FZ749892 Force DECAL, Front 1991 Maxum Models

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A (1)     9U-6198     Crankshaft Turning Tool     1    
A (2)     9U-7336     Housing     1    
5P-7305 Engine Turning Tool     1    
B     367-8608     Engine Timing Pin     1    
C     298-5564     T40 Torx Socket     1    
D     227-4389     E10 Torx Socket     1    
E     370-4657     Rocker Arm Spacer     6    
( 1 ) The Crankshaft Turning Tool is used on the front pulley.
( 2 ) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02004077
The correct location of valve bridges on valve stems is shown.
Clean valve bridges (6) . Inspect the valve bridges for wear and damage. Replace any valve bridges that are worn or damaged.
Lubricate valve bridges (6) with clean engine oil.
Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.
Install valve bridges (6) to the valve stems.Note: Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation.
Illustration 2 g02004093
Clean the pushrods. Inspect the pushrods for wear and damage. Replace any pushrods that are worn or damaged.
Apply clean engine lubricating oil to both ends of pushrods (9) . Install the pushrods to the engine with the cup upward.Note: Ensure that the pushrods are installed in the original location and that the ball end of each pushrod is correctly seated in the valve lifters.
Illustration 3 g02085993
If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure. Install Tooling (B) through Hole (W) in order to lock the crankshaft.Note: Do not use excessive force to install Tooling (B) . Do not use Tooling (B) to hold the crankshaft during repairs.
Remove Tooling (B) .
Failure to ensure that the crankshaft is positioned at 60 degrees before or after top dead center will cause interference between the pistons and valves. Failure to ensure that the crankshaft is positioned at 60 degrees before or after top dead center will result in damage to the engine.
Use Tooling (A) in order to rotate the crankshaft to 60 degrees before or after top dead center.
Illustration 4 g02003035
Illustration 5 g02307257
Ensure that the rocker shaft assembly is clean and free from wear and damage.
Position the rockershaft assembly with Spotfaces (Y) for Torx screws (7) in the up ward position.
Install Tooling (E) to rocker shaft assembly.
Install Torx screws (7) to the rocker shaft.Note: Ensure that correct Torx screw (7) is installed to Position (X) .