Cylinder Block/Crankcase
Powerhead
Section 4A - Cylinder Block/Crankcase
Table of Contents
Cylinder Block/Crankcase Specifications.........4A-2
Cylinder Block Components.............................4A-6
Crankshaft, Piston and Connecting Rod
Components.....................................................4A-8
Lower Cowl Removal.....................................4A-10
Powerhead Removal......................................4A-12
Removing Powerhead Components .............4A-16
Wire Harness Assembly Removal..........4A-16
Intake Manifold Assembly Removal........4A-21
Throttle Bracket Removal and Disassembly
................................................................4A-23
FSM Assembly and Mounting Bracket
Removal..................................................4A-24
Alternator Assembly and Mounting Bracket
Removal..................................................4A-25
Starter Assembly Removal.....................4A-26
Thermostat Housing Assembly Removal
................................................................4A-27
Flywheel, Ground Strap, and Electrical Plate
Grommet Removal..................................4A-28
Powerhead Disassembly...............................4A-30
Cylinder Head Removal .........................4A-30
Crankcase and Crankshaft Disassembly/
Removal..................................................4A-33
Cleaning, Inspection and Repair....................4A-36
Measuring Cylinder Bore........................4A-36
Measuring Piston....................................4A-37
Measuring Connecting Rod ...................4A-39
Measuring Crankshaft.............................4A-40
Powerhead Reassembly................................4A-41
Installing Oil Galley Plugs ......................4A-41
Powerhead Pre‑Assembly Cleaning
Recommendations..................................4A-42
90-899185 SEPTEMBER 2006
Selecting New Crankshaft Bearings.......4A-43
Crankshaft Main Bearing Grade Selection
................................................................4A-43
Piston/Connecting Rod Assembly..........4A-44
Connecting Rod Bearing Grade Selection
................................................................4A-44
Piston Ring Installation...........................4A-46
Piston Assembly Installation...................4A-47
Installing the Timing Chain onto the
Crankshaft..............................................4A-49
Cylinder Head Installation.......................4A-51
Installing the Camshaft Gears and the Timing
Chain......................................................4A-57
Installing Upper Crankshaft Seal............4A-60
Installing the Lower Crankshaft Seal .....4A-64
Installing Powerhead Components................4A-65
Flywheel, Ground Strap, and Electrical Plate
Grommet Installation...............................4A-65
Thermostat Removal and Installation.....4A-68
Thermostat Housing Assembly Installation
................................................................4A-70
Starter Assembly Installation..................4A-73
Alternator Assembly and Mounting Bracket
Installation...............................................4A-74
Fuel Supply Module (FSM) Assembly and
Mounting Bracket Installation..................4A-76
Throttle Bracket Reassembly and Installation
................................................................4A-77
Intake Manifold Assembly Installation.....4A-81
Wire Harness Installation........................4A-84
Powerhead Installation...................................4A-91
Lower Cowl Installation..................................4A-94
Engine Break‑in Procedure............................4A-97
Page 4A-1
4
A
Cylinder Block/Crankcase
Cylinder Block/Crankcase Specifications
Cylinder Block/Crankcase Specifications
Number of cylinders
Displacement
Compression ratio
4
1.7 liters (105.6 CID)
10:1
Standard bore
82.0 mm (3.228 in.)
Stroke
82.0 mm (3.228 in.)
Cylinder bore maximum taper (service)
0.0762 mm (0.003 in.)
Cylinder bore maximum out of round (service)
0.0762 mm (0.003 in.)
Cylinder block main bearing
65.997 ‑ 66.013 mm (2.5982 ‑ 2.5989 in.)
Crankshaft main bearing journal ‑ Grade A
59.993 ‑ 60.001 mm (2.3619 ‑ 2.3622 in.)
Crankshaft main bearing journal ‑ Grade B
59.985 ‑ 59.993 mm (2.3616 ‑ 2.3619 in.)
Crankshaft pin journal ‑ Grade C
49.982 ‑ 50.00 mm (1.9678 ‑ 1.968 in.)
Crankshaft pin journal ‑ Grade D
49.982 ‑ 49.991 mm (1.9677 ‑ 1.9681 in.)
Bottom main bearing width
31.4 ‑ 31.6 mm (1.236 ‑ 1.244 in.)
Crankshaft end play
0.08 ‑ 0.19 mm (0.003 ‑ 0.007 in.)
Crankshaft run out
0.05 mm (0.002 in.)
Crankshaft main bearing oil clearance (without
expansion)
0.014 ‑ 0.042 mm (0.0005 ‑ 0.0016 in.)
Connecting rod bearing oil clearance (without
expansion)
0.020 ‑ 0.050 mm (0.0008 ‑ 0.0019 in.)
Connecting rod wrist pin bore diameter
22.005 ‑ 22.014 mm (0.8663 ‑ 0.8666 in.)
Connecting rod crankshaft pin diameter ‑ Grade I
53.000 ‑ 53.009 mm (2.0866 ‑ 2.0869 in.)
Connecting rod crankshaft pin diameter ‑ Grade 0
53.009 ‑ 53.018 mm (2.0869 ‑ 2.0873 in.)
Piston skirt standard diameter
81.975 mm (3.2273 in.)
Piston wrist pin bore diameter
22.004 ‑ 22.011 mm (0.8662 ‑ 0.8665 in.)
Wrist pin diameter
21.997 ‑ 22.000 mm (0.8660 ‑ 0.8661 in.)
Top ring groove width
1.22 ‑ 1.25 mm (0.048 ‑ 0.049 in.)
Middle ring groove width
1.21 ‑ 1.23 mm (0.047 ‑ 0.048 in.)
Oil ring groove width
2.03 ‑ 2.05 mm (0.079 ‑ 0.080 in.)
Top ring thickness
1.19 mm (0.047 in.)
Middle ring thickness
1.19 mm (0.047 in.)
Oil ring thickness
1.98 mm (0.078 in.)
Top ring side clearance
0.04 ‑ 0.08 mm (0.001 ‑ 0.003 in.)
Middle ring side clearance
0.04 ‑ 0.08 mm (0.001 ‑ 0.003 in.)
Oil ring side clearance
0.05 ‑ 0.17 mm (0.002 ‑ 0.006 in.)
Top ring end gap
0.27 ‑ 0.42 mm (0.010 ‑ 0.016 in.)
Middle ring end gap
0.42 ‑ 0.62 mm (0.016 ‑ 0.024 in.)
Oil ring end gap
0.2 ‑ 0.7 mm (0.007 ‑ 0.027 in.)
Thermostat
Start to open temperature
Full open temperature
Piston height @ full open temperature
Page 4A-2
48.8 ± ‑15 °C (120 ± 5 °F)
65.5 °C (150 °F)
7.62 mm (0.300 in.)
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Lubricant, Sealant, Adhesives
Tube Ref No.
Description
9
Loctite 567 PST Pipe Sealant
25
Liquid Neoprene
66
Loctite 242 Threadlocker
95
2-4-C with Teflon
110
4-Stroke 10W-30 Outboard Oil
113
Loctite Moly Paste (Molybdenum
Disulfide Grease)
135
Three Bond 1217F
136
139
Where Used
Part No.
Oil galley plugs
Oil pressure sensor threads
92-809822
Strainer fitting threads
Ground screw
Ground location of the ground strap
Alternator ground cable connection
Screws securing the battery cable
92-25711-3
ground and the engine harness
grounds to the cylinder block
Nut securing the battery charge wire
Engine harness ground
Throttle follower lever screw
Throttle lever screw
92-809821
Throttle bracket assembly screws
Throttle follower lever bushing
92-802859A1
Throttle lever bushing
Piston rings
Thermostat housing O-ring
92-802833A1
Lower dump fitting O-rings
Long screw
Obtain Locally
Main bearing long bolt threads
Crankcase cover perimeter
Obtain Locally
Fixed and moveable guide screw
Crankshaft main bearings and
connecting rod bearings
Piston wrist pin
Connecting rod bearing
Crank pin
Lubriplate SPO 255
Screws securing the timing chain Obtain Locally
tensioner, the timing chain guide and
the plug O-ring
Crankshaft main bearings
Cylinder block seal area, crankshaft
seal area, crankshaft seal inside
diameter and outside diameter
Piston rings
Piston rings, cylinder bore
Rod cap screw threads
Synthetic Blend 4-Stroke Outboard Oil
Timing chain tensioner
92-883722K01
25W-40
Inside diameter of cylinder block
crankshaft seal area
Inside diameter of crankshaft seal
Engine oil sump
90-899185 SEPTEMBER 2006
Page 4A-3
Cylinder Block/Crankcase
Special Tools
Fuel Pressure Gauge Kit
91‑881833A03
Tests the fuel pump pressure; can be used to relieve fuel
pressure.
rms32
Digital Pressure Meter
91‑892651A01
Connects to the fuel system/manifold and can be used in
conjunction with Computer Diagnostic System (CDS).
5786
Flywheel Puller/Lifting Ring
91‑895343T02
14869
Cam Brake
Removes flywheel from engine. Used for lifting powerhead/
engine.
Part number not available for this printing.
Prevents the intake and exhaust cam from turning while
removing or installing cam retaining bolts.
5539
Rod Guide Dowel
Part number not available for this printing.
Prevents cylinder bore and crankshaft from damage while
installing or removing connecting rod assembly.
4735
Ring Compressor
Part number not available for this printing
Compresses piston rings when installing the piston into the
cylinder block.
4739
Page 4A-4
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Crankshaft Retainer
Part number currently not available for this printing.
Secures crankshaft to cylinder block while rotating block to
install the cylinder head.
6191
Crankshaft Seal Installation Tool
Part number not available for this printing
Aids in the installation of the crankshaft seal.
15499
Hose Clamp Tool Kit
91‑803146A2
Aids in the installation of high pressure (Oetiker ®) hose
clamps.
5819
13 mm Torque Adapter
91‑809905001
4631
90-899185 SEPTEMBER 2006
Aids in the removal and installation of powerhead nuts, and
torquing nuts to specification.
Page 4A-5
Cylinder Block/Crankcase
Cylinder Block Components
22
7
27
3
1
8
14 13
19
2
15 11
12
18
21
4
20
3
29
5
2
4
16
9
23
10
113
17
24
28
26
25
136
6
6
6th
6
6
6
7th
8th
2nd
3rd
5th
1st
4th
14756
Page 4A-6
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Cylinder Block Components
Torque
Ref. No.
Qty.
Nm
lb. in.
1
1
Cylinder block assembly
2
2
Starter motor mounting bracket
3
4
Screw (M8 x 40)
17
150.4
4
2
Dowel pin
5
10
Rubber damper
6
5
Plug (12 mm)
9
79.6
7
2
Plug (24 mm)
55
40.5
8
1
Plug (14 mm)
24
17.7
9
10
Washer
First torque
27
20
Second torque
55
40.5
10
10
Description
Long screw (M10 x 342)
Final torque
lb. ft.
Turn additional 270° after second torque
is attained
11
2
Stud (M8 x 55)
10
88.5
12
2
Nut (M8)
27
20
13
6
Stud (M10 x 1.5)
22
16
14
6
Washer
15
6
Nut (M10)
61
45
16
8
Screw (M10 x 120)
50
37
17
2
Screw (M8 x 50)
35
26
18
1
Crank Position Sensor (CPS)
19
2
Screw (M5 x 13)
5
44.2
20
1
Cylinder block coolant temperature sensor
15
132.7
21
1
O‑ring
22
1
Gasket
23
1
Fixed guide
24
1
Moveable guide
25
2
Screw
26
1
Gasket
27
1
28
29
24
18
Plug (18 mm)
22
16
2
Screw (M8 x 70)
35
26
8
Screw (M8 x 90)
35
26
Tube Ref No.
Description
Where Used
Part No.
113
Loctite Moly Paste
(Molybdenum Disulfide Grease)
Long screw
Obtain Locally
136
Lubriplate SPO 255
Fixed and moveable guide
screw
Obtain Locally
90-899185 SEPTEMBER 2006
Page 4A-7
Cylinder Block/Crankcase
Crankshaft, Piston and Connecting Rod Components
21
20
17
19
136
4
136
18
5
16
136
2
9
15
8
14
136
10
7
1
136
12
13
15
11
110
3
136
22
6
23
14759
Page 4A-8
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Crankshaft, Piston and Connecting Rod Components
Torque
Ref. No.
Qty.
1
1
Crankshaft
2
1
Flywheel key
3
1
Lower crankshaft thrust bearing
4
1
Top main bearing seal
5
4
Crankshaft main bearing
6
1
Camshaft drive chain
7
4
Connecting rod assembly
8
8
Description
Bolt
Nm
lb. in.
