Oil Pressure Relief Valve Removal4B-12 Crankshaft Timing...

Cylinder Block/Crankcase

90-892248R01 JUNE 2005 Page 4B-1

4B

PowerheadSection 4B - Cylinder Block/Crankcase

Table of Contents

Cylinder Block Specifications...........................4B-2Piston Specifications........................................4B-3Cylinder Block/Crankcase Components..........4B-6Crankshaft Components..................................4B-8Cylinder Block Disassembly...........................4B-10

Crankshaft Timing Gear Removal..........4B-10Thermostat, Anode, Exhaust Cover Removal................................................................4B-10Crankcase And Crankshaft Removal......4B-11Oil Pressure Relief Valve Removal.........4B-12Piston Disassembly................................4B-12

Cleaning/Inspection/Repair............................4B-13Flywheel..................................................4B-13Crankshaft Timing Gear..........................4B-13Timing Belt..............................................4B-13Anode.....................................................4B-13Oil Pressure Switch................................4B-14

Cylinder Bore Measurement...................4B-14Piston......................................................4B-14Piston Pin................................................4B-15Piston Rings............................................4B-16Crankshaft..............................................4B-16Crankcase Main Bearings.......................4B-17Connecting Rod Oil Clearance...............4B-20

Powerhead Reassembly................................4B-21Piston Assembly.....................................4B-21Piston Ring Installation...........................4B-21Piston Installation....................................4B-22Crankshaft Installation............................4B-23Exhaust Cover, Thermostat and AnodeInstallation...............................................4B-25Oil Pressure Switch, Oil Pressure Valve, OilStrainer Installation.................................4B-26Powerhead Installation...........................4B-26


Page 4B-2 90-892248R01 JUNE 2005

Cylinder Block SpecificationsCylinder Block Specifications

Cylinder Bore

Standard 55 mm (2.1654 in.)

Oversize 55.5 mm (2.185 in.)

Maximum taper/out of round 0.06 mm (0.0024 in.)

Stroke 44 mm (1.73 in.)

Displacement 209 ml (12.8 cu. in.)

Number of Cylinders 2

Rotation Clockwise

Crankshaft

Run Out 0.05 mm (0.002 in.)

Crank Pin Journal (Standard) 26.98 mm (1.0622 in.)

Crank Pin Journal (Service Limit) 26.95 mm (1.0610 in.)

Main Bearing (Standard) 29.99 mm (1.1807 in.)

Main Bearing (Service Limit) 29.97 mm (1.1799 in.)

Main Bearing Oil Clearance (Standard) 0.012 ‑ 0.044 mm (0.0005 ‑ 0.0118 in.)

Main Bearing Oil Clearance (Service Limit) 0.06 mm (0.0024 in.)

Crankshaft to Connecting Rod Side Clearance 0.01 ‑ 0.6 mm (0.0004 ‑ 0.0236 in.)

Connecting Rod

Wrist Pin I.D. (Standard) 14.01 mm (0.5516 in.)

Wrist Pin I.D. (Service Limit) 14.04 mm (0.5528 in.)

Crank Pin Oil Clearance (Standard) 0.015 ‑ 0.041 mm (0.0006 ‑ 0.0016 in.)

Crank Pin Oil Clearance (Service Limit) 0.060 mm (0.0024 in.)


90-892248R01 JUNE 2005 Page 4B-3

Piston SpecificationsPiston Specifications

Piston Outside Diameter (Standard) 54.960 mm (2.1638 in.)

Piston Outside Diameter (Service Limit) 54.90 mm (2.1614 in.)

Piston Clearance (Standard) 0.020 ‑ 0.055 mm (0.0008 ‑ 0.0022 in.)

Piston Clearance (Service Limit) 0.15 mm (0.0059 in.)

Piston Ring Side Clearance (Standard)

Top 0.04 ‑ 0.08 mm (0.0016 ‑ 0.0031 in.)

Middle 0.03 ‑ 0.07 mm (0.0012 ‑ 0.0028 in.)

Bottom 0.05 ‑ 0.15 mm (0.002 ‑ 0.0059 in.)

Piston Ring Side Clearance (Service Limit)

Top 0.10 mm (0.0039 in.)

Middle 0.09 mm (0.0354 in.)

Bottom 0.18 mm (0.0071 in.)

Piston Ring End Gap (Standard)

Top 0.15 ‑ 0.30 mm (0.0059 ‑ 0.0118 in.)

Middle 0.30 ‑ 0.45 mm (0.0118 ‑ 0.0177 in.)

