Exhust Cover Instlltion.......................... 4B-33 Drive Ger Instlltion................ 4B-34 Instlling Powerhed Components...... 4B-35 Engine Wiring Hrness nd Ignition Eletril Component Instlltion...... 4B-35 Ignition Components.................. 4B-35 Chrging nd Strting System Components........................ 4B-35 Fuel Components.................... 4B-35 Powerhed Instlltion................... 4B-36 Tiller Hndle Models.................. 4B-39 4 B Pge 4B-1
Speifitions CYLINDER BLOCK Type Displement Numer of Cylinders 4 Stroke Cyle Overhed Cmshft 45.6 u. in. (747 ) 3 STROKE Length 2.953 in. (75 mm) CYLINDER BORE PISTON PISTON CLEARANCE RINGS COMPRESSION RATIO Dimeter Stndrd Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Tper/Out of Round Mximum Bore Type Piston Type O.D. t Skirt Stndrd Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Piston to Cylinder Clerne Ring End Gp (Instlled) Top Middle Bottom (Oil Ring) Side Clerne: Top Middle Compression Rtio Cylinder Compression (Eletri Models Only, Cold Engine @ W.O.T.) 2.5591 in. (65 mm) 2.5689 in. (65.25 mm) 2.5787 in. (65.5 mm) 0.003 in. (0.08 mm) Cst Iron Aluminum 2.5570-2.5578 in. (64.950-64.965 mm) 2.5669-2.5675 in. (65.2-65.215 mm) 2.5768-2.5774 in. (65.450-65.465 mm) 0.0014 -.0026 in. (0.035-0.065 mm) 0.006-0.012 in. (0.15-0.03 mm) 0.012-0.020 in. (0.30-0.50 mm) 0.008-0.028 in. (0.20-0.70 mm) 0.0008-0.0024 in. (0.02-0.06 mm) 0.0008-0.0024 in. (0.02-0.06 mm) 9.7:1 180-210 psi PISTON PIN Piston Pin Dimeter 0.6285-0.6287 in. (15.965-15.970 mm) CONNECTING ROD CRANKSHAFT Oil Clerne (Big End) Smll End Inside Dimeter Min Bering Clerne Crnkshft Run-out 0.0008-0.0020 in. (0.020-0.052 mm) 0.6293-0.6298 in. (15.985-15.998 mm) 0.0005-0.0017 in. (0.012-0.044 mm) 0.0018 in. (0.046 mm) Pge 4B-2
Speil Tools CYLINDER BLOCK/CRANKCASE 1. Oil Filter Wrenh (91-802653Q02) 2. Flywheel Holder (91-83163M) 3. Flywheel Puller (91-83164M) 4. Piston Ring Compressor (FT2997) 5. Piston Ring Expnder (91-24697) Pge 4B-3
Crnkshft 110 12 2 10 9 8 110 7 110 6 11 1 110 12 5 110 4 110 110 3 110 4-stroke Outord Oil Pge 4B-4
Crnkshft TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 CRANKSHAFT 2 1 OIL SEAL 3 1 OIL SEAL 4 4 CONNECTING ROD 5 6 BOLT 150 17 6 BEARING (BROWN) 6 6 BEARING (BLACK) 6 BEARING (BLUE) 7 3 PISTON 8 3 PISTON RING (TOP) 9 3 PISTON RING (SECOND) 10 3 PISTON OIL RING 11 3 PISTON PIN 12 6 RETAINER Pge 4B-5
Cylinder Blok And Crnkse 9 Lotite PST Pipe Selnt 12 Lotite Mster Gsket 110 4 Stroke Oil A = TO VST COOLER B = TO FITTING IN ADAPTOR PLATE Pge 4B-6
Cylinder Blok And Crnkse TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 CYLINDER BLOCK 2 2 DOWEL PIN 3 3 PLUG 79 9 4 1 PIPE PLUG (1/2-14) 24 33 5 1 PIPE PLUG (3/4-14) 24 33 8 BEARING (BROWN) 6 8 BEARING (BLACK) 8 BEARING (BLUE) 7 1 NIPPLE 29.5 40 8 8 SCREW (M8 X 82) 22 30 9 8 SCREW (M6 X 35) 102 12 10 1 GASKET 11 1 OIL FILTER 70 8 12 1 GASKET 13 1 EXHAUST COVER 14 1 PIPE PLUG Drive Tight 15 1 THERMOSTAT 16 1 GASKET 17 1 COVER 18 10 SCREW (M6 X 35) 106 12 19 1 ELBOW Drive Tight 20 3 CABLE TIE 21 1 TUBING (10 IN.) 22 1 ENGINE COOLANT TEMPERATURE (ECT) SENSOR 15 1.5 23 1 O-RING 24 1 LIFTING EYE 25 1 SCREW (M8 X 35) 29 39.5 26 1 HOSE (19 IN.) Pge 4B-7