First torque
15
132.7
Second torque
30
Final torque
9
4
Connecting rod bearing
10
4
Piston assembly
11
4
Piston top ring
12
4
Piston oil ring
13
4
Piston second ring
14
4
Piston pin
15
8
Piston pin circlip
16
1
Flywheel
17
1
Bolt (M20 x 68)
18
1
Washer
19
1
Spacer
20
1
Retaining ring
21
1
Cap
22
1
Oil seal
23
1
Retaining ring
Tube Ref No.
lb. ft.
22
Turn an additional 90° after second
torque is attained
First torque
60
44
Second torque
180
133
Description
Where Used
Part No.
110
4-Stroke 10W-30 Outboard Oil
Piston rings
92-802833A1
136
Lubriplate SPO 255
Crankshaft main bearings and
connecting rod bearings
Obtain Locally
90-899185 SEPTEMBER 2006
Page 4A-9
Cylinder Block/Crankcase
Lower Cowl Removal
! WARNING
Always disconnect battery cables from battery before working on engine to prevent fire
or explosion.
1.
2.
3.
4.
5.
Disconnect the positive and negative battery cables from the battery.
Disconnect the remote control harness from the engine.
Disconnect the fuel line.
Cut the cable tie securing the cowl grommet.
Remove the cowl seal from the port side cowl. Allow the cowl seal to hang from the
starboard side cowl.
b
c
a
22050
a - Fuel line removed
b - Cowl seal
c - Cable tie (remove)
6. Remove the two screws securing the cowl insert onto the port cowl. Remove the cowl
insert.
a
a
22051
a - Screws securing the cowl insert (2)
Page 4A-10
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
7. Remove the throttle and shift cables.
b
a
22052
a - Shift cable
b - Throttle cable
8. Remove the cowl front screw.
a
b
c
22045
a - Cowl front screw
b - Battery cables
c - Engine fuel line
9. Remove the five screws securing the cowls.
22053
10. Remove the screw securing the cowl latch to the cowl.
90-899185 SEPTEMBER 2006
Page 4A-11
Cylinder Block/Crankcase
11. Remove the lower screw securing the cowl. Carefully pull the port cowl off the adapter
plate seal.
b
a
c
22046
a - Lower screw securing the cowl
b - Screw securing the cowl latch
c - Cowl seal
12. Disconnect the cowl trim switch from the engine harness connector.
13. Pull the starboard cowl off the adapter plate seal.
a
b
22054
a - Trim switch engine harness
connector
b - Cowl trim switch
Powerhead Removal
1.
2.
3.
4.
Page 4A-12
Drain the engine oil from the sump.
Disconnect the battery cables from the battery.
Remove the flywheel cover.
Remove the green cap to access the purge valve for the Fuel System Module (FSM)
pressure release.
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
! CAUTION
Pressurized fuel system! Release all pressure before servicing any part of the fuel
system. This system can build pressure if the engine has not run for an extended period
of time. If the fuel system is not relieved of pressure, fuel and vapors may be expelled at
a significant velocity. Always protect your eyes and skin from pressurized fuel and vapors
when servicing the fuel system.
22611
5. Place a rag over the valve and press on the center of the valve to relieve any pressure
inside the FSM.
13282
6. Attach a fuel pressure gauge to the fuel pressure valve on the fuel rail. Relieve the fuel
pressure into an appropriate container.
22612
90-899185 SEPTEMBER 2006
Page 4A-13
Cylinder Block/Crankcase
Fuel Pressure Gauge Kit
91‑881833A03
Digital Pressure Meter
91‑892651A01
7. Disconnect the brown/white trim position sensor bullet connectors.
8. Disconnect the neutral switch harness connector from the engine harness connector.
9. Remove the hose clamp securing the water hose to the FSM and remove the hose.
10. Cut the cable tie securing the water hose leading to the driveshaft housing at the tee
fitting and remove the hose.
11. Remove the dipstick.
12. Disconnect the blue and green power trim motor bullet connectors.
a
b
c
f
e
d
22613
abcdef-
Trim position sensor bullet connector
Neutral switch harness connector
FSM water hose
Water hose to driveshaft housing
Dipstick
Power trim motor bullet connectors
13. Remove the flywheel grease cap from the flywheel. Install the lifting tool to the flywheel.
Tighten the base bolts to the specified torque.
a
b
c
d
22611
a - Flywheel grease cap
b - Lifting eye
Page 4A-14
22641
c - Base
d - Bolts (3)
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Flywheel Puller/Lifting Ring
91‑895343T02
Description
Nm
Flywheel Puller/Lifting Ring base bolts
23.7
lb. in.
lb. ft.
17.5
14. Install a lift hook into the lifting ring on the flywheel.
15. Remove the three bolts securing the exhaust plenum to the adapter plate and remove
the exhaust plenum.
16. Remove the two locknuts from the powerhead studs.
a
a
a
c
b
a - Bolts (M6)
b - Exhaust plenum
22614
c - Powerhead stud (M8 x 55)
17. Remove the six locknuts (three each side) from the powerhead studs.
a
22643
a - Locknut/powerhead stud (M10 x 154) (3 each side)
18. Remove the powerhead from the adapter plate.
NOTE: While lifting the powerhead off of the adapter plate, it may be necessary to gently
rock the powerhead fore and aft to prevent the mounting studs from binding in the adapter
plate.
90-899185 SEPTEMBER 2006
Page 4A-15
Cylinder Block/Crankcase
Removing Powerhead Components
Wire Harness Assembly Removal
! CAUTION
Disconnect the battery leads before removing, repairing or installing any electrical or fuel
delivery component.
1. Disconnect the Idle Air Control (IAC) harness connector from the IAC.
a
22799
a - IAC harness connector
2. Disconnect the Manifold Absolute Pressure (MAP) sensor harness connector from the
MAP sensor.
b
c
a
22204
a - IAC
b - MAP sensor harness connector
c - Vent Canister Purge Valve (VCPV)
3. Cut the cable tie securing the Vent Canister Switch (VCS) harness connector to the
engine harness.
4. Disconnect the VCS harness connector from the VCS.
5. Disconnect the Vent Canister Purge Valve (VCPV) harness connector from the VCPV.
Page 4A-16
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
6. Carefully pull the engine harness out from the top of the intake manifold.
b
c
d
a
22205
a - Vent Canister Switch (VCS)
b - Cable tie securing the Vent
Canister Switch (VCS)
c - Vent Canister Purge Valve (VCPV)
d - VCPV harness connection
7. Disconnect the cylinder block coolant temperature sensor harness connector from the
cylinder block coolant temperature sensor.
b
a
22206
a - Vent Canister Purge Valve (VCPV)
b - Cylinder block coolant temperature sensor harness connector
8. Cut the cable tie securing the Manifold Absolute Temperature (MAT) sensor harness
connector to the MAT sensor.
9. Disconnect the MAT sensor harness connector from the MAT sensor.
10. Cut the four cable ties securing the fuel injector harness to the fuel rail.
11. Disconnect the four fuel injectors from the engine harness.
12. Cut the two cable ties securing the engine harness to the cam cover.
90-899185 SEPTEMBER 2006
Page 4A-17
Cylinder Block/Crankcase
13. Remove the screw securing the engine harness ground to the cylinder head.
c
b
a
d
22210
abcd-
Cable ties securing the fuel injector harness (4)
Cable tie securing the engine harness to the MAT sensor
Screw securing the engine harness ground
Cable ties securing the engine harness (2)
14. Disconnect the Throttle Position Sensor (TPS) harness connector from the TPS.
15. Disconnect the Fuel Supply Module (FSM) harness connector from the FSM.
a
b
22800
a - FSM harness connector
b - TPS harness connector
16. Remove the breather hose from the air filter.
17. Remove the alternator battery charge wire from the alternator.
Page 4A-18
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
18. Disconnect the engine harness sense lead connector from the alternator.
a
b
c
22801
a - Alternator battery charge wire
b - Engine harness sense lead
c - Breather hose
19. Disconnect the Crankshaft Position Sensor (CPS) harness connector from the CPS.
20. Disconnect the engine harness connectors from the Electronic Control Module (ECM).
21. Disconnect the starter power cable from the starter.
22. Disconnect the starter exciter wire from the engine harness.
23. Remove the screw securing the wire harness bracket and the ECM.
a
b
c
e
d
22802
a - CPS harness connector
b - ECM harness connector
c - Screw securing the wire harness
bracket and the ECM
d - Starter exciter wire
e - Starter power cable
24. Cut the two cable ties securing the engine harness to the FSM bracket.
25. Remove the hose from the clip on the 14 pin engine harness bracket.
90-899185 SEPTEMBER 2006
Page 4A-19
Cylinder Block/Crankcase
26. Remove the two screws and washers securing the 14 pin engine harness bracket.
b
c
a
22804
a - Clip on the 14 pin engine harness bracket
b - Screws and washers securing the 14 pin engine harness bracket
c - Cable ties securing the engine harness to the FSM bracket
27. Disconnect the oil pressure sensor harness connector from the oil pressure sensor.
28. Remove the two screws securing the engine harness grounds to the cylinder block.
29. Remove the engine harness CAN 1 resistor and the boat sensor harness connector
from the support bracket.
c
d
b
a
a - Boat sensor harness connector
b - Engine harness CAN 1 resistor
22805
c - Oil pressure sensor connector
d - Screws securing the engine
harness grounds
30. Disconnect the engine harness connector from the camshaft position sensor.
31. Disconnect the engine harness connector from the pencil coils.
32. Remove the rubber engine harness retainers on the coil bracket from each pencil coil.
33. Remove the screws securing the pencil coils to the cam cover.
34. Remove the seven screws securing the coil bracket to the cam cover.
Page 4A-20
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
35. Remove the engine harness from the retaining clip on the bottom of the cam cover.
a
d
b
c
e
f
g
22810
abcdefg-
Camshaft position sensor harness connector
Rubber engine harness retainer (4)
Screws securing the coil bracket (M6 x 12) (3)
Screws securing the pencil coils (M6 x 25) (4)
Screws and washers securing the coil bracket (M6 x 25) (2)
Screws retaining the coil bracket (M6 x 90) (2)
Retaining clip securing the engine harness
36. Remove the electrical plate from the rubber support grommets.
a
22812
a - Rubber support grommets
Intake Manifold Assembly Removal
1. Remove the cotter pin and washer securing the throttle body cable to the throttle arm.
90-899185 SEPTEMBER 2006
Page 4A-21
Cylinder Block/Crankcase
2. Loosen the throttle body cable nuts. Remove the throttle body cable from the throttle
arm bracket.
a
b
c
22813
a - Throttle body cable nuts (2)
b - Washer
c - Cotter pin
3. Remove all of the fuel lines and the reference hose from the FSM.
4. Remove the vent canister float switch line from the clip securing the line to the FSM
mounting bracket.
c
b
d
e
a
22814
a - Vent canister float switch line
b - Low pressure fuel inlet line
c - Fuel pressure regulator reference
hose
Page 4A-22
d - Clip
e - High pressure fuel outlet line
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
5. Remove the two screws securing the intake manifold to the cylinder block.
a
22820
a - Screws (2)
6. Remove the five screws securing the intake manifold to the cylinder head. Remove the
intake manifold from the engine assembly.
22823
Throttle Bracket Removal and Disassembly
1. Remove the three screws securing the throttle bracket to the cylinder block. Remove
the throttle bracket from the cylinder block.
22827
2. Remove the screw securing the throttle lever to the throttle bracket. Remove the throttle
lever from the throttle bracket.
90-899185 SEPTEMBER 2006
Page 4A-23
Cylinder Block/Crankcase
3. Remove the screw securing the throttle follower lever to the throttle bracket.
b
a
22896
a - Screw securing the throttle follower lever to the throttle bracket
b - Screw securing the throttle lever to the throttle bracket
FSM Assembly and Mounting Bracket Removal
1. Remove the hose clamp securing the water inlet hose to the FSM. Remove the water
inlet hose from the FSM.