Bottom 0.20 ‑ 0.7 mm (0.0079 ‑ 0.0276 in.)

Piston Ring End Gap (Service Limit)

Top 0.5 mm (0.0197 in.)

Middle 0.7 mm (0.0276 in.)

Piston Pin Diameter (Standard) 14.0 mm (0.5512 in.)

Piston Pin Diameter (Service Limit) 13.97 mm (0.5500 in.)

Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.

9 Loctite 567 PST Pipe Sealant Sensor threads and pipe fitting threads 92-809822

12 Loctite Master Gasket Kit Cylinder block and crankcase cover matingsurfaces 92-12564-2

95 2-4-C with Teflon Driveshaft splines 92-802859A1

110 4 Stroke 10W30 Outboard OilPiston pin

Piston ringsCrankshaft journals and bearing surfaces

92-802833A1

Special Tools

Crankshaft Holding Tool 91‑895191

3455

Holds crankshaft while servicing the powerhead.


B-4 90-892248R01 JUNE 2005

Piston Ring Compressor Tool 91‑895192

3456

Compresses piston rings for easy pistion installation.


Notes:

90-892248R01 JUNE 2005 Page 4B-5


Page 4B-6 90-892248R01 JUNE 2005

Cylinder Block/Crankcase Components

2648

1

2

2

3

4

5

6

7

8910

11

1216

15

13

14

17

18

19

20

21

21

22

23

24

25


90-892248R01 JUNE 2005 Page 4B-7

Cylinder Block/Crankcase Components

Ref. No. Qty. Description

Torque

Nm lb. in. lb. ft.

1 1 Cylinder block

2 2 Pin

3 8 Screw 24 17.5

4 1 Nipple

5 1 Exhaust cover

6 1 Gasket

7 5 Screw 6 53

8 1 Thermostat

9 1 Thermostat cover

10 1 Gasket

11 2 Screw 6 53

12 1 Anode

13 1 Anode cover

14 1 Gasket

15 1 Screw 6 53

16 2 Screw 6 53

17 1 Oil pressure relief valve 22 16

18 1 Hose

19 1 Oil strainer

20 1 Hose

21 2 Cable tie

22 1 Gasket

23 6 Screw 24 17.5

24 6 Washer

25 1 Dipstick


Page 4B-8 90-892248R01 JUNE 2005

Crankshaft Components

12

2

3

4

5

6

6

78

9

10

11

11

2649


90-892248R01 JUNE 2005 Page 4B-9

Crankshaft Components

Ref. No. Qty. Description

Torque

Nm lb. in. lb. ft.

1 1 Crankshaft

2 4 Bearing ‑ MainBlack

Brown

3 2 Piston

4 1 Rings ‑ Piston

5 2 Pin, Piston

6 4 Clip ‑ Piston pin

7 2 Rod ‑ Connecting

8 4 Screw ‑ Connecting rod cap 12 106

9 1 Key ‑ Flywheel

10 1 Key ‑ Drive pulley

11 2 Seal ‑ Oil


Page 4B-10 90-892248R01 JUNE 2005

Cylinder Block DisassemblyCrankshaft Timing Gear Removal

1. Install the crankshaft flywheel key.2. Install the crankshaft holding tool.3. Use a wrench to hold the crankshaft timing gear nut while turning the crankshaft with

the crankshaft holding tool.

a

b

c

3064

de

f

a - Wrenchb - Socketc - Crankshaft holding tool

d - Timing gear washere - Timing gear nutf - Timing gear


4. Remove the timing gear and timing gear key from the crankshaft.

Thermostat, Anode, Exhaust Cover Removal1. Remove the starter support bracket mounting screws.2. Remove the oil pressure switch.3. Remove the screws securing the thermostat housing to the exhaust cover.4. Remove the engine anode. Replace the engine anode if 50% or more is missing.5. Remove the remaining exhaust cover screws. Remove the exhaust cover.

a b c

d

e

3071

a - Starter support bracket mountingscrews

b - Oil pressure switchc - Thermostat housing screws

d - Exhaust cover screwse - Engine anode screws


90-892248R01 JUNE 2005 Page 4B-11

6. Inspect the water cooling passages in the block and the exhaust cover for debris.

Crankcase And Crankshaft Removal1. Remove the eight crankcase cover screws.

