CYLINDER BLOCK/CRANKCASE
POWERHEAD Section 4B – Cylinder Block/Crankcase
Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Cylinder Block And Covers . . . . . . . . . . . . . . . . . 4B-6 Preparing Powerhead for Removal . . . . . . . . . . 4B-8 Remote Control Models . . . . . . . . . . . . . . . . . 4B-8 Tiller Handle Models . . . . . . . . . . . . . . . . . . . . 4B-8 Electric Start Models . . . . . . . . . . . . . . . . . . . . 4B-9 Manual Start Models . . . . . . . . . . . . . . . . . . . . 4B-9 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-10 Preparing Powerhead for Disassembly . . . . . . 4B-11 Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4B-12 Thermostat, Exhaust, and Breather Cover Removal . . . . . . . . . . . . . . . . . . . . . . . 4B-12 Anode Removal . . . . . . . . . . . . . . . . . . . . . . . 4B-13 Crankcase and Crankshaft Removal . . . . . 4B-14 Piston Disassembly . . . . . . . . . . . . . . . . . . . . 4B-15 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4B-15 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-15 Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-15 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . 4B-16 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
90-856159R1 AUGUST 1998
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase and Bearing . . . . . . . . . . . . . . . . Connecting Rod Oil Clearance . . . . . . . . . . Powerhead Reassembly . . . . . . . . . . . . . . . . . . Piston Ring Installation . . . . . . . . . . . . . . . . . Piston Installation . . . . . . . . . . . . . . . . . . . . . Crankcase and Crankshaft Installation . . . Anode Installation . . . . . . . . . . . . . . . . . . . . . Thermostat, Exhaust, and Breather Cover Installation . . . . . . . . . . . . . . . . . . . . . . Following Powerhead Assembly . . . . . . . . . . . . Timing Belt Installation . . . . . . . . . . . . . . . . . Electrical Component Installation . . . . . . . . Carburetor Installation . . . . . . . . . . . . . . . . . Powerhead Installation . . . . . . . . . . . . . . . . . . . . Following Powerhead Installation . . . . . . . . . . . Electric Start Models . . . . . . . . . . . . . . . . . . . Manual Start Models . . . . . . . . . . . . . . . . . . . All Models (If Equipped) . . . . . . . . . . . . . . . . Driveshaft Housing Covers . . . . . . . . . . . . .
4B-18 4B-19 4B-20 4B-20 4B-21 4B-22 4B-25 4B-27 4B-27 4B-28 4B-29 4B-32 4B-33 4B-36 4B-36 4B-37 4B-37 4B-37 4B-39 4B-40 4B-40 4B-40 4B-40
Page 4B-1
4 B
CYLINDER BLOCK/CRANKCASE
Specifications CYLINDER BLOCK STROKE
Type Displacement Number of Cylinders Length
CYLINDER BORE
Diameter Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type
PISTON
Piston Type O.D. at Skirt Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm)
PISTON CLEARANCE
RINGS
COMPRESSION RATIO PISTON PIN
Piston to Cylinder Clearance Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle Compression Ratio Cylinder Compression (cold engine @ W.O.T.)
