POWERHEAD

90-831996R1 JUNE 1996

POWERHEAD

4-1

Table Of Contents
Page Page

Powerhead Specifications BOTTOM GUIDED PISTON . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Finished Hone Bore Size . . . . . . . . . . . . . . . Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . Powerhead Specifications TOP GUIDED PISTON . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Finished Hone Bore Size . . . . . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . Powerhead Removal . . . . . . . . . . . . . . . . . . . . . . Powerhead Disassembly . . . . . . . . . . . . . . . . . . . Removing Crankshaft . . . . . . . . . . . . . . . . . . Disassembling Crankshaft . . . . . . . . . . . . . . Disassembling Piston . . . . . . . . . . . . . . . . . . . Disassembling Cylinder Head . . . . . . . . . . . Inspecting and Repairing . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-1 4-1 4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-4 4-5 4-5 4-6 4-6 4-7 4-7

Connecting Rods . . . . . . . . . . . . . . . . . . . . . . 4-7 Bottom/Top Guided Pistons . . . . . . . . . . . . 4-10 Bottom Guided Piston . . . . . . . . . . . . . . 4-10 Top Guided Piston . . . . . . . . . . . . . . . . . 4-10 Cylinder Block and Crankcase Cover . . . . 4-11 Powerhead Reassembly . . . . . . . . . . . . . . . . . . 4-11 Assembling Bottom Guided Piston - 1995-1/2 Model Year S/N 0E125508 and Below . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Assembling Top Guided Piston - 1996 Model Year S/N 0E125509 and Above . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Assembling Crankshaft . . . . . . . . . . . . . . . . 4-14 Installing Pistons Into Cylinder Block . . . . 4-15 Assembling Cylinder Head . . . . . . . . . . . . . 4-19 Completing Assembly . . . . . . . . . . . . . . . . . . . . . 4-20 Installing Powerhead . . . . . . . . . . . . . . . . . . . . . 4-20 Powerhead Components 90/95 HP . . . . . . . . . 4-22 Crankshaft Components 90/95/120 HP . . . . . 4-24 Powerhead Components 120 HP . . . . . . . . . . 4-26

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POWERHEAD

90-831996R1 JUNE 1996

Powerhead Specifications BOTTOM GUIDED PISTON

Special Tools
Description 12-point Socket Piston Tool Ring Remover/Installer Ring Compressor Lockring Installer Compression Tester *Torque Wrench (0200 lb. ft.) *Torque Wrench (0150 lb. in.) Flywheel Puller Lifting Hook *May Be Obtained Locally Part No. FT 2953 FT 2990-1 FT 8926 FT 2996 FT 11291 91-29287 91-32610 91-66274 FT 8948-1 FT 8933

IMPORTANT: Measure piston skirt at right angle (90) to piston pin center-line, 2.0 in. (50.8 mm) up from bottom edge of skirt.

2.0 in. (50.8 mm)

Major Diameter measured 90_ to piston pin center line

Finished Hone Bore Size

Standard Size
Fraction 3-3/8 in. 3.375 (mm) (85.725)

2.0 in. (50.8 mm)

Minor Diameter measured parallel to piston pin center line

.010 Oversize
in. 3.385 (mm) (85.979)

Piston Ring
90/120 HP Top Piston Ring Bottom Piston Ring End Gap 0.010 - 0.020 in. (0.254 - 0.508 mm) 0.006 - 0.016 in. (0.15 - 0.4 mm)

.030 Oversize
in. 3.405 (mm) (86.487)
TOP

CENTER

BOTTOM

NOTE: Measure cylinder bore at Top, Center and Bottom.

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Powerhead Specifications TOP GUIDED PISTON

Special Tools
Description 12-point Socket Piston Tool Ring Remover/Installer Ring Compressor Lockring Removal Tool Lockring Installation Tool Flywheel Puller Powerhead Lifting Ring Part No. FT2953 91-74607A3 91-24697 FT2996 91-52952A1 91-77109A2 91-73687A1 91-90455

PISTON IMPORTANT: A zero minus tolerance and a plus .001 tolerance is acceptable. IMPORTANT: Measure piston skirt at right angle (90) to piston pin center-line, .15 in. (3.81 mm) up from bottom edge of skirt.