3080

2. Remove the crankcase cover.3. Remove the connecting rod cap screws.IMPORTANT: Do not intermix the connecting rod caps with the connecting rods.4. Remove the crankshaft.5. Remove the crankshaft seals.

a

b3081

a - Crankshaft seals b - Connecting rod caps

6. Reinstall the connecting rod caps. Tighten the connecting rod caps finger tight.

3082


Page 4B-12 90-892248R01 JUNE 2005

7. Push connecting rod assembly out of the cylinder block.

3083

8. Remove the main bearings from the cylinder block and crankcase cover.IMPORTANT: Do not interchange the main bearing location. Re‑install in their originallocation.

a

3096

a - Main bearings

Oil Pressure Relief Valve RemovalNOTE: The oil pressure relief valve is a non‑serviceable component. Inspect all bearingsand oil pump for proper clearances before replacing the oil pressure relief valve. Visuallyinspect the valve for debris.1. Remove the oil pressure relief valve.

a

b

3094

a - Oil pressure relief valve b - Oil pick up

Piston DisassemblyIMPORTANT: Disassemble each piston separately to ensure the components will not beintermixed. After disassembly, place components into a container that identifies thecylinder location.


90-892248R01 JUNE 2005 Page 4B-13

1. Remove the piston pin clips, and piston pin. Separate the connecting rod from thepiston.

2. Remove the top ring and the second ring.3. Remove the oil ring top scraper, bottom scraper and the oil control ring.

ab c

d

e3102

a - Oil ringsb - Second ringc - Top ring

d - Piston pine - Piston pin clip

Cleaning/Inspection/RepairFlywheel

Inspect the flywheel key way and teeth. Replace if damaged or worn.

3116

Crankshaft Timing GearInspect the crankshaft timing gear and key. Replace if damaged or worn.

3117

Timing BeltInspect the timing belt. Replace if worn, stretched, or damaged.

3118

AnodeReplace the engine water jacket anode if partially consumed.


Page 4B-14 90-892248R01 JUNE 2005

Oil Pressure SwitchApply a controlled air pressure to the oil pressure switch. Check for continuity specification.

3119

Oil Pressure Switch

Continuity 25.5 kPa (3.7 PSI)

Cylinder Bore Measurement1. Inspect the water jacket areas for mineral deposit and blockage. Clean the water jacket

area as needed.2. Inspect the the surface of the cylinder bores. Deep scoring will require the cylinder block

to be bored oversize and finished honed.3. Measure the cylinder bore in six places with a cylinder bore gauge. Determine the

maximum taper/out of round of the cylinder bore.

3129

bc

a

a - 60 mm (2.4 in.)b - 40 mm (1.6 in.)

c - 20 mm (0.8 in.)

Cylinder Bore

Maximum taper/out of round 0.06 mm (0.0024 in.)

Standard bore finish hone 55 mm ± 0.01 mm (2.17 in ± 0.0004 in.)

Oversize bore finish hone 55.5 mm ± 0.01 mm (2.185 ± 0.0004 in.)

Piston1. Inspect the piston. Replace if damaged or worn.


90-892248R01 JUNE 2005 Page 4B-15

2. Measure the piston at a point 7.0 mm (0.276 in.) from the bottom of the piston skirt and90° from the wrist pin.

ab

ob01349

a - Piston diameter (replace if out oflimit)

b - 7.0 mm (0.276 in.) from bottom ofpiston skirt

Piston

Outside Diameter 54.900 ‑ 54.960 mm (2.1614 ‑ 2.1638 in.)

Clearance 0.15 ‑ 0.020 mm (0.0059 ‑0.0008 in.)

3. To determine a piston to cylinder wall clearance, use this formula:• Minimum cylinder bore measurement – maximum piston diameter measurement

= piston to cylinder wall clearance. If out of specification, replace piston and/orbore cylinder 0.5 mm (0.1968 in.) oversize.

Piston Pin1. Measure the piston pin.

3132

Piston Pin

Diameter 13.97 ‑ 14.00 mm (0.550 ‑ 0.5512 in.)

2. Place the piston pin into the connecting rod and check for free play. There should beno noticeable free play. Replace the pin and or the connecting rod as necessary.

3133

3. Place the piston pin into the piston and check for free play. There should be nonoticeable free play. Replace the pin and or the piston as necessary.

3134


Page 4B-16 90-892248R01 JUNE 2005

Piston RingsPISTON RING SIDE CLEARANCE

Measure the piston ring side clearance. Replace the piston and or rings if out ofspecification.

3136

Piston Ring Side Clearance

Top 0.04 ‑ 0.10 mm (0.0016 ‑ 0.004 in.)