2. Remove the upper left screw and washer securing the FSM to the mounting bracket.
3. Remove the lower screw and washer securing the FSM to the mounting bracket.
4. Remove the FSM from the rubber grommet on the mounting bracket.
a
b
c
22836
a - Upper left screw and washer securing the FSM
b - Hose clamp securing the water inlet hose to the FSM
c - Lower screw and washer securing the FSM
Page 4A-24
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
5. Remove the three screws and washers securing the mounting bracket to the cylinder
block. Remove the mounting bracket from the cylinder block.
a
22839
a - Screws and washers securing the mounting bracket (3)
Alternator Assembly and Mounting Bracket Removal
1. Remove the nut and washer securing the alternator to the mounting bracket.
a
22841
a - Nut and washer securing the alternator
2. Use a pry bar to relieve the belt tension on the screw. Remove the screw from the
alternator and mounting bracket.
a
b
22843
a - Pry bar
b - Screw
3. Remove the alternator belt.
90-899185 SEPTEMBER 2006
Page 4A-25
Cylinder Block/Crankcase
4. Remove the screw and tab washer securing the alternator and the ground lead to the
mounting bracket. Remove the alternator from the mounting bracket.
b
c
a
22847
a - Tab washer
b - Ground lead
c - Screw
5. Remove the three screws and six washers securing the mounting bracket to the
crankcase cover.
NOTE: Do not lose the three washers that are between the mounting bracket and the
crankcase cover.
a
22852
a - Screws and washers (3 screws, 6 washers)
Starter Assembly Removal
1. Identify the location and orientation of the starter mounting brackets with a marking pen
or paint.
2. Remove the screw and washer securing the ECM to the cylinder block.
Page 4A-26
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
3. Remove the four screws and three clips securing the starter to the cylinder block.
Remove the starter from the cylinder block.
a
b
22855
a - Screw and washer securing the
ECM
b - Four screws and three clips
securing the starter
Thermostat Housing Assembly Removal
1. Remove the oil filter.
2. Remove the oil pressure sensor.
3. Remove the hose clamp securing the water dump hose to the thermostat housing and
the lower dump fitting. Remove the water dump hose.
4. Remove the strainer fitting from the cylinder block
5. Remove the two screws securing the thermostat housing to the cylinder block.
6. Remove the screw securing the lower dump fitting to the cylinder block. Remove the
thermostat housing and the lower dump fitting from the cylinder block as an assembly.
7. Remove the block coolant temperature sensor from the cylinder block.
b
a
c
d
e
f
a - Block coolant temperature sensor
b - Screws securing the thermostat
housing
c - Strainer fitting
90-899185 SEPTEMBER 2006
22866
d - Oil pressure sensor
e - Oil filter
f - Screw securing the lower dump
fitting
Page 4A-27
Cylinder Block/Crankcase
Flywheel, Ground Strap, and Electrical Plate Grommet Removal
1. Remove the screw securing the ground strap to the cylinder head.
2. Remove the pin securing the ground strap to the cylinder block.
3. Loosen the flywheel bolt four turns out.
c
d
a
b
22867
abcd-
Screw securing the ground strap to the cylinder head
Ground strap
Pin securing the ground strap to the cylinder block
Flywheel bolt
4. Install the flywheel puller base to the flywheel with three bolts. Tighten the three bolts
to the specification.
Description
Flywheel puller bolts (3)
Nm
lb. in.
20 ‑ 27
lb. ft.
14.7 ‑ 20.0
a
b
22353
a - Bolts (3)
Flywheel Puller/Lifting Ring
b - Flywheel puller base
91‑895343T02
5. Thread the flywheel puller adapter into the puller base until it bottoms out.
6. Thread the flywheel puller bolt into the flywheel puller adapter.
7. Tighten the flywheel puller bolt until the flywheel becomes loose. Remove the flywheel.
Page 4A-28
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
NOTE: Do not use power tools to remove the flywheel.
a
b
22354
a - Flywheel puller adapter
b - Flywheel puller bolt
8. Remove the flywheel key.
9. Remove the pin.
10. Remove the two screws securing the CPS to the cylinder block.
b
a
c
22870
a - Pin
b - Flywheel key
c - Screws securing the CPS (2)
11. Remove the ventilation hose from the cam cover.
12. Remove the two screws securing the washers and grommets to the cylinder head.
a
b
22876
a - Ventilation hose on the cam cover
b - Screws securing the washers and grommets (2)
90-899185 SEPTEMBER 2006
Page 4A-29
Cylinder Block/Crankcase
Powerhead Disassembly
Cylinder Head Removal
IMPORTANT: The removal and disassembly procedure of the cylinder head and cams
must be strictly followed. Failure to follow the removal procedure may damage the valve
train components.
IMPORTANT: Do not inter‑mix the location of the valve train parts.
IMPORTANT: This engine is an interference valve train design. Do not rotate the crankshaft
or cams when the timing chain is loose or removed from the cam gears unless advised to
do so. Failure to adhere to this important information will result in valve or piston damage.
1. Remove the bolts securing the cam cover to the cylinder head.
2. If necessary, rotate the crankshaft with the flywheel so the timing marks are in
alignment.
b
a
14763
a - Flywheel timing mark
b - Cylinder block timing mark
3. Remove the short span chain guide bolts. Remove the short span chain guide.
a
b
3467
a - Short span chain guide
b - Short span chain guide bolts
4. Ensure the cam gear timing marks are visible. If the cam timing marks are not visible,
rotate the crankshaft one revolution. The timing marks should be visible.
5. Install the cam gear brake between the intake and exhaust cam.
Page 4A-30
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
NOTE: When installing the cam gear brake, it may be necessary to rotate one of the cams
slightly to align the cam gear brake to the cam gears.
b
a
c
d
5541
a - Timing chain anodized link
b - Cam gear brake
Cam Brake
c - Cam gear timing mark
d - Cam gear retaining bolt (left hand
thread)
Part number not available for this printing.
NOTE: Cams must be locked with a special tool to prevent loading of the cam gears and
chain. Loading the cam gear and chain may damage the cam gear and chain.
6. Loosen the cam gear retaining bolts.
NOTE: Cam gear retaining bolts are left hand thread.
7. Remove the cam gear brake and cam gear retaining bolts.
8. Remove the cam tensioner cover bolts.
b
a
22465
a - Cam tensioner cover bolts
90-899185 SEPTEMBER 2006
b - Clip
Page 4A-31
Cylinder Block/Crankcase
9. Place your hand over the cam tensioner bore. With the heal of your other hand, press
on the timing chain between the cam gears. This will assist to dislodge the cam
tensioner from the cylinder head bore.
a
3476
a - Cam tensioner
10. Remove the cam gears. Allow the timing chain to drop into the cylinder block area.
11. Remove the flywheel.
12. In a chronological sequence, loosen the long main bolts. Remove the long main bolts.
IMPORTANT: It is not necessary to remove the long main bolts when repairing the cylinder
head only. If the cylinder block is to be disassembled, the long main bolts must be removed
and replaced.
NOTE: The cylinder block has rubber dampeners for the long main bolts. The long main
bolt threads will be difficult to pull past the dampeners. Unthread the main long bolts past
the rubber dampeners.
8
10
6
2
4
1
3
7
Page 4A-32
9
5
22466
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
13. Remove the four M8 x 60 screws, three M6 x 40 screws, and one M6 x 16 screw from
the cylinder head. Remove the cylinder head.
a
a
b
c
a - Screws (M8 x 60) (4)
b - Screw (M6 x 16) (1)
22467
c - Screws (M6 x 40) (3)
IMPORTANT: Do not set the cylinder head down on its deck. Damage to the valves may
result. Set the cylinder head on pillow blocks to prevent damage to the valves.
Crankcase and Crankshaft Disassembly/Removal
1. Remove all of the anodized aluminum oil galley plugs from the cylinder block.
NOTE: If any of the oil galley plugs or water galley plugs are difficult to remove, place a
brass drift on the anodized plug and strike the brass drift lightly with a hammer to assist in
breaking the plugs loose.
a
b
b
22789
a - Oil galley plug (18 mm) (1)
90-899185 SEPTEMBER 2006
b - Oil galley plugs (12 mm) (6)
Page 4A-33
Cylinder Block/Crankcase
2. Remove the two M8 x 50 screws, two M8 x 70 screws, two M10 x 120 screws, and
eight M8 x 90 screws securing the crankcase cover to the cylinder block.
a
c
b
d
22479
a - Screws (M8 x 50) (2)
b - Screws (M8 x70) (2)
c - Screws (M10 x 120) (2)
d - Screws (M8 x 90) (8)
3. Pry the crankcase cover loose with two large screwdrivers. Lift the crankcase cover off
of the cylinder block.
4. Remove the upper and lower crankshaft seal retaining rings. Remove the upper and
lower crankshaft seals and spacer.
5. Mark all of the connecting rod caps and rod locations with indelible marker or paint
(Example: 1, 2, 3, 4).
IMPORTANT: Do not use a scribe or a metal punch on the connecting rod or rod cap for
identification purpose. Using a scribe or metal punch will damage the connecting rod and
may cause premature engine failure.
6. Remove the rubber dampeners
a
b
b
4486
a - Rubber dampeners
b - Perimeter crankcase cover screw holes
Page 4A-34
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
7. Remove the two 24 mm plugs from the bottom of the cylinder block.
c
b
a
a - Plugs (24 mm) (2)
b - Movable timing chain guide
22483
c - Fixed timing chain guide
8. Remove the screw securing the fixed timing chain tensioner. Remove the fixed timing
chain tensioner.
9. Remove the screws securing the moveable timing chain guide. Remove the moveable
timing chain guide.
b
a
22521
a - Moveable timing chain guide
screw
b - Fixed timing chain guide screw
10. Remove the timing chain.
NOTE: If the timing chain's three anodized links cannot be identified, a new chain must be
installed.
11. Paint the rod cap screws to identify them as used.
IMPORTANT: Rod cap screws that have been torqued to specification, must not be used
for reassembly.
12. Remove the rod cap screws with a Torx #E‑12. Remove the rod cap.
90-899185 SEPTEMBER 2006
Page 4A-35
Cylinder Block/Crankcase
13. Install the rod guide dowels to protect the crank pin and cylinder bore from damage.
a
4834
a - Rod guide dowel
Rod Guide Dowel
Part number not available for this printing.
14. Push the connecting rod assembly out of the cylinder bore.
15. Mark the connecting rod up side orientation with indelible marker or paint. Do not use
a scribe or punch for identification of the connecting rod orientation.
NOTE: The up side orientation of the connecting rod is the same orientation as the dot on
the dome of the piston.
16. Re‑install the rod cap to the connecting rod assembly. Ensure the rod cap fits perfectly.
Thread the rod cap screw into the connecting rod. Tighten the rod screws securely, but
do not torque.
17. Remove the remaining connecting rod assemblies the same way.
18. Remove the crankshaft. Secure the crankshaft in a manner that will prevent damage.
19. Remove the crankshaft main bearings from the cylinder block and crankcase cover.
NOTE: A small screwdriver or awl will assist in removing the crankshaft main bearings.
4369
Cleaning, Inspection and Repair
Measuring Cylinder Bore
Measure the cylinder walls for taper, out of round or excessive ridge at the top of the ring
travel. This should be done with a cylinder bore dial indicator or an inside micrometer.
Carefully move the gauge up and down the cylinder bore to determine taper. Turn the
gauge to different points around the cylinder wall to determine the out of round condition.
Page 4A-36
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
The measurement for cylinder taper should be taken at three depth locations:
20 mm (0.8 in.), 60 mm (2.4 in.) and 100 mm (3.9 in.).
a
b
c
3129
a - 100 mm (3.9 in.)
b - 60 mm (2.4 in.)
c - 20 mm (0.8 in.)
Cylinder Bore Specification
Standard
82.0 mm (3.228 in.)
Out of round (production)
0.015 mm (0.0006 in.)
Out of round (service)
0.0762 mm (0.003 in.)
Taper (production)
0.015 mm (0.0006 in.)
Taper (service)
0.0762 mm (0.003 in.)
Measuring Piston
Inspect piston wall for wear or damage. Replace the piston if necessary.
PISTON DIAMETER
1. Measure the piston at a point 10 mm (0.394 in.) from the bottom, 90° to the piston pin.
Replace the piston if out of specification.
a
b
22022
a - Piston diameter
b - Measure point 10 mm (0.394 in.)
Piston
Diameter
81.975 mm (3.227 in.)
2. Measure the piston to cylinder clearance. If out of specification, examine the piston,
and cylinder bore further to determine repair/replacement.
The minimum piston to cylinder wall clearance is defined by the formula: Minimum
cylinder bore measurement - Maximum piston diameter measurement = Piston to
Cylinder Clearance.
Piston To Cylinder Wall Clearance
Minimum clearance
90-899185 SEPTEMBER 2006
0.06 mm (0.0024 in.)
Page 4A-37
Cylinder Block/Crankcase
PISTON RING GROOVE
Measure the piston ring groove. Replace the piston if out of specification.
a
b
c
a - Top ring groove
b - Middle ring groove
22410
c - Oil ring groove
Piston Ring Groove
Top "a"
1.22 ‑ 1.25 mm (0.048 ‑ 0.049 in.)
