0383960 EVINRUDE RUBBER MOUNT, Upper

ILLUSTRATION Use 5P3519 Piston Ring Groove Gauge to check top and intermediate ring grooves with straight sides. For instructions on the use of the gauge, see the GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. REG01660.(1) 9S2263 Top Ring: Width of groove in piston (new) ... .0995 .0005 in.(2.527 0.013 mm)Clearance between ring and groove ... .0055 to .0073 in.(0.14 to 0.19 mm)Clearance between ends of piston ring installed in liner with bore size of 5.400 to 5.402 in. (137.16 to 137.21 mm) ... .0285 .0075 in.(0.724 .191 mm)(2) 9S2264 Intermediate Ring: Groove width (new) ... .0970 .0005 in.(2.464 0.013 mm)Clearance between ring and groove ... .0030 to .0048 in.(0.076 to 0.122 mm)Clearance between ends of piston ring installed in liner with bore size of 5.400 to 5.402 in. (137.16 to 137.21 mm) ... .0265 .0075 in.(0.673 0.191 mm)(3) 1P708 Oil Control Ring: Groove width (new) ... .2510 .0005 in.(6.375 0.013 mm)Clearance between ring and groove ... .0015 to .0035 in.(0.038 to 0.089 mm)Clearance between ends of piston ring installed in liner with bore size of 5.400 to 5.402 in. (137.16 to 137.21 mm) ... .0225 .0075 in.(0.572 0.191 mm)(4) Bore in piston for pin ... 2.0005 .0002 in.(50.813 0.005 mm) Clerance between pin and bore in piston ... .0003 to .0011 in.(0.008 to 0.028 mm)Maximum permissible clearance (worn) ... .002 in.(0.05 mm)(5) Pin diameter ... 1.9998 .0002 in.(50.795 0.005 mm)(6) Bore in bearing for the piston pin ... 2.0013 .0003 in.(50.833 0.008 mm) Maximum permissible clearance between pin and bore in the bearing (worn) ... .003 in.(0.08 mm)(7) Distance from center of piston pin to center of bearing for crankshaft ... 12.630 .001 in.(320.802 0.025 mm)(8) Clearance between bearing surface of crankshaft (journal) and inside diameter of connecting rod bearing* ... .0028 to .0059 in.(0.071 to 0.150 mm) Bore in bearing for crankshaft bearing surface (journal)* ... 4.3783 to 4.3804 in.(111.209 to 111.262 mm)Maximum permissible clearance of used bearing and worn bearing surface (journal) ... .008 in.(0.20 mm)Bore in connecting rod after tightening connecting rod bolts (9) to the correct torque* ... 4.7205 .0005 in.(119 0.0177 mm)*Bearings are available in .025 in. (0.64 mm) and .050 in. (1.27 mm) smaller than original size and .005 in. (0.13 mm) larger than original size for the outer diameter.(9) Torque for bolts: 1. Put 4S9416 Anti-Seize Compound on bolt thread and bolt head seats.2. First tighten both bolts to ... 90 5 lb.ft.(12.4 0.7 mkg)3. Put a mark on connecting rod and head of each bolt.4. Tighten bolts farther from mark on connecting rod ... 120°After tightening connecting rod bolts; end clearance between bearing caps ... .012 to .021 in.(0.305 to 0.533 mm) Connecting rod bearings in later engines do not have locating tabs but are positioned by dowels in the connecting rods. The rods with dowel located bearings are marked "Even Cyl Only ..." or "Odd Cyl Only ..." These rods must be installed in the correct bank. They may be installed in earlier engines if the correct piston cooling jets are installed. Refer to Special Instruction (GEG02495) for complete instructions.