Middle 0.03 ‑ 0.09 mm (0.0012 ‑ 0.003 in.)

Bottom 0.05 ‑ 0.18 mm (0.002 ‑ 0.0059 in.)

PISTON RING END GAP CLEARANCE1. Measure piston ring end gap clearance. Replace piston ring if out of specification.2. Push the piston ring into the bore of the cylinder with the crown of the piston to a depth

of 20 mm (0.8 in.).3. If piston rings require replacement, replace rings as a set.

a

3137

a - 20 mm (0.8 in.)

Piston Ring End Gap

Top 0.15 ‑ 0.50 mm (0.0059 ‑ 0.019 in.)

Middle 0.30 ‑ 0.70 mm (0.0118 ‑ 0.027 in.)

Bottom 0.20 ‑ 0.7 mm (0.0079 ‑ 0.0276 in.)

CrankshaftCRANKSHAFT RUN-OUT

1. Thoroughly clean the crankshaft and inspect the bearing surfaces. Replace thecrankshaft if the bearing surfaces are pitted, scored or discolored.


90-892248R01 JUNE 2005 Page 4B-17

2. Measure the crankshaft for run‑out. Replace the crankshaft if out of specification.

3138

Crankshaft

Run‑out 0.05 mm (0.002 in.)

CRANKSHAFT BEARING JOURNALS1. Measure the crank pin journals.2. Measure the crankshaft main bearing journals.3. Replace the crankshaft if journals are out of specification.

a

b3149

a - Crank pin journals b - Main bearing journals

Crankshaft to Connecting Rod Side Clearance

Side clearance 0.01 ‑ 0.6 mm (0.0039 ‑ 0.0236 in.)

Crankshaft Bearing Journal

Crank Pin Journal 26.95 ‑ 26.98 mm (1.061 ‑ 1.0622 in.)

Main Bearing Journal 29.97 ‑ 29.99 mm (1.1799 ‑ 1.1801 in.)

Crankcase Main BearingsMeasure the crankshaft main bearing clearance as outlined in the following procedure.Replace the bearings as a set if the clearance is out of specification.

Main Bearing

Clearance 0.012 ‑ 0.066 mm (0.0005 ‑ 0.0024 in.)

CRANKSHAFT MAIN BEARING CLEARANCE MEASUREMENTIMPORTANT: Do not interchange the main bearings. Install in their original position.1. Clean all the old sealing material from the split line on the crankcase cover and cylinder

block.2. Clean all the oil from the following areas:

• Main bearing surfaces on the cylinder block and crankcase cover• Main bearings• Crankshaft bearing surfaces

3. Install half of the upper and lower main bearings and crankshaft into the cylinder block.NOTE: Align each bearing projection with the notch in the cylinder block.4. Place a piece of plastigauge onto each crankshaft bearing surface.


Page 4B-18 90-892248R01 JUNE 2005

NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft.

aa

bb3140

a - Plastigaugeb - Bearing projection the cylinder block notch

5. Install the bearing halves into the crankcase.NOTE: Align each bearing projection with the notch in the crankcase.6. Install crankcase onto cylinder block.7. Apply oil to the crankcase cover screws. Torque screws to specification and in the

sequence shown on the crankcase cover.IMPORTANT: Do not move crankshaft until measurement has been completed.

3142

1

23

4 5

6

7

8

Description Nm lb. in. lb. ft.

Crankcase Cover Screw 24 17.4

8. Remove the crankcase cover screws. Remove the crankcase cover.


90-892248R01 JUNE 2005 Page 4B-19

9. Measure the plastigauge at its maximum compressed width.

a

b

3143

a - Compressed plastigauge b - Plastigauge scale

10. If the oil clearance is out of specification limit, measure the diameter of the cylinderblock/crankcase cover main bearing journals.

Main Bearing Oil Clearance (Service Limit)

Clearance 0.06 mm (0.0024 in.)

SELECTING NEW MAIN BEARINGS1. Locate the main bearing code on the cylinder block2. The journal size is stamped with a code letter on the upper side of the cylinder block.NOTE: The I.D. code for the upper main bearing is A, B. The I.D. code for the lower mainbearing is X, Y.

3144

a

a - Main bearing journal code

Main Bearing Journal Size

A, X (Brown) 33.000 ‑ 33.008 mm (1.2992 ‑ 1.2995 in.)

B, Y (Black) 33.008 ‑ 33.016 mm (1.2995 ‑ 1.2998 in.)


