CYLINDER HEAD

POWERHEAD
Section 4A - Cylinder Head
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Valve Removal . . . . . . . . . . . . . . . . . . . . . . . 4A-26
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Rocker Shaft and Rocker Arm . . . . . . . . . . 4A-27
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4A-28
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28
Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . 4A-8 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-30
Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . 4A-10 Valve Guide inspection . . . . . . . . . . . . . . . . 4A-30
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Valve Guide Replacement . . . . . . . . . . . . . 4A-31
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4A-13
4A-13
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . .
4A-32
4A-33
4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-15 Valve Seat Reconditioning . . . . . . . . . . . . . 4A-35 A
Valve Clearance Adjustment . . . . . . . . . . . . . . 4A-18 Valve Refacing Steps . . . . . . . . . . . . . . . . . 4A-36
Checking Valve Clearance . . . . . . . . . . . . . 4A-18 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-37
Adjusting Valves . . . . . . . . . . . . . . . . . . . . . 4A-19 Valve Installation . . . . . . . . . . . . . . . . . . . . . 4A-37
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Camshaft Oil Seal Installation . . . . . . . . . . 4A-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Camshaft Installation . . . . . . . . . . . . . . . . . 4A-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-21 Oil Pump Installation . . . . . . . . . . . . . . . . . . 4A-40
Cylinder Head Removal . . . . . . . . . . . . . . . . . . 4A-22 Rocker Arm Shaft Assembly . . . . . . . . . . . 4A-40
Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-24 Rocker Arm Shaft Installation . . . . . . . . . . 4A-41
Rocker Arm Assembly Removal . . . . . . . . 4A-24 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4A-42
Oil Pump Removal . . . . . . . . . . . . . . . . . . . 4A-24 Cylinder Head Installation . . . . . . . . . . . . . . . . 4A-43
Camshaft Removal . . . . . . . . . . . . . . . . . . . 4A-25

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Specifications

Camshaft Dimensions
Intake “A” 1.214 - 1.222 in. (30.83 - 31.03 mm)
Exhaust “A” 1.214 - 1.222 in. (30.83 - 31.03 mm)
A
Intake “B” 1.020 - 1.028 in. (25.90 - 26.10 mm)
Exhaust “B” 1.020 - 1.028 in. (25.90 - 26.10 mm)

Run-out Limit B 0.0039 in. (0.1 mm)

Camshaft Bearing Diameter “b” 1.4541 - 1.4549 in.
(36.935 - 36.955 mm)

CAMSHAFT

b
b b

Free Length “a” 1.491-1.569 in. (37.85-39.85 mm)

Tilt Limit “b” Less than 0.060 in. (1.7 mm)
bb

aa
VALVE SPRING

Compressed Pressure (Installed)

Intake 19.8 - 22.0 lbs. (9.0 - 10.0 kg)
Exhaust 19.8 - 22.0 lbs. (9.0 - 10.0 kg)
Tilt Limit (Intake & Exhaust) 0.043 in. (1.1 mm)
Dir. of Winding (Intake & Exhaust) Left Hand

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Warp Limit 0.004 in. (0.1 mm)

* Lines indicate
straight edge 56899
measurement
CYLINDER HEAD
Camshaft Bore Inside Diameter “a” 1.4567 - 1.4577 in.
(37.000 - 37.025 mm)
a
a
a

