To assure personal safety, each individual spark plug lead should be grounded to engine. If piston pin is bent, connecting rod must be checked for straightness. Remove water pump assembly and water pump base. Check for a steady stream of water flowing out of the water pump indicator hole. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Secure fuel line to carb with sta-strap.
If not within specifications, adjustment will be required. Bearing Puller Tool 91-27780 5. Position alignment hole on assembly over post on bottom of carburetor. Position the outboard in a vertical position. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. Remove water pump assembly as shown.
Remove cylinder block from crankshaft assembly. Place drain pan below outboard. Carefully pry up the valve pad and remove it. Place the rubber seal side with holes towards front onto the control cables and install control cables, barrel holder and rubber seal into the cable holder as shown. Remove 6 bolts securing powerhead. Place pulley and cable assembly into pulley case. Place forward gear on a press with gear teeth down.
Place outboard in a vertical operating position. Remove 3 bolts and lift rewind starter from engine. Install compression gauge in spark plug hole. The boat bottom should be aligned or be within 1 in. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lu- bricant with Teflon. Contaminants water, dirt, Check fuel in tank and replace if necessary. Clean crankcase sealing surfaces according to Loctite Master Gasket instructions.
Slide reverse gear into bearing carrier assembly. Bottom cable wraps and locks in bottom groove. Measure piston skirt at right angle 90° to piston pin centerline. This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Insert the proper valve pad into the valve lifter. Loosen timing belt tensioner bolt and remove tensioner spring. Place outboard in a vertical operating position.
Install starter sheave into housing aligning notches in sheave with appropriate loca- tions on recoil spring. Heat the bearing carrier a until it feels warm to the touch. Incorrect float setting Reset float. Refer to Section 2D for wiring connections. Position harness clamp onto clamp bracket in bottom cowl.
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. Remove access plug from carburetor air intake cover. Start engine and allow to warm up run for several minutes. Remove timing belt and driven sprockets. Insert driveshaft into gear housing while holding pinion in place with other hand.
Fasten bearing cup puller on a threaded rod as shown. Using Water Pump Cartridge Puller 91-27780 , as shown, remove the driveshaft oil seals from gear housing. Plug remote control harness connector into engine wiring harness connector and se- cure with harness connector retainer. Gear housing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller is turned coun- terclockwise. Position the remote wiring harness and battery cables thru the bottom cowl rubber grommet as shown.