POWERHEAD

POWERHEAD
Section 4 - Powerhead
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . 4-29
Cylinder Block and Covers . . . . . . . . . . . . . . . 4-6 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Crankshaft, Pistons and Flywheel . . . . . . . . . 4-8 Reed Block . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4-10 Bleed System . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Powerhead Removal . . . . . . . . . . . . . . . . . . . . 4-11 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Powerhead Disassembly . . . . . . . . . . . . . . . . .
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . .
4-13
4-13
Powerhead Reassembly . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . .
4-36
4-36
4
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Powerhead Cleaning and Inspection . . . . . . . 4-23 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . 4-47
Cylinder Block and Crankcase Cover . . . 4-23 Powerhead Installation . . . . . . . . . . . . . . . . . . . 4-52
Exhaust Manifold and Exhaust Cover . . . 4-24 Set-Up and Test-Run Procedures . . . . . . . . . . 4-53
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . 4-53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

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Specifications
HORSEPOWER Model 20 Jet 20 (14.9)
(KW) Model 20 20 (14.9
Model 25 25 (18.7)
CYLINDER Type Two Cylinder - Two Cycle
BLOCK Displacement 24.4 cu. in. (400 cc)
STROKE Length 2.362 in. (60 mm)
CYLINDER Diameter (Standard) 2.562 in. (65.01 mm)
BORE Taper/Out of Round Maximum* 0.003 in. (0.08 mm)*
Bore Type:
S/N 0G202749 and Below Chrome
S/N 0G202750 and Above Mercosil
CRANK SHAFT Top Main Bearing Journal 1.251 in. (31.77 mm)
Center Main Bearing Journal 1.000 in. (25.40 mm)
Bottom Main Bearing Journal 1.125 in. (28.58 mm)
Connecting Rod Journal 0.883 in. (22.43 mm)
End Play 0.004-0.019 in. (0.10-0.64 mm)
CONNECTING Piston Pin End (I.D.) 0.897 in. (22.78 mm)
ROD Crankpin End (I.D.) 1.196 in. (30.38 mm)
PISTON Piston Type Aluminum
O.D. at Skirt (Standard) 2.5583 - 2.5593 (64.98 - 65.00)
Ring End Gap 0.011-0.025 (.28 mm - .64 mm)
PISTON DIA. 2.5583 in. ± .0005 in.
(64.98 mm ± .0127 mm) Using a
micrometer, measure dimension
“A” at location shown. Dimension
“A” should be 2.5583 in. ± .0005 for
Dimension “A” a STANDARD size piston (new) Di-
at Right Angle
mension “A” will be 0.001 – 0.0015
(90°) to Pis-
ton Pin less if coating is worn off piston
0.50 in. (used)
(12.7 mm)

*Models S/N 0G202749 and Below:

NOTE: The cylinder bores are chrome and cannot be be rebored or efficiently honed.
Check each cylinder bore for an out-of-round egg shaped cylinder. A maximum of 0.003
in. (0076mm) is allowable.
*Models S/N 0G202750 and Above:
NOTE: The cylinder block is Mercosil and the cylinders can be rebored to 0.030 in. over-
sized. Check each cylinder bore for an out-of-round egg shaped cylinder. A maximum of
0.003 in. (0.076mm) is allowed.

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Special Tools
1. Powerhead Stand 91-25821A1

2. Piston Pin Tool 91-76160A2

3. Piston Ring Expander 91-24697

4. Torque Wrench (0 – 200 lb. ft.) 91-32610

5. Torque Wrench (0 – 150 lb. in.) 91-66274

90-826883R03 NOVEMBER 2002 Page 4-3

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6. Flywheel Puller 91-83164M

a - Bolts 10mm (3) 91-83191M

7. Compression Tester 91-29287

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Notes:

90-826883R03 NOVEMBER 2002 Page 4-5

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Cylinder Block and Covers

33
34 46
35
36 37 7 45
27 40
32 41 42 44
39
25 4
31
38
28

30 47
29 43

5 6

26 24
23 7
22
7
7

3 8
2 11
18
21
A 12 14
1 95 13
20 19
10 9
7 16

7 15

17

7 Loctite 271 Thread Locker

9 Loctite 567 PST Pipe Sealant
12 Loctite Master Gasket
95 2-4-C with Teflon
A = SIDE SHIFT AND TILLER SHIFT ONLY

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Cylinder Block and Covers

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 CYLINDER BLOCK
2 1 STUD (M6x1x32) Drive Tight
3 2 ELBOW (45 deg.)
4 1 STUD (M6x1x50) (Commercial) Drive Tight
5 1 DOWEL PIN
6 5 SCREW (60 MM) 30 40.7
7 1 STUD (M6x1x32) Drive Tight
8 2 STUD Drive Tight
9 1 SCREW
10 1 NUT
11 1 GASKET
12 1 REED BLOCK
13 1 GASKET
14 1 PLATE–carb adaptor
15 2 CHECK VALVE
16 3 SCREW (M5x.8x20) 80 9.0
17 2 TUBING (13-1/4 IN.)
18 2 O-RING
19 2 COVER
20 4 SCREW (M5x.8x16) 40 4.5
21 1 BALL–threaded 40 4.5
22 6 SCREW (M5x.8x16) 40 4.5
23 2 COVER
24 2 O-RING
25 1 GASKET
26 1 COVER CASTING
27 1 COVER ASSEMBLY
28 1 PIPE PLUG (BRASS) Drive Tight
29 5 SCREW (30 MM) 140 15.8
30 1 FITTING
31 1 HOSE–tell tale (8 IN.)
32 1 ELBOW Drive Tight
33 2 SCREW (M6x1x40) 140 15.8
34 1 COVER
35 1 GASKET
36 1 GASKET
37 1 THERMOSTAT
38 1 PLUG–serial number Stake Tight
39 2 O-RING
40 2 COVER
41 1 STRAP
42 4 SCREW (M5x.8x16) 40 4.5
43 1 GASKET–exhaust manifold
44 1 EXHAUST MANIFOLD
45 1 GASKET–exhaust manifold cover
46 1 COVER–exhaust manifold
47 9 SCREW (M6 x 1 x 40) 140 15.8