0.15 in. (3.81 mm)

Measured 90_ to piston pin center line

PISTON RING

Specifications Finished Hone Bore Size

Standard Size
Fraction 3-3/8 in. 3.375 (mm) (85.725)

95/120 HP Top Piston Ring

End Gap 0.010 - 0.020 in. (0.254 - 0.508 mm)

.015 Oversize
in. 3.390 in. 3.405 (mm) (86.10) (mm) (86.487)

.030 Oversize

4-2

POWERHEAD

90-831996R1 JUNE 1996

Powerhead Removal
1. Disconnect battery lead form battery. 2. Remove spark leads from spark plugs. 3. Disconnect remote control harness from engine. 4. Disconnect fuel line to fuel pump. 5. Remove throttle and shift cables. 6. Disconnect water inlet hose from pump cover. 7. Loosen top exhaust boot clamp.

10. Install lifting ring on end of crankshaft. If lifting hook has less than five turns of engagement remove flywheel nut.

a
a - Lifting Ring

11. Lift powerhead off pump cover.

WARNING
DO NOT leave powerhead suspended from hoist. Powerhead should be installed on a suitable stand or lowered to the floor upon removal from pump cover.

b
a - Exhaust Boot Clamp b - Water Inlet Hose

NOTE: Refer to appropriate sections in service manual for removal of individual fuel and electrical subassemblies from powerhead. Component/Assembly Section
Starter Motor Flywheel Ignition Components (Switch Box, Stator, Trigger) Carburetor and Linkage Fuel Pump *1996 Models, CDM Ignition 2C 2A/2B* 2A/2B* 3A 3B

8. Remove four 13-mm nuts from studs that hold powerhead adapter plate to pump cover. 9. Remove four 15-mm nut from studs that hold adapter plate to pump cover.

NOTE: All ignition and electrical components can be removed and installed as an assembly.

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Powerhead Disassembly
1. Remove intake manifold and reed assemblies. See Section 3B. 2. Remove exhaust manifold. Discard gasket. Clean all gasket surfaces. 3. Remove cylinder head. Discard gasket. Clean all gasket surfaces. 4. Remove transfer port covers. Discard gasket. Clean all gasket surfaces.

6. Remove oil injection pump and driven gear.

a - Oil Injection pump b - Driven Gear

7. Remove crankcase cover screws.

a b c d e

Cylinder Block (120 HP Shown) Transfer Port Cover (4 on the 120 HP) Cylinder Head Exhaust Manifold Bearing Cage

5. Remove bearing cage.

a - Cover Screws (120 HP) b - Cover Screws (90/95 HP)

4-4

POWERHEAD

90-831996R1 JUNE 1996

8. Install four bolts in cylinder block to protect gasket surface on cylinder block.

2. Remove bearing cage half. Rotate crankshaft and remove remaining bearing cage half. IMPORTANT: DO NOT use a magnet to retrieve bearings. 3. Push connecting rod down to clear crankshaft. 4. Repeat steps 1 through 3 for each cylinder. 5. Lift crankshaft out of cylinder block.

Disassembling Crankshaft
1. Remove snap rings from center main bearings. Remove bearing races and caged rollers. 9. Remove bolts securing adapter plate to bottom of cylinder block. Remove adapter plate. Remove and discard gasket. Clean all gasket surfaces. 10. With all cover screws removed, pry crankcase apart starting at corner locations. IMPORTANT: Keep bearings separated, do not intermix components.

2. Remove and discard crankcase seals.

Removing Crankshaft
IMPORTANT: Mark rod caps and pistons as to the cylinder they are removed from. 1. Remove connecting rod screws with 12-point socket.

a - Crankshaft Seals

3. If replacement of the upper ball bearing is necessary, remove using univeral bearing puller Special Tool 91-37241. Press new bearing onto crankshaft.

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4. Remove lower crankcase seal. a. Slide lower main bearing to end of crankshaft. b. Pry seal out.

AS NEEDED

WARNING
Eye protection MUST be worn when removing piston pin lockrings. 1. Snap out and discard piston lockring from both ends of piston pin.

a
a - Seal

5. If replacement of the oil injection drive gear is necessary, the gear can be remove using universal bearing puller Special Tool 91-37241. The new gear must be pressed on the crankshaft.