Torque Sequene Exhust Cover Crnkse Cover Intke Mnifold Powerhed Pge 4B-8
Powerhed Removl WARNING CYLINDER BLOCK/CRANKCASE The possiility exists tht the engine ould strt when turning the flywheel. To void possile serious injury, lwys disonnet the ttery nd remove sprk plug leds from sprk plugs efore working on motor. 1. On eletri strt models, disonnet the ttery les from the ttery. Remove ttery les from engine. 2. Disonnet the power trim wires if equipped. 3. Remove the ottom owls. -Srew (M6 x 30) 6 -Lower Cowl -Srew (M6 x 60) 4. Drin the engine oil. 5. Remove the ontrol le nhor rket srews on remote ontrol models. 6. Remove the throttle/shift lever srew nd swing the entire shift linkge to the side. 58810 Remote Control Model (BigFoot) -Control le nhor rket srew (M6 x 16) 2 -Throttle/Shift lever -Shift lever srew (M8 x 70) 1 Pge 4B-9
7. Push retiner up nd slide over to disengge the vertil shift shft. 2 1 -Retiner Remote Control Model (Non - BigFoot) 8. Remove the shift guide rket srews. TILLER HANDLE MODEL 58479 Tiller Hndle Model -Shift guide rket -Srew (M6 x 25) (2) Pge 4B-10
9. Disonnet the rnkse vent hose. 10. Disonnet fuel supply hose from wter seprting fuel filter. CYLINDER BLOCK/CRANKCASE 58974 -Crnkse vent hose -Fuel supply hose to wter seprting fuel filter 11. Disonnet the power trim wires from the trim motor. Pge 4B-11
12. Remove powerhed mounting olts. 13. Lift powerhed from driveshft housing. 58979 -Powerhed mounting olts (M8 x 45) (4 eh side) -Hoist Removing Powerhed Components 1. Ple powerhed on enh. 2. Remove intke ssemly. Refer to Setion 3C - Intke Assemly Removl. 3. Remove Vpor Seprtor Assemly. Refer to Setion 3C - Vpor Seprtor Removl. 4. Remove flywheel, sttor nd strter. Refer to Setion 2B - Chrging & Strting System. 5. Disonnet/Remove omponents in the following order: 3 ECM rket srews, min hrness ground wire srews ner ottom of strter, strter solenoid mounting srews, oil pressure swith, ECT sensor, regultor/retifier mounting srews, rnk position sensor mounting srews, ignition oil mounting srews. 6. Remove eletril omponents s n ssemly. Disonnet wiring nd ut le ties s neessry. 7. Remove ylinder hed. Refer to Setion 4A - Cylinder Hed Removl. Pge 4B-12
Cylinder Blok Disssemly CYLINDER BLOCK/CRANKCASE 1. Remove the drive ger omponents. -Lod ring -Drive ger -Woodruff key 2. Remove exhust over nd gsket. 3. Remove oil filter. f e d h g -Srew nd wsher (M6 x 35) (10) -Thermostt over -Gsket (disrd) d-thermostt e -Exhust over f -Gsket g-oil filter h-oil filter wrenh (91-802653Q02) Pge 4B-13
Crnkse nd Crnkshft Removl 1. Remove rnkse over nd dowel pins. d 56875 -Srew nd wsher (M8x82) (8) -Srew nd wsher (M6x35) (8) -Crnkse over d-dowel pin (2) 2. With ruer or plsti hmmer, lightly strike the rnkse over in order to seprte it from the lok. If the over will not seprte, try prying it off with srewdriver. Do not dmge the split line seling surfe when prying the over off. Pge 4B-14