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Crankshaft, Pistons and Flywheel

1 2

4 3 2
1

95

8 14 7
A
9
23 14
11
10

22
21 25
24
16
18
19 23
20
16 18
14
95
21

15 35
32 95
14 95 95
17 31
13
28 26
12 34
33
30
29 27
7 Loctite 271 Thread Locker
14 2 Cycle Premium Outboard Oil
95 2-4-C with Teflon
A=ELECTRIC START MODELS ONLY

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Crankshaft, Pistons and Flywheel

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 DECAL–warning (NOT A SERVICE PART)
2 1 DECAL–warning (NOT A SERVICE PART)
3 1 SCREW–flywheel to crankshaft 50 67.8
4 1 WASHER–flywheel screw
5 1 FLYWHEEL
6 1 RING GEAR–flywheel ELECTRIC
7 4 SCREW (M5x.8x13) 65 7.4
8 1 OIL SEAL–crankshaft-upper (Qty. of 2 used on Electric RC)
9 1 ROLLER BEARING–upper
10 1 KEY–flywheel drive
11 1 CRANKSHAFT ASSEMBLY
12 1 WEAR SLEEVE KIT
13 1 O-RING (Part of Ref. #12)
14 1 OIL SEAL–crankshaft - lower
15 1 ROLLER BEARING–lower
16 2 CONNECTING ROD ASSEMBLY
17 4 SCREW 175 19.8
18 2 ROLLER BEARING ASSEMBLY
19 24 ROLLER (Part of Ref. #18)
20 54 NEEDLE BEARING–piston end
21 4 BEARING–thrust
22 2 PISTON AND PIN ASSEMBLY
23 4 LOCK RING–piston pin USA-S/N 0G202749 & BELOW
24 1 PISTON RING BEL-09855586 & BELOW
25 2 PISTON RING (Part of Ref. #24)
2 PISTON AND PIN ASSEMBLY (STD.)
22
2 PISTON AND PIN ASSEMBLY (.030 O/S)
23 4 LOCK RING–piston pin USA-S/N 0G202750 & UP
1 PISTON RING ASSEMBLY (STD. BEL-09855587 & UP
24
1 PISTON RING ASSEMBLY (.030 O/S)
25 2 PISTON RING (Part of Ref. #24)
26 1 BEARING ASSEMBLY–center main
27 1 BEARING
28 1 BEARING
29 1 THRUST WASHER
30 1 THRUST WASHER
31 1 NEEDLE ROLLER
32 1 THRUST WASHER
33 1 NEEDLE ROLLER
34 1 BEARING
35 1 THRUST WASHER

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Torque Sequence
1. Exhaust Cover [140 lb. in. (15.8 N·m)]


 



2. Crankcase Cover [30.0 lb. ft. (41.1 N·m)]

 



 

3. Cylinder Block Cover [140 lb. in. (15.8 N·m)]

 



 

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Powerhead Removal
1. Remove the following components/assemblies referring to the listed service manual
sections:

Component/Assembly Section
Rewind Starter 8
Flywheel and Ignition/Electrical Components 2A/B
Throttle/Shift Mechanism 7A/B/C
Carburetor 3A

2. Disconnect tell-tale hose from bottom cowl.

57073

a - Tell-Tale Hose

3. Remove 4 bolts.

57076

a - Bolts (2 each side)

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4. Remove 6 bolts securing powerhead.

a a

57077

a - Bolts (3 each side)

5. Rock powerhead to break gasket and lift powerhead from drive shaft housing.
6. Place powerhead on bench or powerhead stand mounted in vise.

53203

53197

a - Powerhead Stand (91-25821A1)

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Powerhead Disassembly
Cylinder Block
1. Remove 3 bolts and remove intake manifold/reed block.

57079
a - Bolts
b - Intake Manifold/Reed Block

IMPORTANT: Reed block can be inspected without disassembling. If inspection of

reed block indicates that replacement of a part is necessary, entire reed block as-
sembly must be replaced as individual parts are not sold separately.
2. Inspect seal for cuts or abrasions. If seal is damaged, entire reed block assembly must
be replaced.
3. Inspect reeds for cracks or chips.

a
57080

a - Seal
b - Reeds
c - Reed Valve Opening – Maximum Opening 0.007 in. (0.178mm)

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4. Remove 2 bolts and remove thermostat cover.

57081

a - Bolts (2)
b - Cover

5. Remove thermostat (if equipped).

6. Remove 5 bolts and remove cylinder block cover.

a a

57082

a - Bolts
b - Cover
c - Thermostat (if equipped)

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7. Remove 9 bolts and separate exhaust cover and exhaust manifold from cylinder
block.
c

a
57084

a - Bolts (9)
b - Exhaust Cover
c - Exhaust Manifold

NOTE: If engine is suspected of having been overheated or spark plugs are grayish col-
ored (a sign of possible water intrusion), inspect exhaust manifold for warpage or for prop-
er placement and integrity of gaskets which will allow water to enter cylinders through ex-
haust ports.
8. Remove 10 bolts and 4 transfer covers – Starboard Side.

