BRP US Inc. Technical Publications 250 Sea Horse Drive Waukegan, Illinois 60085 United States † AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of Tyco International, Ltd. † Amphenol is a registered trademark of The Amphenol Corporation. † Champion is a registered trademark of Federal-Mogul Corporation. † Deutsch is a registered trademark of The Deutsch Company. † Dexron is a registered trademark of The General Motors Corporation. † Fluke is a registered trademark of The Fluke Corporation † Frahm is a registered trademark of James G. Biddle Co. † Gasoila is a registered trademark of The Federal Process Corporation. † GE is a registered trademark of The General Electric Company. † GM is a registered trademark of The General Motors Corporation. † Locquic and Loctite are registered trademarks of The Henkel Group. † Lubriplate is a registered trademark of Fiske Brothers Refining Company. † NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc. † NMEA is a registered trademark of the National Marine Electronics Association. † Oetiker is a registered trademark of Hans Oetiker AG Maschinen. † Packard is a registered trademark of Delphi Automotive Systems. † Permatex is a registered trademark of Permatex. † Plastigage is a registered trademark of The Dana Corporation. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. † ThreeBond is a registered trademark of Three Bond Co., Ltd.
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The following trademarks are the property of BRP US Inc. or its affiliates: Carbon Guard™
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DPL™ Lubricant
QuikStart™
Evinrude ®
S.A.F.E.™
Evinrude ® E-TEC ®
S.L.O.W.™
Evinrude ® / Johnson ® XD30™ Outboard Oil
Screw Lock™
Evinrude ® / Johnson ® XD50™ Outboard Oil
SystemCheck™
Evinrude ® / Johnson ® XD100™ Outboard Oil
Triple-Guard ® Grease
Extreme Pressure Grease™
Twist-Grip™
FasTrak™
2+4 ® Fuel Conditioner
Gel-Seal II™
Ultra™ 4-Stroke Outboard Oil
Hi-Vis™ Gearcase Lubricant
HPF XR™ Gearcase Lubricant
Johnson ®
Ultra Lock™
Moly Lube™
Printed in the United States. © 2006 BRP US Inc. All rights reserved. TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
SAFETY INFORMATION Before working on any part of the outboard, read the SAFETY section at the end of this manual. This manual is written for qualified, factory-trained technicians who are already familiar with the use of EvinrudeÂŽ/JohnsonÂŽ Special Tools. This manual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s). This manual uses the following signal words identifying important safety messages.
DANGER Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.
CAUTION Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.
IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety alert signal words mean: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you. It is understood that this manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail. To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual. DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs. Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect. When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction. Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts. If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.
DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Remove propeller before servicing and when running the outboard on a flushing device. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.
WARNING Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa). The motor cover and flywheel cover are machinery guards. Use caution when conducting tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts. During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service. To prevent accidental starting while servicing, twist and remove all spark plug leads. The electrical system presents a serious shock hazard. DO NOT handle primary or secondary ignition components while outboard is running or flywheel is turning. Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system. Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling. Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and causing an explosion. Always work in a well ventilated area. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.
TABLE OF CONTENTS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS . 15 2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 27 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4 IGNITION AND ELECTRICAL . . . . . . . . . . . . . . . . . . . . 53 5 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 6 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 7 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 8 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 9 MANUAL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . 139 10 WIRE/HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . 145 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index–1
4
INTRODUCTION
INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TYPICAL PAGE – A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TYPICAL PAGE – B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 TYPICAL PAGE – C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TYPICAL PAGE – D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5
INTRODUCTION MODELS COVERED IN THIS MANUAL
MODELS COVERED IN THIS MANUAL This manual covers service information on Johnson 2.5 HP 4-Stroke models. Use this manual together with the proper Parts Catalog for part numbers and for exploded views of the outboard, which are a valuable aid to disassembly and reassembly. Model Number
Start
Shaft
Steer
J2R4SUC
Rope
15 in.
Tiller
Identifying Model and Serial Numbers Outboard model and serial numbers are located on the starboard midsection and on the powerhead.
1
Starboard Midsection 1. Model and serial number
005512
1
Powerhead 1. Serial number
6
005513
INTRODUCTION MODEL DESIGNATION
MODEL DESIGNATION
STYLE: J = Johnson E = Evinrude
PREFIX
HORSEPOWER
4-STROKE
MODEL RUN or SUFFIX
B J 2 R 4 SU C DESIGN FEATURES:
MODEL YR:
AP = Advanced Propulsion B = Blue Paint C = Counter Rotation D = Evinrude E-TEC E = Electric Start w/Remote Steering F = Direct-Injection G = Graphite Paint H = High Output J = Jet Drive M = Military P = Power Trim and Tilt R = Rope Start w/Tiller Steering S = Saltwater Edition T = Tiller Steering TE = Tiller Electric V = White Paint W = Commercial Model
I =1 N=2 T =3 R=4 O=5 D=6 U=7 C=8 E=9 S=0 Ex: SD = 2006
7
INTRODUCTION TYPICAL PAGE – A
TYPICAL PAGE – A
Subsection title indicates beginning of the subsection.
Italic subheading above Service Chart indicates pertaining models.
Bold letter indicates liquid product to be applied to a surface
Pay attention to torque specifications. Some units appear as in. lbs. Use appropriate torque.
Exploded view of Service Chart assists in identifying parts and positions
Tightening torque for a fastener.
Indicates list corresponding to applicable letter in exploded view of the Service Chart.
Page Number
8
INTRODUCTION TYPICAL PAGE – B
TYPICAL PAGE – B Section Title Subsection Section Title Title
Model specific illustrations designated with image captions
Products and lubricants italicized
9
INTRODUCTION TYPICAL PAGE – C
TYPICAL PAGE – C
Denotes necessary step or information to prevent damage or control correct procedure
Title in italics indicates a procedure concerning a particular model Title indicates the procedure specific to V4 Models is finished. From this point, this particular procedure concerns V6 Models.
Title indicates from this point, All Models are concerned
10
INTRODUCTION TYPICAL PAGE – D
TYPICAL PAGE – D
Illustration components numbered to correspond to image
Typical illustration for lower pulse hose of V4 or V6 Models
Cross references direct readers to related topics
Section tabs allow for quicker reference when thumbing through manual
11
INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL Units of Measurement
List of Abbreviations
A
Amperes
ABYC
American Boat & Yacht Council
amp-hr
Ampere hour
ATDC
after top dead center
fl. oz.
fluid ounce
AT
air temperature sensor
ft. lbs.
foot pounds
BPS
barometric pressure sensor
HP
horsepower
BTDC
before top dead center
in.
inch
CCA
cold cranking amps
in. Hg
inches of mercury
CPS
crankshaft position sensor
in. lbs.
inch pounds
DI
Direct-Injection
kPa
kilopascals
ECU
electronic control unit
ml
milliliter
EMM
engine management module
mm
millimeter
ICOMIA
N·m
Newton meter
International Council of Marine Industry Associations
P/N
part number
MCA
marine cranking amps
psi
pounds per square inch
MWS
modular wiring system
RPM
revolutions per minute
NMEA
National Marine Electronics Assoc.
°C
degrees Celsius
NTC
negative temperature coefficient
°F
degrees Fahrenheit
PDP
power distribution panel
ms
milliseconds
PTC
positive temperature coefficient
µs
microseconds
ROM
read only memory
Ω
Ohms
S.A.F.E.™ speed adjusting failsafe electronics
V
Volts
SAC
start assist circuit
VAC
Volts Alternating Current
SAE
Society of Automotive Engineers
VDC
Volts Direct Current
S.L.O.W.™ speed limiting operational warning
12
SYNC
synchronization
TDC
top dead center
TPS
throttle position sensor
WOT
wide open throttle
WTS
water temperature sensor
INTRODUCTION PRODUCT REFERENCE AND ILLUSTRATIONS
PRODUCT REFERENCE AND ILLUSTRATIONS BRP US Inc. reserves the right to make changes at any time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts, at any time, without incurring any obligation to equip same on models manufactured prior to date of such change. Specifications used are based on the latest product information available at the time of publication.
SYMBOLS Throughout this service manual, symbols are used to interpret electrical troubleshooting results or to assign values in drawings.
Electrical When “∞” shows on the meter face, no continuity, or very high resistance, is indicated. The symbol is referred to as infinity.
The continuing accuracy of this manual cannot be guaranteed. All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only. Certain features or systems discussed in this manual might not be found on all models in all marketing areas. All service technicians must be familiar with nautical orientation. This manual often identifies parts and procedures using these terms.
Nautical Orientation
DR4203
When “V” follows a value on the meter face, the procedure is measuring voltage.
DR4204
When “Ω” follows a value on the meter face, the procedure is measuring resistance. Ω is the sym-
13
INTRODUCTION SYMBOLS bol for ohm, the unit of measurement for resistance.
When “≥” precedes a value on the meter face, the reading should be greater than, or equal to, the value shown.
DR4205 DR4207
Values When “≤” precedes a value on the meter face, the reading should be less than, or equal to, the value shown.
DR4206
14
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
1
TABLE OF CONTENTS TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUE – IMPORTANT FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUE – GENERAL BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL / IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHOP AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 18 18 19 20 20 21 21 22 22 23 24
15
SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA
FUEL SYSTEM
ENGINE
TECHNICAL DATA HP
2.5
Full Throttle Operating Range RPM
5250-5750
Power
2.5 HP (1.8 kw) @ 5500 RPM
Idle RPM in Gear
1800 to 2000
Weight
30.1 lbs. (14 kg)
Lubrication
Evinrude/Johnson Ultra 4-Stroke outboard oil Refer to Oil Requirements on p. 32.
