90-830234R3
DECEMBER 1997
POWERHEAD - 4-41
CYLINDER BORE SIZE
Piston Size
Cylinder Block Fin-
ish Hone
Standard Diameter
3.501 in.
(88.77mm)
0.015 Oversize
3.516 in.
(89.15mm)
0.030 Oversize
3.531 in.
(89.54mm)
•
Inspect cylinder bores for scoring (a transfer of
aluminum from piston to cylinder wall). Cylinder
wall scoring usually can be “cleaned up” by hon-
ing or reboring.
When reboring cylinder block, remove hone fre-
quently and check condition of cylinder walls.
DO NOT hone any more than absolutely neces-
sary, as hone can remove cylinder wall material
rapidly.
HONING PROCEDURE
•
Follow hone manufacturer’s recommendations
for use of hone cleaning and lubrication during
honing.
IMPORTANT: After honing, bores should be thor-
oughly cleaned with hot water and detergent.
Scrub well with stiff bristle brush and rinse with
hot water. If any abrasive material is allowed to
remain in the cylinder bore, it will cause a rapid
wear of new piston rings and cylinder bore. After
cleaning, bores should be swabbed several
times with 2 cycle engine oil and a clean cloth.
Wipe excess oil with clean, dry cloth. Cylinders
should not be cleaned with kerosene or gasoline.
Clean remainder of cylinder block.
•
Hone all cylinder walls just enough to de-glaze.
•
Measure cylinder bore inside diameter (with an
inside micrometer) of each cylinder, as shown
below. Check for tapered, out-of-round (“egg-
shaped”) and oversize bore.
A
B
C
•
If a cylinder bore is tapered, out-of-round or
worn more than 0.003 in. (0.08mm) from stan-
dard “Cylinder Block Finish Hone” diameter (re-
fer to chart), it will be necessary to rebore that
cylinder(s) to designated oversize bore and
install oversize piston(s) and piston rings during
reassembly.
NOTE: The weight of an oversize piston is approxi-
mately the same as a standard size piston; therefore,
it is not necessary to rebore all cylinders in a block
just because one cylinder requires reboring.
IMPORTANT: Ports must be deburred after hon-
ing.
•
After honing and thoroughly cleaning cylinder
bores, apply 2 cycle outboard oil to cylinder walls
to prevent rusting.
Summary of Contents for 100 FourStroke
Page 5: ...1 A 52485 IMPORTANT INFORMATION SPECIFICATIONS ...
Page 13: ...1 C IMPORTANT INFORMATION GENERAL INFORMATION ...
Page 23: ...1 D IMPORTANT INFORMATION OUTBOARD INSTALLATION ...
Page 37: ...A 2 53970 ELECTRICAL IGNITION ...
Page 81: ...B 2 11669 ELECTRICAL CHARGING AND STARTING SYSTEM ...
Page 108: ...C 2 22480 ELECTRICAL TIMING SYNCHRONIZING ADJUSTING ...
Page 119: ...D 2 ELECTRICAL WIRING DIAGRAMS ...
Page 146: ...A 3 53992 FUEL SYSTEM FUEL PUMP ...
Page 148: ...90 830234R3 DECEMBER 1997 FUEL SYSTEM 3A 1 Notes ...
Page 161: ...B 3 FUEL SYSTEM CARBURETOR ...
Page 190: ...C 3 FUEL SYSTEM OIL INJECTION ...
Page 192: ...90 830234R3 DECEMBER 1997 FUEL SYSTEM 3C 1 Notes ...
Page 211: ...4 20032 POWERHEAD ...
Page 215: ...90 830234R3 DECEMBER 1997 POWERHEAD 4 3 Notes ...
Page 292: ...A 5 MID SECTION CLAMP SWIVEL BRACKETS DRIVE SHAFT HOUSING ...
Page 294: ...90 830234R3 DECEMBER 1997 MID SECTION 5A 1 Notes ...
Page 317: ...5 51485 B MID SECTION POWER TRIM S N USA 0G360002 BEL 9934136 BELOW ...
Page 359: ...C 5 55331 MID SECTION POWER TRIM S N USA 0G360003 BEL 9934137 UP ...
Page 364: ...5C 4 MID SECTION 90 830234R3 DECEMBER 1997 Notes ...
Page 408: ...5 D MID SECTION SHOCK ABSORBER ...
Page 413: ...5 E MID SECTION MANUAL TILT ...
Page 451: ...A 6 791 H LOWER UNIT GEAR HOUSING ...
Page 489: ...6 B LOWER UNIT JET DRIVE ...
Page 491: ...90 830234R3 DECEMBER 1997 LOWER UNIT 6B 1 Notes ...
Page 513: ...A 7 50099 ATTACHMENTS CONTROL LINKAGE THROTTLE SHIFT LINKAGE ...
Page 543: ...7 B ATTACHMENTS CONTROL LINKAGE TILLER HANDLE ...
Page 545: ...90 830234R3 DECEMBER 1997 ATTACHMENTS CONTROL LINKAGE 7B 1 Notes ...
Page 567: ...51605 8 MANUAL STARTER ...
Page 569: ...90 830234R3 DECEMBER 1997 MANUAL STARTER 8A 1 Notes ...