57083

a - Transfer Covers

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9. Remove 4 bolts and 2 transfer covers – Port Side.

57085
a - Transfer Covers

10. Remove 6 bolts which secure crankcase cover to cylinder block.

a a

57090
a - Bolts (6)

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11. Use soft mallet to break seal between crankcase cover and cylinder block.

57086

12. Lift crankcase cover from block.

57087

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Crankshaft
1. Remove cylinder block from crankshaft assembly.

57088

2. Slide upper and lower roller bearings and seals off of crankshaft. Discard seals.

a b b c

57089

a - Crankshaft Seal (Upper)

b - Bearing
c - Crankshaft Seal (Lower)

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CENTER MAIN BEARING REMOVAL

1. Remove retaining ring from groove of center main bearing race.

57092

a - Retaining Ring

2. Remove center main bearing races and center main bearing halves. Remove main
bearing thrust washers.

b
57093
a - Bearing Halves
b - Thrust Washers

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PISTON AND ROD DISASSEMBLY

CAUTION
Eye protection MUST BE worn while removing piston pin lockrings.
IMPORTANT: Identify upper (#1) and lower (#2) pistons and connecting rods. Store
piston pin, piston pin needle bearings, locating washers, connecting rod bearings,
rod caps and bolts together with corresponding piston and connecting rod for
reassembly.
1. Using Piston Ring Expander ,remove (and discard) piston rings.

57094
a - Ring Expander (91-24697)

2. Remove (and discard) piston pin lockrings.

57098
a - Lockrings (discard)

IMPORTANT: It is recommended that the piston and rod assembly be removed from
the crankshaft before removing the piston pin to prevent possible bending of the
connecting rod.
IMPORTANT: It is recommended that new needle bearings be installed in connect-
ing rod to assure lasting repair. If needle bearings must be reused, they should be
reassembled on the same crankpin throw and on the same connecting rod.

Page 4-20 90-826883R03 NOVEMBER 2002

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IMPORTANT: Keep the same connecting rod, cap, cage and roller bearings (if re-
used) together and install them in their original location on the crankshaft.
3. Remove (and discard) rod bolts and remove piston and rod assembly from crank-
shaft.

57099
a - Rod Bolts (discard)

4. While supporting piston, use Piston Pin Tool and soft faced mallet to drive piston pin
from piston.

57100
a - Piston Pin Tool (91-76160A2)
b - Piston Pin

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IMPORTANT: Piston pin needle bearings and locating washers will fall out when
piston is removed from connecting rod.
5. Slide piston pin tool from piston and remove piston, needle bearings and locating
washers.

57101
a - Needle Bearings
b - Locating Washers

6. Remove (and discard) coupling seal using:

Snap-On* Expanding Rod (CG 40-4)
Snap-On* Collet (CG 40-A6)
Slide Hammer (91-34569A1)
*Purchase from: Snap On Tools Corporation
2801 - 80th Street
Kenosha, WI 53141-1410

CG 40-4 CG 40-A6
53045
a
b
c

57102

a - Coupling Seal 53184

b - Collet (CG 40-15)
c - Expanding Rod (CG 40-4)
d - Slide Hammer (91-34569A1)

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Powerhead Cleaning and Inspection

Cylinder Block and Crankcase Cover
IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored as-
sembly and must be replaced as a set.
1. Thoroughly clean cylinder block and crankcase cover with Power Tune Engine Clean-
er. Verify that all sealant and old gaskets are removed from mating surfaces. Remove
all carbon deposits from exhaust ports, decompression ports and cylinder dome.
2. Inspect cylinder block and crankcase cover for cracks or fractures.
3. Check gasket surfaces for nicks, deep grooves, cracks and distortion.
4. Inspect all water and fuel passages in cylinder block and crankcase cover for obstruc-
tions.
5. Verify that all fittings and plugs are tight. If the center main bearing alignment pin is
loose, cylinder block and crankcase cover must be replaced.

57125
a - Alignment Pin

57103
a - Decompression Ports 53148

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Exhaust Manifold and Exhaust Cover

1. Remove all carbon deposits and gasket material from exhaust manifold and cover.
2. Inspect for grooves, cracks or distortion that could cause leakage. Replace parts as
required.
Cylinder Bore
CHROME BORE – ALL MODELS S/N OG202749 AND BELOW
Cylinder bores which are chrome cannot be bored or efficiently honed. Honing a chrome
cylinder bore is not necessary nor is it recommended. Do not mistake cylinder bore poros-
ity (pitting) for cylinder damage. Porosity in a chrome lined cylinder is normal and is not
detrimental to engine operation or performance.
1. If chrome surface is flaking, or if a groove or any other mark penetrates the chrome
surfacing to the aluminum portion of the cylinder wall, the cylinder block must be
replaced.
2. To determine if a groove or mark on the cylinder wall penetrates the chrome surfacing
to the aluminum cylinder wall, apply a small amount of diluted muriatic acid (TIDY
BOWL CLEANER) to the groove or mark. If the groove or mark begins to fizz, the
aluminum wall is exposed and the cylinder block and crankcase cover must be
replaced.
3. If a piston is scored and transferred aluminum to the cylinder walls, remove the alumi-
num from the wall as follows:
a. Remove all loose aluminum deposits from cylinder walls with a stiff bristle brush.
b. Apply a small amount of diluted muriatic acid (TIDY BOWL CLEANER) onto alumi-
num deposits. A fizzing action will appear indicating that aluminum is being dis-
solved.
c. Leave the acid solution on the aluminum deposit for 1 to 2 minutes, then wash cyl-
inder thoroughly with hot water and detergent.
d. Steps “b” and “c” may require repeating several times before all aluminum depos-
its are gone.
e. After cleaning aluminum deposits from cylinder bores, apply light oil to each
cylinder bore with a clean cloth.
4. Check each cylinder bore for an out-of -round egged shaped cylinder. A maximum of
0.003 in. (0.076mm) is allowable. If out-of-round is more than 0.003 in. (0.076 mm),
cylinder block and crankcase cover must be replaced.

