0388263 EVINRUDE COVER,Air silencer,115,140hp

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-6683 Ring Expander 1
B 1P-1857 Retaining Ring Pliers 1
C 1P-0510 Driver Group 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The connecting rod controls the piston height above the cylinder block. The connecting rod and the piston must be assembled and installed in the correct cylinder. Refer to Testing and Adjusting, "Connecting Rod - Inspect" for the correct procedure on checking the length of the connecting rod.
Illustration 1 g00964649
Use Tooling (C) and a suitable press to install piston pin bushing (4) into connecting rod (5). Note: Ensure that the oil hole in the piston pin bushing is aligned with the oil hole at the top of the connecting rod.
Machine the piston pin bushing in order to obtain a clearance of 0.0330 0.0102 mm (0.0013 0.0004 inch) between the piston pin and the piston pin bushing.
The identification number that is on the top of the piston must be installed with the corresponding connecting rod. Position the piston and the connecting rod so that the identification numbers are located on the same side. Install piston pin (7) into the piston and through connecting rod (5). Note: If the piston pin cannot be installed by hand, heat the piston to a temperature of 45° 5°C (113° 9°F). Do Not use a torch to heat the piston.
Use Tooling (B) in order to install retaining rings (8) that hold the piston pin in position.
Illustration 2 g00888215
Use Tooling (A) in order to install the piston rings on piston (6) with the following steps.
Install the oil control ring (3) in the groove that is lowest on the piston. The latch pin that is on the oil control ring must be inside the ends of the spring. Note: Ensure that the latch pin that is on the oil control ring is 180 degrees from the oil control ring gap.
Install the intermediate compression ring (2) with the tapered face into the second groove on the piston. The stamp "TOP" must be toward the top of the piston. Note: The intermediate compression ring has a step at the bottom of the tapered face.Note: Intermediate compression rings that are new have a green mark which must be on the left of the piston ring gap when the piston ring is installed.
Install the top compression ring (1) into the top groove on the piston. The stamp "TOP" must be toward the top of the piston. Note: Top compression rings that are new have a red mark which must be on the left of the ring gap when the ring is installed.
Position the piston ring gaps at 120 degrees away from each other.
Align the tabs on the connecting rod bearings with the tab grooves on the connecting rod. Install the connecting rod bearing in the connecting rod.
Repeat Steps 1 through 7 in order to assemble the remaining pistons and connecting rods. End By:
Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Install".