0322987 JOHNSON WASHER, Throttle lever

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1
B 173-5528 Piston Ring Compressor 1
C 8T-3052 Degree Wheel 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Verify correct assembly of the pistons and the connecting rods. Ensure that the etched numbers on the rod and the rod cap are in the correct positions. The etched number on the rod and the rod cap correspond to the cylinder in which it should be installed.
The joint between the connecting rod and the connecting rod cap is produced by fracturing. The connecting rod assembly must be handled with care in order to avoid damage to the mating surfaces. The connecting rod assembly must be replaced if any damage occurs to the mating surfaces. New connecting rod assemblies come with the connecting rod caps bolted on the connecting rod.Use only a soft jawed vise to hold the connecting rod assembly when removing the connecting rod cap bolts. Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod.Failure to use a soft jawed vise and a soft faced hammer may result in damage to the connecting rod assembly.
Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the connecting rod bearings for final assembly.
Remove the connecting rod cap from the connecting rod. If necessary, remove the upper and lower connecting rod bearings from the connecting rod and the connecting rod bearing cap. Install a suitable protective cap on the ends of the connecting rod in order to prevent damage to the fractured faces of the connecting rod.Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.
Apply clean engine oil to the cylinder liner bore, to the piston rings, and to the outer surface of the piston.
Illustration 1 g01144266
Position the piston rings so that the end gaps are located 120 degrees from each other. Install Tooling (B) to compress the piston rings.
Use Tooling (A) to rotate the crankshaft throw to the bottom center. Install the piston and connecting rod in the engine. Ensure that the proper piston and connecting rod are in the corresponding cylinder with the identification mark on the connecting rod on the side that is toward the camshaft.Note: The forged part number on the connecting rod must be installed toward the flywheel end of the engine.
Line up the piston and the connecting rod with the crankshaft. Use a soft faced hammer and tap the piston into the cylinder bore until Tooling (B) comes off the piston.
Illustration 2 g01145042
Before connecting rod (5) comes in contact with the crankshaft, remove the protective caps from the end of the connecting rod and install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in the connecting rod.
Pull the connecting rod assembly onto the crankshaft.
Install the lower half of connecting rod bearing (3) into connecting rod cap (1). Ensure that the bearing tab engages with the slot in the connecting rod cap.
Apply clean engine oil to the surface of the lower half of connecting rod bearing (3). Do not put oil on the back of the connecting rod bearing.Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side to prevent damage to the fractured faces of the connecting rod cap.
Install connecting rod cap (1) and new bolts (2).Note: Fractured split rods utilize torque to yield bolts and therefore those bolts must be replaced anytime the joint is disturbed.Note: The "R" on the connecting rod cap must be installed toward the flywheel end of the engine. Ensure that the number on the connecting rod cap matches the number on the connecting rod, and that the numbers are on the same side.
Illustration 3 g01144320
Tighten connecting rod bolts (2) to a torque of 50 5 N m (37 3 lb ft).
Tighten each connecting rod bolt (2) for an additional 90 5 degrees (1/4 turn).Note: If Tooling (C) is not used, place an index mark on bolt (2) and connecting rod cap (1).
Rotate the crankshaft to ensure that the crankshaft turns freely.End By:
Install the piston cooling jets. Refer to the Disassembly and Assembly Manual, "Piston Cooling Jets - Remove and Install".
Install the engine oil pump. Refer to the Disassembly and Assembly Manual, "Engine Oil Pump - Install".
Install the cylinder head. Refer to the Disassembly and Assembly Manual, "Cylinder Head - Install".