Engine Type
4-Stroke OHV 1-cylinder
Displacement
4.2 cu. in. (68 cm 3)
Bore
1.89 in. (48 mm)
Stroke
1.50 in. (38 mm)
Compression ratio
9.0:1
Carburetion
One single-throat carburetor, float feed
Main Jet
#70
Pilot Jet
#32
Starting Enrichment
Manual
Float Level Setting
10 ± 2 mm
Preferred Fuel
Regular unleaded, plus grade unleaded, premium unleaded gasolines
Acceptable Fuel
Any of the above gasolines with 10% Ethanol or 5% Methanol with 5% co-solvents
Minimum Octane
87 AKI (R+M)/2 or 90 RON ®
Additives
16
2+4 Fuel Conditioner, Fuel System Cleaner, Carbon Guard Use only Evinrude/Johnson recommended fuel additives. The use of other additives may result in engine damage. See Fuel Requirements on p. 31 for additional information.
GEARCASE
IGNITION
COOLING
SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA HP
2.5
Thermostat opens
118 to 126°F (48 to 52°C)
1 Type
Transistorized
RPM Limit
6500 RPM
Spark Plugs
NGK † CR6HSA @ 0.030 in. (0.76 mm) Gap: 0.024 to 0.028 in. (0.6 to 0.7 mm)
Ignition Timing
30° BTDC
Gear Ratio
13:28 (2.15:1)
Lubricant
HPF XR Gearcase Lube
Capacity
2.0 fl. oz. (60 ml)
17
SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS Tightening Torque – Important Fasteners ITEM Cylinder head cover bolt Cylinder head bolt Crankcase bolt Connecting rod cap bolt Valve adjusting lock nut Intake pipe bolt Carburetor mounting bolt Flywheel nut Igniter unit bolt Engine oil drain plug Powerhead mounting bolt Tiller handle pivot bolt Lower cover bolt Swivel shaft nut Gearcase bolt Water pump case bolt Propeller shaft bearing housing bolt
18
THREAD DIAM. 5 mm 6 mm 6 mm 5 mm 5 mm 6 mm 6 mm 10 mm 6 mm 10 mm 6 mm 8 mm 6 mm 8 mm 6 mm 6 mm 6 mm
N·m 7 13 11 7 7 11 10 45 10 10 10 17 8 10 8 5 8
TIGHTENING TORQUE kg-ft 0.7 1.3 1.1 0.7 0.7 1.1 1.0 4.5 1.0 1.0 1.0 1.7 0.8 1.0 0.8 0.5 0.8
lb-ft 5.0 9.5 8.0 5.0 5.0 8.0 7.0 32.5 7.0 7.0 7.0 12.5 6.0 7.0 6.0 3.5 6.0
SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS
Tightening Torque – General Bolt IMPORTANT: These values apply only when a specific torque for a specific fastener is not listed in the appropriate section. When tightening two or more screws on the same part, DO NOT tighten screws completely, one at a time. THREAD DIAM.
ITEM
(Conventional or “4” marked bolt)
(Stainless steel bolt)
(7 marked or
marked bolt)
5 mm 6 mm 8 mm 10 mm 5 mm 6 mm 8 mm 10 mm 5 mm 6 mm 8 mm 10 mm
TIGHTENING TORQUE N·m kg-ft lb-ft 2–4 0.2 – 0.4 1.5 – 3.0 4–7 0.4 – 0.7 3.0 – 5.0 10 – 16 1.0 – 1.6 7.0 – 11.5 22 – 35 2.2 – 3.5 16.0 – 25.5 2–4 0.2 – 0.4 1.5 – 3.0 6 – 10 0.6 – 1.0 4.5 – 7.0 15 – 20 1.5 – 2.0 11.0 – 14.5 34 – 41 3.4 – 4.1 24.5 – 29.5 3–6 0.3 – 0.6 2.0 – 4.5 8 – 12 0.8 – 1.2 6.0 – 8.5 18 – 28 1.8 – 2.8 13.0 – 20.0 40 – 60 4.0 – 6.0 29.0 – 43.5
WARNING Torque wrench tightening specifications must be strictly adhered to. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.
19
1
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS
SPECIAL TOOLS Electrical / Ignition
Digital multimeter Ohms resolution 0.01 Purchase through local supplier
Ignition analyzer P/N 501890
20
DRC7265
49791
CD Peak reading voltmeter P/N 507972
49799
Multimeter, analog P/N 501873
49793
Spark checker P/N 508118
49798
Tachometer/timing light P/N 507980
49789
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS
Fuel and Oil
1
Fuel/Oil pressure gauge P/N 5000902
002275
Fuel vacuum tester P/N 390954
23286
Oil pressure test adapter P/N 350930
002623
Universal pinion bearing remover and installer kits P/N 5005927 and P/N 5005928
33974
Installer handle P/N 345822
002575
Prop shaft remover P/N 5034237
002630
Gearcase
Gearcase filler P/N 501882
49790
Gearcase pressure tester P/N 507977 (Stevens P/N S-34) Gearcase vacuum tester P/N 507982 (Stevens P/N V-34)
49794
Dial indicator set
Gearcase fill/drain adapter P/N 5037486
005517
Gearcase fill/drain adaptor P/N 772269
48642
21
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS
Powerhead
Crankshaft holder P/N 5034236
002587
Compression gauge adapter P/N 5037485
005515
Crankshaft upper seal remover/installer kit P/N 391060 (9.9-15 HP)
Cylinder bore gauge P/N 771310
45303
Valve lifter adapter kit P/N 5000899
Tappet adjusting tool P/N 341444
38202
Valve spring compressor P/N 346186
23102
Starter
Starter rope threading tool P/N 387784
22
23682
Starter spring winder/installer P/N 392093
CO3583
002625
DRC50025
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS
Universal
1
Puller Bridge P/N 432127
23146
Slide hammer P/N 391008
CO1577
Puller jaws (small) P/N 432131 (replacement jaws P/N 437952)
23150
Slide hammer P/N 432128
15345
Puller jaws (large) P/N 432129 (replacement jaws P/N 437954)
23148
Tie strap installation tool P/N 323716
18105
Puller jaws (bearing) P/N 432130 (replacement jaws P/N 437953)
23149
Temperature gun P/N 772018
45240
(
Universal Puller Set P/N 378103
32885
23
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS
SHOP AIDS
Cleaning Solvent P/N 771087
Engine Tuner P/N 777185
Anti-Corrosion Spray P/N 777193
“6 in 1” Multi-Purpose Lubricant P/N 777192
D.P.L. Spray P/N 777183
Silicone spray P/N 775630
Ultra 4-Stroke Outboard Oil, P/N 775594
4-Stroke Outboard Oil, P/N 775597
HPF PRO™ Gear Lube P/N 778755
HI-VIS™ Gearcase Lube P/N 775605
Triple-Guard® Grease P/N 508298
Extreme Pressure Grease™ P/N 508303
24
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS
1
Moly Lube P/N 175356
Needle Bearing Grease, P/N 378642
Starter Bendix Lube P/N 337016
Storage Fogging Oil P/N 777186
Power Trim/Tilt and Power Steering Fluid P/N 775612
Adhesive 847 P/N 776964
Lubriplate† 777 P/N 317619
Black Neoprene Dip P/N 909570
Electrical Grease P/N 504824
2 + 4™ Fuel conditioner P/N 775613
Fuel System Cleaner P/N 777184
Carbon Guard™ P/N 775629
25
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS
Gasket Sealing Compound P/N 317201
ThreeBond† 1104, P/N 351052 ThreeBond 1207B, P/N 351053
Permatex† No. 2, P/N 910032
GE† RTV Silicone Sealant P/N 263753
Pipe Sealant with Teflon P/N 910048
Thermal Joint Compound P/N 322170
GM† Gear Mark Compound P/N 772666
Locquic Primer P/N 772032
1
2
1. Screw Lock P/N 500417 (Loctite† Purple 222 equivalent 2. Nut Lock P/N 500421 (Loctite Blue 242 Equivalent) 3. Ultra Lock P/N 500423 (Loctite Red 271 Equivalent)
26
3
INSTALLATION AND PREDELIVERY
INSTALLATION AND PREDELIVERY TABLE OF CONTENTS HULL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAXIMUM CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOUNTING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOP EDGE OF TRANSOM OR BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSOM CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOUNTING HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSOM MEASURING AND DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HULL CENTERLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSOM HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSOM DRILLING LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTBOARD MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RUNNING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BREAK-IN (10 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTBOARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . START-IN-GEAR PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP OVERBOARD INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER HARDWARE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 28 28 28 28 28 28 29 29 29 29 30 30 31 31 32 33 33 34 34 34 34 34 34 35 35 36
27
2
INSTALLATION AND PREDELIVERY HULL PREPARATION
HULL PREPARATION
Top Edge of Transom or Bracket
Maximum Capacity WARNING Do not overpower the boat by installing an outboard that exceeds the horsepower indicated on the boat’s capacity plate. Overpowering could result in loss of control. Before installing outboard: • Refer to the boat manufacturer's certification label for maximum horsepower rating. • Refer to ABYC Standards to determine the maximum horsepower capacity for boats without certification labeling.
Transom thickness or off-sets must also be considered. The top edge of the transom or bracket must provide a proper surface for stern brackets. The stern brackets must contact the flat surface of the transom or bracket. Modify moldings or components that prevent the stern brackets from resting against the transom surface. Do not modify transom brackets.
