INTAKE MANIFOLD

EPC3471
6 15
Ref P/N Name of Part Qty 11 12
1 5035951 MANIFOLD, INTAKE 1 9 1
2 5033688 GASKET 1 14
3 5033689 COVER, WATER JACKET 1 2
4 5033690 RING 1
5 5033726 GASKET, IAC VALVE 1 10
6 5033727 VALVE, IAC 1 5
7 5033728 HOSE, IAC 1
8 5030121 INSULATOR 1
9 5030979 BOLT, STUD 1
10 5034122 BOLT, STUD 1
11 5030000 BOLT 10
12 5030998 BOLT 8
13 5031069 BOLT 1 7
14 5033288 PIN 2
15 5031021 NUT 2

13

4
3 11

90–115 4-STROKE
THERMOSTAT
EPC3484
24
Ref P/N Name of Part Qty 5
1
2
5033644
5035956
HOSE, WATER RETURN
COVER, WATER PRESSURE VALVE
1
1
TO
HOLDER 21 19
3 5033720 VALVE, WATER PRESSURE 1
4 5033721 THERMOSTAT (60.C) 1 4 1
4 5033722 THERMOSTAT (71.C) Opt. 1 19 16
5 5036683 COVER, THERMOSTAT 1
6 5033724 3 way, WATER HOSE 1 17 22
7 5030391 BOLT (6X25mm) 2 19
8 5030541 O RING 1
23 18
9
10
5033621
5030122
HOSE (HOLDER TO 3 way) A
HOSE (INMF CVR TO 3 way - L:50mm A
1
1 19 19
11
12
5030122
5030122
HOSE (3 way TO 3 way - L:50mm) A
HOSE (3 way TO Fuel CLR - L:160mmA
1
1 TO 10
INMF
13
14
5030122
5030122
HOSE (3 way TO INMF - L:200mm) A
HOSE (3 way TO C/C LOWER - L:370 A
1
1
13 19 21 15
15 5030122 HOSE (3 way TO INDICATOR - L:370 A 1 TO
TO INDICATOR
16 5030122 HOSE (C/C UPPER TO 3 way - L:450 A 1 COOLER 19
17
18
5033024
5030127
HOSE (3-way TO HOLDER - L:690mmA
3 way, WATER HOSE
1
2 18 19 TO CRKC
19 5037047 CLIP New 16 19 14
20 5033626 CLIP 2
12 11 9 19
21 5037177 CLIP New 2
22
23
5033629
5033630
CLIP
CLIP
1
1
19 20 7
24 5030990 BOLT 3
6 20 3 8 2
A Cut to length from bulk roll

15
TIMING CHAIN
EPC3470
20 12
15 Ref P/N Name of Part Qty
16 1 5033662 GEAR, DRIVEN 1
8 2 5033663 PLUG, DRIVEN GEAR 1
13 3 5033664 SPROCKET, CAM SHAFT TIMING 2
4 5033585 BOLT (12X25mm) 2
14 5 5033608 BEARING 1
18 6 5033609 BEARING 1
10
19 7 5033516 O RING 1
8 5031015 PIN 2
3 9 5034140 CIRCLIP 1
5 10 5033665 CHAIN, TIMING 1
3 11 5033666 GUIDE, TIMING CHAIN 1
9 4 12 5033667 TENSIONER, TIMING CHAIN 1
7 13 5031337 *PAD, TIMING CHAIN TENSIONER 1
2 14 5033668 SPACER, TIMING CHAIN TENSIONER 1
15 5036680 ADJUSTER, TENSIONER New 1
16 5034121 BOLT, STUD 1
1 17 5034125 BOLT 2
18 5031666 BOLT 1
17 19 5034126 BOLT 1
11 20 5034138 NUT 1