Page 4B-20 90-892248R01 JUNE 2005

3. Use the color coded main bearing chart that match the main bearing thickness codesletters on the cylinder block.

3147

Main Bearing Code and Thickness

A, X (Brown) 1.488 ‑ 1.494 mm (0.0586 ‑ 0.0588 in.)

B, Y (Black) 1.494 ‑ 1.500 mm (0.0588 ‑ 0.0590 in.)

Connecting Rod Oil ClearanceMeasure the connecting rod oil clearance using the measurement steps outlined following.Replace the connecting rod if out of specification.

Connecting Rod

Oil Clearance 0.015 ‑ 0.060 mm (0.0006 ‑ 0.0024 in.)

CONNECTING ROD OIL CLEARANCE MEASUREMENTIMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings in theiroriginal position.1. Clean all the oil from the connecting rod bearing surfaces and connecting rod journals

on the crankshaft.2. Install the connecting rod to the crankshaft.IMPORTANT: Install connecting rods in their original positions (top and bottom). Make surethe "UP" mark on the connecting rod faces towards the flywheel end of the crankshaft.3. Place a piece of plastigauge on the crankpin journals.NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft.

a

3148

b

a - Plastigauge b - Crankshaft oil hole

4. Install the connecting rod cap and tighten the connecting rod cap screw to specification.IMPORTANT: Do not rotate crankshaft while performing this measurement.


90-892248R01 JUNE 2005 Page 4B-21


Connecting Rod Cap Screw 12 106

5. Remove the connecting rod cap.6. Measure the plastigauge at its maximum compressed width.7. If the oil clearance is out of specification limit, measure the diameter of the connecting

rod and the crank pin journal. Replace as needed.

Powerhead ReassemblyPiston Assembly

1. Assemble connecting rod to piston. Lubricate piston pin with 10W30 oil. Install pistonpin and secure with a new piston pin clip.

IMPORTANT: Ensure the "UP" on the connecting rod and piston are facing the samedirection.

c

6366

a

b

c

dc

a - Connecting rodb - Piston

c - Piston pin clipd - Piston pin

Tube Ref No. Description Where Used Part No.

110 4 Stroke 10W30 Outboard Oil Piston pin 92-802833A1

Piston Ring InstallationIMPORTANT: Use caution when installing piston rings to avoid scratching piston.1. Install oil ring, second ring, and top ring.IMPORTANT: The "T" on the first and second ring must face the crown of piston.


Page 4B-22 90-892248R01 JUNE 2005

2. Lubricate rings with 10W30 engine oil after rings are installed on piston.

110110

abc 110110

e

d

TT

TT

4545 oo 4545 oo

cb

a

ed

UPf g

h

3150

i

a - Top oil control ringb - Expanderc - Bottom oil control ringd - Second ringe - Top ring

f - End gap ‑ Top ringg - End gap ‑ Bottom oil control ringh - End gap ‑ Second ringi - End gap ‑ Top oil control ring


110 4 Stroke 10W30 Outboard Oil Piston rings 92-802833A1

Piston InstallationIMPORTANT: Cylinder bores must be clean before installing pistons. Clean with lighthoning, as necessary. After honing, clean cylinder bores with water and detergent. Aftercleaning, swab cylinder bores several times with engine oil and a clean cloth, then wipewith a clean dry cloth.1. Lubricate piston, rings and cylinder bore with 10W30 engine oil.2. Use piston ring compressor tool to compress the piston rings.3. Install the piston/connecting rod assembly with the piston ring compressor tool, onto

the cylinder block.4. Push down on the piston ring compressor tool to ensure tool is completely flush with

the cylinder block.


90-892248R01 JUNE 2005 Page 4B-23

5. Ensure the "UP" mark on the piston is towards the flywheel. Push the piston into thecylinder bore until all the rings have entered the cylinder.

a

b

c3151

a - "UP" facing towards flywheelb - Piston ring compressor tool

c - Piston ring compressor tool flushwith cylinder block.

Piston Ring Compressor Tool 91‑895192

Crankshaft Installation1. Install the crankshaft main bearings into the cylinder block and crankcase cover.2. Lubricate the following areas generously with 10W30 engine oil.

• Crankshaft seal and main bearing area• Crankshaft connecting rod journals

3. Lubricate the upper and lower oil seal lips with 10W30 engine oil and install onto thecrankshaft ends.

NOTE: Refer to the Crankshaft Components assembly view for correct installation directionof the crankshaft seals.4. Carefully place the crankshaft onto the cylinder block main bearings.