Transom Clearances Make sure the transom and splash well area provide adequate clearances. • The top edge of the transom should be wide enough to allow full steering travel. The ABYC standard for most single outboard installations is 33 in. (84 cm). • Check cable and hose routing clearances. • Make sure there is clearance for mounting bolts and washers. Check the inside area of the transom for obstructions prior to drilling holes.
Water Flow
1029A
Mounting Surface Inspect transom surface prior to drilling mounting holes. • The transom should meet ABYC Standards. • The transom must be flat and cannot have any protrusions. • The transom angle should be approximately 14 degrees. • Check transom strength and height.
WARNING DO NOT install an outboard on a curved or irregular surface. Doing so can wear, bind, and damage components, causing loss of control.
28
Inspect the hull area directly in front of the mounting location. • Boat-mounted equipment should not create turbulence in the water flow directly in front of the outboard's gearcase. Turbulence or disruptions in the water flow directly in front of the gearcase will affect engine cooling and propeller performance.
Mounting Hardware WARNING Use all mounting hardware supplied with the outboard to help ensure a secure installation. Substituting inferior hardware can result in loss of control.
INSTALLATION AND PREDELIVERY TRANSOM MEASURING AND DRILLING
TRANSOM MEASURING AND DRILLING Hull Centerline Locate the centerline of the boat transom as it relates to the hull (bottom) of the boat. Use a straightedge to draw a line connecting the port and starboard chines. The chines should be used as reference points for determining the centerline of the hull. Use a framing square to accurately place a line on the transom. The centerline of the hull should be in line with the keel of the hull and perpendicular to the midpoint of the line connecting the port and starboard chines.
Transom Heights Make sure the transom height is consistent with the height of the outboard to be installed. • A 19 to 21 in. (48.3 to 53.3 cm) transom height uses a 20 in. (50.8 cm) shaft outboard. • The shaft length of the outboard being installed should come close to matching the transom height of the boat. Determine transom height by measuring from the top edge of the transom, along the centerline. Use a straightedge as a reference to extend the bottom of the boat. Position the straightedge along centerline. The distance from the top edge of the straightedge to the top edge of the transom is the actual transom height. 1
2
1 1. 2. 3. 4.
Chine Strake Keel Hull centerline
2
3
1. Top edge of transom 2. Actual transom height
4
DR5541
DR5568
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2
INSTALLATION AND PREDELIVERY OUTBOARD MOUNTING
Lifting the Outboard
OUTBOARD MOUNTING
Lift the outboard using the lift grips (NOT the tilt grip or steering handle) and place it in the center of the boat’s transom.
Fastening the Outboard to the Transom WARNING The outboard must be correctly installed. Failure to correctly install the outboard could result in serious injury, death, or property damage.
1 TYPICAL 1. Lift grips
1 DR4661
Before Mounting Outboard to Transom Some rigging components that attach directly to the outboard should be assembled before the outboard is mounted to the boat's transom. Steering system components and gearcase speedometer pickup hoses are the most common. Determine what equipment will be installed prior to mounting the outboard to the transom or bracket.
30
IMPORTANT: Follow all directions carefully. The outboard’s warranty will not cover product damage or failure resulting from incorrect outboard installation. WARNING Even if equipped with clamp screws, the outboard must be bolted to the boat to prevent it from “working off the transom” during operation. Center the outboard on the boat’s transom (or mounting bracket) and tighten the clamp screws by hand, NOT with tools. An accessory transom plate is recommended to protect the boat’s transom (or mounting bracket).
INSTALLATION AND PREDELIVERY FUEL AND OIL WARNING If either side of the transom deforms or cracks when the bolts are tightened to their recommended torque, the transom construction may not be adequate or may be deteriorated. Structural failure of the transom could result in loss of boat control and injury to the occupants.
IMPORTANT: • Use a marine sealant rated for above or below waterline use. RTV silicone is not approved for below waterline use. Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces when removed. • After 30 minutes of operation, retighten clamp screws by hand. DO NOT use tools to tighten clamp screws. Check clamp screws regularly.
FUEL AND OIL Fuel Requirements WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Improper handling of fuel could result in property damage, serious injury or death. Always turn off the outboard before fueling. Never permit anyone other than an adult to refill the fuel tank. Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun. Remove portable fuel tanks from the boat before fueling. Always wipe off any fuel spillage. Do not smoke, allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.
Minimum Octane Evinrude/Johnson outboards are certified to operate on unleaded automotive gasoline with an octane rating equal to or higher than: • 87 (R+M)/2 AKI, or • 90 RON Use unleaded gasoline that contains methyl tertiary butyl ether (MTBE) ONLY if the MTBE content does not exceed 15% by volume. Use alcohol-extended fuels ONLY if the alcohol content does not exceed: • 10% ethanol by volume • 5% methanol with 5% cosolvents by volume
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2
INSTALLATION AND PREDELIVERY FUEL AND OIL When using alcohol-extended fuels, be aware of the following: • The boat’s fuel system may have different requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide. • Alcohol attracts and holds moisture that can cause corrosion of metallic parts in the fuel system. • Alcohol blended fuel can cause engine performance problems. • All parts of the fuel system should be inspected frequently and replaced if signs of deterioration or fuel leakage are found. Inspect at least annually.
Oil Requirements IMPORTANT: 4-Stroke outboards are shipped without oil in the crankcase. Oil must be added before starting the engine for the first time.
IMPORTANT: During the initial 10-hour break-in period, use Evinrude/Johnson 4-Stroke Outboard Oil or SAE 10W-40, API SE, SF, SG, SH, or SJ rated. DO NOT use synthetic or synthetic blend oils during break-in period. Evinrude/Johnson Ultra™ 4-Stroke synthetic outboard oil is recommended for normal use in these outboards after break-in.
IMPORTANT: Always use fresh gasoline. Gasoline will oxidize, resulting in loss of octane and volatile compounds, as well as the production of gum and varnish deposits which can damage the outboard.
If Ultra 4-Stroke oil is not available, you must use SAE 10W-40, API SE, SF, SG, SH, or SJ rated.
Additives
dation could void the outboard warranty if a lubrication-related failure occurs.
IMPORTANT: The only fuel additives approved ®
for use in Evinrude outboards are 2+4 fuel conditioner and Evinrude/Johnson Fuel System Cleaner. Use of other fuel additives can result in poor performance or engine damage. Evinrude/Johnson 2+4 Fuel Conditioner will help prevent gum and varnish deposits from forming in fuel system components and will remove moisture from the fuel system. It can be used continuously and should be used during any period when the outboard is not being operated on a regular basis. Its use will reduce spark plug fouling, fuel system icing, and fuel system component deterioration. Evinrude/Johnson Fuel System Cleaner will help keep fuel injectors in optimal operating condition. Evinrude/Johnson Carbon Guard will minimize carbon deposit build-up when used as directed.
32
IMPORTANT: Failure to follow this recommen-
If SAE 10W-40 motor oil is not available, select an alternative according to the following chart:
Engine Oil
Temperature
004813
INSTALLATION AND PREDELIVERY RUNNING CHECKS
RUNNING CHECKS WARNING DO NOT run outboard without a water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur.
DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.
DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.
Break-In (10 Hours) Follow this procedure to protect the outboard during its initial hours of operation. Careful break-in allows internal engine components to seat properly, resulting in maximum engine life and performance. Failure to carefully follow the break-in procedures can result in engine damage.
IMPORTANT: DO NOT perform break-in using a flushing device. DO NOT start-up or run the engine out of water. DO NOT leave a running engine unattended. During the break-in, check water pump operation often. Look for a steady stream of water from the water pump indicator. If the stream of water stops, shut off the engine to prevent damage. Find and correct the cause before continuing. Change the RPM often. Avoid holding a throttle setting longer than 15 minutes. Check the crankcase oil level often. Add oil if needed. First 10 minutes of operation — Operate engine in gear at idle only. Balance of First 2 hours of operation — Operate in gear below 3000 RPM or 1/2 throttle only. With easy planing boats, use full throttle to quickly accelerate boat onto plane. Immediately reduce throttle to one-half as soon as the boat is on plane. BE SURE boat remains on plane at this throttle setting. Third hour of operation — Run the engine in gear at various speeds up to 4000 RPM or 3/4 throttle only. Balance of first 10 hours of operation — Run the engine in gear at various engine speeds including full throttle, but remain at full throttle no longer than 5 minutes. Change the engine speed every 15 minutes. DO NOT exceed recommended maximum engine RPM. Refer to TECHNICAL DATA on p. 16.
Perform the 10-Hour break-in procedure with the boat and engine in the water, using an appropriate propeller.
33
2
INSTALLATION AND PREDELIVERY RUNNING CHECKS
Fuel System
Water Pump Overboard Indicator
Perform running checks of the fuel system by following these steps: • Start outboard. Visually inspect all oil hoses and connections and fuel hoses and connections. Repair any leaks or misrouted hoses.
A steady stream of water should flow from the overboard indicator.
Emergency Stop Switch 1
Check emergency stop function. With outboard running at IDLE, pull safety lanyard from emergency stop switch. Outboard must stop immediately.
Outboard Controls Confirm that controls can be easily moved into all gear and throttle settings. Do not shift outboard when propeller shaft is not turning.
