2004 SR Johnson 2 Stroke 9.9, 15, 25, 30 HP Outboards Service Manual, Page 200Get this manual
POWERHEAD ASSEMBLY9.915 Slide the connecting rod with the needle bearings and washer up and off the wrist pin, being careful not to disturb the bearingsPlace the connecting rod and the two wrist pin washers in position in the piston cavity, aligned with the wrist pin boss
IMPORTANT: The piston rings must be correctly
located on their dowel pins to prevent permanent powerhead damageStart the piston into bore of the cylinder with deflector of the piston (sharp edge) toward intake port side of the cylinder block
2 1Wrist pin washer
COB1137
Finish installing the wrist pin through the connecting rod and the piston until the wrist pin contacts the installed retaining ringCheck to be sure none of the needle bearings have been disturbed and pushed out of the connecting rodInstall second new retaining ringInstall piston rings on each pistonTapered ring must be installed in top grooveSpread each ring with ring expander just enough to slip it over the head of the piston and down into placeCoat the piston and cylinder bore with oilPlace the piston in Ring Compressor, PIN 339754, (PIN 339755 for oversize pistons)Make certain that the rings are correctly positioned in their grooves with respect to the dowel pinsDamaged pistons and broken rings may result from imperfect alignment of the ring gap and the dowel pins