Disassembling Piston
1. Hold connecting rod so that it does not scratch cylinder bore. Push piston out of cylinder block.

2. Press piston pin out using Special Tool FT 2990-1 on Bottom Guided piston. Use Special Tool 91-74607A3 on Top Guided piston.

Disassembling Cylinder Head

1. Remove thermostat housing and components. 2. Remove piston ring using ring expander.

a b c d e f g
a b c d Screw (4) Housing Gasket Spring e - Thermostat f - Retainer g - Seal

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90-831996R1 JUNE 1996

NOTE: Test the thermostat by removing the rubber grommet and placing the thermostat in hot water. The thermostat should open at the temperature stamped on it.
AS NEEDED 2. Remove thermoswitch by removing snap ring retainer and pry/pull thermoswitch from cavity. 3. Remove bolts from cylinder head cover. Remove cover. Discard gasket. Clean all gasket surfaces.

4. Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearings. Recheck surfaces of crankshaft. Replace crankshaft if surfaces cannot be properly cleaned up. If crankshaft will be reused lubricate surfaces with 2 cycle oil to prevent rust.

Connecting Rods
1. Check connecting rods for alignment by placing rods on a surface plate. If light can be seen under any portion of machined surfaces, if rod has a slight wobble on plate, or if a 0.002 in. (0.051mm) feeler gauge can be inserted between any machined surface and surface plate, rod is bent and must be discarded. 2. Overheating: Overheating is visible as a bluish bearing surface color that is caused by inadequate lubrication or excessive RPM. 3. Rust: Rust formation on bearing surfaces causes uneven pitting of surface(s).

Inspecting and Repairing

Crankshaft
1. Inspect crankshaft to drive shaft splines for wear. Replace crankshaft if necessary. 2. Inspect upper and lower crankshaft bearings for roughness and excessive looseness. Replace as necessary. 3. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear and/or overheating. S If necessary clean surfaces with crocus cloth as shown.

a
a - Pitting

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4. Water Marks: When bearing surfaces are subjected to water contamination, a bearing surface etching occurs. This etching resembles the size of the bearing.

5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping. Spalling will be most evident on the thrust portion of the connecting rod in line with the I beam. General bearing surface deterioration could be caused by or accelerated by improper lubrication.

6. Chatter Marks: Chatter marks are the result of a combination of low speed - low load - cold water temperature operation, aggravated by inadequate lubrication and/or improper fuel. Under these conditions, the crankshaft journal is hammered by the connecting rod. As ignition occurs in the cylinder, the piston pushes the connecting rod with tremendous force, and this force is transferred to the connecting rod journal. Since there is little or no load on the crankshaft, it bounces away from the connecting rod. The crankshaft then remains immobile for a split second until the piston travel causes the connecting rod to catch up to the waiting crankshaft journal, then hammers it. The repetition of this action causes a rough bearing surface(s) which resembles a tiny washboard. In some instances, the connecting rod crank pin bore becomes highly polished. During operation , the engine will emit a whirr and/or chirp sound when it is accelerated rapidly from idle speed to approximately 1500 RPM, then quickly returned to idle. If the preceding conditions are found, replace both the crankshaft and connecting rod(s).

a
a - Spalling

a
a - Chatter Marks Between Arrows

7. Uneven Wear: Uneven wear could be caused by a bent connecting rod.

a
a - Uneven Wear

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POWERHEAD

90-831996R1 JUNE 1996

CAUTION
Crocus cloth MUST BE USED to clean bearing surface at CRANKSHAFT END OF CONNECTING ROD. 320 grit Carborundum cloth MUST BE USED to clean bearing surface at PISTON PIN END OF CONNECTING ROD. VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS. DO NOT continue to clean connecting rod bearing surfaces after marks have been removed. 8. Clean connecting rods as necessary.

a d b

c
a b c d Attached to Drill Motor Crocus Cloth Torque to 16 lb. ft. (21.7 Nm) Use 320 Carborundum Cloth

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Bottom/Top Guided Pistons

IMPORTANT: There are two types of piston/rod assemblies available: Bottom Guided (centered in bore by crankshaft) 1995-1/2 Model Year S/N 0E123456 and Below Bottom Guided Piston Top Guided (centered in bore by piston) 1995-1/2 Model Year S/N 0E123456 and Above Top Guided Piston

a a b

c c

51536 51536 a - Ridged Washer b - Smooth c - Scalloped a - Flat Washer b - Scalloped c - Smooth

4-10

POWERHEAD

90-831996R1 JUNE 1996

Cylinder Block and Crankcase Cover

1. Inspect cylinder head gasket surface for erosion across gasket surface. Excessive erosion requires cylinder head replacement. 2. Inspect cylinder head for warpage.