Start-In-Gear Prevention WARNING Make certain that the starter will not operate when the outboard is in gear. The startin-gear prevention feature is required by the United States Coast Guard to help prevent personal injuries. Start outboard and shift outboard into FORWARD. Turn outboard OFF while lever is in FORWARD. Attempt to restart the outboard. Outboard should not start.
34
1. Water pump overboard indicator
DRC4952
Operating Temperature An outboard running at idle speed should achieve a temperature based on the engine’s thermostatic control. In general, the powerhead temperature should reach at least 100°F (38°C) after five minutes of idling. Confirm that the powerhead reaches idle temperature.
INSTALLATION AND PREDELIVERY PROPELLER SELECTION
PROPELLER SELECTION Refer to Propeller Hardware Installation on p. 36 before installing propeller. The correct propeller, under normal load conditions, will allow the engine to run near the midpoint of the RPM operating range at full throttle. Refer to TECHNICAL DATA on p. 16.
5 1
3
6 2
7
Procedure The propeller selection process is very important to the engine’s service life and to boat performance. Proceed carefully and thoroughly while considering the following points: • During the engine break-in period, run the outboard at wide-open throttle for only brief periods of time to check full-throttle RPM. • Use an accurate tachometer to determine the engine’s full-throttle RPM while testing various propellers. • Select a propeller that suits the customer’s application and allows the engine to run near the midpoint of the full-throttle operating range when the boat has a normal load in it. Refer to TECHNICAL DATA on p. 16. • To compensate for changes in boat loading, the engine’s full-throttle RPM must be verified periodically.
IMPORTANT: If the propeller blades have too 4
1. 2. 3. 4. 5.
Percentage of horsepower (kw) Engine RPM Horsepower curve Full throttle operating range Midpoint of full throttle operating range, horsepower rating in kilowatts (kw)) 6. Engine is overloaded at full throttle 7. Engine is overspeeding at full throttle
DR1261
CAUTION Selection of the wrong propeller could reduce engine service life, affect boat performance, or cause serious damage to the powerhead.
much pitch, the engine is operating below its normal range at full throttle, power is being lost, and powerhead damage could occur. If the propeller blades have too little pitch, the engine is operating above its normal range at full throttle and damage from overspeeding could occur.
WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally.
35
2
INSTALLATION AND PREDELIVERY PROPELLER SELECTION
Propeller Hardware Installation WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally. Apply Triple-Guard grease to the entire propeller shaft before installing the propeller. Install shear pin onto propeller shaft. Install propeller on propeller shaft. Install the cotter pin through the propeller shaft, then bend its ends to secure the propeller.
1. Shear pin 2. Propeller 3. Cotter pin
005947
IMPORTANT: After fastening cotter pin, make sure outboard is in NEUTRAL and carefully spin propeller. Propeller must turn freely and should not spin off center. If propeller appears to wobble, check for possible bent propeller shaft.
36
MAINTENANCE
MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-HOUR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SACRIFICIAL ANODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING PROCEDURE – CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METALLIC COMPONENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTERIOR FINISHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER INTAKE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BREATHER AND FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINKAGES AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 40 40 40 41 41 41 42 42 42 42 43 43 43 43 43 43 44 45 46 46 46 47 48 49 50 50 50 50 51 51 51 51 51 51
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3
MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE
INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outboard inspection and maintenance to be performed by an authorized Dealer.
IMPORTANT: Outboards used for rental operations, commercial applications, or other high hour use applications require more frequent inspections and maintenance. Inspection and maintenance should be adjusted according to operating conditions and use; and environmental conditions. .
Engine Maintenance and Inspection Schedule
Every 200 Hours or Biannually
Every 100 Hours or Annually
Every 50 Hours or 6 months
Description
10-Hour Inspection
Engine Care Product
Each Use
Frequency
Swivel bracket, inspect and lubricate (1)
D
Every 60 days / Every 30 in Saltwater
Clamp screws, inspect and lubricate (1)
D
Every 60 days / Every 30 in Saltwater
D
Every 60 days / Every 30 in Saltwater
D
Every 60 days / Every 30 in Saltwater
D
Every 60 days / Every 30 in Saltwater
A
Every 60 days / Every 30 in Saltwater
Throttle linkage, inspect and lubricate
(1)
Steering bracket, lubricate (1) Shift lever, lubricate
(1)
Lubrication and corrosion protection for metallic components Anticorrosion anodes, check operation Water intake screens, check condition Overboard water pump indicator, check operation Steering friction, check/adjust Throttle and shift operation, check function Emergency stop circuit and lanyard, check function Clamp screws, tighten Starter, inspect cord Crankcase oil level, check
H
Flush cooling system Operator’s Guide, onboard Fuel system components, inspect and repair leaks (3)
Thermostat, inspect and check operation Fuel filter inspection, eliminate contamination Electrical and ignition wires and connections, inspect
Powerhead synchronization and linkage, inspect
38
B (3)
3 3 3 3 3 3 3 3 3
3 3 3 3 3
Fastener inspection, tighten loosened components
Gearcase lubricant, replace
3 3 3 3 3 3 3 3 3 3 3
D
3 3
3 3 3 3 3 3 3
MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE Engine Maintenance and Inspection Schedule
Crankcase oil, replace (2)
H
Oil filter, replace Valve tappet clearance, inspect (3) Engine upper and lower motor covers, clean and wax Starter pinion shaft, inspect and lubricate
F
Gearcase lubricant, inspect fill level and condition of lube
B
Propeller shaft, inspect and lubricate
D
Spark plugs, replace
3 3 3
Every 200 Hours or Biannually
3 3 3
G
Operator’s Guide, review Breather and fuel line, replace Carburetor, inspect Driveshaft splines, inspect and lubricate
3
3 3 3
(3)
Decarbonize
Every 100 Hours or Annually
Every 50 Hours or 6 months
Description
10-Hour Inspection
Engine Care Product
Each Use
Frequency
E
Fuel filter, replace Ignition timing, inspect Water pump, inspect and replace
3 3 3 3 3 3 3 3 3 3
(1) Also recommended at 10-Hour Inspection (2) Replace every 100 hours or annually if Ultra 4-Stroke oil is not used. (3) Emission-related component
A B C D E F G H
Evinrude/Johnson Anti-Corrosion Spray or Evinrude/Johnson “6 in 1” Multi-Purpose Lubricant HPF XR Gearcase Lubricant Power Trim/Tilt and Power Steering Fluid Triple-Guard Grease Evinrude/Johnson Moly Lube Starter Bendix Lube Only Evinrude/Johnson Engine Tuner Evinrude/Johnson Ultra 4-Stroke synthetic blend oil
39
MAINTENANCE 10-HOUR INSPECTION
10-HOUR INSPECTION IMPORTANT: All Johnson outboard owners are encouraged to return their new engines to an authorized dealer for a mechanical check. This check should be performed after approximately 10 operating hours. The cost of this check should be figured at local dealer labor rates and paid for by the engine owner. The 10-hour inspection should check: • Anticorrosion anodes functionality • Water intake screens • Overboard water pump indicator • Steering operation • Throttle and shift operation • Emergency stop circuit and lanyard functionality • Fuel system components, repair any leaks • Fuel filter, eliminate any contamination • Fasteners, tighten loose components • Thermostat operation • Engine to transom mounting hardware • Electrical and ignition wires and connections
ANTI-CORROSION PROTECTION Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to protect the underwater metal components of the outboard from galvanic corrosion. Outboards are equipped with sacrificial anodes.
1
1. Gearcase housing anode
005882
Powerhead Anode
005883
Visually inspect anodes and metal components below water level. Erosion of anodes is normal and indicates the anodes are functioning properly.
IMPORTANT: Anodes that are not eroding may indicate that the anodes are not properly grounded. Anodes and the mounting screws must be clean and tight for effective corrosion protection.
40
MAINTENANCE ANTI-CORROSION PROTECTION For best anode performance: • Replace all anodes that have eroded or disintegrated to two-thirds of their original size. • Do not paint or apply protective coatings to anodes or anode fasteners. • Avoid using metal-based antifouling paint on the boat or outboard.
IMPORTANT: The anode securing should be covered with silicone sealant.
screw
Metallic Component Protection Protect metal components on outboards from corrosion. Use the following products to minimize corrosion. • Anti-Corrosion Spray provides a heavy, waxy coating to protect components. • “6 in 1” Multi-Purpose Lubricant provides a thin film of anti-corrosion protection.
Exterior Finishes Maintain the outboard’s exterior finish to prevent corrosion and reduce oxidation. • Use automotive wax to protect the outboard’s exterior finish from oxidation. • Clean regularly using clean water and mild detergent soap. • Touch-up damage to painted surfaces promptly. • Protect moving components with appropriate lubricants.
1. Anode 2. Silicone sealant
004779
Testing Procedure – Continuity Calibrate multimeter on “HIGH” ohm scale. Connect meter leads between engine ground and anode surface. The multimeter should indicate little or no resistance. If resistance is high, check the following: • Remove the anode and clean the area where the anode is installed. • Clean the mounting screws. • Install the anode and test again.
41
3
MAINTENANCE COOLING SYSTEM
COOLING SYSTEM Check the condition of cooling system components regularly. The outboard cooling system consists of: • water intake screens • overboard water pump indicator • water pump • all internal water passages • thermostat
IMPORTANT: To prevent damage, do not run outboard above fast idle. Water must flow from the water pump indicator. If it does not, shut off the outboard and repair as needed. Shut OFF the outboard. Leave the outboard in VERTICAL (DOWN) position long enough for the water to drain from the powerhead completely.