4 Stroke Cycle – Over Head Camshaft 19.7 cu. in. (323cc) 2 2.323 in. (59 mm) 2.3228–2.3236 in. (59.00-59.02 mm) 2.3327-2.3335 in. (59.25-59.27 mm) 2.3425-2.3433 in. (59.50-59.52 mm) 0.003 in. (0.08 mm) Cast Iron Aluminum 2.3209 - 2.3214 in. (58.950 - 58.965 mm) 2.3307 - 2.3313 in. (59.200 - 59.215 mm) 2.3406 - 2.3411 in. (59.450 - 59.465 mm) 0.0014 - 0.0026 in. (0.035 - 0.065 mm)
0.006 - 0.012 in. (0.15 - 0.30 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.0016 - 0.0032 in. (0.04 - 0.08 mm) 0.0012 - 0.0028 in. (0.03 - 0.07 mm) 9.3:1 185 - 190 psi (Peak)
Piston Pin Diameter
0.5510 - 0.5512 in. (13.996 - 14.000 mm)
CONNECTING ROD
Oil Clearance (Big End) Small End Inside Diameter
0.0008 - 0.0018 in. (0.021 - 0.045 mm) 0.5518 - 0.5523 in. (14.015 - 14.029 mm)
CRANKSHAFT
Main Bearing Clearance Crankshaft Run-out
Page 4B-2
0.0004 - 0.0015 in. (0.011 - 0.039 mm) 0.0008 in. (0.02 mm)
90-856159R1 AUGUST 1998
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CYLINDER BLOCK/CRANKCASE
Special Tools 1. Oil Filter Wrench (P/N 91-802653).
55851
2. Flywheel Holder (P/N 91-83163M)
3. Flywheel Puller (P/N 91-83164M)
56570
4. Piston Ring Compressor (P/N FT2997)
5. Powerhead Stand (P/N 83190M)
56571
90-856159R1 AUGUST 1998
Page 4B-3
CYLINDER BLOCK/CRANKCASE
Crankshaft 11
9
13
2 10 14
8
1 15
12
4 6
7
5
13
4
3
Page 4B-4
90-856159R1 AUGUST 1998
CYLINDER BLOCK/CRANKCASE
Crankshaft REF. REF NO. QTY. 1 1 2 1 3 1 AR AR 4 AR 5 2 6 4 7 4 8 2 9 2 10 2 11 2 12 2 13 4 14 1 15 1
TORQUE DESCRIPTION CRANKSHAFT OIL SEAL OIL SEAL BEARING (BROWN) BEARING (BLACK) BEARING (BLUE) CONNECTING ROD BOLT (M7 x 38) WASHER PISTON PISTON RING PISTON RING OIL RING PISTON PIN SNAP RING KEY KEY
90-856159R1 AUGUST 1998
lb-in.
lb-ft
Nm
16.2
22
Page 4B-5
CYLINDER BLOCK/CRANKCASE
Cylinder Block And Covers 21 37
33
19
35 36
12
Loctite Master Gasket “514” (92-12564-2)
110
4-Stroke Outboard Oil (92-828000A12)
20
32
34
110
18
110
31 30 29 28
13
27
43
44
45
26
1
38
9 12
10
6
2
1
11
12 7 2
3
5
17
8
A
12 14 15
4 22 16 23
40
110
22
39 41 39 42
25 24
A= TO TELL-TALE
Page 4B-6
90-856159R1 AUGUST 1998
CYLINDER BLOCK/CRANKCASE
Cylinder Block And Covers REF. REF NO. QTY. 1 1 2 2 3 4 4 6 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 7 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 3 22 2 23 1 24 6 25 6 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1
TORQUE DESCRIPTION CYLINDER BLOCK DOWEL PIN BOLT (M8 x 20) BOLT (M6 x 14) PIPE PLUG GASKET EXHAUST COVER FITTING THERMOSTAT (60C/140F) COVER-Thermostat GASKET BOLT (M6 x 30) HOSE STA-STRAP TUBING (16 IN.) OIL FILTER UNION PIPE (M20) PLUG-Serial Number BREATHER COVER SEAL BOLT (M6 x 20) GASKET PLATE-Oil Deflection BOLT (M8 x 35) WASHER ANODE GROMMET COVER BOLT (M5 x 12) PLATE BOLT (M6 x 20) CHOKE CABLE NUT (.375-24) BRACKET RETAINING RING BOLT (M6 x 13) BALL SOCKET DIPSTICK STA-STRAP PIPE JOINT HOSE OIL SCREEN CLAMP CLAMP GROMMET
90-856159R1 AUGUST 1998
lb-in.
lb-ft
Nm
104
22 9
30 12.2
104
9
12.2
156
13 29
18 40
70
8
22
30
44
5
70
8 Drive Tight
HANDLE 70
8
Page 4B-7
CYLINDER BLOCK/CRANKCASE
Preparing Powerhead for Removal 1. Drain engine oil (refer to “Changing Engine Oil” in Section 1B).