16
 CAMSHAFT
EPC3469
Ref P/N Name of Part Qty 5 10
1 5033901 CAMSHAFT, INTAKE - 90HP 1 11 7 8
1 5033660 CAMSHAFT, INTAKE - 115HP 1 9 3 4
2 5033902 CAMSHAFT, EXHAUST - 90HP 1
2 5033661 CAMSHAFT, EXHAUST - 115HP 1
3 5033669 TAPPET 16 6 9
4 5033670 SHIM, TAPPET (T:2.18mm) AR
4 5033671 SHIM, TAPPET (T:2.20mm) AR 10
4 5033672 SHIM, TAPPET (T:2.23mm) AR
4 5033673 SHIM, TAPPET (T:2.25mm) AR
11
4 5033674 SHIM, TAPPET (T:2.28mm) AR 7
4 5033675 SHIM, TAPPET (T:2.30mm) AR
4 5033676 SHIM, TAPPET (T:2.33mm) AR
4 5033677 SHIM, TAPPET (T:2.35mm) AR 8
4 5033678 SHIM, TAPPET (T:2.38mm) AR 9 9 2
4 5033679 SHIM, TAPPET (T:2.40mm) AR
4 5033681 SHIM, TAPPET (T:2.43mm) AR
3 1
4 5033682 SHIM, TAPPET (T:2.45mm) AR
4 5033683 SHIM, TAPPET (T:2.48mm) AR 4
4 5033684 SHIM, TAPPET (T:2.50mm) AR
4 5033685 SHIM, TAPPET (T:2.53mm) AR
4 5033686 SHIM, TAPPET (T:2.55mm) AR
4 5033874 SHIM, TAPPET (T:2.58mm) AR
4 5033875 SHIM, TAPPET (T:2.60mm) AR
4 5033876 SHIM, TAPPET (T:2.63mm) AR
4 5033877 SHIM, TAPPET (T:2.65mm) AR
4 5033878 SHIM, TAPPET (T:2.68mm) AR
4 5033879 SHIM, TAPPET (T:2.70mm) AR
4 5033880 SHIM, TAPPET (T:2.73mm) AR
4 5033881 SHIM, TAPPET (T:2.75mm) AR
4 5033882 SHIM, TAPPET (T:2.78mm) AR

90–115 4-STROKE
4 5033883 SHIM, TAPPET (T:2.80mm) AR
4 5033884 SHIM, TAPPET (T:2.83mm) AR
4 5033885 SHIM, TAPPET (T:2.85mm) AR
4 5033886 SHIM, TAPPET (T:2.88mm) AR
4 5033887 SHIM, TAPPET (T:2.90mm) AR
4 5033888 SHIM, TAPPET (T:2.93mm) AR
4 5033889 SHIM, TAPPET (T:2.95mm) AR
4 5033890 SHIM, TAPPET (T:2.98mm) AR
4 5033891 SHIM, TAPPET (T:3.00mm) AR
4 5033892 SHIM, TAPPET (T:3.03mm) Opt. AR
4 5033893 SHIM, TAPPET (T:3.05mm) Opt. AR
4 5033894 SHIM, TAPPET (T:3.08mm) Opt. AR
4 5033895 SHIM, TAPPET (T:3.10mm) Opt. AR
4 5033896 SHIM, TAPPET (T:3.13mm) Opt. AR
5 5033897 VALVE, INTAKE 8
6 5034594 VALVE, EXHAUST 8
7 5033899 SPRING, VALVE 16
8 5033900 RETAINER, VALVE SPRING 16
9 5033687 VALVE COTTER 32
10 5031959 SEAT, VALVE SPRING 16
11 5033614 SEAL, VALVE STEM 16

