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Powerhead Reassembly and
Installation
General Information
Before proceeding with powerhead reassembly, be sure
that all parts to be reused have been carefully cleaned and
thoroughly inspected, as outlined in "Cleaning and Inspec-
tion". Parts, which have not been properly cleaned (or
which are questionable), can severely damage an other-
wise perfectly good powerhead within a few minutes of op-
eration. All new powerhead gaskets must be installed dur-
ing assembly.
During reassembly, lubricate parts with Quicksilver
2-Cycle Outboard Oil whenever 2-cycle oil is specified, and
Quicksilver 2-4-C Marine Lubricant whenever grease is
specified.
A torque wrench is essential for correct reassembly of pow-
erhead. Do not attempt to reassemble powerhead without
using a torque wrench.
End Cap
1. Clean thoroughly, including seal and O-ring seats; re-
move Perfect Seal residue and clean cap-to-head mat-
ing surface.
2. Using suitable mandrel, press oil seals into cap until
fully seated.
NOTE: Lip of smaller seal faces away from powerhead. Lip
of larger seal faces towards powerhead.
3. Lubricate oil seal lips with 2-cycle oil.
4. Lubricate O-ring seal with 2-cycle oil and install in
groove.
5. Apply Perfect Seal to flange of end cap.
Lip of Larger Seal
Lip on Bottom of
Smaller Seal
a - 2-Cycle Oil
b - Perfect Seal
4-26 - POWERHEAD
!
Any GREASE used for bearings INSIDE the powerhead
MUST BE gasoline soluble. Use only Quicksilver
Needle Bearing Assembly Lubricant. DO NOT use
2-4-C Marine Lubricant, or other lubricants inside the
powerhead, or damage may occur.
Assembling Rod to Piston
!
Never intermix new needle bearings with used needle
bearings. It is required to replace needle bearings as
a set. Never intermix needle bearings from one con-
necting rod with those of another connecting rod
1. Place clean needle bearings on a clean sheet of paper
Service Tip
a
b
If the tip of an awl can be inserted between needle bear-
ings, one or more needles are missing and must be re-
placed.
PE-51088
CAUTION
CAUTION
and lubricate with Quicksilver Needle Bearing Lubri-
cant.
PE-51228
90-817643R1 DECEMBER 1996
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