Flushing 1
Flush the outboard with fresh water following each use in brackish, salt, or polluted water to minimize the accumulation of scale and silt deposits in cooling system passages.
WARNING Prevent injury from contact with rotating propeller; remove the propeller before flushing.
1. Water pump indicator
005884
Remove outboard from tank and install propeller.
Procedure
Water Intake Screen
Remove propeller and shift the outboard to NEUTRAL.
Inspect condition of water intake screen. Clean or replace as needed.
Run the outboard in a large container of water, such as a 30-gallon garbage can. If needed, insert a board between the rim of the can and the outboard’s clamp screws for thickness. Be sure water covers the water intakes.
1
1. Water intake screen
005885
Water Pump Inspect water pump every 200 hours of operation. Refer to Water Pump on p. 127. TYPICAL
dr6434
START outboard. Run outboard at IDLE only for at least five minutes.
42
MAINTENANCE FUEL SYSTEM
FUEL SYSTEM
LUBRICATION
Breather and Fuel Line
Engine Oil
If leakage, cracks, swelling, or other damage is found, replace the breather and/or the fuel line.
Refer to INSPECTION AND MAINTENANCE SCHEDULE on p. 38 for oil change schedule.
IMPORTANT: Engine oil should be changed while engine is warm.
3
Place outboard upright on a level surface. Remove the oil filler cap.
005886
Fuel Filter If water accumulation, sediment, leakage, cracks, or other damage is found, replace the fuel filter.
1
1. Oil filler cap
005888
Place a container under engine oil drain plug (underside of lower engine cover), then remove plug and gasket to drain engine oil.
005887
1
Carburetor If damage is found, replace the carburetor.
1. Oil drain plug
005889
Install new gasket and oil drain plug. Tighten plug to 7 ft. lbs. (10 N¡m).
IMPORTANT: Do not re-use gasket once removed. Always use a new gasket.
005945
43
MAINTENANCE LUBRICATION Pour recommended oil into oil filler opening, then install filler cap.
Gearcase Lubricant
Recommended oil: • Evinrude/Johnson Ultra 4-Stroke oil, or • SAE 10W-40, API classification SE, SF, SG,
gearcase lubricant prior to removing drain/fill plug. A tie strap can be used to check lubricant level.
IMPORTANT: Always check the fill level of the
SH, SJ.
Oil amount: • Oil change only: 0.33 Qt. (0.38 L) Start the engine and allow it to run for several minutes at idle speed. Turn off engine and wait for approximately two minutes. Check oil level.
1 TYPICAL 1. Tie strap
Oil level window
000072
Examine drained lubricant for excessive metal fragments and for any indication of water in oil (cloudy or milky appearance). Lubricant that is black in color with a burnt odor indicates worn, overheated oil. Pressure and vacuum check gearcases with apparent leaks. Repair all leaks. Refer to INSPECTION AND MAINTENANCE SCHEDULE on p. 38 for service frequency and recommended lubricants. 005890
Oil level should be between full level and low level in the oil level window.
Refer to LUBRICANT on p. 122 for complete gearcase lubricant filling procedures.
004363
44
MAINTENANCE LUBRICATION
Linkages and Fittings Apply Triple-Guard grease to the points shown.
3 Throttle cable
Swivel bracket
Clamp screws
Propeller shaft
WARNING When servicing the propeller, always shift the outboard to NEUTRAL position, and twist and remove all spark plug leads so the engine cannot be started accidentally.
45
MAINTENANCE SPARK PLUG
SPARK PLUG
VALVE CLEARANCE
The spark plug should be removed and examined periodically. Replace worn, fouled or damaged spark plug. • Remove spark plug and inspect condition. • Set spark plug gap on new, replacement spark plug. • Apply Electrical Grease to the ribbed portion of the spark plug ceramic and to the opening of the spark plug cover to prevent corrosion.
Measurement Remove engine cover. Remove recoil starter. Refer to starter REMOVAL on p. 141. Remove spark plug. Remove four screws and cylinder head cover.
Recommended spark plug and gap setting:
• NGK CR6HSA @ 0.026 in. (0.65 mm). 1
Tighten spark plug 8 ft. lbs. (11 N·m).
2
1. Screw (4) 2. Cylinder head cover
005895
005896
Rotate the flywheel clockwise to bring the piston to Top Dead Center (TDC) on compression stroke.
IMPORTANT: Rotate the crankshaft in the normal running direction only (clockwise) to prevent water pump impeller damage. To confirm whether the piston is at the TDC position on a compression stroke or on a exhaust stroke, rotate the flywheel within ±15° beyond the TDC position: • If both rocker arms do not move at all, the piston is at the position on a compression stroke. • If any rocker arm moves, the piston is at the TDC position on an exhaust stroke. Rotate the flywheel one more turn.
IMPORTANT: The piston must be at its TDC position on a compression stroke to check or adjust valve clearance.
46
MAINTENANCE VALVE CLEARANCE Use a feeler gauge to measure clearance between valve stem end and valve adjusting screw on rocker arm. valve clearance
Adjustment Loosen the valve adjusting lock nut while holding the valve adjusting screw. Turn valve adjusting screw using to bring valve clearance within specification.
3 1 005897
2
Valve clearance: (cold engine) • IN: 0.005 to 0.007 in. (0.13 to 0.17 mm) • EX: 0.005 to 0.007 in. (0.13 to 0.17 mm)
1. Lock nut 2. Adjusting screw
If measurement is out of specification, adjust valve clearance.
IMPORTANT: The valve clearance specification is for COLD engine condition.
005899
Tighten valve adjusting lock nut while holding valve adjusting screw. Tighten lock nut to 5 ft. lbs. (7 N·m).
005900 005898
Recheck valve clearance.
47
MAINTENANCE IDLE SPEED Tighten the four cylinder head screws to 5 ft. lbs. (7 N¡m).
Untie the knot in grip holder and remove the grip holder and starter grip.
1
1. Screw (4)
005896
IMPORTANT: Do not re-use gasket once removed. Always use a new gasket.
005942
Completely remove the engine cover. Reinstall the starter grip and grip holder. Loosen the knot previously tied in the rope.
IDLE SPEED Check throttle link mechanism and carburetor throttle valve for smooth operation. The starter grip must be removed before the engine cover can be completely removed. Tie a knot in the rope inside the engine cover in order to prevent the rope from winding onto the recoil reel when the starter grip is removed.
005943
Connect a shop tachometer to the engine.
005902
005901
48
MAINTENANCE IGNITION TIMING Start and warm the engine.
IGNITION TIMING
Engine idle speed: • 1800 to 2000 RPM
IMPORTANT: Before checking ignition timing, make sure idle speed is adjusted within specification.
IMPORTANT: Check and/or adjust idle speed after the engine speed has stabilized.
Start and warm the engine.
If idle speed is out of specification, adjust as follows:
Connect a shop tachometer and timing light to the engine.
Turn the throttle stop screw: • Clockwise: Engine speed increases • Counterclockwise: Engine speed decreases.
Check the ignition timing while operating the engine at 1900 RPM (idle speed). Ignition timing: • 30° BTDC @ 1900 RPM
1 1. Throttle stop screw
005944 005946
49
3
MAINTENANCE STORAGE
STORAGE WARNING To prevent injury from contact with rotating propeller, remove the propeller before flushing.
IMPORTANT: DO NOT start outboard without a water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur.
Fuel System Treatment Stabilize the boat’s fuel supply with Evinrude/Johnson 2+4 Fuel Conditioner following the instructions on the container. START outboard and RUN at IDLE speed for five minutes to ensure that the entire fuel system is filled with the storage mixture. Proceed with Internal Engine Treatment.
Internal Engine Treatment Check level and condition of crankcase oil. Change oil and filter if required. Refer to INSPECTION AND MAINTENANCE SCHEDULE on p. 38. Use Evinrude/Johnson Storage Fogging Oil to prevent corrosion of internal engine components during periods of storage. Remove spark plugs and spray a liberal amount of Evinrude/Johnson Storage Fogging Oil into the spark plug hole.
50
Turn the flywheel in a clockwise direction to distribute the fogging oil throughout the cylinder. Install and torque the spark plug.
IMPORTANT: DO NOT restart outboard until it goes back into service. If the outboard is removed from boat, examine all loosened and removed hardware. Replace damaged or missing parts with genuine Evinrude/Johnson parts or equivalent.
Additional Recommendations • • • • • •
Replace gearcase lubricant. Remove and inspect propeller. Clean and grease propeller shaft. Lubricate all grease fittings and linkages. Clean or replace fuel filter element. Inspect outboard. Replace all damaged and worn components. Refer to manufacturer’s maintenance and lubrication recommendations. • Touch up painted surfaces as needed. Coat outer painted surfaces with automotive wax. • Store outboard in upright (vertical) position. • Check for fuel leakage.
WARNING Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.
MAINTENANCE PRE-SEASON SERVICE
PRE-SEASON SERVICE
SUBMERGED ENGINES
If the outboard was removed from the boat for storage, make certain it has been reinstalled with factory specified hardware.
Once an outboard has been submerged in fresh or salt water, it must be serviced within three (3) hours of recovery. Immediate service can minimize the corrosive affect that air has on the polished surfaces of the crankshaft, connecting rods, and internal powerhead bearings.
Crankcase Oil • Check oil level • Add oil as needed
Gearcase Lubricant • Check the lubricant level. • Inspect gearcase for leaks. If leak is apparent, pressure and vacuum test gearcase. • Repair gearcase as needed.