17
CYLINDER HEAD
EPC3467
8
6 7 Ref P/N Name of Part Qty
5 1 5035936 HEAD, CYLINDER 1
18 19 2 5033636 *GUIDE, VALVE 16
11 20
22 3 5033638 *BOLT, CAM SHAFT HOUSING 21
4 5030515 *PIN 18
5 5034866 COVER, Anode 2
9 6 5035305 O RING 2
7 5031705 ANODE, Protection 2
13
26 8 5036691 BOLT, Anode New 2
21 9 5030994 BOLT 2
25
10 5031914 BOLT, CYLINDER HEAD 10
10 15 22 11 5033639 GASKET, CYLINDER HEAD 1
12 5034541 BOLT 8
13 5031014 PIN 2
14 5033640 COVER, CYLINDER HEAD 1
15 5033641 PLATE, BREATHER 1
3 16 16 5033642 GASKET, SPARK PLUG HOLE 4
17 5033643 GASKET, CYLINDER HEAD COVER 1
18 5030633 CAP, OIL FILLER 1
19 5032912 PROTECTOR, BREATHER HOSE 1
Cut to length from bulk roll
24 23 20 5030541 O RING 1
12 21 5031064 HOSE, BREATHER 1
3 17
1 Cut to length from bulk roll
22 5037165 CLIP New 2
14 23 5030985 BOLT 11
24 24 5034124 BOLT 4
25 5034132 SCREW 7
26 5033634 SPARK PLUG (BKR6E) 4

CYLINDER & CRANKCASE

EPC3466
10 7
3 Ref P/N Name of Part Qty
8 1 5033646 HOOK, ENGINE 1
6 2 2 5034129 BOLT 2
3 5034542 BLOCK, CYLINDER 1
4 5033637 *BOLT, CRANKCASE 10
5 5 5033645 *GASKET, OIL GALLERY PLUG 3
6 5033604 *PLUG, OIL GALLERY 3
1 7 5034146 *COVER, C/C WTR JKT 1
8 5033648 *O RING, C/C WTR JKT COVER 1
9 5031066 *PIN 5
11 10
11
5030000
5034545
*BOLT
*BOLT
8
10
12 5034544 *PLUG, Oil Venturi 1
4 13 5030521 PLUG 1

13
9

12
5
6

18
 CRANKSHAFT & PISTONS
EPC3468
Ref P/N Name of Part Qty 13
1 5035947 PISTON 4
2 5033654 RING SET, PISTON 4
3 5033871 PIN, PISTON 4
4 5033623 CIRCLIP 8
5 5033522 CONNECTING ROD Assy 4 11
6 5033514 *NUT 8
7 5033521 BEARING SET, Connecting rod 4
7 5033911 BEARING SET, Connecting rod Opt. 4 4 12
(US:0.25mm)
8 5033523 CRANKSHAFT 1 3
9 5033529 BEARING SET, Crankshaft - Green 5
9 5033530 BEARING SET, Crankshaft - Black 5 1 2
5
9 5033531 BEARING SET, Crankshaft - No color 5 6
9 5033532 BEARING SET, Crankshaft - Yellow 5
9 5033533 BEARING SET, Crankshaft - Blue 5
9 5033524 BEARING SET, Crankshaft Opt. 5
(US:0.25mm) - Green 8
9 5033525 BEARING SET, Crankshaft Opt. 5
(US:0.25mm) - Black
9 5033526 BEARING SET, Crankshaft Opt. 5 7
(US:0.25mm) - No color
9 5033527 BEARING SET, Crankshaft Opt. 5
(US:0.25mm) - Yellow
9 5033528 BEARING SET, Crankshaft Opt. 5
10
(US:0.25mm) - Blue
10 5033872 BEARING SET, CRANK THRUST 1
10 5033873 BEARING SET, CRANK THRUST Opt. 1 9
(OS:0.12mm)
11 5030550 SEAL, OIL 1
12 5035946 PISTON SET (OS:0.50mm) Opt. 4