56900

Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.006 - 0.010 in. (0.15 - 0.25 mm)
Exhaust 0.010 - 0.014 in. (0.25 - 0.35 mm)
Valve Dimensions:
“A” Head Diameter
Intake 1.256 - 1.264 in. (31.9 - 32.1 mm)
Exhaust 1.020 - 1.028 in. (25.9 - 26.1 mm)
“B” Face Width
Intake 0.079 - 0.124 in. (2.00 - 3.14 mm)
Exhaust 0.079 - 0.124 in. (2.00 - 3.14 mm)
“C” Seat Width
Intake 0.035 - 0.043 in. (0.9 - 1.1 mm)
Exhaust 0.035 - 0.043 in. (0.9 - 1.1 mm)
“D” Margin Thickness
VALVES Intake 0.020 - 0.035 in. (0.5 - 0.9 mm)
Exhaust 0.020 - 0.035 in. (0.5 - 0.9 mm)
Stem Outside Diameter
Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm)
Exhaust 0.2150 - 0.2156 in. (5.460 - 5.475 mm)
Guide Inside Diameter
Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm)
Exhaust 0.2165 - 0.2170 in. (5.500 - 5.512 mm)
Stem To Guide Clearance
Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm)
Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm)
Stem Run-out Limit (max.) 0.0006 in. (0.016 mm)

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Valve Dimensions

“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness

ROCKER SHAFT Outside Diameter 0.6288 - 0.6296 in.

(15.971 - 15.991 mm)
ROCKER ARM Inside Diameter of Bore 0.6299 - 0.6306 in.
(16.000 - 16.018 mm)

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Special Tools
1. Flywheel Holder P/N 91-83163M

2. Valve Guide Remover P/N 91-809495A1

3. Valve Guide Installer Bushing P/N 91-809496A1

4. Valve Guide Reamer P/N 91-809497A1

5. Valve Spring Compressor P/N 91-809494A1

6. Valve Seat Cutter Kit (Obtain Locally).

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CYLINDER HEAD

110

110

110

110 4-Stroke Outboard Oil

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CYLINDER HEAD
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 CYLINDER HEAD (ELECTRIC)
–
1 CYLINDER HEAD (MANUAL)
1 1 CYLINDER HEAD
2 6 GUIDE
3 3 SCREW M6 X 8 57 6.0
4 3 GASKET
5 1 OIL SEAL
6 5 PIPE PLUG
7 1 O RING
8 1 COVER
9 1 BREATHER PIPE
10 1 DECAL-Servicing Referral
11 1 DECAL-Engine Oil/Valve Clearance
12 8 SCREW (M9 x 1.5 x 95) 35.0 47
13 4 SCREW (M6 x 25) 106 12
14 1 GASKET
15 7 SCREW (M6 x 20) 70 8
16 1 BAFFLE PLATE
17 4 SCREW (M4 x 10)
18 1 ELBOW
19 1 BRACKET (HANDLE)
20 2 SCREW (M6 x 13) (HANDLE)
21 1 PLUG
22 1 O RING
1 DECAL - HP ID (30)
23
1 DECAL - HP ID (40)
24 2 DOWEL PIN

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CAMSHAFT/OIL PUMP
1

3
4

7
110
6

8
110

10
9
12 11

13

51
110 4-Stroke Outboard Oil
51 Loctite 222

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CAMSHAFT/OIL PUMP
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SCREW (M8 x 40 x 1.25) 28 38
2 1 WASHER
3 1 BELT
4 1 GEAR-Driven
5 1 DOWEL PIN
6 1 CAMSHAFT (MANUAL)
7 1 CAMSHAFT (ELECTRIC)
8 1 PIN
9 1 OIL PUMP ASSEMBLY
10 1 O RING
11 1 O RING
12 1 O RING
13 4 SCREW (M6 x 35) 70 8

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INTAKE/EXHAUST VALVES
110

110

110

110

110 4-Stroke Outboard Oil

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INTAKE/EXHAUST VALVES
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 3 EXHAUST VALVE
2 3 INTAKE VALVE
3 6 SEAL–Valve Stem
4 6 VALVE SPRING–Outer
5 6 RETAINER–Valve Spring
6 12 KEY
7 6 ROCKER ARM
8 6 SCREW
9 6 NUT 120 10 13.5
10 1 ROCKER SHAFT
11 2 PLUG
12 1 BRACKET
13 1 SPRING
14 1 BRACKET
15 1 SPRING
16 1 SEAL
17 1 PIN - CAM THRUST
18 4 SCREW (M8 x 23) 160 13.3 18
19 2 SPRING - Overload (If Equipped) 160 13.3 18

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Torque Sequence
7 6
8
4

4
2
3
3 4

1
1 2
1
2
5

3
6
5

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Valve Cover
NOTE: Valves should be adjusted when engine is cold.