110

110

a

b

b

a

c

d3153

a - Main bearingsb - Crankshaft seals

c - Connecting rodd - Connecting rod cap


Page 4B-24 90-892248R01 JUNE 2005


110 4 Stroke 10W30 Outboard Oil Crankshaft journals and bearingsurfaces 92-802833A1

5. Assemble the connecting rods to the crankshaft journals.6. Install the connecting rod cap and screws onto their respective crank pin journals.7. Tighten the connecting rod screws to the specified torque.


Connecting rod screw 12 106

8. Ensure the crankshaft seals are parallel with the crankshaft and centered in the theseal area of the cylinder block.

9. Clean the cylinder block to crankcase mating surfaces of oil and debris.10. Apply a continuous bead of gasket maker to the contact surface of crankcase. Follow

the instructions contained in gasket maker kit.11. Install dowel pins into the cylinder block. Install crankcase, oil the crankcase screws

and torque cover in sequence shown.

12

a

a

3155

3142

1

23

4 5

6

7

8

a - Dowel pins


Crankcase Screw 24 17.4


12 Loctite Master Gasket Kit Cylinder block and crankcasecover mating surfaces 92-12564-2

12. Install the timing gear key into the crankshaft. Install the timing gear.13. Install the timing gear washer.14. Install the timing gear nut with the chamfered side towards the timing gear washer.IMPORTANT: The timing gear washer outside edge is curved. Ensure the timing gearwasher outside curved edge faces towards the flywheel.15. Install the flywheel key. Install the crankshaft holding tool and tighten the timing gear

nut to the specified torque.


90-892248R01 JUNE 2005 Page 4B-25

16. Install the starter mounting bracket. Secure starter mounting bracket with the startermounting bracket screws. Tighten the starter mounting bracket screws to the specifiedtorque.

a

b

c

3165

d

a - Starter mounting bracket screwsb - Timing gear

c - Timing gear washerd - Torque wrench


Timing gear nut 49 36.2

Starter mounting bracket screw 11.8 104


Exhaust Cover, Thermostat and Anode Installation1. Install a new exhaust cover gasket and install the exhaust cover. Install the exhaust

cover screws. Do not tighten the exhaust cover screws.2. Install thermostat, thermostat cover gasket and thermostat cover. Secure with the

thermostat cover screws. Do not tighten the thermostat cover screws.3. Install a new anode to the anode cover. Securely tighten.

ab

c

3156

a - Anode coverb - Anode

c - Anode retainer screw

4. Install a new anode cover gasket.5. Install the anode cover and secure with the anode cover screws.


Page 4B-26 90-892248R01 JUNE 2005

6. Tighten the exhaust cover screws, thermostat cover screws and the anode coverscrews to the specified torque and in the sequence shown.

13

4

5

78

2

63158

9


Exhaust, Thermostat, Anode Cover Screw 6 53

Oil Pressure Switch, Oil Pressure Valve, Oil Strainer Installation1. Apply Loctite PST Pipe Sealant to the oil pressure switch threads.2. Install the oil pressure switch and tighten to the specified torque.3. Install the oil pressure relief valve and tighten to the specified torque.4. Secure the oil strainer to the cylinder block nipple with a cable tie.

b ca

d 14104

a - Oil strainerb - Oil pressure relief valve

c - Oil pressure switchd - Cable ties


9 Loctite 567 PST Pipe Sealant Sensor threads and pipe fittingthreads 92-809822


Oil pressure switch 10 89

Oil pressure relief valve 22 16

Powerhead Installation1. Install a new powerhead base gasket.2. Lubricate the driveshaft splines with 2‑4‑C with Teflon.


95 2-4-C with Teflon Driveshaft splines 92-802859A1


90-892248R01 JUNE 2005 Page 4B-27

3. Set powerhead onto the adaptor plate.4. Install the 6 screws (3 each side) securing the powerhead to the driveshaft housing.5. Tighten the port and starboard side center screws to the specified torque.6. Tighten the remaining screws to the specified torque, in a cross (X) pattern.

a

3013

a - Powerhead mounting screws (3 each side)


Powerhead Mounting Screw 24 17.4

7. Spread the cowl apart and install onto the driveshaft housing.8. Secure the cowl with the 2 screws. Tighten securely.

ab

3012

a - Cowl screws b - Spread cowl here to install


Notes:

Page 4B-28 90-892248R01 JUNE 2005

Oil Pressure Relief Valve Removal4B-12 Crankshaft Timing...

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