4. Measure piston ring end gap.

NOTE: Refer to Specifications for dimensions. If gap is too small widened with a file. If gap is too wide recheck bore measurements.
S A cylinder head with 0.012 in. (0.305 mm) or less can be resurfaced. S If warped more than 0.012 in. (0.305 mm) replace cylinder head. 3. Measure cylinder bore diameter at top, middle and bottom of each cylinder as shown. Check for tapered, out-of-round and oversized bore.

Powerhead Reassembly
Assembling Bottom Guided Piston 1995-1/2 Model Year S/N 0E125508 and Below
1. Install piston pin needle bearings in pin bore of connecting rod using. Lubricate needle bearings with Quicksilver Needle Bearing Lubricant.

a
a - Bearings (26 per set)

S Refer to Specifications for Finished Hone Bore Size for Bottom Guided pistons and Top Guided pistons.

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6. Install piston pin.

CAUTION
DO NOT intermix new needle bearings with used needle bearings. Needle bearings MUST BE REPLACED AS A SET. DO NOT intermix needle bearings from one connecting rod with those of another connecting rod. 2. Install alignment pin (Special Tool No. FT-2990B) through one side of piston.

a a
a - Block (Special Tool FT 2990D)

WARNING
Eye protection must be worn while installing piston pin lockrings. IMPORTANT: Use only new piston pin lockrings.

a - Spacer b - Alignment Pin

3. Install first spacer with small end toward the inside of piston. 4. Install connecting rod in piston. S Slide connecting rod with bearings over alignment tool. S Install second spacer with small end toward inside of piston. S Push alignment pin through second spacer and through piston bore.

7. Install NEW piston lockrings (one at each end of piston pin) with lockring installation tool (Special Tool No. FT 11291) as shown.

a b

5. Place piston on pillow block (Special Tool No. FT-2990D).

a - Lockring b - Special Tool FT 11291

IMPORTANT: Be sure piston pin lockrings are properly seated in piston grooves.

4-12

POWERHEAD

90-831996R1 JUNE 1996

8. Install piston rings (Special Tool No. FT-8926).

2. Place flat washers on connecting rod; keeping washers in place, carefully place piston over end of rod. Use disassembly marks for matching rod to piston and direction of insertion (which side of rod is UP).

a - Upper Piston Ring b - Lower Piston Ring

IMPORTANT: Gaps in piston rings must fit over pins in ring grooves.

51083

a - Scribed Identification Number b - Locating Washer

Assembling Top Guided Piston - 1996 Model Year S/N 0E125509 and Above
Place clean needle bearings on a clean sheet of paper and lubricate with Quicksilver Needle Bearing Lubricant (92-42649A1). NOTE: There are 29 needle bearings per piston.

3. Insert piston pin tool through piston in the direction shown, pushing out sleeve.

a b

CAUTION
Never intermix new needle bearings with used needle bearings at the same connecting rod end. Never intermix needle bearings on one connecting rod with those of another connecting rod. Should one (or more) piston pin needle bearing of a connecting rod require replacement (or should one or more be lost), replace all of that connecting rods piston pin needle bearings. 1. Place sleeve, which is part of Piston Pin Tool (91-74607A3), into connecting rod and install needle bearing around sleeve, as shown.
a - Sleeve b - Piston Pin Tool (91-74607A3)

51080

19537 a - Needle Bearings (29) b - Sleeve [From Piston Pin Tool (91-74607A3)]

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4. Place piston pin over end of tool, and tap into position (driving tool out other side).

b a

51086

51086 a - Piston Pin b - Piston Pin Tool

6. Install piston rings. Top piston ring has one dot: install facing up. Bottom piston ring has two dots and a white stripe: install with dots facing up.

Assembling Crankshaft WARNING

1. Install new seal into lower main bearing. Press seal into bearing with garter spring facing up. Use Special Tool FT 8925. 2. Apply Needle Bearing Lubricant 92-825265A1 between libs of seal and slide bearing on crankshaft.