WARNING
Engine could possibly start when turning flywheel during adjustment. To prevent
this type of accidental engine starting and possible serious injury, always remove
spark plug leads from spark plugs.
Removal
1. Disconnect spark plug leads and remove spark plugs.
2. Remove flywheel cover/manual starter components (if equipped).
3. Remove lower cowl (if desired) for easier access to lower screws.
NOTE: Refer to section 8 for removal of manual starter.

a - Screw (4) M6 x 25
b - Flywheel Cover

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4. Disconnect the crankcase breather hose, vent hose, and fuel pump in/out hoses.
5. Disconnect fuel cooler in/out hoses (If equipped).
IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pull-
ing off the hoses. Remove fuel pump hoses by slowly prying them off using a small
screwdriver.
6. Remove coils from valve cover. Refer to section 2A - Ignition Coil Removal.
7. Remove valve cover.

h d

59250
g
f
a - Screw (7) M6 x 20
b - Valve Cover
c - Crankcase Breather Hose
d - Crankcase Vent Hose
e - Fuel Pump Output Hose
f - Fuel Pump Input Hose
g - Fuel Cooler OUT Hose
h - Fuel Cooler IN Hose

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Installation
1. Install valve cover seal into groove.
2. If removed, reinstall baffle plate. Tighten screws securely.

a - Baffle Plate
b - Screw (4) M4 x 10
c - Cover Seal

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3. Reinstall the valve cover. Tighten screws to the specified torque.

4. Install coils. Refer to section 2A - Ignition Coil Installation.
5. Install fuel pump. Refer to section 3C - Fuel Pump Installation.
6. Connect fuel pump in/out hoses, fuel cooler in/out hoses, crankcase breather and vent
hose. Secure all with sta-straps.
7. Reinstall spark plugs and spark plug leads.

h d

59250
g
f
a - Screw (7) M6 x 20
b - Valve Cover
c - Crankcase Breather Hose
d - Crankcase Vent Hose
e - Fuel Pump Output Hose
f - Fuel Pump Input Hose
g - Fuel Cooler OUT Hose
h - Fuel Cooler IN Hose
Valve Cover Screw Torque
70 lb-in. (8 Nm)

Coil Mounting Screw

75 lb-in. (8.5 Nm)

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8. Install flywheel cover/manual starter components (if equipped). Tighten screws to speci-
fied torque.
NOTE: Refer to section 8 for installation of manual starter.

a - Flywheel Cover
b - Screw (4) M6 x 25
Flywheel Cover Screw Torque
75 lb. in. (8.5 N·m)

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Valve Clearance Adjustment

NOTE: Valve should be adjusted when the engine is cold.

WARNING
Engine could possibly start when turning flywheel during adjustment. To prevent
this type of accidental engine starting and possible serious injury, always remove
spark plug leads from spark plugs.
Checking Valve Clearance
1. Remove valve cover as outlined in “Valve Cover Removal”.
2. Measure valve clearance with a feeler gauge. Adjust if out of specification.
NOTE: When loosening lock nuts, hold the adjusting screw with a screw driver to prevent
it from moving.

Valve Clearance (Cold)

Intake 0.006 - 0.010 in. (0.15 - 0.25 mm)
Exhaust 0.010 - 0.014 in. (0.25 - 0.35 mm)

d c

a - Lock nut
b - Adjusting Screw
c - Intake Valve Clearance
d - Exhaust Valve Clearance

