309S67521-0 Tohatsu CARRYING HANDLE

Illustration 1 g02901037
Table 1
Specifications for 417-7902 Connecting Rods, 417-7903 Connecting Rods, 376-4939 Connecting Rods, 376-4938 Connecting Rods, 434-0486 Connecting Rods, and 434-0487 Connecting Rods
Item Qty Part Specification Description
A 1 357-6282 Bushing After installation, bore in bushing for new piston pin is 75.040 0.008 mm (2.9543 0.0003 inch).
Bore in the connecting rod for the bushing is 82.985 0.015 mm (3.2671 0.0006 inch).
B - - Distance between center of bearings is 420 mm (16.54 inch).
C - - After the bolts are tightened, the bore in the connecting rod for the bearing is 150.000 0.013 mm (5.9055 0.0005 inch).
- - - Connecting rod end play is 0.62 to 1.38 mm (0.024 to 0.054 inch).
- - - The 417-7903 Connecting Rods, 376-4939 Connecting Rods, and 434-0487 Connecting Rods are assembled into the odd number cylinder bank of the engine. The chamfer side is facing the fillet radius of the crankshaft. When the marking on the side of the rod indicates "Odd Front", the arrow points to the front of the engine.
- - - The 417-7902 Connecting Rods, 376-4938 Connecting Rods, and 434-0486 Connecting Rods are assembled into the even number cylinder bank of the engine. The chamfer side is facing the fillet radius of the crankshaft. When the marking on the side of the rod indicates "Even Front", the arrow points to the front of the engine.
- - - Careful handling of the connecting rod is required at all times. The fracture face of the connecting rod and the fracture face of the connecting rod cap must not contact any surface. The connecting rod and the connecting rod cap must be laid flat on the sides. When possible, the rod assembly should be kept together in order to protect the fracture face when the connecting rod is out of the engine.
- - - The connecting rod and the connecting rod cap must be marked only with a mechanical etcher with the number of the cylinder. The cylinder number must be etched on the same surface as the part number and the serial number for the connecting rod.
Illustration 2 g03321313
The arrow represents the front of the engine block
(A) Bearing tab side
(3) Odd numbered connecting rod
(4) Even numbered connecting rod
Table 2
Assembly Specifications for Type 2 Connecting Rods with 290-2541 Bolts
Item Qty Part Specification Description
1 6 290-2541 Bolt Use the following procedure to tighten the bolts of the connecting rod:
Apply Bel-Ray Molylube 67700 to the threads and middle rings of bolt and the contact surface under the bolt head.
1. Install bolts (1) and spacers (2). Hand tighten the bolts.
Bolt 1 is identified as the middle bolt on the tab side of the bearing on the connecting rod. Tighten this bolt first to seat the bearing into the bore.
2. Tighten bolt 1 and bolt 2 to 85 5 N m (63 4 lb ft).
3. Tighten bolt 3 and bolt 4 to 85 5 N m (63 4 lb ft).
4. Tighten bolt 5 and bolt 6 to 85 5 N m (63 4 lb ft).
5. Again tighten bolt 1 and bolt 2 to 85 5 N m (63 4 lb ft).
6. Again tighten bolt 3 and bolt 4 to 85 5 N m (63 4 lb ft).
7. Again tighten bolt 5 and bolt 6 to 85 5 N m (63 4 lb ft).
8. Turn bolt 3 and bolt 4 for an additional 90 5 degrees.
9. Turn bolt 5 and bolt 6 for an additional 90 5 degrees.
10. Turn bolt 1 and bolt 2 for an additional 90 5 degrees.
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Table 3
Assembly Specifications for Type 2 Connecting Rods with 428-7386 Bolt As
Item Qty Part Specification Description
1 6 428-7386 Bolt As Use the following procedure in order to tighten the bolts of the connecting rod:
Lubricate each bolt with Bel-Ray Molylube 67700 by fully coating the elastomer rings, threads, and the contact surface under the bolt head.
1. Install all of the bolts into the spacers by pushing and rotating the bolt simultaneously.
Note: Rotating the bolt while pushing will avoid damage to the bolts.
2. Install the bolts into the connecting rod cap by pushing and rotating the bolt simultaneously.
3. Engage the threads by pushing and slowly rotating the bolt. Do not tap the bolt. All six bolts should have the threads engaged before the joint is drawn together on either side. The order of engaging the threads is bolts 1-2-3-4-5-6. Engaging bolt 1 and 2 first helps center the cap to the connecting rod. Once bolts 1 and 2 threads have engaged install the remaining bolts in order.
4. Tighten bolt 1 and bolt 2 to 85 5 N m (63 4 lb ft).
5. Tighten bolt 3 and bolt 4 to 85 5 N m (63 4 lb ft).
6. Tighten bolt 5 and bolt 6 to 85 5 N m (63 4 lb ft).
7. Again tighten bolt 1 and bolt 2 to 85 5 N m (63 4 lb ft).
8. Again tighten bolt 3 and bolt 4 to 85 5 N m (63 4 lb ft).
9. Again tighten bolt 5 and bolt 6 to 85 5 N m (63 4 lb ft).
10. Turn bolt 3 and bolt 4 an additional 90 5 degrees.
11. Turn bolt 5 and bolt 6 an additional 90 5 degrees.
12. Turn bolt 1 and bolt 2 an additional 90 5 degrees.
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