3. Use 5/16 in. 12 point soket nd remove onneting rod olts nd ps. NOTE: Eh onneting rod nd p re mthed set. 4. Remove ron ridge from the ylinder ore using urr knife. Push out the onneting rod/piston ssemly. Keep eh piston, onneting rod, nd p together s n ssemly. 56876 -Conneting rod srew (6) -Conneting rod p (3) -Conneting rod/piston ssemly (3) NOTE: Use n indelile mrker to srie the ylinder numer on eh piston nd onneting rod so they n e reinstlled in their originl lotion. 5. Disssemle piston/onneting rod ssemly. Remove irlip with needle nose pliers. 6. Remove piston rings. Use piston ring expnder tool to prevent rings from reking during removl. d e f 53824 -Cirlip -Conneting rod nd p -Srie the ylinder numer here d-conneting rod erings e -Piston rings f -Piston ring expnder (91-24697) Pge 4B-15
7. Remove rnkshft from lok. 56877 -Crnkshft -Upper oil sel -Lower oil sel NOTE: Do not interhnge min erings, re-instll in their originl lotions. 8. Remove min ering hlves from rnkse over nd ylinder lok. 56878 -Min ering hlves-crnkse over (4) -Min ering hlves-cylinder lok (4) Pge 4B-16
Inspetion Cylinder Bore CYLINDER BLOCK/CRANKCASE MEASURING CYLINDER BORE 1. Mesure the ylinder ore dimeter t three lotions in oth X nd Y xis. 2. If the ylinder ore is eyond the stndrd limits listed in the tles elow, it will e neessry to re-ore the ylinder to ept the oversize piston. NOTE: Mesure t three lotions (L 1, L 2, nd L 3 ) in oth X nd Y xis (D 1-6 ). L 1 =0.8 in. (20 mm) L 2 =1.6 in. (40 mm) L 3 =2.4 in. (60 mm) 1. Inspet:. Wter jket for minerl deposits/orrosion, len if neessry.. Inner surfe for sore mrks, repir if neessry. 2. Mesure ore dimeter with ylinder guge, re-ore or reple if neessry. L 2 L 1 D 1,2 L 3 D 3,4 D 5,6 55837 Cylinder Bore Speifitions Bore Size Mximum Tper/Out-of-Round Stndrd Bore 2.5591 in. (65 mm) 0.003 in.(0.08 mm) Oversize Bore - 0.010 in. (0.25 mm) 2.5689 in. (65.25 mm) 0.003 in.(0.08 mm) Oversize Bore - 0.020 in. (0.50 mm) 2.5787 in. (65.5 mm) 0.003 in.(0.08 mm) NOTE: Tper=(Mximum of D 1 or D 2 ) (Minimum of D 5 or D 6 ) Pge 4B-17
Piston 1. Inspet piston wll wer/dmge. Reple if neessry. 2. Mesure the piston t point 0.2 in (5.0 mm) from the ottom. Reple if out of speifition. -Piston dimeter -0.2 in. (5.0 mm) Piston Dimeter Piston Size Dimeter Stndrd 2.5570-2.5578 in. (64.950-64.965 mm) Oversize-0.010 in. (0.25 mm) 2.5669-2.5675 in. (65.2-65.215 mm) Oversize -0.020 in. (0.50 mm) 2.5768-2.5774 in. (65.450-65.465 mm) 3. Mesure piston to ylinder lerne. If out of speifition exmine piston nd ylinder ore further to determine repir/replement.. Piston to ylinder wll lerne n e defined y: Minimum ore mesurement mximum piston mesurement = piston to ylinder wll lerne. Piston to Cylinder Clerne 0.0014-0.0026 in. (0.035-0.065 mm) Pge 4B-18
Piston Pin 1. Mesure piston pin dimeter. Reple piston pin if out of speifition. CYLINDER BLOCK/CRANKCASE 55839 Piston Pin Dimeter 0.6285-0.6287 in. (15.965-15.970 mm) 1. Ple the piston pin into the onneting rod nd hek for free ply. There should e no notiele free ply. 55840 2. Ple the piston pin into the piston nd hek for free ply. There should e no notiele free ply. Piston Rings PISTON RING SIDE CLEARANCE 1. Mesure piston ring side lerne. Reple piston nd/or piston rings if out of speifition. 55841 55842 Top Middle Piston Ring Side Clerne 0.0008-0.0024 in. (0.02-0.06 mm) 0.0008-0.0024 in. (0.02-0.06 mm) Pge 4B-19