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Adjusting Valves
1. Perform the following adjustment steps:
a. Turn the driven gear and align the “1 / ∆” mark on the driven gear with the “∆” mark
on the cylinder block.
b. Adjust the intake and exhaust valve clearance for cylinder #1.
c. Turn the driven gear 120° clockwise and align the “∆” mark on the driven gear with
the “∆” on the cylinder block.
d. Adjust the intake and exhaust valve clearance for cylinder #2
e. Turn the driven gear 120° clockwise and align the “∆” mark on the driven gear with
the “∆” on the cylinder block.
f. Adjust the intake and exhaust valve clearance for cylinder #3

d c

b
1

57191
a
a - Cylinder Block “∆” Mark
b - Driven Gear “1 or ∆” Mark (Cylinder #1)
c - Driven Gear “∆” Mark at 120° (Cylinder #2)
d - Driven Gear “∆” Mark at 240° (Cylinder #3)

2. Tighten the lock nuts.

NOTE: When tightening lock nuts, hold the adjusting screw with a screw driver to prevent
it from moving.

Valve Adjusting Lock Nut Torque

120 lb. in. (13.5 N·m)

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Timing Belt
Removal
1. Remove flywheel and stator. Refer to section 2B Charging and Starting System.
2. Remove timing belt from driven gear and drive gear.

a - Timing Belt

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Installation
Timing Belt Installation Notes:
• Protect the timing belt from water and oil.
• Use care not to scratch the belt.
• Do not use any metal device to help stretch the belt onto the driven gear.
1. Align marks on drive and driven gear with marks on cylinder block as shown.
2. Install timing belt onto drive gear as shown. Numbers/letters on belt should be readable
once belt is installed.
3. Install stator and flywheel. Refer to section 2A - Ignition.

a d
1

b
c c e

a - Drive Gear Mark

b - Driven Gear Mark
c - Cylinder Block Marks
d - Timing Belt Installed Correctly
e - Timing Belt Installed Incorrectly

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Cylinder Head Removal

WARNING
Engine could possibly start when turning flywheel during adjustment. To prevent
this type of accidental engine starting and possible serious injury, always remove
spark plug leads from spark plugs.
1. Remove valve cover. Refer to Valve Cover Removal.
2. Remove timing belt from driven gear.

a - Timing Belt
b - Driven Gear
3. Remove the throttle and shift levers from side of cylinder head.
4. Remove the cylinder head and intake manifold assembly mounting screws.

a - Center Screw (8) M9 x 95

b - Flange Screw (4) M6 x 25
c - Intake Manifold Screw (6)

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5. Separate cylinder head from cylinder block.

NOTE: Cylinder head gasket is not reusable.

a - Gasket (Discard)
b - Dowel Pins (2) (Retain)

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Cylinder Head Disassembly

Rocker Arm Assembly Removal
1. Remove screws securing rocker arm shaft to cylinder head. Remove rocker arm assem-
bly and retainers.

b
a

a - Screws (4) M8 x 30
b - Rocker Arm Assembly

Oil Pump Removal

1. Refer to section 4C - Oil Pump Removal.

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Camshaft Removal
1. Hold driven gear using tool (91-83163M) and loosen screw. Remove screw, washer,
driven gear and dowel pin.
NOTE: The camshaft can be removed from the top without removing the cylinder head from
the engine.

b
a

91-83163M

a - Holder 91-83163M
b - Driven Gear
c - Screw M8 x 40
d - Washer
e - Dowel Pin
2. Remove camshaft retaining pin and seal.
3. Remove oil seal and camshaft.

a - Oil Seal
b - Camshaft
c - Camshaft Retaining Pin with Seal

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Valve Removal
VALVE COMPONENTS

e
d
c
b
a
a - Valve
b - Valve Seal
c - Valve Spring
d - Spring Retainer
e - Valve Keepers

REMOVING VALVES
NOTE: Anytime a valve is removed, replace the valve seal.
1. Compress valve springs using tool (91-809494A1). Remove valve keepers and valves.