Remote Control Models 1. Disconnect shift lever.
b
a a-Shift Lever b-Shift Link Rod 2. Disconnect throttle linkage.
a a-Throttle Linkage
Tiller Handle Models 1. Disconnect throttle linkage.
a a-Throttle Linkage
Page 4B-8
90-856159R1 AUGUST 1998
CYLINDER BLOCK/CRANKCASE
2. Disconnect choke linkage. Remove two (2) bolts and remove choke bracket.
a
c
b a-Choke Linkage b-Bolts (2)-M6x13 c-Choke Bracket
Electric Start Models 1. Remove battery cables at the starter motor side. 2. Remove flywheel cover.
Manual Start Models 1. Remove starter rewind, refer to Section 8 “Manual Starter”.
All Models (If So Equipped) 1. Disconnect the following leads, refer to the wiring diagrams in Section 2D. •
Engine stop switch leads.
•
Neutral start switch lead.
•
Fuse lead.
•
Oil light leads.
2. Remove inlet fuel hose from fuel pump.
a
a-Fuel Hose (Inlet)
90-856159R1 AUGUST 1998
Page 4B-9
CYLINDER BLOCK/CRANKCASE
3. Remove tell–tale water hose.
a
a-Water Hose
Powerhead Removal 1. Remove driveshaft housing covers (4 bolts and nuts).
NOTE: To aid in removal of bolts, a small straight screwdriver should be placed in nut pocket to prevent turning of nuts.
a
b
56919
a-Driveshaft Housing Covers b-Bolts (4), Nuts (4)
Page 4B-10
90-856159R1 AUGUST 1998
CYLINDER BLOCK/CRANKCASE
2. Remove dipstick. 3. Remove powerhead bolts. Place powerhead on powerhead stand. 4. Remove powerhead gasket and dowel pins. 5. Cut sta-straps securing oil strainer assembly to powerhead. Remove oil strainer assembly 6. Separate oil strainer assembly as needed.
NOTE: Do not re-use powerhead gasket.
a
c f d c e d
b a-Dipstick b-Bolts (6)-M8x45 c-Dowel Pins (2) d-Powerhead Gaskets (2) (New) e-Oil Deflection Plate f-Oil Strainer Assembly
Preparing Powerhead for Disassembly 1. Refer to Section 2A for removal of the following components. •
Rectifier/regulator
•
CDI and flywheel pickup
•
Ignition coil
2. Remove carburetor unit and breather hose. Refer to “Carburetor Removal” in Section 3B. 3. Remove cylinder head. Refer to “Cylinder Head Removal” in Section 4A.
90-856159R1 AUGUST 1998
Page 4B-11
CYLINDER BLOCK/CRANKCASE
Powerhead Disassembly 1. Remove oil filter (if necessary).
NOTE: Slide boot off of oil pressure switch. 2. Remove oil pressure switch.
d e
f c
a
b a-Oil Filter b-Oil Filter Plug c-Boot d-Screw w/Washer e-Oil Pressure Switch Lead f-Oil Pressure Switch
Thermostat, Exhaust, and Breather Cover Removal 1. Remove thermostat cover, gasket, and thermostat. 2. Remove exhaust cover and gasket.
f
e
h g d
c
b
a
a-Bolts (2)-M6x30 b-Thermostat Cover c-Gasket-Thermostat Cover (Discard) d-Thermostat e-Bolts (5)-M6x30 f-Washers (7) g-Exhaust Cover h-Gasket-Exhaust Cover (Discard) Page 4B-12
90-856159R1 AUGUST 1998
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