PISTON RING END GAP CLEARANCE 1. Insert piston ring into the ylinder ore. 2. Push the piston ring into the ylinder ore with the piston to n pproximte depth of 0.8 in. (20 mm). 3. Mesure piston ring end gp lerne. Reple piston ring if out of speifition. -Piston ring depth 0.8 in. (20 mm) 53747 Top 2nd Oil Piston Ring End Gp 0.006-0.012 in. (0.15-0.30 mm) 0.012-0.020 in. (0.30-0.50 mm) 0.008-0.028 in. (0.20-0.70 mm) Crnkshft 1. Thoroughly len rnkshft nd inspet ering surfes. Reple rnkshft if ering surfes re pitted, sored, or disolored. 2. Mesure Run-out. Reple rnkshft if out of speifition. 3. Clen oil holes in rnkshft. Crnkshft Run-out 0.0018 in. (0.046 mm) Pge 4B-20
Cheking Min Bering Clerne CYLINDER BLOCK/CRANKCASE IMPORTANT: Do not interhnge the min erings. Reinstll in their originl position. 1. Clen ll the old seling mteril from the split line on the rnkse over nd ylinder lok. 2. Clen ll the oil from the following res: Min ering surfes on the ylinder lok nd rnkse over. Min erings. Crnkshft ering surfes. NOTE: For seleting nd instlling min erings, refer to Setion 4B - Cylinder Blok Ressemly. 3. Instll min erings. 4. Ple rnkshft into ylinder lok. 53811 5. Ple piee of plstiguge onto eh rnkshft ering surfe. 53812 -Plstiguge NOTE: Do not instll plstiguge over the oil hole on the ering surfe of the rnkshft. Pge 4B-21
6. Instll rnkse over. Apply oil to the over olts nd torque over olts in sequene nd in two steps. Crnkse Cover Bolt Torque Center olts 1st Torque: 11 l. ft. (15 Nm) (M8x82) 8 2nd Torque: 22 l. ft. (30 Nm) Outer Bolts 1st Torque: 53 l. in. (6 Nm) (M6x35) 8 2nd Torque: 106 l. in. (12 Nm) 7. Remove the rnkse over. Mesure the ompressed plstiguge to hek the min ering oil lerne. Reple erings if lerne is not in speifition. Min Bering Oil Clerne 0.0005-0.0017 in. (0.012-0.044 mm) 53751 NOTE: For seleting nd instlling min erings, refer to Setion 4B - Seleting New Min Berings. Pge 4B-22
Cheking Conneting Rod Bering Clerne CYLINDER BLOCK/CRANKCASE IMPORTANT: Do not interhnge used onneting rod erings. Reinstll erings in their originl position. 1. Clen ll the oil from the onneting rod ering surfes nd onneting rod journls on the rnkshft. NOTE: For seleting nd instlling onneting rod erings, refer to Setion 4B -Seleting New Conneting Rod Berings. 2. Ple piee of plstiguge on the onneting rod journls. 53751 -Plstiguge IMPORTANT: Do not rotte onneting rod when heking lerne. 3. Instll the onneting rod to the respetive journl. Tighten onneting rod olts in sequene nd in two steps to the speified torque. -Conneting rod p -Srie mrks on p nd rod -Conneting rod olts Conneting Rod Bolt Torque 1st Torque: 53 l. in. (6 Nm) 2nd Torque: 150 l. in. (17 Nm) Pge 4B-23
4. Remove the onneting rod p. Mesure the ompressed plstiguge to hek the onneting rod oil lerne. Reple erings if oil lerne is not in speifition. 53810 Conneting Rod Oil Clerne 0.0008 0.0020 in. (0.020-0.052 mm) Thermostt 1. Mesure the lift of the thermostt t the operting wter temperture listed. Oil Pressure Swith Wter Temperture Vlve Lift 118-123 F (48-51 C) Strts to Open Aove 145 F (63 C) Minimum 0.12 in. (3 mm) 1. Chek ontinuity of swith. 55845 Oil Swith Continuity Chek Below 2.9 psi (20.0 kp) Aove 2.9 psi (20.0 kp) Continuity No Continuity Pge 4B-24