91-809494A1

58256

a - Valve Spring Compressor (P/N 91-809494A1)

b - Valve Keepers

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Rocker Shaft and Rocker Arm

1. Measure rocker shaft diameter. Replace shaft if out of specification.

Rocker Shaft Diameter

0.6288 - 0.6296 in. (15.971 -15.991 mm)

2. Measure rocker arm inside diameter. Replace rocker arms if out of specification.

55804

Rocker Arm Inside Diameter

0.6299 - 0.6306 in. (16.000 -16.018 mm)

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Cleaning/Inspection/Repair
Camshaft
Manual start models are equipped with a cam shaft featuring a compression release
mechanism. The compression relief mechanism releases a percentage of the cylinder
compression during engine cranking, which lowers the starter rope pull force.
At cranking speeds (RPM) the cam shaft decompression levers rest against the side of the
exhaust cam lobes, protruding out from the heal of the lobe. This protrusion contacts the
exhaust valve rocker arms during the compression stroke, slightly opening the exhaust
valve.
With the increase of centrifugal force at engine running speeds, the decompression levers
swing out of contact with the exhaust valve rocker arms, allowing the exhaust valves to operate
normally (fully closed) during the compression stroke.

a - Exhaust Valve Rocker Arm

b - Decompression Lever

1. Inspect the camshaft for pitting, heat discoloration, or scratches, and for the following
measurements. Replace camshaft if worn or not within specification.
2. Inspect the compression relief cam lever (if equipped) for free movement. Replace cam-
shaft if necessary.

a - Compression Relief Cam

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3. Measure the cam lobe length (a) and width (b).

a
b

Cam Lobe Specifications

a Intake 1.214 - 1.222 in.
(30.83 - 31.03 mm)
Exhaust 1.214 - 1.222 in.
(30.83 - 31.03 mm)
b Intake 1.020 - 1.028 in.
(25.90 -26.10 mm)
Exhaust 1.020 - 1.028 in.
(25.90 -26.10 mm)
4. Measure the camshaft bore diameters (a) and camshaft bearing diameters (b).

b b

b a

Camshaft Bore Inside Diameter “a”

1.4567 - 1.4577 in. (37.000 - 37.025 mm)

Camshaft Bearing Inside Diameter “b”

1.4541 - 1.4549 in. (36.935 - 36.955 mm)

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Cylinder Head
1. Inspect the cylinder head for the following conditions:
• Mineral deposits/corrosion in water passage ways.
• Carbon deposits in combustion chamber (use round scraper to clean away depos-
its). Be careful not to scratch or remove material.
2. Using a straight edge and a thickness gauge inspect cylinder head for warpage. Re-
place cylinder head if out of specification. Measure in locations illustrated.

56899

Cylinder Head Warpage Limit

0.004 in. (0.1 mm)

Valve Guide inspection

1. Measure the valve guide bore (a). If valve guide wear is out of specification, replace the
valve guide.

58257

Valve Guide Inside Diameter

Intake Valve 0.2165 - 0.2170 in.
Exhaust Valve (5.500
(5 500 - 5
5.512
512 mm))

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Valve Guide Replacement

1. Heat the cylinder head in an oven to 390° F (200° C). This will help to ease guide removal
and installation and to maintain correct interference fit.
2. Remove the valve guide using a valve guide remover.

a - Valve Guide Remover (91-809495A1)

3. Install the new valve guide and circlip using a valve guide installer bushing along with
the valve guide remover.

a - Valve Guide Remover (91-809495A1)

b - Valve Guide Installer Bushing (91-809496A1)

4. After installing the valve guide, ream the valve guide using a valve guide reamer to ob-
tain proper stem-to-guide clearance.

a - Valve Guide Reamer (91-809497A1)

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Valves
1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned
valves.
2. Measure the valve stem diameter to check for wear. Replace valves if not within specifi-
cation.

Valve Stem Diameter

Intake Valve 0.2156 - 0.2161 in.
(5.475 - 5.490 mm)
Exhaust Valve 0.2150 - 0.2156 in.
(5.460 - 5.475 mm)
3. Check the valve face for pitting. Valves faces that are pitted must be refaced.
NOTE: Several different types of equipment are available for refacing valves. Follow the
equipment manufacturer’s instructions.
NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat
and valve face should be lapped.
4. Check the margin thickness (a) of the valves after the valves have been ground. Any
valve with a margin thickness of less than the specification, should be replaced.