Middle "b"
1.21 ‑ 1.23 mm (0.047 ‑ 0.048 in.)
Oil "c"
2.03 ‑ 2.05 mm (0.079 ‑ 0.080 in.)
PISTON RING SIDE CLEARANCE
Measure the piston ring side clearance. Replace the piston rings as a set if out of
specification.
a
b
c
22023
a - Top ring
b - Middle ring
c - Oil ring
Piston Ring Side Clearance
Top "a"
0.04 ‑ 0.08 mm (0.0015 ‑ 0.0031 in.)
Middle "b"
0.04 ‑ 0.08 mm (0.0015 ‑ 0.0031 in.)
Oil "c"
0.05 ‑ 0.17 mm (0.002 ‑ 0.0066 in.)
PISTON RING END GAP
Measure the piston ring end gap clearance. Replace the piston rings as a set if out of
specification.
Page 4A-38
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
NOTE: The ring must be level for measurement. Push the ring 25.4 mm (1.0 in.) into the
bore with the crown of the piston.
a
22024
a - 25.4 mm (1.0 in.)
Piston Ring End Gap
Top
0.27 ‑ 0.42 mm (0.0106 ‑ 0.0165 in.)
Middle
0.42 ‑ 0.62 mm (0.0165 ‑ 0.0244 in.)
Oil
0.20 ‑ 0.70 mm (0.0078 ‑ 0.0275 in.)
PISTON WRIST PIN DIAMETER
Measure the piston pin bore diameter. Replace the piston if out of specification.
22025
Piston Pin
Bore diameter
22.004 ‑ 22.011 mm (0.8662 ‑ 0.8665 in.)
PISTON WRIST PIN
Measure the wrist pin diameter. Replace the wrist pin if out of specification.
22026
Piston Wrist Pin
Diameter
21.997 ‑ 22.0 mm (0.8660 ‑ 0.8661 in.)
Measuring Connecting Rod
1. Ensure the rod cap fits perfectly. Tighten the connecting rod cap screws to the specified
torque.
90-899185 SEPTEMBER 2006
Page 4A-39
Cylinder Block/Crankcase
Description
Rod cap screws
Nm
lb. in.
10
88
lb. ft.
2. Measure the small (piston pin) and large (crankshaft pin journal) ends of the connecting
rod.
a
b
22418
a - Crankshaft pin journal end
b - Piston pin end
3. Compare the connecting rod crankshaft pin journal measurement with the crankshaft
pin journal grade specifications listed in the following chart. If the connecting rod
crankshaft pin journal measurement does not match the stamped connecting rod
crankshaft pin journal grade, replace the connecting rod.
b
c
a
a
b
4458
a - Stamped connecting rod crankshaft pin journal grade
b - Marker indicating cylinder location
c - Paint on rod cap screw
Connecting Rod
Wrist pin diameter
22.005 ‑ 22.014 mm
(0.8667 ‑ 0.8664 in.)
Crankshaft pin journal grade "I" diameter
53.000 ‑ 53.009 mm
(2.0866 ‑ 2.0869 in.)
Crankshaft pin journal grade "0" diameter
53.009 ‑ 53.018 mm
(2.0869 ‑ 2.0873 in.)
Measuring Crankshaft
CRANKSHAFT RUN-OUT
1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if
bearing surfaces are pitted, scored or discolored.
2. Measure run‑out on all of the main bearing journals. Replace crankshaft if out of
specification.
Page 4A-40
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
3. Clean oil holes in crankshaft.
14781
Crankshaft
Run‑out limit
0.05 mm (0.002 in.)
CRANKSHAFT MAIN BEARING AND CRANK PIN MEASUREMENT
1. Measure crankshaft journal diameter and crank pin diameter. Replace if out of
specification.
2. Measure the bottom main bearing width. Replace if out of specification.
a
b
a - Crank pin journals
b - Main bearing journals
c
14782
c - Bottom main bearing width
Crankshaft Journal Specifications
Description
Main Bearing Journal
Crank Pin Journal
Bottom Main Bearing Width
Dimension
Grade
59.993 ‑ 60.001 mm (2.3619 ‑ 2.3622 in.)
A
59.985 ‑ 59.993 mm (2.3616 ‑ 2.3619 in.)
B
49.991 ‑ 50.000 mm (1.9681 ‑ 1.9685 in.)
C
49.982 ‑ 49.991 mm (1.9677 ‑ 1.9681 in.)
D
31.4 ‑ 31.6 mm (1.236 ‑ 1.244 in.)
Powerhead Reassembly
Installing Oil Galley Plugs
1. Install new O‑rings onto the oil galley plugs.
2. Apply Loctite 567 Pipe Sealant onto the threads of the oil galley plugs.
90-899185 SEPTEMBER 2006
Page 4A-41
Cylinder Block/Crankcase
3. Install the oil galley plugs. Tighten to the specified torque.
a
b
b
22789
a - Oil galley plug (18 mm) (1)
Tube Ref No.
9
b - Oil galley plug (12 mm) (6)
Description
Loctite 567 PST Pipe Sealant
Where Used
Part No.
Oil galley plugs
92-809822
Description
Nm
Oil Galley Plug ‑ 18 mm (1)
22
Oil Galley Plug ‑ 12 mm (6)
9
lb. in.
lb. ft.
16
80
Powerhead Pre‑Assembly Cleaning Recommendations
IMPORTANT: Any threaded hole or bolt with thread‑locking compound that is
contaminated with oil, must be thoroughly cleaned with a solvent to remove all traces of
oil contamination. Failure to remove oil contamination will result in poor thread‑locking
compound adhesion.
Prior to assembling the powerhead, all threaded holes on the cylinder head and cylinder
block must be cleared of thread‑locking compound dust. Use compressed air to clear
thread‑locking compound dust.
Wash the cylinder block and crankcase cover with hot soapy water to remove debris and
honing compound. Dry the cylinder block with compressed air. Failure to thoroughly clean
the cylinder block of honing compound and/or debris will result in premature engine failure.
Page 4A-42
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Selecting New Crankshaft Bearings
When replacing the crankshaft main bearings and crank pin bearings, select the suitable
bearing from the bearing grade identifier located at the flywheel end of the crankshaft and
on the bottom of the cylinder block.
b
a
c
d
e
5142
a - Bar code
b - Manufacture date
c - Part number
d - Main bearing journal grade
e - Crank pin journal grade
a
22787
a - Cylinder block main bearing journal grade
NOTE: When reading the main bearing journal grade on the crankshaft, the journal grade
is in sequential order from J1 to J5 in a clockwise orientation.
NOTE: When reading the crank pin bearing journal grade on the crankshaft, the journal
grade is in sequential order from P1 to P4 in a clockwise orientation.
NOTE: When reading the main bearing journal grade on the cylinder block, the journal
grade is in sequential order from the top main bearing to the bottom thrust bearing.
Crankshaft Main Bearing Grade Selection
Crankshaft
Main bearing oil clearance
0.014 ‑ 0.042 mm (0.0005 ‑ 0.0016 in.)
IMPORTANT: Ensure all mating surfaces, oil passages, water jackets and cylinder bores
are clean prior to assembling the powerhead. Always install new gaskets, seals, O‑rings,
piston ring and wrist pin retaining clips. Replace torque to yield screws where advised to
do so. Follow all advised lubrication during assembly.
1. Check the crankshaft journal size code and the cylinder block main bearing code.
2. Refer to the bearing selection chart to select the correct crankshaft main bearings.
90-899185 SEPTEMBER 2006
Page 4A-43
Cylinder Block/Crankcase
IMPORTANT: After selecting the correct bearing, install the bearing halves in the cylinder
block and crankcase cover matching journal location to avoid mixing bearing sizes.
Crankshaft Journal Code
Cylinder Block Code
Bearing Color Selection
A
A
Green
A
B
Blue
A
C
White
B
A
Blue
B
B
White
B
C
Orange
a
14788
b
a - Main bearings
b - Main thrust bearing
3. Ensure debris is removed from the cylinder block and crankcase cover main bearing
area, and install the selected main bearings.
Piston/Connecting Rod Assembly
1. Lubricate the piston wrist pin with Lubriplate SPO 255.
2. Assemble the piston, connecting rod, piston wrist pin, and new piston pin retaining clips.
IMPORTANT: Always install new piston pin retaining clips.
cc
b
a
c
d
6366
a - Paint on connecting rod
b - Piston
Tube Ref No.
136
Description
Lubriplate SPO 255
c - Piston pin retaining clip
d - Piston wrist pin
Where Used
Part No.
Piston wrist pin
Obtain Locally
Connecting Rod Bearing Grade Selection
Connecting Rod
Bearing oil clearance
Page 4A-44
0.020 ‑ 0.050 mm (0.0008 ‑ 0.0019 in.)
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
1. Check the crank pin journal size code on the flywheel end of the crankshaft.
b
a
c
d
e
22420
a - Bar code
b - Manufacture date
c - Part number
d - Main bearing journal grade
e - Crank pin journal grade
2. Check the journal code on the connecting rod cap.
c
b
a
a
b
4458
a - Stamped connecting rod crank pin
journal grade
b - Marker indicating cylinder location
c - Paint on rod cap screw
Connecting Rod Specifications
Piston Pin
22.005 ‑ 22.014 mm
(0.8662 ‑ 0.8665 in.)
Crank Pin Journal Grade "I"
53.000 ‑ 53.009 mm
(2.0866 ‑ 2.0869 in.)
Crank Pin Journal Grade "0"
53.009 ‑ 53.018 mm
(2.0869 ‑ 2.0873 in.)
3. Refer to the bearing selection chart following, to select the correct crankshaft
connecting rod bearings.
IMPORTANT: After selecting the correct bearing, install the bearing halves in the
connecting rod and the matching connecting rod cap to avoid mixing bearing sizes.
Connecting Rod Journal Code
Crankshaft Pin Journal Code
Bearing Color Selection
I
C
Blue
I
D
White
0
C
White
0
D
Orange
4. Ensure the connecting rod bearing area is free of debris.
90-899185 SEPTEMBER 2006
Page 4A-45
Cylinder Block/Crankcase
5. Install the locating tab of the upper half of the bearing into the slot on the connecting
rod, and the locating tab of the lower half of the bearing into the slot on the connecting
rod cap. Carefully push the bearing onto the connecting rod and connecting rod cap.
a
b
4389
a - Connecting rod
b - Connecting rod locating tab
Piston Ring Installation
IMPORTANT: Do not reuse the original rings during reassembly. Always install new rings
when rebuilding the engine.
IMPORTANT: Use caution when installing piston rings to avoid scratching the piston.
1. Apply Synthetic Blend 4‑Stroke Outboard Oil 25W‑40 engine oil to the piston ring
grooves.
2. Install the oil ring spacer onto the lower ring groove of the piston.
NOTE: Ensure the oil ring spacer gap is properly orientated on the piston. The oil ring
spacer cannot be rotated after the bottom and top oil control rings are installed.
3. Install the bottom oil control ring.
4. Install the top oil control ring. The top oil control ring uses a locating pin on the piston.
5. Install the second compression ring.
6. Install the top compression ring.
7. Position the piston ring gaps as shown.
Page 4A-46
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
NOTE: The second piston compression rings must be installed with the "T" side up. Spread
the rings just enough to slip over piston.
a
b
c
d
e
139
1
139
1
g
h
45 o
45 o
f
i
T
c
b
a
e
d
j
23841
abcde-
Top oil control ring
Oil ring spacer
Bottom oil control ring
Top compression ring
Second compression ring
Tube Ref No.
139
Description
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
fghij-
Top compression ring gap
Oil ring spacer gap
Top oil control ring gap
Bottom oil control ring gap
Second compression ring gap
Where Used
Part No.
Piston rings
92-883722K01
Piston Assembly Installation
1. Install the piston rod guide dowels onto the connecting rod assembly. Lubricate the
piston rings with Synthetic Blend 4‑Stroke Outboard Oil 25W‑40.
2. Lubricate the connecting rod bearing with Lubriplate SPO 255.
90-899185 SEPTEMBER 2006
Page 4A-47
Cylinder Block/Crankcase
3. Lubricate the cylinder bore with Synthetic Blend 4‑Stroke Outboard Oil 25W‑40.
139
b
a
136
4388
a - Rod Guide Dowels
Rod Guide Dowel
b - Connecting rod bearing
Part number not available for this printing.
Tube Ref No.
Description
139
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
136
Lubriplate SPO 255
Where Used
Part No.
Piston rings, cylinder bore
92-883722K01
Connecting rod bearing
Obtain Locally
4. Slide the piston ring compressor over the piston so about 50% of the piston is showing
below the ring compressor.