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MERCOSIL BORE – ALL MODELS S/N OG202750 AND ABOVE

1. Inspect cylinder bores for scoring, scuffing or a transfer of aluminum from piston to
cylinder wall. Scoring or scuffing, if NOT TOO SEVERE, can normally be removed by
honing. If a transfer of aluminum has occurred, a diluted muriatic acid such as TIDY
BOWL CLEANER should be applied to the areas of the cylinder bore where transfer
of aluminum has occurred. After the acidic solution has removed the transferred alu-
minum, thoroughly wash the cylinder bore with hot water and detergent to remove any
remaining acid. Cylinder walls may now be honed to remove any glaze and to aid in
the seating of new piston rings.
2. The cylinder block is Mercosil and if necessary can be rebored to 0.030 in. (0.762 mm)
oversized.
3. Check each cylinder bore for an out-of -round egged shaped cylinder. A maximum of
0.003 in. (0.076 mm) is allowable. If out-of-round is more than 0.003 in. (0.076 mm),
cylinder must be bored out to +0.030 in. (0.762 mm) or cylinder block and crankcase
cover must be replaced.
MEASURING CYLINDER BORE
1. Measure ring traveled area of cylinder bore at 3 depths, (6 places) by positioning mea-
suring instrument in-line with and at right angle (90°) to piston pin centerline.
2. If cylinder bore is tapered, egg shaped or out-of-round by more than 0.003 in. (0.076
mm), replace cylinder block.

TOP

CENTER

BOTTOM

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STANDARD CYLINDER BORE DIAMETER

20/25/20 JET BORE TYPE STANDARD BORE DIAMETER

ALL MODELS S/N OG202749 The cylinder bores are chrome 2.562 in. (65.01 mm)
AND BELOW and cannot be rebored or effi-
ciently honed. Check each cylin-
der bore for an out-of-round
“egged shaped” cylinder. A maxi-
mum of 0.003 in. (0.076 mm) is
allowable.
ALL MODELS S/N OG202750 The cylinder block is Mercosil 2.562 in. (65.01 mm)
AND ABOVE and the cylinders can be rebored
to 0.030 in. (0.762 mm) over-
sized. Check each cylinder bore
for an out-of-round “egged
shaped” cylinder. A maximum of
0.003 in. (0.076 mm) is allow-
able.

RECOMMENDED HONING METHODS FOR MEROSIL CYLINDER BORES

The preferred method is to use a diamond cutter. Honing is not required with a diamond
cutter. If a diamond cutter is not available, use a carbide cutter. Slight honing is necessary.
The carbide cutter requires sharpening after each bore. Carbide cutter tool life is approxi-
mately six bores.
HONING PROCEDURE
a. When cylinders are to be honed, follow the hone manufacturer’s recommenda-
tions for use of the hone and cleaning and lubrication during honing.
b. For best results, a continuous flow of honing oil should be pumped into the work
area. If pumping oil is not practical, use an oil can. Apply oil generously and fre-
quently on both stones and work area.

CAUTION
When honing cylinder block, remove hone frequently and check condition of cyl-
inder walls. DO NOT hone any more than absolutely necessary, as hone can re-
move cylinder wall material rapidly.
c. Start stroking at smallest diameter. Maintain firm stone pressure against cylinder
wall to assure fast stock removal and accurate results.
d. Localize stroking in the smallest diameter until drill speed is constant throughout
length of bore. Expand stones, as necessary, to compensate for stock removal
and stone wear. Stroke at a rate of 30 complete cycles per minute to produce best
cross-hatch pattern. Use honing oil generously.
e. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a
stiff bristle brush and rinse thoroughly with hot water. A good cleaning is essential.
If any of the abrasive material is allowed to remain in the cylinder bore, it will cause
rapid wear of new piston rings and cylinder bore in addition to bearings. After
cleaning, bores should be swabbed several times with engine oil and a clean
cloth, then wiped with a clean, dry cloth. Cylinders should not be cleaned with
kerosene or gasoline. Clean remainder of cylinder block to remove excess materi-
al spread during honing operation.

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3. Hone all cylinder walls just enough to de-glaze walls.

4. Measure cylinder bore diameter (with a snap gauge micrometer) at top, middle and
bottom of each cylinder. Check for tapered, out-of-round (egg-shaped) and oversize
bore.
IMPORTANT: Ports must be deburred after honing.
Crankshaft
1. Inspect crankshaft to drive shaft splines for wear.
2. Check crankshaft for straightness – runout – 0.003 in. (0.076 mm).
3. Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or
scratched. If top crankshaft sealing surface is severely worn, replace crankshaft. If
bottom crankshaft sealing surface is worn, replace crankshaft coupling seal.
4. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven
wear and/or overheating (blued).
5. If necessary, clean crankshaft bearing surfaces with crocus cloth.