45 °

Margin Thickness “a”

Intake Valve 0.020 - 0.035 in.
(0.5 - 0.9 mm)
Exhaust Valve 0.020 - 0.035 in.
(0.5 - 0.9 mm)

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5. Measure valve stem runout, replace if out of specification.

Valve Stem Runout Limit (Max.)

Intake Valve 0.0006 in. (0.016 mm)
Exhaust Valve

Valve Springs
1. Check each spring under load on a spring tester. Replace any weak springs.

2. Check free length limit of each spring. Replace valve springs if not in specification.

Valve Spring Free Length

1.491 - 1.569 in. (37.85 – 39.85 mm)

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3. Check each spring on a flat surface using a square. Rotate spring and check space be-
tween the top coil and square. Replace valve springs if not in specification.

Valve Spring Tilt Specification “a”

Less than 0.06 in. (1.7 mm)

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Valve Seat Reconditioning

Clean the carbon deposits from the combustion chambers and valve seats and check for
pitting.
Several different types of equipment are available for reseating valve seats. Follow the
equipment manufacturer’s instructions.
Measure valve seat width (a). Resurface the valve seat if not in specification.
Reface valve seat, use a 60°, 45°, 15° valve seat cutter.
NOTE: When twisting cutter, keep an even downward pressure to prevent chatter marks.

Valve Seat Width Specification “a”

Intake Valve 0.035 - 0.043 in.
Exhaust Valve (0.9 - 1.1 mm)

NOTE: If resurfacing the valve seats is required, resurface the valve seats to the specified
angles shown in chart following.

b
a

Valve Seat Angle Specifications

a 15°
b 45°
c 60°

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CYLINDER HEAD

Valve Refacing Steps

Condition: The valve seat is centered on valve face but it is too wide.

Valve Seat Cutter Set Desired Results

Use 15° Cutter To reduce valve seat
Lightly
Li htl 60° Cutter width
idth

Condition: The valve seat is in the middle of the valve face but it is too narrow.

Valve Seat Cutter Set Desired Results

Use 45° Cutter To achieve a uniform valve
seatt width
idth

Condition: Valve seat is too narrow and it is near valve margin.

Valve Seat Cutter Set Desired Results

Use 15° Cutter, First To center the seat and to
45° Cutter achieve
hi itits Width

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 CYLINDER HEAD

Condition: Valve seat is too narrow and is located near the bottom edge of the valve face.

Valve Seat Cutter Set Desired Results

Use 60° Cutter, First To center the seat and to in-
45° Cutter crease itits Width

Cylinder Head Reassembly

Valve Installation
INTAKE AND EXHAUST VALVE COMPONENTS

e
d
c
b
a
a - Valve
b - Valve Seal
c - Valve Spring
d - Spring Retainer
e - Valve Keepers

90-857046R1 NOVEMBER 2001 Page 4A-37

CYLINDER HEAD

INSTALLING VALVES
NOTE: Always use new valve seals.
1. Apply engine oil to the valves and valve seats.
2. Compress the valve spring and retainer and install the valve keepers around the valve
stem. You may have to tap lightly on the end of the valve to seat the keepers.
NOTE: Valve springs are symmetrical and may be installed in either direction.

91-809494A1

a - Valve Spring Compressor Tool (91-809494A1)

b - Valve Keepers

Camshaft Oil Seal Installation

1. If removed, install new oil seal. Position seal so part number side is facing outward.
Press seal in until it makes contact with the inside flat surface.