Eye protection must be worn while installing piston pin lockrings. 5. Install new piston pin lockrings (each side of piston) using Lockring Tool (91-77109A2). Make sure lockrings are properly seated in piston grooves.

CAUTION
Do not reuse piston pin lockrings. Use only new lockrings and make sure they are properly seated in piston grooves.

a - Garter Spring (Faces Up Toward Flywheel When Installed)

51086 a - Lockring Installation Tool (91-77109A2) b - Lockring (2)

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90-831996R1 JUNE 1996

3. Scrape old Loctite off upper bearing. Clean bearing surfaces with Locquic Primer 92-59327--1.

6. Install lower bearing on crankshaft with seal.

a b

4. Install new crankshaft seals on crankshaft.

a - Lower Bearing b - Seal

Installing Pistons Into Cylinder Block

1. Coat pistons, rings, and cylinder bores with 2-cycle oil. 2. Install piston in ring compressor, Special Tool FT 2996. IMPORTANT: Be sure to position end gap of rings at the ring alignment pin.

NOTE: Pins are 180 apart on piston.

a - Crankcase Seals

5. Install center main bearings on crankshaft with alignment holes of bearing race between snap ring groove and crankcase seal.

a b c

a - Alignment Pin

a - Snap Ring Groove b - Alignment Hole

c - Crankcase Seal

NOTE: Position snap ring on center main bearings so that the gap is not over the fracture area of the bearings.

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3. Install piston in cylinder bore. Position piston so that piston dome faces intake port of cylinder block.

S Align holes in center main bearings with location pins in cylinder block.

a a

a - Intake Ports b - Piston Dome

a - Center Main Bearing Hole b - Locating Pin

4. Push piston into cylinder bore.

NOTE: Be sure piston is installed in the same bore it was removed from.
5. Install cylinder head to prevent pistons from falling out. Do Not torque the cylinder head bolts at this time. 6. Clean cylinder block upper bearing bore with Locquic Primer 92-59327--1. 7. Apply Loctite to upper main bearing bore.

IMPORTANT: Install crankshaft with sealing ring gaps facing up. When the crankshaft is seated the ends of the sealing rings must be able to touch. IMPORTANT: Make sure crankshaft is fully seated by pushing ends of crankshaft: there should be no rocking. 9. Spin crankshaft seals so that openings face down. IMPORTANT: Seal rings break easily; handle carefully when turning. IMPORTANT: Make sure upper crankshaft bearing is fully seated against the flange in the cylinder block. Tap on end of crankshaft to ensure seating.

8. Install crankshaft in cylinder block.

a - Bearing Seated Against Cylinder Block Flange

10. Install one half of bearing cage in connecting rod. S Apply Needle Bearing Lubricant 92-825265A1 to cage half to hold needle bearings in place (Bottom Guided rods, not necessary on Top Guided rods).

NOTE: Bottom Guided rods use loose needle bearing with a cage. Top Guided rods use a cage that contains the needle bearings.
S Install nine rollers (Bottom Guided rods).
4-16 POWERHEAD 90-831996R1 JUNE 1996

IMPORTANT: Do Not intermix rollers. Rollers can only be replaced as a set.

S Install new rod cap screws and thread until cap and rod fit together. Inspect for alignment.

a
a - Bearing Cage Half b - Roller (9)

b
a - Correct Fit b - Incorrect Fit - Gap Present c - Incorrect Fit - Ridge Present

11. Carefully align connecting rod with crankshaft.

S Correct any misalignment. 14. Remove cap screws and apply Loctite FT 8936-1 to cap screw threads. Hand tight cap screws and check alignment. If alignment is good torque cap screws in increments of 50 lb. in. (5.65 Nm) until a torque of 120 lb. in. (13.55 Nm) is reached, then turn an additional 90. 15. Repeat procedure for the remaining connecting rods. 12. Install second half of bearing cage in connecting rod. S Apply Needle Bearing Lubricant 92-825265A1 to cage half to hold needle bearings in place. S Install remaining seven rollers (Bottom Guided). S Rotate the crankshaft after each rod is installed to check for binding. If any binding is present remove rod cap and check alignment. 16. Apply Loctite 92-823089--1 to the exposed portion of the upper bearing.