Ring Compressor
Part number not available for this printing
5. Insert the piston assembly into the cylinder bore. Ensure the dot on the piston is pointing
towards the flywheel end of the crankshaft.
6. Ensure the ring compressor is fully seated on the cylinder block.
b
a
4393
a - Piston skirt
b - Ring compressor
7. Ensure the rod guide dowels straddle the crank pin.
8. Push the piston assembly into the cylinder bore and onto the crank pin.
9. Remove the rod guide dowels.
Page 4A-48
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
10. Lubricate the crank pin with Lubriplate SPO 255.
a
136
4390
a - Rod guide dowels
Rod Guide Dowel
Part number not available for this printing.
Tube Ref No.
136
Description
Lubriplate SPO 255
Where Used
Part No.
Crank pin
Obtain Locally
11. Install the rod cap/bearing assembly.
12. Ensure the rod cap orientation is correct. The rod cap must fit perfectly.
13. Lubricate the new rod cap screw threads and head with Synthetic Blend 4‑Stroke
Outboard Oil 25W‑40.
Tube Ref No.
139
Description
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
Where Used
Part No.
Rod cap screw threads
92-883722K01
14. Install the new rod cap screws.
15. Tighten the rod cap screws in two stages to the specified torque.
NOTE: After the second torque, paint a line on the rod cap screw parallel with the
crankshaft. This will help distinguish when the rod cap screw has turned the additional 90°.
16. Turn the rod cap screw an additional 90° after the second torque.
Description
Connecting rod screw
Nm
lb. in.
First
15
132.7
Second
30
Final
lb. ft.
22
Turn additional 90°
17. Install the remaining connecting rod assembles in the same sequence.
Installing the Timing Chain onto the Crankshaft
1. Rotate the crankshaft so the timing mark points towards the cylinder head and the oil
pump drive pins are parallel with the cylinder block.
2. Slide the timing chain, with the anodized links facing towards the oil pump drive pins,
onto the crankshaft and into the cylinder block timing chain area.
90-899185 SEPTEMBER 2006
Page 4A-49
Cylinder Block/Crankcase
NOTE: Do not force the timing chain past the cylinder block crankshaft seal area.
a
b
22526
a - Oil pump drive pins
b - Crankshaft timing mark
3. There are three anodized timing chain links. The two anodized timing chain links that
are closest to each other are the timing marks for the camshaft gears. Locate the
crankshaft anodized timing chain link. Install the timing chain onto the crankshaft with
the anodized link 180° from the crankshaft timing mark.
a
b
a - Anodized link
22527
b - Crankshaft timing mark
4. Lubricate the timing chain moveable guide screw and the timing chain fixed guide screw
with Lubriplate SPO 255.
5. Install the timing chain moveable guide and secure it to the cylinder block with a screw.
Tighten the screw to the specified torque.
6. Install the timing chain fixed guide and secure it to the cylinder block with a screw.
Tighten the screw to the specified torque.
Page 4A-50
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
7. Install a new O‑ring onto the two 24 mm plugs. Lubricate the O‑rings with Lubriplate
SPO 255 and install the plugs into the cylinder block. Tighten the plugs to the specified
torque.
c
b
d
a
e
22530
a - Timing chain guide screw (2)
b - Timing chain moveable guide
c - Anodized link
Tube Ref No.
136
Description
Lubriplate SPO 255
d - Timing chain fixed guide
e - Plug 24 mm (2)
Where Used
Part No.
Screws securing the timing
chain tensioner, the timing
chain guide and the plug O-ring
Obtain Locally
Description
Nm
lb. in.
lb. ft.
Timing chain guide screw (2)
24
18
Plug 24 mm (2)
55
40.5
Cylinder Head Installation
! CAUTION
This engine is an interference valve train design. Do not rotate the crankshaft or cams
when the timing chain is loose or removed from the cam gears unless advised to do so.
Failure to adhere to this caution may result in valve and/or piston damage.
IMPORTANT: The installation of the cylinder head must be strictly followed. Failure to
follow the installation procedure may damage the valve train components.
1. Install the flywheel key onto the crankshaft and install the flywheel.
2. Install the flywheel bolt and washer. Tighten the flywheel bolt until it is snug.
90-899185 SEPTEMBER 2006
Page 4A-51
Cylinder Block/Crankcase
3. Rotate the engine so the flywheel timing mark aligns with the rear starter mount. This
will allow sufficient piston to valve clearance to rotate the cams.
a
b
c
4035
a - Rear starter mount
b - Cylinder block timing mark
c - Flywheel timing mark
4. Install the crankshaft retainer on one of the center main bearings. Tighten the
crankshaft retainer bolts securely.
b
5755
a - Crankshaft retainer bolts
Crankshaft Retainer
b - Crankshaft retainer
Part number currently not available for this printing.
5. Rotate the cylinder block to install the head.
6. Place a new head gasket on the cylinder block.
7. Install the cylinder head to the cylinder block.
Page 4A-52
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
8. Install four M8 x 60 screws, three M6 x 40 screws, and one M6 x 16 screw into the
cylinder head so they are snug. Do not tighten the cylinder head perimeter bolts.
a
a
b
c
a - Screws (M8 x 60) (4)
b - Screw (M6 x 16) (1)
22467
c - Screws (M6 x 40) (3)
9. Rotate the cylinder block and remove the crankshaft retainer.
10. Install the rubber dampeners into the cylinder block. Ensure the dampeners are seated
completely in the cylinder block.
a
b
b
a - Rubber dampener seated
4486
b - Crankcase cover perimeter screw
holes
11. Apply a 1 mm (0.040 in.) by 1 mm (0.040 in.) thin continuous bead of Three Bond 1217F
around the crankcase cover perimeter. Do not allow Three Bond 1217F to contact the
main bearings.
12. Lubricate the crankshaft main bearings with Lubriplate SPO 255.
b
a
21973
a - Three Bond 1217F
90-899185 SEPTEMBER 2006
b - Lubriplate SPO 255
Page 4A-53
Cylinder Block/Crankcase
Tube Ref No.
Description
Where Used
Part No.
135
Three Bond 1217F
Crankcase cover perimeter
Obtain Locally
136
Lubriplate SPO 255
Crankshaft main bearings
Obtain Locally
13. Carefully place the crankcase cover onto the cylinder block.
14. Install two M8 x 50 screws, two M8 x70 screws, two M10 x 120 screws, and eight M8
x 90 screws to secure the crankcase cover to the cylinder block. Do do not tighten the
screws.
a
c
b
d
22479
a - Screws (M8 x 50) (2)
b - Screws (M8 x70) (2)
c - Screws (M10 x 120) (2)
d - Screws (M8 x 90) (8)
15. Lubricate the threads of the main bearing long bolts with molybdenum disulfide grease.
Tube Ref No.
113
Description
Where Used
Loctite Moly Paste
Main bearing long bolt threads
(Molybdenum Disulfide Grease)
Part No.
Obtain Locally
16. Insert the main bearing long bolts into the crankcase cover. Thread the main bearing
long bolts through the rubber dampeners and into the cylinder head.
NOTE: Do not force the main bearing long bolts past the cylinder block rubber dampeners.
Forcing the main bearing long bolts past the cylinder block rubber dampeners may damage
or fold the cylinder block rubber dampeners.
17. Tighten the long main bolts in sequence and in two steps to the specified torque.
NOTE: After the second torque is attained, mark all of the long main bolt heads with a line
of paint parallel to the crankshaft. This will help ensure the 270° turn is correctly attained.
Page 4A-54
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
18. Turn the bolts in sequence an additional 270°.
7
3
1
5
9
8
4
2
6
10
Description
22487
Nm
Long main bolt
lb. In.
lb. ft.
First
27
20
Second
55
40.5
Turn additional 270° after second torque
is attained
Final
19. Tighten the crankcase cover perimeter screws in the order listed on the crankcase
cover to the specified torque
23
17
13
11
15
19
21
22
20
24
18
14
12
16
Description
Crankcase cover perimeter screws
22522
Nm
lb. in.
lb. ft.
M8 x 50 (2)
35
26
M8 x70 (2)
35
26
M10 x 120 (2)
50
37
M8 x 90 (8)
35
26
20. Tighten the cylinder head perimeter screws to the specified torque.
21. Secure the ground strap to the cylinder head with a M6 x 16 screw. Tighten the M6 x
16 screw to the specified torque.
90-899185 SEPTEMBER 2006
Page 4A-55
Cylinder Block/Crankcase
22. Apply Liquid Neoprene to the M6 x 16 screw.
a
a
b
c
a - Screws (M8 x 60) (4)
b - Screw (M6 x 16) (1)
22467
c - Screws (M6 x 40) (3)
Description
Nm
Cylinder head perimeter screws
Tube Ref No.
M8 x 60 (4)
28
M6 x 16
10
88.5
M6 x 40 (3)
8
70.8
Description
Liquid Neoprene
25
lb. in.
lb. ft.
20.5
Where Used
Part No.
Ground screw
92-25711-3
23. Check the valve lash clearance on all the valves. If the valve lash is not within
specification, refer to Section 4B - Valve Clearance and Adjustments. If the valve
lash is within specification, proceed with the next step.
24. Rotate the cams so the cam lobes for cylinder number one (intake and exhaust) point
towards the spark plug hole.
NOTE: The cams will be in correct alignment when the machined groove on the top of the
cams are aligned.
b
c
d
a
4044
a - Machined groove on top of cams
b - Exhaust cam lobe position
Page 4A-56
c - #1 spark plug hole
d - Intake cam lobe position
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
25. Rotate the flywheel clockwise so the flywheel timing mark aligns with the arrow on the
cylinder block.
a
b
3465
a - Timing mark on cylinder block
b - Timing mark on flywheel
Installing the Camshaft Gears and the Timing Chain
! CAUTION
This engine is an interference valve train design. Do not rotate the crankshaft or cams
when the timing chain is loose or removed from the cam gears unless advised to do so.
Failure to adhere to this caution may result in valve and/or piston damage.
IMPORTANT: The removal, disassembly, reassembly, and installation procedure of the
head and cams must be strictly followed. Failure to follow the removal procedure may
damage the valve train components.
1. Install the timing chain on the intake cam gear. The anodized link of the timing chain
must align with the timing mark on the cam gear.
2. Install the cam gear on the intake cam. Rotating the crankshaft a few degrees may
ease the installation of the timing chain/cam gear onto the cam. Secure the cam gear
with the cam gear screw and washer. Do not tighten the cam gear screw.
NOTE: Cam gear screws are left hand thread.
3. Place the exhaust cam timing gear in the chain, ensuring the timing mark on the cam
gear and the anodized timing chain link are aligned. Install the cam gear with the timing
chain onto the exhaust cam. Secure with the cam gear retaining screw and washer.
Do not tighten the cam gear screw.
4. Inspect the timing chain installation on the crankshaft and the camshafts for correct
alignment of the timing chain anodized links.
a
b
22539
a - Timing chain anodized link
b - Exhaust cam gear timing mark
5. Install the cam brake.
90-899185 SEPTEMBER 2006
Page 4A-57
Cylinder Block/Crankcase
6. The cam gear screws should be tightened in two steps. Tighten the cam gear screw to
the first specified torque.
NOTE: The cams must be locked with a special tool to the prevent loading of the cam gears
and chain. Loading the cam gear and chain may damage the cam gear and chain.
7. Paint an orientation line on the cam gear in‑line with the mark on the cam gear washer.
Turn the cam gear screw so the second mark on the cam gear washer aligns with the
paint orientation line. This is the additional 20° turn after the first torque is attained.
a
c
d
e
b
5555
a - First torque
b - Second torque
c - Anodized link
d - Cam gear timing mark
e - Cam brake
NOTE: The cam gear screws are left hand thread.
Description
Nm
lb. ft.
45
First
Cam gear screw (M12 x 40) LEFT HAND
lb. In.
33
Turn additional 20° after first torque is
attained
Final
Cam Brake
Part number not available for this printing.
8. Remove the cam brake.
9. Install the short span chain guide. Tighten the short span chain guide bolts to the
specified torque.
a
b
3467
a - Short span chain guide
b - Short span chain guide bolts
Description
Nm
lb. in.
Short span chain guide bolt (M6 x 30)
12
106.2
lb. ft.
10. Install a new O‑ring on the timing chain tensioner assembly.
11. Compress the timing chain tensioner assembly and release the tensioner slowly. The
tensioner should remain compressed.
Page 4A-58
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
12. Lubricate the timing chain tensioner with Synthetic Blend 4‑Stroke Outboard Oil
25W‑40.