Operational Checks • Steering • Throttle and shift • All other accessories
Fuel System • Inspect entire fuel system for leaks prior to starting outboard. Repair all leaks.
• Start outboard and reinspect. WARNING Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.
IMPORTANT: If outboard cannot be started or serviced immediately, it should be resubmerged in fresh water to avoid exposure to the atmosphere.
Engine Dropped Overboard (Not Running) Disconnect battery cables at the battery. Rinse powerhead with clean water. Remove spark plug leads and spark plugs. Place outboard in horizontal position (cylinder heads down). Slowly rotate flywheel in a clockwise rotation to work all water out of powerhead.
IMPORTANT: If sand or silt may have entered the outboard, DO NOT attempt to start the it. Disassemble and clean. Place engine in upright position. Drain, disassemble, and clean carburetor. Disassemble all electrical connectors. Clean connectors and terminals, and treat with water displacing electrical spray. Apply Electrical Grease to terminals prior to reassembly. Coat all exposed solenoid terminals and engine grounds with Black Neoprene Dip. Clean and inspect all electrical components. Replace damaged or corroded components prior to returning the outboard to service. Electric starters should be disassembled, cleaned, flushed with clean water, and treated with water displacing electrical spray prior to reassembly. Change oil and filter. Remove carburetor for draining, disassembly and cleaning.
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3
MAINTENANCE SUBMERGED ENGINES Disconnect fuel supply hose from outboard. Drain and clean all fuel hoses, filters, and fuel tanks. Refill fuel tank with fresh fuel. Inject a small amount of outboard lubricant into spark plug holes and install new spark plugs. Reinstall all removed or disconnected parts. Run the outboard below 1500 RPM for one-half hour. Change oil and filter again.
Engine Dropped Overboard (Running) Follow the same procedures as Engine Dropped Overboard (Not Running). However, if there is any binding when the flywheel is rotated, it may indicate a bent connecting rod and no attempt should be made to start the outboard. Powerhead must be disassembled and serviced immediately.
Engine Dropped Overboard (In Salt Water) Follow the same procedures used for Engine Dropped Overboard (Not Running) and Engine Dropped Overboard (Running). Disassemble and clean outboards that have been submerged in salt water for prolonged periods of time. Clean or replace electrical components as necessary.
Prolonged Submersion (Fresh or Salt Water) Outboards that have been dropped overboard and not recovered immediately, must be serviced within three hours of recovery. Follow the same procedures used for Engine Dropped Overboard (Not Running) and Engine Dropped Overboard (Running).
52
IGNITION AND ELECTRICAL
IGNITION AND ELECTRICAL TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITER AIR GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 55 57 58 58 58 58 59 59 59 60
53
4
IGNITION AND ELECTRICAL SERVICE CHART
SERVICE CHART 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Flywheel Ignition coil Bolt Nut Key Cap, spark plug Seal, spark plug Seal, high tension cord Switch assembly, emergency Plate, lock Nut Label, stop Clamp Holder, throttle cable
A B C D
Triple-Guard Grease Gasket Sealing Compound Adhesive 847
F
F Blue Nut Lock R DPL Penetrating Lube W HPF XR Gear Oil
Moly Lube EPC4223
54
IGNITION AND ELECTRICAL OPERATION
OPERATION The outboard uses a transistorized ignition circuit. The ignition system consists of a flywheel magneto, an igniter unit, a spark plug and an emergency stop switch. Flywheel magneto
Igniter unit
4
Spark plug Emergency stop switch
55
IGNITION AND ELECTRICAL OPERATION When the recoil starter is pulled, the flywheel is turned. An electromotive force generated in the primary winding (n1) of the ignition coil makes the transistor (TR1) conduct through the resistor (R1) and forms the primary circuit (indicated by dashed lines). As the flywheel turns further, the primary current increases, and the terminal voltage of the circuit consisting of the resistor (R1) and transistor (TR1) increases. This increases the working voltage at the connection of the series circuit (R2 and R3) connected in parallel to the primary circuit. As the flywheel turns further, the terminal voltage of the resistor (R3) in the resistor circuit (R2 and R3) rises to the level of working voltage of the transistor (TR2) when the ignition timing approaches, and thus the transistor (TR2) is turned on. As a result, the base current of (TR1) flowing through the resistor (R1) is bypassed, and the transistor (TR1) is turned off from the conductive state. The current flowing through the primary winding (n1) is thus interrupted, and a rapid change occurs in the magnetic flux across the ignition coil. The result is a high surge voltage in the secondary winding (n2). Transistor Ignition coil
Spark plug
Flywheel magneto
56
Emergency stop switch
IGNITION AND ELECTRICAL TROUBLESHOOTING
TROUBLESHOOTING Perform the following ignition system tests when engine is hard to start to determine if the cause is in the ignition or other system. OK
START
Check spark condition. No or weak sparks
Check ignition timing by using timing light. (30° BTDC at 1900 RPM)
Sparks
Check if spark plug is in good condition (Refer to SPARK PLUG on page 46).
The cause is not in the ignition system NO
NO
Replace spark plug with a new one
Sparks
Check and/or replace the emergency stop switch (Refer to Engine Stop Switch on page 58).
4
OK Disconnect the emergency stop switch lead wire (black). No or weak sparks Check the air gap between the igniter unit core and the flywheel. Air gap: 0.02 in. (0.5 mm)
Out of Spec. Adjust the air gap (Refer to Igniter Air Gap on page 59).
OK Check the igniter unit resistance (Refer to Igniter Unit on page 58). Primary: 0.5 to 0.9 kΩ Secondary: 10 to 16 kΩ
Out of Spec.
OK Check the spark plug cap for any evidence NO of a high-tension leak.
Replace the spark plug cap.
OK Check the spark plug cap resistance (Refer to Spark Plug Cap on page 58). Cap resistance: 4 to 6 kΩ
Out of Spec.
Replace the igniter unit.
57
IGNITION AND ELECTRICAL IGNITION TESTS
IGNITION TESTS
Spark Plug Cap Resistance Test
Igniter Unit
Measure spark plug cap resistance.
Resistance Test Remove the spark plug cap from the high-tension cord.
Spark plug cap resistance: • 8 to 12 kΩ
Connect Ohmmeter test probes to igniter unit coils as shown: Tester probe connection Probe Other Probe Primary coil
Terminal
Core
Secondary coil
High-tension cord
Core
Igniter unit coil resistance: • Primary coil resistance: 0.5 to 0.9 kΩ • Secondary coil resistance: 10 to 16 kΩ
004698
If measurement is out of specification, replace the spark plug cap.
Engine Stop Switch Check continuity of the emergency stop switch: Switch condition Lock plate IN Lock plate OUT Lock plate IN & button depressed Primary Coil
Continuity No Yes Yes
005950
1 2
CONT 005954 Secondary Coil
005953
If measurement is out of specification, replace the igniter unit.
58
If the result is out of specification, replace the emergency stop switch.
IGNITION AND ELECTRICAL COMPONENT SERVICING
COMPONENT SERVICING
Use strap-type flywheel holder, P/N 507976, or equivalent to loosen the flywheel nut.
Igniter Air Gap Use a thickness gauge to measure the air gap between the flywheel and the igniter unit: • Air gap: 0.02 in. (0.5 mm)
IMPORTANT: Do not remove the flywheel nut. It prevents damage to the crankshaft when using flywheel remover tools.
1
4 1. Flywheel holder
005955
Removal
005957
Install the puller on flywheel. Hold puller by its handle, and tighten pressing screw until flywheel releases.
WARNING Before removing ignition parts, twist and remove spark lead.
Flywheel Remove the manual starter. Refer to starter REMOVAL on p. 141. Disconnect the emergency stop switch lead wire from the igniter unit, and remove the two bolts securing the igniter unit.
Universal Puller
005958
2
1 1. Emergency stop switch lead wire 2. Bolts
005956
59
IGNITION AND ELECTRICAL COMPONENT SERVICING Remove the flywheel nut, starter pulley, flywheel, and key.
1
Igniter Unit Install the igniter unit with an air gap of 0.02 in. (0.5 mm) between both core ends and the flywheel. Check the gaps as shown.
2
3 005955
Tighten igniter unit bolts to 7.0 ft. lbs. (10 N¡m). Reconnect emergency stop switch lead wire.
4 1. 2. 3. 4.
Flywheel nut Starter pulley Flywheel Key
005959
1
Installation Installation is reverse order of removal with special attention to the following steps:
2 Flywheel Clean flywheel and crankshaft mating surfaces with cleaning solvent. Use strap-type flywheel holder, P/N 507976, or equivalent to hold the flywheel. Tighten nut to 32.5 ft. lbs. (45 N¡m).
1
1. Flywheel holder
60
005957
1. Bolts 2. Emergency stop switch lead wire
005956
Final Assembly Check Perform the following checks to ensure proper and safe operation: All parts removed have been returned to their original positions. Wire routings are correct. Refer to WIRE/HOSE ROUTING on p. 145.
