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Special Tools
Description Part No.
12-point Socket FT 2953
Piston Tool FT 2990-1 2.0 in.
Ring Remover/Installer FT 8926 (50.8 mm)
Ring Compressor FT 2996
Lockring Installer FT 11291 Major Diameter
measured 90
Compression Tester 91-29287 to piston pin
center line
*Torque Wrench (0–200 lb. ft.) 91-32610
*Torque Wrench (0–150 lb. in.) 91-66274
Flywheel Puller FT 8948-1
Lifting Hook FT 8933
*May Be Obtained Locally
TOP
CENTER
BOTTOM
PISTON RING
.015 Oversize
in. (mm)
3.390 (86.10)
.030 Oversize
in. (mm)
3.405 (86.487)
a - Lifting Ring
WARNING
DO NOT leave powerhead suspended from hoist.
Powerhead should be installed on a suitable
stand or lowered to the floor upon removal from
pump cover.
NOTE: Refer to appropriate sections in service
manual for removal of individual fuel and electrical
subassemblies from powerhead.
b
Component/Assembly Section
a - Exhaust Boot Clamp
b - Water Inlet Hose Starter Motor 2C
8. Remove four 13-mm nuts from studs that hold Flywheel 2A/2B*
powerhead adapter plate to pump cover. Ignition Components 2A/2B*
9. Remove four 15-mm nut from studs that hold (Switch Box, Stator, Trigger)
adapter plate to pump cover. Carburetor and Linkage 3A
Fuel Pump 3B
*1996 Models, CDM Ignition
NOTE: All ignition and electrical components can be
removed and installed as an assembly.
c
a
Removing Crankshaft
a - Crankshaft Seals
IMPORTANT: Mark rod caps and pistons as to the
3. If replacement of the upper ball bearing is neces-
cylinder they are removed from.
sary, remove using univeral bearing puller Special
1. Remove connecting rod screws with 12-point Tool 91-37241. Press new bearing onto crank-
socket. shaft.
a - Seal
b
c
d
e
f
g
a - Screw (4) e - Thermostat
b - Housing f - Retainer
c - Gasket g - Seal
d - Spring
a
a - Pitting
a
a - Spalling
a
a - Chatter Marks Between Arrows
a
a - Uneven Wear
c
a - Attached to Drill Motor
b - Crocus Cloth
c - Torque to 16 lb. ft. (21.7 N·m)
d - Use 320 Carborundum Cloth
a b
a b
c
c
51536
51536 a - Flat Washer
a - Ridged Washer b - Scalloped
b - Smooth c - Smooth
c - Scalloped
Powerhead Reassembly
A cylinder head with 0.012 in. (0.305 mm) or less
can be resurfaced. Assembling Bottom Guided Piston -
If warped more than 0.012 in. (0.305 mm) replace 1995-1/2 Model Year S/N 0E125508 and
cylinder head. Below
3. Measure cylinder bore diameter at top, middle 1. Install piston pin needle bearings in pin bore of
and bottom of each cylinder as shown. Check for connecting rod using. Lubricate needle bearings
tapered, out-of-round and oversized bore. with Quicksilver Needle Bearing Lubricant.
a
a - Bearings (26 per set)
a
a
b WARNING
Eye protection must be worn while installing
piston pin lockrings.
IMPORTANT: Use only new piston pin lockrings.
a - Spacer
b - Alignment Pin 7. Install NEW piston lockrings (one at each end of
piston pin) with lockring installation tool (Special
3. Install first spacer with small end toward the inside Tool No. FT 11291) as shown.
of piston.
4. Install connecting rod in piston. a
Slide connecting rod with bearings over alignment
tool. b
Install second spacer with small end toward inside
of piston.
Push alignment pin through second spacer and
through piston bore.
b a 1
CAUTION
Never intermix new needle bearings with used
needle bearings at the same connecting rod end.
Never intermix needle bearings on one
connecting rod with those of another connecting
rod. Should one (or more) piston pin needle
bearing of a connecting rod require replacement
(or should one or more be lost), replace all of that
connecting rod’s piston pin needle bearings. 51080
1. Place sleeve, which is part of Piston Pin Tool a - Sleeve
(91-74607A3), into connecting rod and install b - Piston Pin Tool (91-74607A3)
needle bearing around sleeve, as shown.
a b
19537
a - Needle Bearings (29)
b - Sleeve [From Piston Pin Tool (91-74607A3)]
51086
51086
a - Lockring Installation Tool (91-77109A2)
b - Lockring (2)
b
c
a - Alignment Pin
b
b
a b c
a b
a - Bearing Cage Half
b - Roller (9)
a - Correct Fit
11. Carefully align connecting rod with crankshaft. b - Incorrect Fit - Gap Present
c - Incorrect Fit - Ridge Present
3 4
1 2
a 6 5
90/95 HP
Check crankshaft for free rotation.
9 10
5 6
a - Sealer (92-90113--2) 1 2
18. Install crankcase cover on cylinder block, aligning
corner dowel pins. 4 3
8 7
a
120 HP
a
20. Using new gasket, install adapter plate on bottom
of cylinder block. Torque bolts to 30 lb. ft. (40.7
N·m).
a - Dowel Pins
1. Install cylinder head cover on cylinder head. 4. Torque bolts as shown to 75 lb. in. (8.5 N·m), then
Torque center attaching screws to 70 lb. in. (7.91 torque 50 lb. in. (5.6 N·m) at a time until bolts are
N·m). torqued to 225 lb. in. (29.14 N·m).
For S/N numbers 0E125509 and above apply light oil
to threads and bolt head. Torque in sequence to 120
lb. in. (13.5 N·m). Then turn an additional 90.
13 14
11 12
a
1 4
5 6
b
3 2
c 7 8
a - Cylinder Head Cover c - Cylinder Head Gasket
10
b - Cylinder Head 9
NOTE: 90/95 HP Shown.
90/95 HP
2. Apply sealant 92-90113--2 to cylinder head cover
on cylinder block side of cover.
17 18
3. Using new gasket, install cylinder head.
13 14
9 10
5 6
1 2
4 3
8 7
12 11
16 15
120 HP
CAUTION
SEVERE DAMAGE to your engine can result by
not complying with the proper break-in
procedure.
6 4
2
32 33 4
34
36 44
35 37
38 43 5
39
40 42
7 6
31
41 8
30
29
9
28
26 11 12
27 10
U 21
13
25
24
19
14
23 U
15
Quicksilver Lubrication/Sealant 22 U
Application Points 18 16
17
U RTV Sealant 92-90113--2
18
23
20
24 C 5
V
19 E
6
7
21 8
9
17 10
22
18a
20 V
23a 11
12
19 16 13
18a V
90/120 HP
1995-1/2 S/N 0E125508 and Below
27
E
14
C
15
Quicksilver Lubrication/Sealant
Direction of
Application Points major sealing lip
UP or DOWN
16
17
1 2 3
14 6
28
4
11
12
9
5 28
6
7
8
6
35 28 9
34
33
31 10
13
29 25
32 U
20
30
15
21 18
U
23 24
27
19
22
U
26
Quicksilver Lubrication/Sealant
Application Points
8
2
10
11
10