DIRECT FUEL INJECTION
Page 3B-55
90-888438 JUNE 2002
Air Compressor Disassembly/Reassembly
IMPORTANT: If an internal failure of the air compressor has occurred, i.e. broken
reed, scuffed piston, bearing failure, etc. – all air hoses, fuel rails and injectors
should be disassembled and inspected for metal debris. Failure to remove all metal
debris will result in poor performance and/or powerhead failure.
NOTE: If cylinder bore is scored, air compressor must be replaced as an assembly.
NOTE: The piston and rings are not sold separately. They must be replaced as an assem-
bly. The connecting rod and bearings are not sold separately. They must be replaced as
an assembly.
14
14
14
14
9
9
9
9
6
9
Dielectric Grease
6
Loctite PST Pipe Sealant
9
14
2 Cycle Outboard Oil
c
d
e
f
h
i
j
g
13
a
b
7
Loctite 271
7
k
NOTE: End cap bearing and seal are not sold separately. End cap must be replaced as an assembly
NOTE: Piston Installation – use a metal hose clamp for piston ring compressor. Stagger piston ring openings.
a-Bolt (6 each) (GOLD Pulley) – Torque to 190
lb. in. (21.5 Nm)
(BLACK Pulley) – Torque to 170 lb. in. (19
Nm)
b-Bolt (4 each) [Torque to 20 lb. ft. (27 Nm)]
c-Bolt (4 each) [Torque to 100 lb. in. (11.5 Nm)]
d-End Cap Assembly (Inspect bearing for
roughness)
e-O-Rings (Inspect for cuts or abraisions)
f-Reed Plate (Inspect for broken or chipped
reeds/stops) Maximum Reed Stand-Open –
0.010 in. (0.254 mm)
g-O-Rings (Inspect for cuts or abraisions)
h-Cylinder Head
i-Bolt (Torque to 20 lb. ft. [27 Nm])
j-Temperature Sensor
k-Bolt (Torque to 20 lb. ft. [27 Nm])
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