13. Install connecting rod cap. IMPORTANT: Connecting rods and connecting rod caps are matched halves. Do not torque screws before checking alignment.

NOTE: Do Not re-use old rod cap screws, always use new rod cap screws.

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17. Apply Sealer 92-90113--2 on seal surface and around main bolt holes on block.

19. Install crankcase bolts. Following torque pattern torque bolts to 270 lb. in. (30.5 Nm). 7 8

2 5 90/95 HP

S Check crankshaft for free rotation. 9 10

5 1 4 8 2 3 7 120 HP

a - Sealer (92-90113--2)

18. Install crankcase cover on cylinder block, aligning corner dowel pins.

a a
20. Using new gasket, install adapter plate on bottom of cylinder block. Torque bolts to 30 lb. ft. (40.7 Nm).

a - Dowel Pins

4-18

POWERHEAD

90-831996R1 JUNE 1996

Assembling Cylinder Head

1. Install cylinder head cover on cylinder head. Torque center attaching screws to 70 lb. in. (7.91 Nm).

1995-1/2 Model Year S/N 0E125508 and below: 4. Torque bolts as shown to 75 lb. in. (8.5 Nm), then torque 50 lb. in. (5.6 Nm) at a time until bolts are torqued to 225 lb. in. (29.14 Nm). For S/N numbers 0E125509 and above apply light oil to threads and bolt head. Torque in sequence to 120 lb. in. (13.5 Nm). Then turn an additional 90_. 13 14 12 4 6 2 8 9 90/95 HP 17 13 9 5 1 4 8 12 16 120 HP 15 7 11 2 3 10 6 18 14 10

11 1

b c
a - Cylinder Head Cover b - Cylinder Head c - Cylinder Head Gasket

5 3 7

NOTE: 90/95 HP Shown.

2. Apply sealant 92-90113--2 to cylinder head cover on cylinder block side of cover. 3. Using new gasket, install cylinder head.

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Completing Assembly
1995-1/2 Model Year S/N 0E125508 and below: 1. Install exhaust manifold using new gasket. Torque bolts in sequence from center out to 100 lb. in. (11.3 Nm). For S/N numbers 0E125509 and above apply light oil to threads and bolt head. Torque bolts in sequence to 115 lb. in. (13 Nm). Then re-torque #s 1 - 6.

NOTE: Refer to appropriate sections in service manual for installation of individual fuel and electrical subassemblies on powerhead. Component/Assembly Section
Starter Motor Flywheel Ignition Components (Switch Box, Stator, Trigger) Carburetor and Linkage Fuel Pump, Reed Valves *1996/97 Models, CDM Ignition 2C 2A/2B* 2A/2B* 3A 3B

NOTE: Stainless steel bolts are torqued to 100 lb. in. (11.3 Nm). Grade 8 bolts are torqued to 115 lb. in. (13 Nm). Stainless steel bolts are not magnetic, grade 8 bolts are magnetic.
9 10 5 11 21 3 20 19 18 17 8 6 4 7

NOTE: All ignition and electrical components can be removed and installed as an assembly.

Installing Powerhead
1. Install top exhaust boot and clamp. Install O-ring in counterbore of drive housing cover.

2 1 13 14 16 15 90/95 HP

a c b

12

25 22 14 10 6 1 3 7 11 15 19 23

18 5 4

21 17 13 9 2 8 12 16 20

a - Exhaust Boot b - O-Ring

c - Drive Housing Cover d - Large O-Ring

2. Lubricant driveshaft splines with 2-4-C w/Teflon Lubricant 92-825407A12.

NOTE: DO NOT apply lubricant to TOP of drive shaft as grease may pre-load drive shaft/crankshaft resulting in damage to powerhead and/or pump housing.
3. Lower powerhead on drive housing cover. Align exhaust boot with exhaust elbow, driveshaft splines, and mounting studs. 4. Torque exhaust bellows clamp screws to 50 lb. in. (5.6 Nm).

24

120 HP

4-20

POWERHEAD

90-831996R1 JUNE 1996

5. Connect water inlet hose to fitting on drive housing cover. Snug nut with wrench, then tighten one additional flat (60 degrees).

