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5 HP Outboard • Troubleshooting & Repair Manual
Section 5 • Assembly
Adjust Valve Clearance
Check valve clearance while engine is cold.
1. Turn crankshaft until piston is at TDC of the
compression stroke.
2. Insert a narrow screwdriver or small rod into spark
plug hole against the piston. The screwdriver or rod is
used to gauge piston movement.
NOTE:
Correct positioning of crankshaft is
required to prevent compression release from
holding valves open.
3. While watching screwdriver or rod, turn crankshaft
clockwise (flywheel end) past TDC until piston is 1/4"
(6.35 mm) down.
4. Using feeler gauges
(Figure 101)
clearance. Clearance should be .004 - .008"
(.10 - .20mm) for intake and exhaust valves
Figure 101 — Checking Valve Clearance
3
5. To adjust, loosen set screw
rocker nut
until valve clearance is correct.
2
6. When valves are adjusted, hold rocker nut. Tighten
set screw to 35 in. lbs. (4 Nm).
, check valve
3
.
. Turn
(Figure 102)
1
55
Figure 102 — Adjusting Valve Clearance
1
7. Recheck clearance and adjust, if required.
Install Valve Cover
1. Install valve cover with new gasket. Install four screws.
Torque screws to 85 in. lbs. (10 Nm).
2. Install muffler, exhaust manifold, air guides, shields and
other parts removed from cylinder head.
3. Torque muffler screw to 85 in. lbs. (10Nm).
Carburetor Assembly
Install Welch Plug
Install welch plug
(Figure 103)
slightly smaller than the outside diameter of the plug.
Figure 103 — Install Welch Plug
2
with a pin punch
1
2
2
1
5
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