90-13645--2 495
Table Of Contents
Page Page
Throttle Lever And Linkage Wave Washer
Removal - Models 70-75-80-90-100 4A-1. . . . .
Crankshaft Assembly 4A-2. . . . . . . . . . . . . . . . . . . . .
Powerhead Block and Cover Assemblies 4A-4. . . .
Torque Specifications, Torque Sequences 4A-6. . .
Tools for Powerhead Repair 4A-9. . . . . . . . . . . . . . .
Sealants/Loctitesr Needed 4A-9. . . . . . . . . .
General Information 4A-9. . . . . . . . . . . . . . . . . . . . . .
Disassembly and Reassembly 4A-9. . . . . . .
Powerhead Component Removal 4A-9. . . . . . . . . .
Flywheel Removal 4A-11. . . . . . . . . . . . . . . . . . . .
Powerhead Disassembly 4A-13. . . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-17. . . . . . . . . . . . . . . . . . .
Cylinder Block and Crankcase Cover 4A-17. . . .
Honing Procedure 4A-18. . . . . . . . . . . . . . . . .
Check Valves 4A-19. . . . . . . . . . . . . . . . . . . . . . . . .
Design I
(Models with Check Valve Only) 4A-19. .
Design 2 (Models with Check
Valve and Restrictor) 4A-19. . . . . . . . . . . .
Bleed Check Valve/Restrictor Kit
(22-814204A1) 4A-19. . . . . . . . . . . . . . . . .
Design 3 (Models with Check Valve
and Carrier) 4A-20. . . . . . . . . . . . . . . . . . .
Removal 4A-20. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A-20. . . . . . . . . . . . . . . . . . . . . . . .
Piston and Piston Rings 4A-21. . . . . . . . . . . . . . .
Cleaning Piston Ring Grooves 4A-21. . . . . . .
Measuring Piston Skirt 4A-22. . . . . . . . . . . . .
Crankshaft 4A-22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rods 4A-23. . . . . . . . . . . . . . . . . . . . .
Cylinder Cover, Exhaust Divider Plate
and Exhaust Cover 4A-23. . . . . . . . . . . . . . . . . . . .
Thermostat 4A-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Reed Blocks 4A-24. . . . . . . . . . . . . . . . . . . . . . . . .
Backside - Reed Block Assembled 4A-24. . .
Powerhead Reassembly and Installation 4A-25. . . .
General Information 4A-25. . . . . . . . . . . . . . . . . . .
End Cap 4A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design 1 - Bottom Guided 4A-26. . . . . . . . . .
Design 2 - Top Guided 4A-26. . . . . . . . . . . . . .
Assembling Rod to Piston 4A-27. . . . . . . . . . . . . .
Piston Ring Installation 4A-28. . . . . . . . . . . . . . . .
Crankshaft Installation 4A-29. . . . . . . . . . . . . . . . .
Installing Rods to crankshaft 4A-31. . . . . . . .
Connecting Rod Cap Alignment 4A-32. . . . . . . . .
Crankcase Cover to Block 4A-32. . . . . . . . . . . . . .
Reattach Crankcase Cover 4A-33. . . . . . . . .
Cylinder Block Cover 4A-33. . . . . . . . . . . . . . . . . .
Cylinder Head Cover
Torque Sequence 4A-34. . . . . . . . . . . . . .
Exhaust Plate Cover and Exhaust
Divider Plate 4A-34. . . . . . . . . . . . . . . . . . . . . .
Exhaust Plate Cover Torque
Sequence 4A-34. . . . . . . . . . . . . . . . . . . . .
Powerhead to Driveshaft Housing 4A-35. . . . . . .
Reinstall Wiring Harness and
Components as a Unit 4A-36. . . . . . . . . .
Electrical Components Installed 4A-36. . . . .
Flywheel Installation 4A-37. . . . . . . . . . . . . . . . . . .
Intake Manifold - Torque Sequence 4A-37. .
Attach Rear Cowl Mounting Bracket 4A-38. .
Attach Front Cowl Mounting Bracket 4A-39.
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