139
b
a
c
4056
a - O‑ring
b - Tensioner extended
Tube Ref No.
139
Description
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
c - Tensioner compressed
Where Used
Part No.
Timing chain tensioner
92-883722K01
13. Insert the small diameter end of the timing chain tensioner assembly into the cylinder
head. Carefully push the timing chain tensioner assembly into the cylinder head.
NOTE: The timing chain tensioner O‑ring will retain the timing chain tensioner in the
cylinder head.
4057
14. Install a new O‑ring onto the timing chain tensioner cover.
15. Secure the clip and the cam tensioner cover to the cylinder head with two screws.
16. Tighten the chain tensioner cover screws to the specified torque.
b
a
22465
a - Cam tensioner cover bolts
b - Clip
Description
Nm
lb. in.
Chain tensioner cover screw (M6 x 25) (2)
11
97.3
lb. ft.
17. Install new gaskets onto the cam cover.
90-899185 SEPTEMBER 2006
Page 4A-59
Cylinder Block/Crankcase
18. Install the cam cover onto the cylinder head.
19. Install 11 cam cover screws. Ensure the cam cover screw below the intake cam has a
retaining clip installed.
20. Tighten the cam cover screws to the specified torque in the sequence shown.
3
1
5
11
8
a
7
9
2
6
10
4
22542
a - Screw and retaining clip
Description
Nm
lb. in.
Cam cover screw (M6 x 25) (11)
10
88.5
lb. ft.
Installing Upper Crankshaft Seal
1. Thoroughly clean the inside diameter of the cylinder block crankcase seal area.
2. Lightly lubricate the inside diameter of the cylinder block crankcase seal area with
Synthetic Blend 4‑Stroke Outboard Oil 25W‑40.
5856
a - Area to be lubricated
Tube Ref No.
139
Page 4A-60
Description
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
Where Used
Part No.
Inside diameter of cylinder block
crankshaft seal area
92-883722K01
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
3. Lightly lubricate the crankshaft seal inside diameter with Synthetic Blend 4‑Stroke
Outboard Oil 25W‑40.
139
16027
Tube Ref No.
139
Description
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
Where Used
Part No.
Inside diameter of crankshaft
seal
92-883722K01
NEW CRANKSHAFT INSTALLATION
1. Place the seal spacer inside the seal bore area.
a
14806
a - Seal spacer
2. Install the crankshaft seal into the cylinder block seal bore.
14807
90-899185 SEPTEMBER 2006
Page 4A-61
Cylinder Block/Crankcase
3. Install the seal installation tool with the spacer and guide ring. Ensure the guide ring is
seated on the crankshaft taper.
c
b
a
d
a - Spacer
b - Seal installation tool
Crankshaft Seal Installation Tool
14808
c - Guide ring
d - Seal
Part number not available for this printing
4. Install the flywheel washer and bolt. Tighten the flywheel bolt to the specified torque.
a
b
14809
a - Flywheel washer
b - Flywheel bolt
Description
Nm
Flywheel bolt
27
lb. in.
lb. ft.
20
5. Remove the installation tool and install the retaining ring into the cylinder block retaining
ring groove.
14818
Page 4A-62
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
ORIGINAL CRANKSHAFT INSTALLATION
IMPORTANT: When using the original crankshaft in a replacement cylinder block, or
reusing the original block and the original crankshaft, inspect the crankshaft seal area for
a seal groove. If a seal groove is present, the crankshaft seal must be installed before the
crankshaft seal spacer. If no seal groove is present, follow the installation instructions for
a new crankshaft installation (preceding).
1. Install the crankshaft seal into the cylinder block seal bore.
14807
2. Install the seal installation tool with the spacer and guide ring. Ensure the guide ring is
seated on the crankshaft taper.
c
b
a
d
a - Spacer
b - Seal installation tool
Crankshaft Seal Installation Tool
14808
c - Guide ring
d - Seal
Part number not available for this printing
3. Install the flywheel washer and bolt. Tighten the flywheel bolt to the specified torque.
a
b
14809
a - Flywheel washer
b - Flywheel bolt
Description
Nm
Flywheel bolt
27
90-899185 SEPTEMBER 2006
lb. in.
lb. ft.
20
Page 4A-63
Cylinder Block/Crankcase
4. Install the seal spacer.
14829
5. Install the retaining ring into the cylinder block retaining ring groove.
14818
Installing the Lower Crankshaft Seal
1. Ensure the crankshaft seal area and the cylinder block seal area is void of debris.
a
b
22543
a - Cylinder block seal area
b - Crankshaft seal area
2. Lubricate the cylinder block seal area and the crankshaft seal area with Lubriplate SPO
255.
3. Lubricate the lower crankshaft seal inside diameter and the outside diameter with
Lubriplate SPO 255.
Tube Ref No.
136
Description
Lubriplate SPO 255
Where Used
Part No.
Cylinder block seal area,
crankshaft seal area, crankshaft
seal inside diameter and
outside diameter
Obtain Locally
4. Install the lower crankshaft seal with the metal part of the seal facing out.
Page 4A-64
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
5. Carefully tap the seal into the cylinder block until the lower crankshaft seal is seated
on the cylinder block. The cylinder block retaining ring groove will be exposed when
the lower crankshaft seal is correctly installed.
a
22545
a - Cylinder block retaining ring groove
6. Install the retaining ring. Ensure the retaining ring is seated into the cylinder block
retaining ring groove circumference.
7. Install a new driveshaft O‑ring seal into the crankshaft.
b
a
c
22546
a - Retaining ring
b - Cylinder block retaining ring
groove
c - Driveshaft O‑ring seal
Installing Powerhead Components
Flywheel, Ground Strap, and Electrical Plate Grommet Installation
1. Install the bushing into the grommet.
90-899185 SEPTEMBER 2006
Page 4A-65
Cylinder Block/Crankcase
2. Secure the bushing and grommet to the cylinder block with a washer and screw. Tighten
the screw to the specified torque.
b
c
a
d
14909
a - Bushing
b - Grommet
c - Washer
d - Screw
Description
Nm
Screw (M8 x 35) (2)
24
lb. in.
lb. ft.
17.5
3. Install a 22.6 mm diameter hose clamp onto the ventilation hose. Install the ventilation
hose onto the cam cover. Secure the ventilation hose to the cam cover. Crimp the hose
clamp with the hose clamp tool.
a
b
22876
a - Ventilation hose on the cam cover
Hose Clamp Tool Kit
b - Screws securing the washers and
grommets (2)
91‑803146A2
4. Install the stud into the cylinder block. Tighten the stud to the specified torque.
5. Install the flywheel key.
Page 4A-66
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
6. Secure the crank position sensor to the cylinder block with two screws. Tighten the
screws to the specified torque.
b
a
c
22870
a - Stud
b - Flywheel key
c - Screws (2)
Description
Nm
lb. in.
Stud
8
70.6
Crank position sensor screws (M5 x 13) (2)
5
44.2
lb. ft.
7. Secure the ground strap to the cylinder head with a screw. Tighten the screw to the
specified torque.
8. Secure the ground strap to the cylinder block with a pin. Tighten the pin to the specified
torque.
9. Apply Liquid Neoprene to the ground location of the ground strap.
10. Install the flywheel. Tighten the flywheel bolt in two steps to the specified torque.
c
d
a
b
22867
a - Ground strap screw
b - Ground strap
c - Pin
d - Flywheel bolt
Description
Nm
lb. in.
Screw securing the ground strap to the cylinder head (M6 x 16)
8
70.6
Pin
8
70.6
Flywheel bolt
90-899185 SEPTEMBER 2006
lb. ft.
First Torque
60
44
Final Torque
180
132.5
Page 4A-67
Cylinder Block/Crankcase
Tube Ref No.
25
Description
Liquid Neoprene
Where Used
Part No.
Ground location of the ground
strap
92-25711-3
Thermostat Removal and Installation
THERMOSTAT REMOVAL
1. To remove the thermostat, push down on the thermostat retainer to disengage the
thermostat retainer.
2. Turn the thermostat retainer to unlock.
a
b
3864
a - Retainer lock
b - Retainer
THERMOSTAT TEST
Thermostat Specifications
Start to open temperature
48.8 ± ‑15 °C (120 ± 5 °F)
Full open temperature
65.5 °C (150 °F)
Piston height @ full open temperature
7.62 mm (.300 in.)
1. Measure the height of the thermostat piston at room temperature.
a
23566
a - Height of the thermostat piston at room temperature
2. Suspend the thermostat in water.
Page 4A-68
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
3. Slowly heat the water while observing the water temperature.
23570
4. At the specified temperature, remove the thermostat and measure the height of the
piston. If the piston has not changed height at the specified temperature, replace the
thermostat.
a
23571
a - Height of the thermostat piston at 65.5 °C (150 °F)
THERMOSTAT INSTALLATION
a
b
c
d
3874
a - Housing
b - Thermostat
c - Spring
d - Retainer
1. Align the thermostat with the thermostat housing.
3871
90-899185 SEPTEMBER 2006
Page 4A-69
Cylinder Block/Crankcase
2. Install the thermostat spring. The small end of the spring is inserted first.
3872
3. Install the thermostat retainer onto the thermostat spring.
4. Push down on the thermostat retainer. Turn the retainer and lock into the thermostat
housing.
a
b
3873
a - Retainer lock
3864
b - Retainer
Thermostat Housing Assembly Installation
1. Install a new O‑ring onto the block coolant temperature sensor.
13384
2. Install the block coolant temperature sensor onto the cylinder block. Tighten the block
coolant temperature sensor to the specified torque.
3. Apply Loctite 567 PST Pipe Sealant to the oil pressure sensor threads.
4. Install the oil pressure sensor. Tighten the oil pressure sensor to the specified torque.
Page 4A-70
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
5. Install the oil filter.
a
b
c
22878
a - Block coolant temperature sensor
b - Oil pressure sensor
Tube Ref No.
Description
Loctite 567 PST Pipe Sealant
9
c - Oil filter
Where Used
Part No.
Oil pressure sensor threads
92-809822
Description
Nm
lb. in.
Block coolant temperature sensor
15
132.7
Oil pressure sensor
15
132.7
lb. ft.
6. Apply Loctite 567 PST Pipe Sealant to the strainer fitting threads.
7. Install the strainer fitting to the cylinder block. Tighten the strainer fitting to the specified
torque.
8. Install a 15.7 mm diameter hose clamp onto the FSM water supply hose. Install the
FSM water supply hose onto the strainer fitting. Crimp the hose clamp with the hose
clamp tool to secure the FSM water supply hose to the strainer fitting.
a
b
22879
a - Strainer fitting
Tube Ref No.
9
Description
Loctite 567 PST Pipe Sealant
b - 15.7 mm diameter hose clamp
Where Used
Part No.
Strainer fitting threads
92-809822
Description
Nm
lb. in.
Strainer fitting
12
106.2
90-899185 SEPTEMBER 2006
lb. ft.
Page 4A-71
Cylinder Block/Crankcase
Hose Clamp Tool Kit
91‑803146A2
9. Install a new O‑ring onto the thermostat housing. Lubricate the O‑ring with 4‑Stroke
10W‑30 Outboard Oil.
Tube Ref No.
110
Description
Where Used
Part No.
4-Stroke 10W-30 Outboard Oil
Thermostat housing O-ring
92-802833A1
10. Secure the thermostat housing to the cylinder block with two screws. Tighten the
screws to the specified torque.
11. Install a 36.1 mm diameter hose clamp onto the thermostat dump hose.
12. Install the thermostat dump hose to the thermostat housing so the word "TOP" faces
out. Secure the thermostat dump hose to the thermostat housing with the hose clamp
tool.
a
b
22880
a - Screws securing thermostat housing (M6 x 25) (2)
b - 36.1 mm diameter hose clamp
Description
Thermostat housing screws (M6 x 25) (2)
Hose Clamp Tool Kit
Nm
lb. in.
8
70.6
lb. ft.
91‑803146A2
13. Install two O‑rings onto the lower dump fitting. Lubricate the O‑rings with 4‑Stroke
10W‑30 Outboard Oil.
Tube Ref No.
110
Description
Where Used
Part No.
4-Stroke 10W-30 Outboard Oil
Lower dump fitting O-rings
92-802833A1
14. Install the lower dump fitting onto the cylinder block.
15. Secure the lower dump fitting to the cylinder block with a screw. Tighten the screw to
the specified torque.
16. Install a 28.6 mm diameter hose clamp onto the thermostat dump hose.
Page 4A-72
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
17. Install the thermostat dump hose to the lower dump fitting. Secure the thermostat dump
hose to the lower dump fitting with the hose clamp tool.
a
b
22881
a - 28.6 mm diameter hose clamp
b - Screw securing the lower dump fitting (M6 x 16)
Description
Lower dump fitting screw (M6 x 16)
Hose Clamp Tool Kit
Nm
lb. in.
