Out of specification: Replace rocker arm shaft Measure rocker arm post bore inside diameter. Loosen one engine mounting nut at a time, add or subtract shims, and re--check alignment. Remove pump assembly as outlined on pages 5. Seat post height is fixed. Screen Fasteners Inspect all fasteners in the pump area and make sure they are tight.
Sacrificial Anode The purpose of these anodes is to prevent corrosion of met- al parts due to electrolysis. These include the steering nozzle mount- ing bolts, steering cable bolt, trim nozzle mounting bolts where applicable , and all reverse mechanism fasteners where applicable. All models for the above stated years and all engine types are included. Oil Pump Fastener Torque: 7 ft. Extreme care must be taken when handling the connectors. From inside the engine compartment, remove the drive coupler guard.
Using the hand crank, crank the timing chain out of the engine. Push pistons so the connecting rods engage the crankshaft. As the battery goes through the charge-discharge cycle, the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged. Gear remov- al is not required. Re--install from back to front. Serious burns can result from contact with the skin, eyes or clothing. Verify the crankcase stud oil jackets are installed on the four studs as outlined in the photo.
Measure crankshaft main bearing clearance. Mark end covers and housing for proper reassembly. Out of specification: Replace valve guide 4. While holding brush springs away from brushes, push brushes back and hold in place. Because of the loss of these gases and the lowering of the electrolyte level, it will be necessary to add pure, clean distilled water to bring the fluid to the proper level.
Remove the fasteners and slide the intercooler forward towards the fuel tank. The orifice should be inspected and cleaned periodically to ensure proper cooling of the exhaust muffler and connector hoses. Illustration of exhaust manifold--to--engine assembly. Carefully pull the cylinder head assembly up and off of the crankcase. Remove tail cone screws 3 and tail cone. Measure distance from straight edge to hull on left and right side.
Remove connectors from front to back. Obtain the engine--side drive coupler. Watercraft must be on engine stand or on trailer to perform test. Out of specification: Replace balance shaft Piston Inspection Measure piston diameter. Install the flywheel on to the crankshaft.
Failure to do so may cause severe engine or vehicle damage. Place cover over spring and insert fastener. This manual is an easy layout format that covers all repair procedures in great detail. These gases are the ingredients of water. Place a straight edge across horizontal center line of steering nozzle or trim nozzle.
Red positive cable first, black negative cable last. With the timing chain removed from the engine, the crankcase can be split in two. Tilt the bow down to prevent coolant from escaping outlet rail. Wrap the chain around the camshaft sprocket. Front Gear Cover Fastener Torque: 7 ft.
Loosen the rear engine mounting strap fasteners and remove the rear mounting strap. Do this until the tensioner goes in past flush and activates. Remove starter motor and disassemble. Clean bilge siphon pickup screens whenever debris are present. Install new o--rings upon reassembly. Never overfill the expansion tank. Apply marine grade silicone to threads when reinstalling.
Do not fold seal lips over when pressing around flange. . The mounting surfaces must be clean and the mounting bolt tight to maintain a good con- nection between the pump and anode. Out of specification: Replace camshaft Measure camshaft bearing hole inside diameter. Out of specification: Replace piston 15mm 4.