57104
a - Crocus Cloth

6. Thoroughly clean crankshaft with solvent and dry with compressed air.
7. Recheck surfaces of crankshaft and replace crankshaft if surfaces can not be properly
cleaned.
8. If crankshaft will be reused, apply light oil to prevent rust.

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Seals
It is recommended that all seals be replaced as a standard rebuilding procedure.
NOTE: Both top and bottom crankshaft seals face down when installed on crankshaft.

53200

a - Top Crankshaft Seal

b - Bottom Crankshaft Seal

Bearings
ROLLER BEARINGS
1. Clean roller bearing with solvent and dry with compressed air.
2. Inspect roller bearing for rust, fracturing, wear, galling or overheating (blued). Always
replace bearings as a set if replacement is necessary.
3. Apply light oil to bearings after inspection to prevent rust.
NOTE: Use 2-4-C with Teflon to hold bearings in place while reassembling roller bearings
to crankshaft.

14

14 2 Cycle Premium Outboard Oil

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Connecting Rod
1. Check connecting rods for alignment by placing rods on a surface plate. If light can
be seen under any portion of machined surfaces, if rod has a slight wobble on plate,
or if a 0.002 in. (0.051 mm) feeler gauge can be inserted between any machined sur-
face and surface plate, rod is bent and must be discarded.

57126

a - Feeler Gauge
b - Surface Plate
c - Even Downward Pressure

2. Overheating: Overheating is visible as a bluish bearing surface color that is caused

by inadequate lubrication or excessive RPM.
3. Rust: Rust formation on bearing surfaces causes uneven pitting of surface.

a
51853

a - Pitting

90-826883R03 NOVEMBER 2002 Page 4-29

POWERHEAD

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

51853

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

a 51853

a - Spalling

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

a
51853
a - Chatter Marks Between Arrows

Page 4-30 90-826883R03 NOVEMBER 2002

 POWERHEAD

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

a
51853
a - Uneven Wear

CAUTION
Crocus cloth MUST BE USED to clean bearing surface at CRANKSHAFT END OF
CONNECTING ROD.
320 grit Carborundum cloth MUST BE USED to clean bearing surface at PISTON
PIN END OF CONNECTING ROD.
VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS.
DO NOT continue to clean connecting rod bearing surfaces after marks have
been removed.
NOTE: Wash rod to remove abrasive grit and apply light oil to bearing surfaces to prevent
rust.

b
c

100 lb. in. (11.3 N·m)

a - To Drill Motor
b - Use 320 Carborundum
c - Crocus Cloth

90-826883R03 NOVEMBER 2002 Page 4-31

POWERHEAD

Pistons
IMPORTANT: If engine was submerged while engine was running, piston and/or
connecting rod may be bent. If piston pin is bent, piston must be replaced. If piston
pin is bent, connecting rod must be checked for straightness.
1. Inspect pistons for scoring and excessive piston skirt wear.
2. Check tightness of piston ring locating pins. Locating pins must be tight.

57105
a - Locating Pins

3. Thoroughly clean pistons. Carefully remove carbon deposits from pistons, with a soft
wire brush or carbon remove solution. Do not burr or round off machined edges.
4. Inspect piston ring grooves for wear and carbon accumulation. If necessary, scrape
carbon from piston ring grooves being careful not to scratch sides of grooves. Re-
fer to procedure following for cleaning piston ring grooves.
CLEANING PISTON RING GROOVES
Keystone (tapered) ring grooves

CAUTION
Care must be taken not to scratch the side surfaces of the ring groove. Scratching
the side surface of the ring groove will damage the ring groove.
1. Use a bristle brush and carbon remover solution to remove carbon from side surfaces.
2. A tool can be made for cleaning the inner diameter of the tapered ring grooves. For
the top ring groove, a tool can be made from a broken tapered piston ring with the side
taper removed to enable the inside edge of the ring to reach the inner diameter of the
groove. For the bottom ring groove, a tool can be made from a broken rectangular ring.
Carefully scrape carbon from inner diameter of ring grooves. Care must be taken not
to damage the grooves by scratching the side surfaces of the grooves.
Piston with 1 half keystone (half tapered) and 1 rectangular ring.

Page 4-32 90-826883R03 NOVEMBER 2002

 POWERHEAD

MEASURING PISTON
1. Measure piston skirt at right angle (90°) to piston pin centerline.

0.50 in.
(12.7mm)

57106

Standard Piston Diameter

20/25/20 JET 2.5583 in. – 2.5593 in. (64.98 mm – 65.00 mm)

PISTON CLEARANCE
MINIMUM BORE MEASUREMENT
– MAXIMUM PISTON MEASUREMENT

= PISTON CLEARANCE

PISTON CLEARANCE
0.003 in. – 0.004 in.
(0.076 mm – 0.101 mm)

Reed Block
IMPORTANT: DO NOT remove reeds from reed block except for inspection pur-
poses only. DO NOT turn used reeds over for reuse. If a reed block component is
damaged, the entire reed block assembly must be replaced. Individual compo-
nents are not sold separately.
1. Thoroughly clean reeds and reed block.
2. Check for wear (indentations), cracks or grooves on sealing surfaces of reed block
that could cause leakage.
3. Check for chipped or broken reeds.
4. Inspect reed block seal for swelling or looseness. Replace reed block assembly if
necessary.
5. If reeds have been removed, retorque screws to 25 lb. in. (2.8 N·m). Check reeds as
outlined in Reed Opening and Reed Stop Opening section following.