Cylinder Blok Ressemly CYLINDER BLOCK/CRANKCASE Seleting New Min Berings 1. Lote the min ering ode letters on the ylinder lok. 2. Refer to the following referene hrt to selet the orret min erings. 3. Use the olor oded min erings tht mth the min ering ode letter. Min Bering Code Letter A B C Min Bering Color Code Blue Blk Brown A B C #1 #2 #3 #4 -Min ering ode letters -Min ering identifition olor lotion Pge 4B-25
Min Bering Instlltion IMPORTANT: Do not interhnge used min erings. Reinstll in their originl position. 1. Chek lerne of eh ering. Refer to Setion 4B -Cheking Min Bering Clerne. 2. Clen ll the oil from the min ering surfes on the ylinder lok nd rnkse over. 3. Instll min erings. Mke sure the loking t on eh ering fits into its noth in the ylinder lok. 110 d 110 4-Stroke Outord Oil -Min ering hlves - Crnkse over (4) -Min ering hlves - Cylinder lok (4) -Projetion in ering d-noth in ylinder ody/rnkse Pge 4B-26
Seleting New Conneting Rod Berings CYLINDER BLOCK/CRANKCASE 1. Lote the onneting rod ering ode letter tht is sried on the side of the onneting rod. 2. Refer to the following referene hrt to selet the orret onneting rod erings. 3. Use the olor oded onneting rod erings tht mth the onneting rod ering ode letter. Conneting Rod Bering Code Letter A B C Conneting Rod Bering Color Code Blue Blk Brown A B C -Conneting rod ering ode letters -Conneting rod ering identifition olor lotion Instlling Conneting Rod Berings 53816 IMPORTANT: Do not interhnge used onneting rod erings. Reinstll erings in their originl position. 1. Clen ll the oil from the ering surfes on the onneting rod. 2. Instll onneting rod erings. Ensure the loking lug on eh ering fits into its noth. 53815 -Conneting rod erings -Fit the loking lugs into the nothes Pge 4B-27
Conneting Rod Instlltion 1. Lurite the piston pin with oil nd ssemle the piston to the onneting rod. Alwys use new irlips. IMPORTANT: Instll the split end of the irlip into the groove first, push the other end down until it snps into the groove. If the shpe of the irlip is permnently distorted when ttempting instlltion, disrd it nd use new one. IMPORTANT: Instll side of onneting rod mrked with Y towrds UP on piston fe. IMPORTANT: Piston pin lip should e instlled with end gp fing opposite of pry point. e f 110 d 110 4-stroke Outord Oil -Conneting rod -Piston -Piston pin d-piston pin lip (2) e -Piston pin lip end gp f -Pry point Pge 4B-28
Piston Ring Instlltion CYLINDER BLOCK/CRANKCASE IMPORTANT: Use ution when instlling piston rings to void srthing piston. 1. Instll the oil ring omponents s shown. Spred rings to slip over piston. 2. Instll the seond nd top ompression rings T side up. Spred rings to slip over piston. 3. Offset the piston ring end gps. 110 110 f e d g UP 50 h i j 110 4-stroke Outord Oil -Oil ring sper -Bottom ril -Top ril d-seond ompression ring - T side up e -Top ompression ring - T side up f - T mrk should fe piston rown g-end gp Top ompression ring h-end gp Seond ompression ring i -End gp Upper oil ring ril j -End gp Lower oil ring ril k -End gp Oil ring sper k Pge 4B-29