90–115 4-STROKE
13 5033656 *RING SET, PISTON (OS:0.50mm) Opt. 4

GASKET SET
EPC3543
2
Ref P/N Name of Part Qty 1
1 5033519 GASKET SET A 1 3
1 5037225 GASKET SET B 1
2 5033639 *GASKET, CYL HEAD 1
3 5033643 *GASKET, CYL HEAD CVR 1
4 5030623 *GASKET, COVER 2
5 5033649 *GASKET, OIL PAN 1
6 5033688 *GASKET, INTAKE 1
7 5033692 *GASKET, THROTTLE BODY 1
8 5033698 *GASKET, RECTIFIER 1 8
9 5030725 *GASKET, WATER PUMP 1
10 5034757 *GASKET, ADAPTER A 1
10 5037205 *GASKET, ADAPTER B 1
9
A 90 HP, Up to SN 029194 – 115 HP, Up to SN 032266 7 6
B 90 HP, SN 029195 & Up – 115 HP, SN 032267 & Up 4

5 10

19
OIL PUMP
EPC3485
10
Ref P/N Name of Part Qty
1 5033534 GEAR, OIL PUMP 1
15 2 5033711 GEAR 1
3 5033712 PUMP Assy, OIL 1
4 5030712 VALVE Assy, OIL RELIEF 1
13 5 5033713 O-RING 1
6 5033714 STRAINER, OIL PUMP 1
7 5030469 GASKET, (16X22X2mm) 1
8 5033600 SHIM, (12X20.0.5mm) 1
9 5033607 PIN (5x8mm) 1
10 5033610 O-RING 1
11 5030985 BOLT 1
7 5 12 5034123 BOLT 2
6 13 5034125 BOLT 3
14 5034139 CIRCLIP 1
4 3 15 778886 FILTER, OIL 1

11
12 8
9 1

2 14

OIL PAN
EPC3486
1
Ref P/N Name of Part Qty
1 5033649 GASKET, OIL PAN 1
2 5035944 PAN, OIL 1
13 3 5032682 PLUG, WATER 1
4 5030850 PIPE, EXHAUST 1
5 5030930 COVER 1
6 5031173 *O-RING 1
7 5030929 TUBE, WTR INDICATOR 1
2 8 5035665 BOLT, (8X40mm) 3
11 10 9 5033588 BOLT 8
5 10 5030465 GASKET 1
11 5034465 PLUG 1
76 12 5030536 O-RING 1
13 5033715 GAUGE, OIL LEVEL 1
14 5033540 GUIDE 1
15 5032782 O-RING 1
8 4 16 5030988 BOLT 1
14
12
16
3
15

20
 EXHAUST ADAPTER (90 HP Up to SN 029194, 115 HP Up to SN 032266)
EPC3488
Ref P/N Name of Part Qty
5
1 5036610 HOLDER, ENGINE 1
2 5030442 *WASHER (18.5X28X2.6mm) A 1
3 5036699 *PLUG A 1 10
4 5033841 UNION, WATER RETURN 1 11
5 5034757 GASKET, ENGINE HOLDER 1
6 5033587 BOLT (8X70mm) 4
7 5035665 BOLT (8X40mm) 4 13 4
8
9
5030515
5030541
PIN
O RING
2
1 31 15
9
10 5033611 SEAL, OIL A 2
1 14
11 5033613 SEAL, OIL A 1
12 5030990 BOLT 1 16
13 5034127 BOLT 1 12
14 5033591 WASHER (8.5X19X2.3mm) 1
15 5033596 WASHER 1
16 5033288 PIN 3 7 6
17 5036553 BOLT, UPPER MOUNT 2
18
19
5033561
5030419
MOUNT, UPPER
NUT
2
2
18 30 8
20 5036612 WASHER (12.5X24X2.5mm) 2 22 28 2 3
21 5036480 WASHER (12X22X3.0mm) 2
21 19 29
22 5033842 MOUNT, UPPER THRUST REVERSE 2
23 5033562 COVER, UPPER MOUNT 2
24 5034787 BOLT (10X45mm) 4
25 5031221 NUT 2 20
27
28
5033597
5034630
WASHER (12.5X22X2.5mm)
BEARING, Clutch shaft A
2
1
27 17
29 5034631 SEAL, Clutch shaft A 1
30
31
5035662
5034601
CIRCLIP
PLUG, Clutch shaft
1
1
23
25

90–115 4-STROKE
A Included in P/N 5036610 24

21