8
70.6
lb. ft.
91‑803146A2
Starter Assembly Installation
1. Attach the starter onto the cylinder block and secure it with the starter mounting
brackets.
2. Secure the starter mounting brackets with two screws. Tighten to the specified torque.
NOTE: The starter mounting brackets must be installed in the same orientation and location
they were removed from.
3. The upper starter mounting bracket must have one clamp on each of the retaining
screws, along with the starter ground cable on the right side retaining screw. The lower
starter mounting bracket must have one clamp on the left side. Tighten the four starter
mounting bracket screws by hand to allow the starter to self‑align with the starter
mounting brackets.
4. Tighten the four starter mounting bracket screws to the specified torque.
5. Secure the crankcase ventilation hose with the upper two clamps.
6. Secure the fuel supply module coolant supply hose with the lower clamp.
90-899185 SEPTEMBER 2006
Page 4A-73
Cylinder Block/Crankcase
7. Secure the ECM to the cylinder block with a screw and washer. Tighten the screw to
the specified torque.
a
b
22855
a - Screw and washer securing the ECM (M6 x 25)
b - Four screws and three clamps securing the starter (M8 x 40)
Description
Nm
lb. in.
ECM mounting screws (M8 x 40) (4)
17
150.4
Starter mounting bracket screws (M6 x 25)
10
88.5
lb. ft.
Alternator Assembly and Mounting Bracket Installation
1. Install the mounts onto the alternator assembly mounting bracket.
2. Align the rubber grommet with the ECM.
3. Install a washer behind the alternator assembly mounting bracket. Secure the
alternator assembly mounting bracket to the cylinder block with three screws.
b
a
c
d
e
22882
a - Washer
b - Mount
c - Washer
Page 4A-74
d - Screw (M10 x 45) (3)
e - Rubber grommet
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
4. Tighten the three screws to the specified torque.
a
22852
a - Screws (3) and washers (6)
Description
Nm
Alternator assembly mounting screws (M10 x 45) (3)
47.5
lb. in.
lb. ft.
35
5. Install the alternator onto the mounting bracket.
6. Install a washer onto the alternator mounting screw. Install the alternator mounting
screw with the washer through the alternator ground cable end.
7. Install the anti‑rotation tab washer onto the alternator mounting screw.
8. Secure the alternator to the alternator mounting bracket with the pivot screw. Thread
the screw into the alternator bracket. Do not tighten the screw at this time.
d
c
b
a
e
a - Anti‑rotation tab washer
b - Alternator ground cable end
c - Washer
22883
d - Pivot screw (M10 x 55)
e - Alternator ground cable
9. Install the alternator belt onto the flywheel and alternator.
90-899185 SEPTEMBER 2006
Page 4A-75
Cylinder Block/Crankcase
10. Use a pry bar tool to stretch the belt to install the alternator bolt. Use the alternator
mounting bracket as a fulcrum pivot to leverage the alternator away from the cylinder
block and install the alternator screw.
a
b
22843
a - Pry bar
b - Screw
11. Install the washer and nut onto the alternator screw. Tighten the alternator nut and
screw to the specified torque.
12. Tighten the pivot screw to the specified torque.
13. Apply Liquid Neoprene to the ground cable connection on the alternator.
a
22841
a - Nut and washer securing the alternator
Description
Nm
Alternator nut and screw
47.5
35
Pivot screw
47.5
35
Tube Ref No.
25
Description
Liquid Neoprene
lb. in.
lb. ft.
Where Used
Part No.
Alternator ground cable
connection
92-25711-3
Fuel Supply Module (FSM) Assembly and Mounting Bracket Installation
1. Secure the FSM assembly mounting bracket to the cylinder block with three screws
and washers.
Page 4A-76
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
2. Tighten the three screws to the specified torque.
a
22839
a - Screws (M8 x 35) (3)
Description
Nm
FSM assembly mounting bracket screws (M8 x 35) (3)
24
lb. in.
lb. ft.
17.7
3. Install the FSM onto the rubber grommet mounted on the FSM assembly mounting
bracket.
4. Secure the FSM to the FSM assembly mounting bracket with two screws and washers.
Tighten the two screws to the specified torque.
5. Install a 15.7 mm diameter hose clamp onto the FSM water inlet hose.
6. Install the FSM water inlet hose to the upper FSM water inlet port. Crimp the hose clamp
with the hose clamp tool to secure the FSM water inlet hose to the FSM water inlet port.
a
b
c
22836
a - Upper left screw and washer securing the FSM (M8 x 35)
b - Hose clamp securing the water inlet hose to the FSM
c - Lower screw and washer securing the FSM (M8 x 35)
Description
Nm
FSM mounting screws (M8 x 35)
24
Hose Clamp Tool Kit
lb. in.
lb. ft.
17.5
91‑803146A2
Throttle Bracket Reassembly and Installation
1. Lubricate the throttle follower lever bushing with 2‑4‑C with Teflon. Install the bushing
onto throttle follower lever screw.
2. Install the wave washer onto the bushing.
3. Install a washer onto the wave washer and bushing. Insert the screw through the throttle
follower lever.
90-899185 SEPTEMBER 2006
Page 4A-77
Cylinder Block/Crankcase
4. Install a washer on the throttle follower lever screw.
a
b
c
e
d
f
22989
a - Throttle follower lever screw (M6 x
20)
b - Bushing
c - Wave washer
Tube Ref No.
Description
2-4-C with Teflon
95
d - Washer
e - Throttle follower lever
f - Washer
Where Used
Part No.
Throttle follower lever bushing
92-802859A1
5. Apply Loctite 242 Threadlocker to the threads of the throttle follower lever screw.
6. Install the throttle follower lever assembly onto the throttle bracket. Tighten the throttle
follower lever screw to the specified torque.
a
22899
a - Throttle follower lever screw (M6 x 20)
Tube Ref No.
66
Description
Loctite 242 Threadlocker
Where Used
Part No.
Throttle follower lever screw
92-809821
Description
Nm
lb. in.
Throttle follower lever screw (M6 x 20)
10
88.5
lb. ft.
7. Lubricate the throttle lever bushing with 2‑4‑C with Teflon. Install the bushing onto the
throttle lever screw.
8. Install a wave washer onto the bushing.
Page 4A-78
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
9. Install the washer onto the wave washer and bushing. Insert the screw and bushing
through the throttle lever.
a
c
b
e
d
f
g
22900
abcd-
Throttle lever screw (M6 x 20)
Throttle lever bushing
Wave washer
Washer
Tube Ref No.
Description
2-4-C with Teflon
95
e - Throttle lever
f - Washer
g - Throttle lever spring
Where Used
Part No.
Throttle lever bushing
92-802859A1
10. Install the washer onto the throttle lever screw.
11. Install the throttle lever spring onto the throttle lever. Ensure the short end of the throttle
lever spring is engaged into the throttle lever.
b
a
22902
a - Short end of the throttle lever spring
b - Washer
12. Apply Loctite 242 Threadlocker to the threads of the throttle lever screw.
13. Install the throttle lever onto the throttle bracket. Ensure the throttle lever spring is
engaged into the throttle bracket. Ensure the throttle lever stop contacts the throttle
bracket. The throttle lever spring will have a slight pre‑load when installed onto the
throttle bracket.
90-899185 SEPTEMBER 2006
Page 4A-79
Cylinder Block/Crankcase
14. Tighten the throttle lever screw to the specified torque.
a
b
22905
a - Throttle lever spring engaged in the throttle bracket
b - Throttle lever stop contacting the throttle bracket
Tube Ref No.
66
Description
Loctite 242 Threadlocker
Where Used
Part No.
Throttle lever screw
92-809821
Description
Nm
lb. in.
Throttle lever screw (M6 x 20)
10
88.5
lb. ft.
15. Install the throttle bracket assembly onto the cylinder block.
16. Apply Loctite 242 Threadlocker to the three throttle bracket assembly screws. Secure
the throttle bracket assembly to the cylinder block. Tighten the screws to the specified
torque.
22827
Tube Ref No.
66
Page 4A-80
Description
Loctite 242 Threadlocker
Where Used
Part No.
Throttle bracket assembly
screws
92-809821
Description
Nm
Throttle bracket assembly screws (M8 x 20) (3)
24
lb. in.
lb. ft.
17.5
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Intake Manifold Assembly Installation
1. Install new seals onto the intake manifold.
a
22906
a - Intake manifold seals
2. Install the intake manifold to the cylinder head. Secure the intake manifold to the
cylinder head with five M6 x 30 screws. Do not torque the screws at this time.
22823
3. Secure the front of the intake manifold to the cylinder block with two M6 x 50 screws.
Do not tighten the screws at this time.
a
22820
a - Screws securing the intake manifold to the cylinder block (M6 x 50) (2)
90-899185 SEPTEMBER 2006
Page 4A-81
Cylinder Block/Crankcase
4. Tighten the seven intake manifold screws in the sequence shown to the specified
torque.
4
7
2
1
6
3
5
22145
Description
Nm
lb. in.
Intake manifold to cylinder head screws (M6 x 30) (5)
10
88.5
Intake manifold to cylinder block screws (M6 x 50) (2)
10
88.5
5.
6.
7.
8.
lb. ft.
Install the vent canister float switch hose to the FSM.
Install the low pressure fuel inlet hose to the FSM.
Install the fuel pressure regulator hose to the FSM.
Secure the vent canister float switch hose to the clip.
c
b
d
e
a
22814
a - Vent canister float switch hose
b - Low pressure fuel inlet hose
c - Fuel pressure regulator reference
hose
Page 4A-82
d - Clip securing the vent canister float
switch hose
e - High pressure fuel outlet line
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
9. Install the throttle body cable end onto the throttle lever. Retain the throttle body cable
end to the throttle lever with a washer and a cotter pin. Bend the ends of the cotter pin
to secure the throttle body cable end and washer to the throttle lever.
b
c
a
22664
a - Throttle body cable end
b - Washer
c - Cotter pin
10. Lightly pull the throttle body cable towards the front of the engine to remove slack within
the throttle body cable.
11. Adjust the throttle body cable nuts so there is a slight amount of throttle body cable
tension. Ensure the tab washer is properly aligned with the throttle bracket. Tighten the
throttle cable nuts to the specified torque.
b
a
22667
a - Cable nuts
Description
Throttle cable nuts
b - Tab washer
Nm
lb. in.
8
70.8
lb. ft.
12. Move the throttle lever to the WOT position.
22908
90-899185 SEPTEMBER 2006
Page 4A-83
Cylinder Block/Crankcase
13. Allow the throttle lever to return to the idle position.
NOTE: The throttle lever has a return spring to ensure it contacts the throttle lever stop.
14. Ensure the throttle body cable has a slight amount of tension. Push on the throttle
follower lever.
22909
15. Check the throttle body lever for movement when pushing on the throttle follower lever.
a
22962
a - Throttle body lever
16. If the throttle body lever moves when pushing on the throttle follower lever, the throttle
body cable is preloaded. The throttle body cable nuts must be readjusted.
Wire Harness Installation
1. Install the electrical plate onto the rubber support grommets.
a
22812
a - Rubber support grommets
2. Secure the engine harness with the retaining clip on the bottom of the cam cover.
3. Install the seven screws securing the coil bracket to the cam cover. Do not tighten the
screws at this time.
Page 4A-84
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
4. Install the pencil coils. Secure each pencil coil to the cam cover with a screw. Tighten
the screws to the specified torque.
5. Tighten the screws securing the coil bracket to the cam cover to the specified torque.
6. Secure the engine pencil coil harness to the coil bracket with the rubber engine harness
retainers.
7. Connect the engine harness connectors to the pencil coils.
8. Connect the engine harness connector to the camshaft position sensor.
a
d
b
c
e
f
g
22810
abcdefg-
Camshaft position sensor harness connector
Rubber engine harness retainer (4)
Screws retaining the coil bracket (M6 x 12) (3)
Screws securing the pencil coils (M6 x 25) (4)
Screws and washers retaining the coil bracket (M6 x 25) (2)
Screws retaining the coil bracket (M6 x 90) (2)
Retaining clip securing the engine harness
Description
Nm
lb. in.
Coil bracket screws ([M6 x 12] [3]), ([M6 x 25] [2]), ([M6 x 90] [2])
10
88.5
Pencil coil screws (M6 x 25) (4)
10
88.5
lb. ft.
9. Install the engine harness CAN 1 resistor and the boat sensor harness connector to
the support bracket.