Piston Instlltion NOTE: Cylinder ores must e len efore instlling pistons. Clen with light honing, s neessry. After honing, len ylinder ores with wter nd detergent. After lening, sw ylinder ores severl times with engine oil nd len loth, then wipe with len dry loth. 1. Lurite pistons, rings. nd ylinder wlls with engine oil. 2. Instll piston/onneting rod ssemly using piston ring ompressor tool. NOTE: Instll used pistons in their originl lotions. Instll piston with UP mrk on piston rown fing towrd the flywheel end of lok. Î Î Crnkshft Instlltion -Piston ring ompressor (FT2997) -Flywheel end 1. Lurite the rnkshft ering surfes, onneting rod journls, nd oil sel lips with engine oil. 110 110 -Upper oil sel -Lower oil sel -Crnkshft ering surfe 110 4-Stroke Outord Oil Pge 4B-30
2. Instll upper nd lower oil sels on rnkshft. Position oil sel lips s shown. 3. Crefully lower rnkshft into ple. IMPORTANT: Mke sure the lower oil sel noth is positioned into the groove in the rnkse. 58273 -Upper oil sel -Lower oil sel - Rised ri -Oil sel groove 4. Assemle the onneting rods to the rnkshft. Instll the onneting rod ps, ligning the ode letter sried on the onneting rod nd p. 5. Apply oil to the onneting rod olts. Tighten olts in two steps to the speified torque. 110 110 4-Stroke Outord Oil -Conneting rod p (3) -Conneting rod olt (6) -Srie ode letter Conneting Rod Bolt Torque 1st Torque: 53 l. in. (6 Nm) 2nd Torque: 150 l. in. (17 Nm) Pge 4B-31
Crnkse Cover Instlltion 1. Clen off ll oil from the ontting surfes of the rnkse over nd ylinder lok. IMPORTANT: Mke sure the ontting surfe of the rnkse over nd ylinder lok re len efore pplying gsket selnt. 2. Apply smooth even ot of Lotite Mster Gsket Selnt to the ontting surfes on the rnkse over. Use smll pint roller to spred out the selnt for smooth even overge. NOTE: Do not pply gsket selnt to the min erings or the olt holes. 12 12 Lotite Mster Gsket 514 -Lotite Mster Gsket selnt -Pint roller 3. Instll rnkse over on ylinder lok. Dowel pins will lign the two mting surfes. 4. Apply oil to srew threds. Torque the srews in the sequene shown elow. Tighten to the 1st torque vlue speified elow. Repet this torque sequene for the 2nd torque vlue. 110 110 4-Stroke Outord Oil -Dowel pin (2) Crnkse Cover Srew Torque Center Srews 1st Torque: 11 l. ft. (15 Nm) (M8x82) 8 2nd Torque: 22 l. ft. (30 Nm) Outer Srews 1st Torque: 53 l. in. (6 Nm) (M6x35) 8 2nd Torque: 106 l. in. (12 Nm) Pge 4B-32
Thermostt nd Exhust Cover Instlltion CYLINDER BLOCK/CRANKCASE 1. Instll oil filter. Tighten to speified torque using oil filter wrenh. 2. Instll exhust over long with the thermostt nd thermostt over. Use new gskets. 3. Tighten srews to the first torque vlue in the sequene shown elow. Repet this proedure for the seond torque vlue. d e f h g -Exhust over -Gsket -Thermostt d-gsket e -Thermostt over f -Oil filter g-oil filter wrenh (91-802653Q02) h-exhust over srew (M6 x 35) (10) Exhust nd Thermostt Cover Srew Torque 1st Torque: 53 l. in. (6 Nm) 2nd Torque: 106 l. in. (12 Nm) Oil Filter Torque 70 l. in. (8 Nm) Pge 4B-33