FUEL SYSTEM
FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62 64 65 65 66 67 68 69 69 70 70 70 71 72
61
5
FUEL SYSTEM SERVICE CHART
SERVICE CHART 1. Carburetor 2. Nozzle, main 3. Jet, main (68) Jet, main (70) Jet, main (72) 4. Valve, needle 5. Float 6. Pin, float 7. Spring 8. Gasket 9. Chamber, float 10. Gasket 11. Screw 12. Spring 13. Screw 14. Screw 15. Jet, pilot (30) Jet, pilot (32) Jet, pilot (34) 16. Screw 17. Jet, air (170) 18. Jet, pilot air (145) 19. Gasket 20. Plate 21. Spring 22. Screw 23. Screw 24. Gasket, carburetor 25. Rod, choke 26. Connector, choke rod 27. Knob, choke 28. Bolt
EPC4225
62
FUEL SYSTEM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Tank, fuel Bracket, fuel tank Cap assembly, fuel tank Gasket, tank cap Cushion Grommet, fuel tank Rubber, fuel tank grommet Valve assembly, fuel Clip, fuel hose Hose, fuel (valve to carb)
5
EPC4224
63
FUEL SYSTEM REMOVAL
REMOVAL
Remove the two bolts securing the carburetor.
WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.
1
1
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling. 1. Bolts
Remove the engine cover. Remove the recoil starter. Refer to MANUAL STARTER on p. 139.
005963
Remove the carburetor and air silencer.
Turn the fuel cock lever to the “OFF� position. Loosen the screw securing the throttle control inner cable and detach the choke rod from the carburetor.
2 1
1 1. Carburetor 2. Air silencer
2
1. Screw 2. Choke rod
005969
Remove fuel hose from the carburetor.
005960
Remove the fuel hose from the fuel cock.
1 2 1. Fuel hose
1
1. Fuel hose 2. Fuel cock
64
005964
Inspect the fuel hose. If cracks, swelling, or other damage is found, replace the fuel hose.
005962
FUEL SYSTEM CARBURETOR
CARBURETOR
Remove the pilot jet.
1
Disassembly Remove the idle adjusting screw and the four screws securing the plate.
2 2 1
1. Pilot jet
3
Remove the bolt and the float chamber.
1. Idle adjusting screw 2. Screw (4) 3. Plate
005975
5 005973
2
Remove the main air jet, the pilot air jet and the screw.
1 3 2 1
1. Bolt 2. Float chamber
005976
Remove the float pin, the float and the float spring.
2 1. Main air jet 2. Pilot air jet 3. Screw
005974
3
1
1. Float pin 2. Float 3. Float spring
005977 005978
IMPORTANT: Always remove the float pin from the right side to the left side.
65
FUEL SYSTEM CARBURETOR
Cleaning and Inspection
Remove the needle valve from the float.
Clean carburetor components thoroughly with cleaning solvent and compressed air before inspection.
WARNING 1
1. Needle valve
005979
Remove the main jet.
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).
IMPORTANT: Do not place any rubber, plastic or non-metallic parts in cleaning solvent, as severe damage or deterioration will result. Do not use a wire or a small drill bit in order to clean the orifices and jets of the carburetor. Carburetor Body and Float Chamber Inspect the carburetor body and the float chamber. If damage is found, replace component.
1
1. Main jet
005980
Remove the main nozzle.
005982
1
Jet and Nozzle Inspect the jets and nozzles. If crack or other damage is found, replace the component.
1. Main nozzle
005981
005983
66
FUEL SYSTEM CARBURETOR Needle Valve Inspect the needle valve. If broken tip or wear is found, replace the valve.
Install the main nozzle to the carburetor body before installing the main jet.
1
2
005984
1. Main nozzle 2. Main jet
005986 005987
5
Install the float with needle valve.
Float Inspect the float. If crack or other damage is found, replace the float.
1 2
1. Float 2. Needle valve 005985
Reassembly Reassembly is reverse order of disassembly with special attention to the following steps.
005988
Install the float pin.
IMPORTANT: Always install the float pin from the left side to the right side.
005989
Install the float pin spring.
67
FUEL SYSTEM INSTALLATION IMPORTANT: After installing float, inspect for smooth movement of float.
INSTALLATION Installation is reverse order of removal with special attention to the following steps.
1
1. Spring
005978
Checking Float Height Measure the float height. • Float height: 10 ± 2 mm
005970
IMPORTANT: Do not re-use the removed gasket. Always use a new gasket. Tighten the carburetor mounting bolts to 7.0 ft. lbs. (10 N·m).
1 Float Height
1
005990
IMPORTANT: Float weight cannot be applied to needle valve. Install the pilot jet, pilot air jet, and main air jet. 1. Bolts
Refer to Throttle Adjustment on p. 69.
1 3 2
1. Pilot jet 2. Pilot air jet 3. Main air jet
68
005991
005963
FUEL SYSTEM INSTALLATION
Leakage Check
Throttle Adjustment
Twist the air-vent screw on the fuel tank cap counterclockwise to open the vent.
Fully close the throttle control grip. Turn the idle adjusting screw counterclockwise until the screw does not touch the stopper plate.
1
2 005966 1. Screw 2. Stopper plate
Turn the fuel cock lever “ON” position.
005971
Insert the throttle control inner cable into the linkage hole. While pulling the cable, tighten the screw in order to secure the cable.
1
005967
2 Check the fuel line for leaks. 1. Cable 2. Screw
005972
Adjust the idle speed. Refer to IDLE SPEED on p. 48.
1
1. Fuel line
005968
69
5
FUEL SYSTEM FUEL TANK
FUEL TANK
Remove the fuel tank.
Removal Remove the motor cover. Remove the recoil starter. Refer to MANUAL STARTER on p. 139.
1
1. Fuel tank
1
1. Recoil starter
005995
Loosen the connecting screw and remove the fuel cock from the fuel tank.
005992
Turn the fuel cock lever to the “OFF” position.
1 2
1
1. Screw 2. Fuel cock
005996
Inspection 1. Fuel cock lever — OFF position
005993
Check the filter. If clogged, or damaged is found, clean the filter, or replace the fuel cock. Inspect the fuel cock. If leakage, deterioration, or other damage is found, replace the assembly.
Remove the fuel hose from the fuel cock.
2 1
1. Fuel hose 2. Fuel cock
70
005994 Fuel Cock and Filter
005997
FUEL SYSTEM FUEL TANK Inspect the fuel tank. If crack, leakage, or deterioration is found, replace the tank. If water or other contamination is found, drain and clean the tank.
Installation Installation is reverse order of removal with special attention to the following steps. Place the fuel tank bracket in position.
1
Fuel Tank
005998
1. Fuel tank bracket
006000
Check that the fuel tank vent opens and relieves internal tank pressure properly.
Install the fuel tank and recoil starter.
If vent does not work, replace the tank cap.
Check the fuel hose routing. Refer to WIRE/HOSE ROUTING on p. 145. Check for fuel leakage.
WARNING Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.
Fuel Tank Cap and Vent
005999
71
5
FUEL SYSTEM NOTES
NOTES Technician’s Notes
Related Documents Bulletins
Instruction Sheets
Other
72
POWERHEAD
POWERHEAD TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 CYLINDER/CRANKCASE/PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 IGNITER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 FINAL ASSEMBLY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 WATER COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
73
6
POWERHEAD SPECIFICATIONS
SPECIFICATIONS Item
Data
Unit
2.5 HP
CYLINDER HEAD / CAMSHAFT Cylinder head distortion Cam height IN, EX Rocker arm shaft hole diameter Rocker arm shaft outside diameter
Limit STD Limit
mm (in) mm (in) mm (in)
0.05 (0.002) 28.480 – 28.680 (1.1213 – 1.1291) 28.180 (1.1094)
STD
mm (in)
4.015 – 4.027 (0.1581 – 0.1585)
STD
mm (in)
3.990 – 4.005 (0.1571 – 0.1577)
IN
IN EX STD
mm (in) mm (in) mm (in)
20.0 (0.79) 18.0 (0.71) 0.13 – 0.17 (0.005 – 0.007)
EX
STD
mm (in)
0.13 – 0.17 (0.005 – 0.007)
IN
IN EX STD Limit STD Limit
— — mm (in) mm (in) mm (in) mm (in)
45° 45° 0.010 – 0.037 (0.0004 – 0.0015) 0.075 (0.0030) 0.025 – 0.052 (0.0010 – 0.0020) 0.090 (0.0035)
IN, EX
STD
mm (in)
4.000 – 4.012 (0.1575 – 0.1580)
Valve guide inside diameter
IN EX
STD STD
mm (in) mm (in)
3.975 – 3.990 (0.1565 – 0.1571) 3.960 – 3.975 (0.1559 – 0.1565)
Valve stem outside diameter
IN, EX
Limit
mm (in)
0.35 (0.014)
Valve stem deflection
IN, EX
Limit
mm (in)
0.05 (0.002)
Valve stem runout
IN EX IN EX
VALVE / VALVE GUIDE Valve diameter Valve clearance (Cold engine condition) Valve seat angle Valve guide to valve stem clearance
EX Valve guide inside diameter Valve stem outside diameter Valve stem deflection Valve stem runout
74
Valve diameter Valve clearance (Cold engine condition) Valve seat angle
Valve guide to valve stem clearance
POWERHEAD SPECIFICATIONS
Item
Unit
Data 2.5 HP
CYLINDER / PISTON / PISTON RING Cylinder distortion Piston to cylinder clearance
Limit STD Limit STD
Cylinder bore Cylinder measuring position Piston skirt diameter STD Piston measuring position Cylinder bore wear Limit Piston ring end STD 1st, gap 2nd Limit Piston ring free STD 1st end gap Limit STD 2nd Limit Piston ring to STD 1st, groove 2nd Limit clearance Piston ring 1st, STD groove width 2nd Pin clearance in piston STD pin hole Limit Piston pin outside STD diameter Limit Piston pin hole diameter STD Limit Pin clearance in STD connecting rod small end Limit
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
0.05 (0.002) 0.018 – 0.033 (0.0007 – 0.0013) 0.100 (0.0039) 48.000 – 48.015 (1.8898 – 1.8904) 20 (0.8) from cylinder top surface 47.975 – 47.990 (1.8888 – 1.8894) 5 (0.2) from piston skirt end 0.100 (0.0039) 0.15 – 0.35 (0.006 – 0.014) 0.50 (0.020) Approximately 6.1 (0.24) 4.9 (0.19) Approx. 5.7 (0.22) 4.6 (0.18) 0.020 – 0.060 (0.0008 – 0.0024)
mm (in)
0.120 (0.0047)
mm (in)
1.21 – 1.23 (0.048 – 0.049)
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
0.002 – 0.013 (0.0001 – 0.0005) 0.040 (0.0016) 11.995 – 12.000 (0.4722 – 0.4724) 11.980 (0.4717) 12.002 – 12.008 (0.4725 – 0.4728) 12.030 (0.4736) 0.006 – 0.019 (0.0002 – 0.0007) 0.050 (0.0020)
6
CRANKSHAFT / CONNECTING ROD Connecting rod small end inside diameter Connecting rod big end oil clearance Connecting rod big end inside diameter Crank pin outside diameter Crank pin outside diameter difference (out-ofround and taper) Connecting rod big end side clearance Connecting rod big end width Crank pin width Crankshaft runout
STD Limit STD Limit
mm (in) mm (in) mm (in) mm (in)
12.006 – 12.014 (0.4727 – 0.4730) 12.040 (0.4740) 0.015 – 0.035 (0.0006 – 0.0014) 0.080 (0.0031)
STD
mm (in)
19.015 – 19.025 (0.7486 – 0.7490)
STD
mm (in)
18.990 – 19.000 (0.7476 – 0.7480)
Limit
mm (in)
0.010 (0.0004)
STD Limit
mm (in) mm (in)
0.20 – 0.70 (0.008 – 0.028) 1.00 (0.039)
STD
mm (in)
17.50 – 17.80 (0.689 – 0.701)
STD Limit
mm (in) mm (in)
18.00 – 18.20 (0.709 – 0.717) 0.05 (0.002)
75
POWERHEAD COMPRESSION TESTING
COMPRESSION TESTING
IMPORTANT: The values shown are guidelines only, not absolute service limits.