90-826883R03 NOVEMBER 2002 Page 4-33

POWERHEAD

REED OPENING
1. Check reeds for preload and stand open conditions. Stand open should not exceed
0.007 in. (0.178 mm). Replace reed block assembly if necessary.
a
b

c
d
e

f
a - Reed
b - Reed Stop
c - Lock Washer
d - Screw
e - Reed Block
f - Seal (Vulcanized to Reed Block)
NOTE: Reed Stop Opening is not adjustable.
Bleed System
1. Inspect bleed hoses for deterioration. Replace hoses as required.
2. Inspect bleed valves in lower crankcase cover for proper function. Valve should flow
fuel only one way – from bottom of crankcase cover to intake transfer port cover side
of each cylinder. If check ball in valve is stuck open or closed, replace check valve.

e
d
c
a - 90° Fitting (2)
b - Bleed Check Valves (2)
c - Starboard Bleed Line (To Bottom 90° Fitting)
d - Port Bleed Line (To Top 90° Fitting)
e - Bleed Hoses Must Be Routed thru Slot

Page 4-34 90-826883R03 NOVEMBER 2002

 POWERHEAD

Thermostat
Wash thermostat with clean water. Using a thermostat tester, similar to the one shown,
test thermostat as follows:
• Open thermostat valve, then insert a thread between valve and thermostat body.
Allow valve to close against thread.
• Suspend thermostat (from thread) and thermometer inside tester so that neither
touches the container. Bottom of thermometer must be even with bottom of thermo-
stat to obtain correct thermostat opening.
• Fill thermostat tester with water to cover thermostat.
• Plug tester into electrical outlet.
• Observe temperature at which thermostat begins to open. Thermostat will drop off
thread when it starts to open. Thermostat must begin to open when temperature
reaches 5° F (3° C) above designated stamping on bottom of thermostat.
• Continue to heat water until thermostat is completely open.
• Unplug tester unit.
• Replace thermostat, if it fails to open at the specified temperature, or if it does not fully
open.

51087

90-826883R03 NOVEMBER 2002 Page 4-35

POWERHEAD

Powerhead Reassembly
General Information
Before proceeding with powerhead reassembly, be sure that all parts to be reused have
been carefully cleaned and thoroughly inspected, as outlined in Cleaning and Inspec-
tion. Parts, which have not been properly cleaned (or which are questionable), can se-
verely damage an otherwise perfectly good powerhead within a few minutes of operation.
All new powerhead gaskets must be installed during assembly.
During reassembly, lubricate parts with 2-Cycle Outboard Oil whenever 2-cycle oil is spe-
cified, and 2-4-C with Teflon whenever grease is specified.

CAUTION
Any GREASE used for bearings INSIDE the powerhead MUST BE gasoline solu-
ble. Use only 2-4-C with Teflon or Needle Bearing Assembly Lubricant. The use
of any other grease may result in powerhead damage.
A torque wrench is essential for correct reassembly of powerhead. Do not attempt to reas-
semble powerhead without using a torque wrench.
Crankshaft
NOTE: Three designs of crankshaft seals have been used. Design 3 is the current
application.

a b

57097

a - Design 1 – O-ring fits in groove on driveshaft

b - Design 2 – O-ring fits inside of carrier
c - Design 3 – 3 lip seal permanently installed inside of carrier

Page 4-36 90-826883R03 NOVEMBER 2002

 POWERHEAD

1. If removed, reinstall new crankshaft carrier as follows:

a. Apply a thin coat of Loctite 271 Thread Locker to carrier surface on crankshaft.
b. Square the carrier with crankshaft and using a 7/8 in. deep well socket and ham-
mer, carefully seat carrier onto crankshaft.

7 Loctite 271 Thread Locker a b

57107
a - Carrier
b - 7/8 in. deep well socket

2. Apply 2-4-C with Teflon to crankshaft roller bearings and thrust washers to hold com-
ponents in place on crankshaft while reassembling.
3. Install roller bearings and thrust washers onto crankshaft.

95

b a

95 2-4-C with Teflon 57108

a - Race Halves with Roller Bearings

b - Thrust Washers

90-826883R03 NOVEMBER 2002 Page 4-37

POWERHEAD

NOTE: Bearing race halves retainer ring groove faces toward flywheel end of crankshaft.
4. Reinstall bearing race halves. Secure halves with retainer ring.
NOTE: Install retainer ring so that ring bridges both fracture lines of bearing race.

b
a

57109

a - Race Halves
b - Retainer Ring

Page 4-38 90-826883R03 NOVEMBER 2002

 POWERHEAD

5. Check center main thrust washers for wear as follows:

a. Push thrust washers and center main bearing toward either end of crankshaft.
b. Use a feeler gauge and check clearance between crankshaft and thrust washers.
c. If clearance between crankshaft and thrust washers is greater than 0.030 in.
(0.762 mm), replace thrust washers.