REFER TO SECTION 6 ENGINE INSTALLATION TO COMPLETE INSTALLATION OF WIRE HARNESS, CONTROL CABLES, SET-UP AND TIMING. IMPORTANT: Follow Break-In procedure as out lined in Section 6: Engine Installation.

CAUTION
SEVERE DAMAGE to your engine can result by not complying with the proper break-in procedure.

a
a - Water Inlet Hose

6. Secure powerhead to drive housing cover with nuts. 7. Torque nuts in sequence shown below. The forward and aft nuts (7,8 and 5,6) are torqued to 35 lb. ft. (47.5 Nm). The left and right nuts (1,2 and 3,4) are torqued to 20 lb. ft. (27.1 Nm). 5 3 1 7

8 6 4 2

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4-21

Powerhead Components 90/95 HP

45

1 2 3

32 33

34

4 36 37 38 43 40 42 7 6 44 5

35

39

31 30 29 28 27
U

41 9 26 21 25 24 19 23
U

10

11 12 13

Quicksilver Lubrication/Sealant Application Points

U

22

15 18 17 16

14

RTV Sealant 92-90113--2

Item 1* 1* 2 3 4 5 6 7 8

Qty. 21 21 1 1 1 2 1 1

Description Bolt (1/4-20x1-1/8) 1995-1/2 Model Year S/N 0E125508 and Below 100

Torque Lb. In. Lb. Ft. Nm 11.3 13

Bolt (1/4-20x1-1/8) S/N 0E125509 and Above - Apply Light Oil to Bolt Head 115 & Threads Manifold Delete Bolt (5/16-18x3/4) Washer Clamp Bellows Cylinder Block 13

17.6

* Refer to torque sequence listed on page 4-20.

4-22 POWERHEAD 90-831996R1 JUNE 1996

Powerhead Components 90/95 HP (Continued)

Item Qty.
9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30* 30* 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 1 7 1 1 1 4 8 2 7 2 1 2 2 2 2 2 1 1 1 Stud Washer Lock Washer Nut (3/8-16) Bolt (3/8-16x2-3/4) Bolt (3/8-16x3) Bolt (1/4-20x3/4) Bolt (3/8-16x1-3/4 Washer Bolt (1/4-20x1-1/4) Gasket Gasket Bolt (1/4-20x5/8) Cover Tube Pin Gasket Head Cover 225 25.4 70 7.9 70 7.9 270 270 270 70 30.5 30.5 30.5 7.9

Description
Lb. In.

Torque
Lb. Ft. Nm

14 Washer - Only Used On 1995-1/2 S/N 0E125508 and Below 14 Bolt (5/16-18x2-3/8) 1995-1/2 Model Year S/N 0E125508 and Below 14 Bolt (5/16-18x2-3/8) S/N 0E125509 and Above Apply Light Oil to Bolt Head & Threads 3 4 1 1 1 1 1 1 1 1 1 1 1 4 Bolt (1/4-20x5/8) Bolt (1/4-20x3/4) Cover Gasket Spring, (Silver) Thermostat (130) Spacer Seal Plug Pin Bolt (1/4-20x3/4) Tube Gasket Plug (1/2-14) 70 7.9 120 lb. in. (13.5 Nm) Then Turn An Additional 90_ 70 70 7.9 7.9

21 Washer - Only Used On 1995-1/2 S/N 0E125508 and Below

* Refer to torque sequence listed on page 4-19.

90-831996R1 JUNE 1996

POWERHEAD

4-23

Crankshaft Components 90/95/120 HP

90/95 3-CYLINDER SHOWN - 120 4-CYLINDER NOT SHOWN
Two Circle Marks - Face Up

1 25 26 2 3 4
V

21
One Circle Mark - Faces Up

22

18 20 19 23 24
C V

5
E

6 7 21 22 18a 20
V

8 17

10

23a 19 90/120 HP 18a 16

V

11

12 13

1995-1/2 S/N 0E125508 and Below 27

E

14 15

Quicksilver Lubrication/Sealant Application Points

C V
E

Direction of major sealing lip

UP or

DOWN

Needle Bearing Assy. Lub. (92-42649A1) Loctite #601 (FT-8938-1) 2 Cycle Outboard Oil (92-13249A24)
POWERHEAD 90-831996R1 JUNE 1996

4-24

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18a 19 20 21 22 23 23a 24 25 26

Qty. 1 1 5 1 1 1 1 3 3 6 2 2 3 1 1 2 2 6 6 3 3 6 3 3 3 3 1 1 Cap Seal Screw (1/4-20x3/4) Cage Assembly Key

Description Lb. In.