58261

a - Upper Camshaft Oil Seal

Page 4A-38 90-857046R1 NOVEMBER 2001

 CYLINDER HEAD

Camshaft Installation
1. Apply engine oil to the main journals (4 places) on the camshaft.
2. Slide camshaft into cylinder head (threaded end towards driven gear).
NOTE: Camshaft retaining pin groove must align with retaining pin hole in cylinder head.
3. Install camshaft retaining pin. Install seal over pin.
4. Place driven gear on camshaft so alignment pin is in hole. Hold gear with tool
(91-83163M) and fasten with washer and screw. Tighten screw to the specified torque.
5. Remove any oil from the camshaft lobes and apply Moly Grease to the lift portion of the
lobes. Obtain Moly Grease from a local source.
NOTE: Rotate camshaft after assembly to ensure it rotates smoothly.

f e

d c

a
b

58477

58287

91-83163M
58278
a - Camshaft d - Driven Gear
b - Camshaft Retaining Pin w/Seal e - Washer
c - Alignment Pin f - Screw M10 x 40
Driven Gear Screw Torque
28 lb-ft (38 Nm)

90-857046R1 NOVEMBER 2001 Page 4A-39

CYLINDER HEAD

Oil Pump Installation

1. Refer to section 4C - Oil Pump Installation.

Rocker Arm Shaft Assembly

1. Apply engine oil to the rocker shaft and arms.
2. Locate the end of the rocker shaft that gets installed towards driven gear (oil holes will
line-up with the mating oil holes in the cylinder head).
3. Slide the rocker arms onto rocker shaft as shown.

c
a
b
c
110

110 4-Stroke Outboard Oil 53739

c
a - Rocker Shaft
b - Rocker Arm (6)
c - Oil Holes (4)

Page 4A-40 90-857046R1 NOVEMBER 2001

 CYLINDER HEAD

Rocker Arm Shaft Installation

1. Install the rocker arm shaft assembly as shown.
2. Install rocker arm retainers on rocker shaft as shown. Tighten screws to the specified
torque.
NOTE: Leave all adjustment screws loose at this time.

110
c
b

58987
110 4-Stroke Outboard Oil
a - Mounting Screw (4)-M8 x 30
b - Rocker Arm Bracket (1)
c - Rocker Arm Spring - Overload (2) Arrow Must Point Toward Driven Gear
d - Rocker Arm Spring (1)
e - Rocker Arm Bracket (1)
f - Rocker Arm Spring (1) Arrow Must Point Toward Driven Gear

Rocker Arm Shaft Mounting Screw Torque

160 lb. in. (18 N·m)

90-857046R1 NOVEMBER 2001 Page 4A-41

CYLINDER HEAD

Cylinder Head Gasket

1. Install new cylinder head gasket and dowel pins.

a - Gasket (New)
b - Dowel Pin (2)

Page 4A-42 90-857046R1 NOVEMBER 2001

 CYLINDER HEAD

Cylinder Head Installation

1. Apply engine oil to the threads of each screw and seat surface.
2. Fasten cylinder head with screws shown. Do not tighten.

110

b
a

110 4-Stroke Outboard Oil

a - Screw (8) M9 x 95
b - Flange Screw (4) M6 x 25

90-857046R1 NOVEMBER 2001 Page 4A-43

CYLINDER HEAD

3. Torque center screws (first) in sequence and in two steps.

4. Torque the cylinder head and carburetor intake manifold screws in sequence and in two
steps.
5. Refer to “Timing Belt Installation” preceding, and install timing belt.
6. Refer to “Valve Clearance Adjustment” preceding, to perform valve clearance adjust-
ments.
7. Refer to “Valve Cover Installation” preceding, and install valve cover.

7 6
8

4 4
3
b
4
2
1
3
2

2
1 5

1 c

3 6

5
a

a - Center Screw (8) M9 x 95

b - Flange Screw (4) M6 x 25
c - Intake Manifold Screw (6) M6 x 25
Intake Manifold Screw Torque
70 lb. in. (8 N·m)

Cylinder Head Screw Torque

Center Screw (Qty. 8)
1st: 17 lb-ft (23 Nm)
2nd: 35 lb-ft (47 Nm)
Cyl. Head Flange Screw (Qty. 4)
1st: 53 lb-in. (6 Nm)
2nd: 106 lb-in. (12 Nm)

Page 4A-44 90-857046R1 NOVEMBER 2001