57110

a - Thrust Washers
b - Feeler Gauge

NOTE: It is recommended that the piston pin and piston be installed on the connecting
rod prior to installing the connecting rod on the crankshaft to avoid possible bending of
the rod during piston pin installation.
IMPORTANT: When replacing needle bearings, replace all needles as a set. DO NOT
use old and new needles together.
6. Install piston onto connecting rod as follows:
a. Lubricate sleeve of Piston Pin Tool (91-76160A2) with 2-4-C with Teflon Marine
Lubricant.
b. Hold lower locating washer and sleeve onto piston pin bore of connecting rod and
install needle bearing set of 27.

a 95
c

95 2-4-C with Teflon

a - Sleeve
b - Locating Washer
c - Needle Bearings (27)

90-826883R03 NOVEMBER 2002 Page 4-39

POWERHEAD

NOTE: If the tip of an awl can be inserted between the needle bearings, one or more
needles are missing and must be replaced.

57111

c. Install upper locating washer.

57113

a - Locating Washer

d. Slide piston onto connecting rod, centering piston pin bore over sleeve.
e. Slide piston tool up through piston pin bore and remove sleeve.

57114
a - Sleeve
b - Piston Pin Tool (91-76160A2)

Page 4-40 90-826883R03 NOVEMBER 2002

 POWERHEAD

f. Apply light oil to piston pin and place piston pin onto tool.

14

b a

14 2 Cycle Premium Outboard Oil 57115

a - Piston Pin
b - Piston Pin Tool (91-76160A2)

g. Support bottom of piston and hold piston pin tool up against piston pin.
h. Drive piston pin into piston pin bore (with a soft face mallet) until pin is flush with
piston.

a
57100
a - Piston Pin Tool (91-76160A2)
b - Piston Pin

90-826883R03 NOVEMBER 2002 Page 4-41

POWERHEAD

i. Move piston pin tool to top of piston pin bore and center piston pin in piston.

57116
a - Piston Pin Tool (91-76160A2)

7. Install new lockrings into grooves in both ends of piston pin bore.

37117

a - Lockring

Page 4-42 90-826883R03 NOVEMBER 2002

 POWERHEAD

8. Install connecting rods onto crankshaft as follows:

a. Apply 2-4-C with Teflon Marine Lubricant to connecting rod big-end bearings.
IMPORTANT: Replace roller bearing halves as a set. DO NOT use old and new
halves together.
b. Place both halves of connecting rod big-end roller bearing onto crank pin.

95

95

95 2-4-C with Teflon 57118

a - Roller Bearing

CAUTION
The word “UP” (cast on the outside of piston) must be toward flywheel end of
crankshaft when installing piston/rod assembly onto crankshaft. Failure to orient
piston/rod assembly correctly on crankshaft will result in piston rings catching
in ports causing powerhead damage. If “UP” is not present on top of piston,
raised rib on wrist pin boss must face up towards flywheel end of crankshaft.

OR

57096 57095

90-826883R03 NOVEMBER 2002 Page 4-43

POWERHEAD

IMPORTANT: Clean connecting rod bolts with solvent and dry with compressed air.
Inspect threads for damage. If threads are not damaged, bolts may be reused.
Apply light oil to threads prior to installation.
c. Observe connecting rod/cap fracture line for correct alignment. Secure connect-
ing rod (with v-notch of rod toward flywheel end of crankshaft) onto crankshaft with
rod cap and bolts. Torque bolts to 150 lb. in. (16.9 N·m).

14

b
e a
d
e

14 2 Cycle Premium Outboard Oil 57119

a - Fracture Line
b - Connecting Rod
c - V-Notch (Toward Flywheel)
d - Rod Cap
e - Bolts – Torque to 150 lb. in. (16.9 N·m)

Page 4-44 90-826883R03 NOVEMBER 2002

 POWERHEAD

d. Correct piston installation:

57120
a - Intake Side
b - Exhaust Side

9. Install new piston rings using Piston Ring Expander. Install RECTANGULAR ring first
in bottom ring groove. Install HALF-KEYSTONE ring in top ring groove. Align piston
rings with each respective ring groove locating pin.

d
a c
b

57121
a - Piston Ring Expander (91-24697)
b - Rectangular Ring
c - Half-Keystone Ring
d - Locating Pin

90-826883R03 NOVEMBER 2002 Page 4-45

POWERHEAD

10. Apply outboard oil to upper and lower roller bearings and install bearings on crank-
shaft. Numbered side of bearing should face UP or OUT on bearings.
11. Install new upper and lower crankshaft seals. Both seal lips face down. Apply 2-4-C
with Teflon to seal lips.

14 14

57089

a b c
d

95 95

14 2 Cycle Premium Outboard Oil

95 2-4-C with Teflon 57089

a - Upper Crankshaft Seal

b - Upper Crankshaft Bearing (Numbers/letters face up/out)
c - Lower Crankshaft Bearing (Numbers/letters face down/out)
d - Lower Crankshaft Seal

Page 4-46 90-826883R03 NOVEMBER 2002

 POWERHEAD

Cylinder Block
CAUTION
Piston rings must be properly positioned with locating pin between piston ring
end gaps. Improperly positioned piston rings will break during installation.
1. Lubricate piston rings, piston and cylinder wall with light oil.
2. Keeping crankshaft horizontal, guide pistons into cylinder bores.
3. Align hole in center main bearing race with pin of cylinder block.

c c
a
b

57122
a - Hole
b - Pin (Hidden)
c - Align Pin In Slot

4. Position alignment boss of upper crankshaft roller bearing into notch in cylinder block.
5. Gently push seals inward to seat.
6. Check each piston ring for spring tension through transfer and exhaust ports by press-
ing with a screwdriver. If no spring tension exists (ring fails to return to position), it is
likely that the piston ring was broken during assembly (replace broken piston ring).
Use caution not to burr piston rings while inspecting.