10. Secure the engine harness grounds to the cylinder block with a screw. Tighten the
screw to the specified torque.
11. Secure the battery negative cable to the cylinder block with a screw. Tighten the screw
to the specified torque.
12. Cover the screws securing the battery negative cable and the engine harness ground
with Liquid Neoprene.
90-899185 SEPTEMBER 2006
Page 4A-85
Cylinder Block/Crankcase
13. Connect the engine harness connector to the oil pressure sensor.
c
d
e
b
a
22915
a - Boat sensor harness connector
b - Engine harness CAN 1 resistor
c - Oil pressure sensor connector
d - Screw securing the engine harness
grounds (M8 x 12)
e - Screw securing the battery cable
ground (M8 x 12)
Description
Nm
lb. in.
Screw securing the engine harness grounds (M8 x 12)
17
150.4
Screw securing the battery cable ground (M8 x 12)
17
150.4
Tube Ref No.
Description
Liquid Neoprene
25
lb. ft.
Where Used
Part No.
Screws securing the battery
cable ground and the engine
harness grounds to the cylinder
block
92-25711-3
14. Secure the 14 pin engine harness bracket to the cylinder block with two washers and
screws. Tighten the screws to the specified torque.
15. Secure the engine harness to the FSM bracket with two cable ties.
16. Install the FSM water inlet hose to the clip on the 14 pin engine harness bracket.
b
c
a
22804
a - Clip
b - Screws and washers (M6 x 25) (2)
c - Cable ties
Description
Screws and washers securing the 14 pin engine harness bracket
(M6 x 25) (2)
Page 4A-86
Nm
lb. in.
8
70.6
lb. ft.
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
17. Install a screw to secure the wire harness bracket and the ECM to the cylinder block.
Tighten the screw to the specified torque.
18. Connect the starter exciter wire to the engine harness.
19. Connect the starter power cable to the starter.
20. Connect the engine harness connectors to the ECM.
21. Connect the engine harness connector to the CPS.
a
b
c
e
d
22802
a - CPS harness connector
b - ECM harness connector
c - Screw (M6 x 25)
d - Starter exciter wire
e - Starter power cable
Description
Nm
lb. in.
Screw securing the wire harness bracket and the ECM (M6 x 25)
10
88.5
lb. ft.
22. Connect the engine harness sense lead to the alternator.
23. Install the alternator battery charge wire to the alternator and secure with a nut. Tighten
the nut to the specified torque.
24. Apply Liquid Neoprene to the nut securing the alternator battery charge wire to the
alternator. Allow the Liquid Neoprene to dry. Cover the nut with the protection boot.
25. Install the breather hose to the air filter.
a
b
c
22801
a - Alternator battery charge wire
b - Engine harness sense lead
90-899185 SEPTEMBER 2006
c - Breather hose
Page 4A-87
Cylinder Block/Crankcase
Description
Nut securing the alternator battery charge wire (M6)
Tube Ref No.
Description
Liquid Neoprene
25
Nm
lb. in.
7
62
lb. ft.
Where Used
Part No.
Nut securing the battery charge
wire
92-25711-3
26. Connect the engine harness connector to the FSM.
27. Connect the engine harness connector to the TPS.
a
b
22800
a - FSM harness connector
b - TPS harness connector
28. Secure the engine harness ground to the cylinder head with a screw. Tighten the screw
to the specified torque.
29. Apply Liquid Neoprene to the screw securing the engine harness ground to the cylinder
head.
30. Secure the engine harness to the cam cover with two cable ties.
31. Connect the engine harness fuel injector connectors to the fuel injectors and secure
the harness to the fuel rail with four cable ties.
Page 4A-88
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
32. Connect the engine harness connector to the MAT sensor and secure the harness to
the MAT sensor with a cable tie.
c
b
d
a
22210
abcd-
Cable ties securing the fuel injector harness (4)
Cable tie securing the engine harness to the MAT sensor
Screw securing the engine harness ground (M6 x 12)
Cable ties securing the engine harness (2)
Description
Nm
lb. in.
Screw securing the engine harness ground (M6 x 12)
10
88.5
Tube Ref No.
Description
Liquid Neoprene
25
lb. ft.
Where Used
Part No.
Engine harness ground
92-25711-3
33. Connect the engine harness connector to the cylinder block coolant temperature
sensor. Secure the cylinder block coolant temperature sensor harness connector to the
crankcase ventilation hose with a cable tie. Do not crush the crankcase ventilation hose
by over tightening the cable tie.
a
b
22918
a - Cable tie
b - Cylinder block coolant temperature
sensor connection
34. Connect the engine harness connector to the VCPV.
35. Connect the engine harness connector to the VCS.
90-899185 SEPTEMBER 2006
Page 4A-89
Cylinder Block/Crankcase
36. Secure the VCS connector to the engine harness with a cable tie.
b
c
d
a
22205
a - Vent Canister Switch (VCS)
b - Cable tie securing the Vent
Canister Switch (VCS) connector
c - Vent Canister Purge Valve (VCPV)
d - VCPV harness connection
37. Guide the engine harness under the MAP sensor.
38. Connect the engine harness connector to the MAP sensor.
c
b
a
22204
a - IAC
b - MAP sensor harness connector
c - Vent Canister Purge Valve (VCPV)
39. Connect the engine harness connector to the IAC.
a
22799
a - IAC harness connector
Page 4A-90
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
Powerhead Installation
1. Ensure the flywheel timing mark points towards the timing mark on the cylinder block.
2. Install the lifting tool onto the flywheel. Tighten the puller base bolts to the specified
torque.
Description
Nm
Puller base bolts
20 ‑ 27
lb. in.
lb. ft.
14.7 ‑ 20.0
3. Thread the lifting eye onto the lifting base securely so it bottoms out on the lifting base.
c
b
a
22646
a - Puller base
b - Bolts (3)
c - Eye
Flywheel Puller/Lifting Ring
91‑895343T02
4. Place a new powerhead gasket onto the adapter plate.
5. Turn the oil pump drive gear so the drive pins point fore and aft.
a
b
22647
a - Powerhead gasket
b - Drive pins
6. Carefully lower the powerhead onto the adapter plate while aligning the powerhead
mounting studs with the adapter plate holes.
NOTE: It may be necessary to gently rock the powerhead once the powerhead mounting
studs are partially through the adapter plate.
7. Remove the lifting tool from the flywheel. Install the flywheel grease cap.
8. Install two nuts onto the aft powerhead mounting studs. Do not torque to specification
until all of the powerhead mounting nuts and bolts are installed.
90-899185 SEPTEMBER 2006
Page 4A-91
Cylinder Block/Crankcase
9. Install the six washers and nuts (3 each side) onto the port and starboard side mounting
studs. Do not torque to specification until all of the powerhead mounting nuts and bolts
are installed.
a
22666
b
a - Aft nuts (M8 x 55) (2)
b - Powerhead nut (M10 x 154) (6)
10. Tighten the six M10 nuts in sequence to the specified torque.
6
2
3
8
7
4
5
1
22665
Description
Nm
lb. in.
lb. ft.
Powerhead nut (M10) (Number 1 to 6)
61
45
Powerhead nut (M8) (Number 7 and 8)
27
16
11. Use the torque adapter to tighten the two M8 nuts securing the powerhead to the
adapter plate/driveshaft housing.
13 mm Torque Adapter
91‑809905001
IMPORTANT: You must calculate the torque value of the nuts securing the powerhead to
the adapter plate when using an extension tool.
a. On beam type torque wrenches, measure from the square drive to the fulcrum
(pivot) point of the handle. Follow steps d through g.
b. On electronic digital type torque wrenches, measure from the square drive to the
center of the handle. Follow steps d through g.
c. On click‑stop or dial type torque wrenches, adjust the torque wrench to the
specified torque. Determine the effective length from the square drive to the center
of the handle. Follow steps d through k.
d. Measure the tool extension from the center of the square drive to the center of the
nut drive. The Torque Adapter Tool length is 30.48 cm (12 in.).
Page 4A-92
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
13 mm Torque Adapter
e.
f.
g.
h.
i.
j.
k.
91‑809905001
Add the torque wrench length and the tool length to find the sum.
Divide the sum by the torque wrench length to find the quotient.
Divide the torque specification by the quotient. This is the torque specification for
the nut or bolt.
Adjust the torque wrench to reflect the new torque calculation.
For greater accuracy, redetermine the effective length of the torque wrench and
the extension tool with the new torque calculation.
Compute for the corrected torque setting.
Adjust the torque wrench to reflect the second new torque calculation. This is the
final torque specification for the aft powerhead nuts when using a click‑stop or dial
type torque wrench.
b
a
4754
a - Torque wrench length
b - Tool extension
12. Attach the exhaust plenum to the adapter plate with three bolts. Tighten the bolts to the
specified torque.
a
a
a
a - Bolt (M6) (3)
b
22668
b - Exhaust plenum
Description
Nm
lb. in.
Exhaust plenum bolts (M6)
10
88.5
lb. ft.
13. Connect the brown/white trim position sensor bullet connectors.
14. Connect the neutral switch harness connector to the engine harness connector.
15. Attach the water line to the FSM and secure the hose with a hose clamp.
16. Attach the water hose leading to the driveshaft housing to the tee fitting and secure
with a cable tie.
17. Install the dipstick.
90-899185 SEPTEMBER 2006
Page 4A-93
Cylinder Block/Crankcase
18. Connect the blue and green power trim motor bullet connectors.
a
b
c
f
e
d
22613
abcdef-
Trim position sensor bullet connectors
Neutral switch harness connector
FSM water hose
Water hose to driveshaft housing
Dipstick
Power trim motor bullet connectors
19. Install the flywheel cover.
20. Connect the battery cables to the battery.
21. Fill the oil sump with 5.0 liter (5.3 U.S. quart) of Synthetic Blend 4‑Stroke Outboard Oil
25W‑40.
Tube Ref No.
Description
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
139
Where Used
Part No.
Engine oil sump
92-883722K01
22. Install the lower cowls.
Lower Cowl Installation
1. Install the starboard side cowl onto the adapter plate seal.
2. Connect the starboard cowl trim switch to the engine harness.
a
b
22054
a - Trim switch engine harness
connector
b - Cowl trim switch
3. Install the port side cowl onto the adapter plate seal.
Page 4A-94
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
4. Ensure the tell‑tale grommet and the idle exhaust boot are correctly installed onto the
port and starboard cowls.
a
b
22061
a - Tell‑tale grommet
b - Idle exhaust boot
5. Install the cowl latch and secure with a screw. Do not tighten the screw until all screws
securing the cowls are installed.
6. Install the lower cowl screw. Do not tighten the screw until all screws securing the cowls
are installed.
b
a
c
22046
a - Screw securing the cowl latch
b - Lower screw securing the cowl
c - Cowl seal
7. Install the five screws into the cowl. Do not tighten the five screws until all screws
securing the cowls are installed.
22053
90-899185 SEPTEMBER 2006
Page 4A-95
Cylinder Block/Crankcase
8. Install the front cowl screw.
a
b
c
22045
a - Cowl front screw
b - Battery cables
c - Engine fuel line
9. Tighten the eight cowl screws to the specified torque.
Description
Cowl screws (8)
Nm
lb. in.
7
62
lb. ft.
10. Install the throttle cable, shift cable, and remote control harness. Refer to Section 1D Outboard Installation for installation instructions.
b
a
22052
a - Shift cable
Page 4A-96
b - Throttle cable
90-899185 SEPTEMBER 2006
Cylinder Block/Crankcase
11. Install the cowl insert and secure with two screws. Tighten the screws to the specified
torque.
a
a
22051
a - Screws securing the cowl insert (2)
Description
Screws securing the cowl insert (2)
Nm
lb. in.
7
62
lb. ft.
12. Install the cowl seal onto the port side cowl. Ensure the cowl seal is fully seated onto
the port cowl.
13. Secure the cowl grommet with a cable tie.
14. Connect the fuel line to the engine fuel connector. Secure with a hose clamp.
b
c
a
22050
a - Engine fuel line
b - Cowl seal
c - Cable tie
Engine Break‑in Procedure
! CAUTION
Severe damage to the engine can result by not complying with the Engine Break‑in
Procedure.
1. For the first two hours of operation, run the engine at varied throttle settings up to 4500
RPM or at three‑quarter throttle, and at full throttle for approximately one minute every
ten minutes.
2. For the next eight hours of operation, avoid continuous operation at full throttle for more
than five minutes at a time.
90-899185 SEPTEMBER 2006
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Cylinder Block/Crankcase
Notes:
Page 4A-98
90-899185 SEPTEMBER 2006