Drive Ger Instlltion 1. Instll the drive ger omponents. NOTE: Lod Ring n only e used one nd must e repled if flywheel is removed. -Lod ring -Drive ger -Drive key Pge 4B-34
Instlling Powerhed Components CYLINDER BLOCK/CRANKCASE 1. Reinstll ylinder hed. Refer to Setion 4A - Cylinder Hed Instlltion. Engine Wiring Hrness nd Ignition/Eletril Component Instlltion Ignition Components 1. Instll the wiring hrness ssemly to the powerhed in the sme order removed. Refer to the pproprite setion for eh omponents torque vlue. 1. Refer to the pproprite setion of the servie mnul for instlltion nd torque vlues of the following ignition omponents.. Timing Belt Setion 4A. Ignition Coils Setion 2A. ECM Setion 3C d. Crnk Position Sensor Setion 3C Chrging nd Strting System Components Fuel Components 1. Refer to Setion 2B for instlltion nd torque vlues of the following omponents:. Strter Motor. Voltge Regultor. Sttor d. Flywheel 1. Refer to Setion 3C for Intke Assemly/Vpor Seprtor Instlltion. Pge 4B-35
Powerhed Instlltion CAUTION When luriting the driveshft splines do not llow ny grese on top of the driveshft. Grese on top of the driveshft will fore the shft down when instlling the gerse, using the pinion ger to ind with the forwrd ger. This n result in dmge or filure of the gers. 1. Instll powerhed nd new se gsket. 2. Tighten the powerhed mounting olts to the first torque vlue in the sequene shown elow. Repet this proedure for the seond torque vlue. IMPORTANT: If the rnk shft splines do not line up with the driveshft splines, shift the gerse into forwrd, ple prop on the propshft nd rotte it ounterlokwise. This will llow the splines to line up. -Powerhed mounting olts (M8 x 110) (4 eh side) -Hoist -Bse gsket Powerhed Mounting Bolt Torque 1st Torque: 20 l. ft. (27.1 Nm) 2nd Torque: + 90 Turn Pge 4B-36
3. Re-onnet throttle/shift linkge nd ontrol le nhor rket. Torque fsteners to speified torque. 58810 Remote Control Model (Bigfoot) -Control le nhor rket srew (M6 x 16) 2 -Throttle/Shift lever -Throttle/Shift lever srew (M8 x 70) 1 Throttle/Shift Lever Mounting Srew Torque 100 l. in. (11 Nm) Cle Anhor Brket Mounting Srew Torque 75 l. in. (8.5 Nm) 4. Instll the shift guide rket srews. Tighten to speified torque. Tiller Hndle Model (Bigfoot) -Shift guide rket -Srew (M6 x 25) 2 Shift Guide Brket Mounting Srew Torque 70 l. in. (8 Nm) 58479 Pge 4B-37
5. Push retiner up nd slide over to engge the vertil shift shft. Non Bigfoot Model -Retiner 6. Reonnet hoses. Use le ties to fsten ll hose onnetions. d e -Crnkse vent hose -Crnkse rether hose -Fuel in hose d-fuel out hose e -Fuel supply hose to wter seprting fuel filter Pge 4B-38
7. Reonnet the power trim hrness wires. 8. Instll sprk plugs 9. Instll ottom owl. Tighten srews to speified torque. CYLINDER BLOCK/CRANKCASE Tiller Hndle Models -Srew (M6 x 30) (6) -Lower owl -Srew (M6 x 60) Bottom Cowl Srew Torque 60 l. in. (7 Nm) 10. Connet ttery les to ttery terminls. 11. Chek engine oil level. 1. Instll throttle les, shift rod nd tiller hndle wiring. Refer to Setion 7B. Pge 4B-39