57124

90-826883R03 NOVEMBER 2002 Page 4-47

POWERHEAD

7. Clean crankcase sealing surfaces according to Loctite Master Gasket instructions.

Apply a continuous bead of Loctite sealant along the inside of the mounting bolt holes
of crankcase cover.

a
57123

a - Sealant

8. Place crankcase cover onto cylinder block and secure with 6 bolts. Torque bolts to
30.0 lb. ft. (40.7 Nm) in numbered torque sequence.

 
a
 a
 

57090
a - Bolts – Torque to 30 lb. ft. (40.7 Nm)

Page 4-48 90-826883R03 NOVEMBER 2002

 POWERHEAD

9. Rotate crankshaft several times to assure free operation.

10. If disassembled, assemble reed block as follows:
a. Torque reed stop screws to 25 lb. in. (2.8 N·m).
b. Lubricate seal with 2-4-C with Teflon and install reed block onto cylinder block.

a
95

95 2-4-C with Teflon 57080

a - Screws [Torque to 25 lb. in. (2.8 N·m)]

b - Seal
c - Reed Valve Opening – Maximum Opening 0.007 in. (0.178 mm)

11. Secure carburetor adaptor plate with new gasket to cylinder block with 3 bolts. Torque
bolts to 80 lb. in. (9.0 N·m).

b
57079

a - Adaptor Plate
b - Bolts – Torque to 80 lb. in. (9.0 N·m)

90-826883R03 NOVEMBER 2002 Page 4-49

POWERHEAD

12. Route upper and lower bleed hoses to their respective fittings as shown.
13. Install starboard transfer port covers with new seals. Torque attaching bolts to 40 lb.
in. (9.0 N·m).

57078
a - Upper Bleed Hose
b - Lower Bleed Hose
c - Transfer Port Covers

14. Install transfer port covers with new seals. Torque attaching bolts to 40 lb. in. (4.5
N·m).
b

57085
a - Transfer Port Covers
b - Bolts – Torque to 40 lb. in. (4.5 N·m)

Page 4-50 90-826883R03 NOVEMBER 2002

 POWERHEAD

15. Install exhaust manifold and exhaust cover with new gaskets. Torque bolts to 140 lb.
in. (15.8 N·m) in torque sequence shown.
a

 


b





57084
a - Exhaust Manifold
b - Exhaust Cover

16. Install cylinder block cover with thermostat and new gaskets. Torque bolts to 140 lb.
in. (15.8 N·m) in torque sequence shown.
NOTE: If tell-tale elbow fitting is removed/replaced at thermostat cover, apply Loctite PST
Pipe Sealant to threads of elbow fitting prior to installation.
9 d
b

 

a f



  e
9 Loctite 567 PST Pipe Sealant 57081
a - Cylinder Block Cover
b - Thermostat (Under Cover)
c - Gasket
d - Gasket
e - Bolts – Torque to 140 lb. in. (15.8 N·m)

90-826883R03 NOVEMBER 2002 Page 4-51

POWERHEAD

Powerhead Installation
1. Verify powerhead base surface and driveshaft housing mating surfaces are free of old
gasket material.
2. Install powerhead with new gasket onto driveshaft housing.
NOTE: It may be necessary to rotate propeller shaft slightly to align crankshaft splines
with driveshaft splines.
3. Secure powerhead to driveshaft with 6 bolts. Torque bolts to 20 lb. ft. (27.1 N·m).

a a

57077

a - Bolts [Torque to 20 lb. ft. (27.1 N·m)]

4. Reinstall trim cover. Torque bolts to 85 lb. in. (9.6 N·m).

57076
a - Bolts – Torque to 85 lb. in. (9.6 N·m)

Page 4-52 90-826883R03 NOVEMBER 2002

 POWERHEAD

5. Install tell-tale hose and attach hose to fitting on bottom cowl.

57073
a - Tell-Tale Hose

6. Install the following components/assemblies referring to the listed service manual

sections.
Component/Assembly Section
Carburetor 3A
Throttle/Shift Mechanism 7A/B/C
Electrical/Ignition Components and Flywheel 2A/B
Rewind Starter 8

Set-Up and Test-Run Procedures

CAUTION
When engine is started, IMMEDIATELY check for fuel leaks and water leaks.
Check for water pump operation by water being discharged from tell-tale.
1. Following powerhead repairs, refer to Section 2C, Timing/Synchronizing/Adjust-
ing and perform set-up procedures.
2. While test running engine, check powerhead assembly for leaks and/or unusual
noises. Make any repairs BEFORE returning engine to service.

Break-In Procedure
CAUTION
To avoid possible engine damage, break-in procedure MUST BE completed BE-
FORE operating engine continuously at full throttle. Failure to break-in engine in
properly will result in engine failure or shortened powerhead life.
IMPORTANT: Advise the owner that the break-in procedure must be followed EX-
ACTLY when returning an overhauled engine to service.
1. Mix gasoline and oil at the normal 50:1 ratio.
2. Operate engine at varied throttle settings for the first hour (1 hour). AVOID both wide-
open-throttle operation and prolonged idle in cold water areas during this period.
3. After the first hour of operation, the engine is may be run at any speed. DO NOT EX-
CEED the full throttle RPM range listed in Specifications, preceding.

90-826883R03 NOVEMBER 2002 Page 4-53