Torque Lb. Ft. Nm

70

7.9

Crank Shaft (90/95 HP Shown) Bearing Cage/Roller Rod Cap Bolt - Apply Light Oil to Bolt Head & Threads Cage/Roller Main Bearing Race Locating Pin Bearing Seal Crank Case Seal Snap Ring Flat Washer (2 Each) S/N 0E125509 and Above Spacer (2 Each) S/N 0E125508 and Below Piston Piston Ring (2 Each) Retainer (2 Each) Piston Pin Needle Bearing (29 Each) S/N 0E125509 and Above Needle Bearing (26 Each) S/N 0E125508 and Below Connecting Rod Nut, Flywheel Washer - Only Used On S/N 0E125509 and Above 125 112
120 lb. in. (13.5 Nm) Then Turn An Additional 90_

90-831996R1 JUNE 1996

POWERHEAD

4-25

Powerhead Components 120 HP

16 14 1 17 2 6 3 28 4 12 11 9 6 5 7 8 28

34 33 31 29 32 20 30

35 10

28

25

13

15 21 23 19 22
U

18 27 24

26

Quicksilver Lubrication/Sealant Application Points

U

RTV Sealant 92-90113--2

4-26

POWERHEAD

90-831996R1 JUNE 1996

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22* 22*

Qty. 1 1 1 2 4 10 2 2 2 3 1 1 3 1 1 1 1 1 1 1 4
18 18

Description Cylinder Block Bolt (3/8-16x3-1/8) Bolt (3/8-16x2-3/4) Bolt (3/8-16x3) Bolt (3/8-16x2) Washer Bolt (3/8-16x1-3/4) Bolt (1/4-20x1-1/4) Dowel Pin (3/8x5/8) Tube Tube Pin Pin Gasket Set Gasket Bolt (5/16-18x3/4) Lock Washer (5/16) Gasket Cylinder Head Cover Bolt (1/4-20x5/8)
Bolt (5/16-18x2-3/8) 1995-1/2 Model Year S/N 0E125508 and Below Bolt (5/16-18x2-3/8) S/N 0E125509 and Above Apply Light Oil to Bolt Head & Threads

Torque Lb. In. Lb. Ft. Nm 270 270 270 270 22.5 22.5 22.5 22.5 22.5 70 30.5 30.5 30.5 30.5 30.5 7.9

13

17.6

70
225

7.9
25.4

120 lb. in. (13.5 Nm) Then Turn An Additional 90_

23 24 25 26 27 28 29 30 31 32 33 34 35

18 3 1 12 3 24 1 4 1 1 1 1 1

Washer - Only Used On 1995-1/2 S/N 0E125508 and Below Cover Kit Plug Bolt (1/4-20x5/8) Gasket Bolt (1/4-20x7/8) Cover Bolt (1/4-20x3/4) Gasket Spring (RED) Thermostat (130) Spacer Seal 70 7.9 70 7.9 70 7.9

* Refer to torque sequence listed on page 4-19.

90-831996R1 JUNE 1996

POWERHEAD

4-27

Powerhead Components (Continued) 6 Exhaust Manifold 120 HP

1 5 7
Not Used on 1996 Models

3 4 10

11

10

Item 1 2 3 4 5 6* 6* 7 8 9 10 11

Qty 1 1 1 4 25 21 21 4 1 2 2 1 Manifold Gasket Strainer Tube Plug (3/4-14)

Description

Torque Lb. In. Lb. Ft. Nm

Washer Only Used On 1995-1/2 S/N 0E125508 and Below Bolt (1/4-20x3) - 1995-1/2 Model Year S/N 0E125508 and Below Bolt (1/4-20x3) - S/N 0E125509 and Above - Apply Light Oil to Bolt Head & Threads Bolt (1/4-20x4) Retainer Clip Clamp Bellows 100 115 115 11.3 13 13

* Refer to torque sequence listed on page 4-20.

4-28

POWERHEAD

90-831996R1 JUNE 1996