Start and run outboard until it achieves operating temperature, then shut OFF.
Cylinder Compression Test
Remove spark plug. Advance throttle linkage to WOT. Install compression tester’s hose attachment into spark plug hole.
WARNING Disconnect the safety lanyard from the emergency stop switch prior to starting the engine. This will prevent any residual fuel from the cylinder from being ignited by a spark from the spark plug cap. While starting the outboard with starter, note maximum pressure reading on gauge.
76
Standard
137 to 199 psi (960 to 1400 kPa)
If engine shows a variation in test, check for: • Excessively worn cylinder wall • Worn piston • Worn or stuck piston ring • Poor seating of valves • Ruptured or damaged cylinder head gasket Install all parts that were removed.
POWERHEAD REMOVAL
REMOVAL
Detach the powerhead and lower cover.
Before removing the powerhead: • Drain the engine oil. Refer to Engine Oil on p. 43. • Shift into “NEUTRAL” position. • Remove the recoil starter assembly. Refer to MANUAL STARTER on p. 139. • Remove the fuel tank. Refer to FUEL TANK on p. 70. • Remove the carburetor assembly. Refer to CARBURETOR on p. 65. • Remove the igniter unit and flywheel magneto. Refer to Removal on p. 59. • Remove the tiller handle assembly. Refer to Tiller Handle on p. 112.
Remove the four lower cover bolts, then detach the powerhead from the lower cover.
1
1. Bolt (4)
006003
Remove the bolt and oil seal protector.
Remove the four engine mounting bolts.
6 2
1
1
1. Bolt 2. Oil seal protector
1. Bolt (4)
006004
006002 006001
77
POWERHEAD CYLINDER HEAD
CYLINDER HEAD
Remove the valve adjusting lock nuts, then the valve adjusting screw. Remove the rocker arm shaft and the rocker arms.
Disassembly Remove the two bolts, intake manifold, and insulator.
4 3 1 3
2
1
2
1. Bolt (2) 2. Intake manifold 3. Insulator
006010
1. 2. 3. 4.
Lock nut (2) Screw (2) Rocker arm shaft Rocker arm (2)
006012
Remove the push rods.
Remove the four cylinder head cover four bolts and cover.
1 1 1. Push rod (2)
2 1. Bolt (4) 2. Cover
006011
006013
Remove the cylinder head gasket and the five cylinder head bolts from the cylinder block.
1
2
1. Gasket 2. Bolt (5)
78
006014
POWERHEAD CYLINDER HEAD Remove the intake valve and exhaust valve.
Remove the retainers.
1 1 2
1. Retainer (2)
006023
IMPORTANT: To remove the retainer, move it in the direction shown, and force it off the valve shaft.
1. Intake valve 2. Exhaust valve
006026
Remove the valve stem seals.
6 1
006024
1. Valve stem seal (2)
006027
IMPORTANT: Do not re-use the removed valve
Remove the valve springs.
stem seal.
1
1. Valve spring (2)
006025
IMPORTANT: Reassemble each valve spring to its original position.
79
POWERHEAD CYLINDER HEAD
Cleaning and Inspection
Cylinder Head Distortion
IMPORTANT: If any excessive wear, cracks,
Using a straightedge and thickness gauge, measure the gasket surface of the cylinder head at six locations as shown.
defects, or other damage is found on any component, replace.
Cylinder head distortion: • Service limit: 0.002 in. (0.05 mm)
Cylinder Head Remove all carbon from the combustion chamber.
IMPORTANT: Do not use any sharp edged tool to scrape carbon off the cylinder head or components. DO NOT scuff or nick the metal surfaces when decarboning.
006030
If the measurement exceeds the service limit, resurface or replace the cylinder head.
006028
Inspect the cylinder head for crack in the intake and the exhaust ports, the combustion chamber and the head surface.
006031
IMPORTANT: The cylinder head can be resurfaced using a surface plate and a #400 grit wet sandpaper. Move the cylinder head in a figure eight pattern when sanding. 006029
Valve Seat Inspect the valve seats for cracks or other damage.
80
POWERHEAD CYLINDER HEAD Water Jacket
Rocker arm shaft hole diameter:
Inspect the water jacket for clogs or obstructions. Clean the water jackets if necessary.
• 0.1581 to 0.1585 in. (4.015 to 4.027 mm)
006034 006032
Measure the rocker arm shaft diameter.
Rocker Arm and Shaft Inspect the rocker arms and shaft for wear, bends, cracks, or other damage. Replace if necessary.
Rocker arm shaft outside diameter:
• 0.1571 to 0.1577 in. (3.990 to 4.005 mm)
6
006035 006033
Measure the rocker arm shaft hole diameter using a small bore gauge.
Push Rod Inspect the push rods for bends or other damage. Replace it necessary.
006036
81
POWERHEAD CYLINDER HEAD Valve and Valve Guide Using a micrometer and a small bore gauge, measure the diameters on the valve stems and the guides in order to check the guide to stem clearance. Measure at more than one place along length of each stem and guide.
If the measurement exceeds the service limit, replace the valve and/or the cylinder head. If unable to measure the valve guide inside diameter, measure the valve stem deflection.
Valve stem outside diameter: • IN: 0.1565 to 0.1571 in. (3.975 to 3.990 mm) • EX: 0.1559 to 0.1565 in. (3.960 to 3.975 mm)
X y
006039
Install valves into the valve guide. Lift valves 8 to 10 mm off seat. 006037
Measure the valve guide inside diameter using a small bore gauge.
Move the valve head in the direction “X – Y” and measure the deflection. Valve stem deflection:
• IN / EX: 0.014 in. (0.35 mm) If the measurement exceeds the service limit, replace the valve and/or the cylinder head.
Valve Stem End Inspect the valve stem end face for pitting and wear. If pitting or wear is found, the valve stem end may be resurfaced. If the chamfer of stem end has been worn away, replace the valve.
006038
Valve guide inside diameter:
• IN / EX: 0.1575 to 0.1580 in. (4.000 to 4.012 mm) Valve guide to valve stem clearance:
• IN: 0.0004 to 0.0015 in. (0.010 to 0.037 mm) • EX: 0.0010 to 0.0020 in. (0.025 to 0.052 mm) Service limit: • IN: 0.0030 in. (0.075 mm) • EX: 0.0035 in. (0.090 mm)
82
006040
POWERHEAD CYLINDER HEAD Valve Stem Runout
Valve Head Thickness
Measure the valve stem runout.
Measure the thickness of the valve head.
006041
Valve stem runout: • 0.002 in. (0.05 mm)
Valve head thickness: • IN / EX: 0.02 in. (0.5 mm)
If the measurement exceeds the service limit, replace the valve.
If the measurement exceeds the service limit, replace the valve.
Valve Head Radial Runout
Valve Seat Contact Width
Measure the valve head radial runout.
Measure the valve seat contact width.
006042
Valve head radial runout: • 0.003 in. (0.08 mm) If the measurement exceeds the service limit, replace the valve.
006044
Remove all carbon from the valve and seat. Coat the valve seat evenly with Prussian Blue (or equivalent). Install the valve into the valve guide. Put the valve lapper on the valve head. Rotate the valve while gently tapping the valve contact area against the seat. Continue coating the valve seating face with Prussian Blue.
83
6
POWERHEAD CYLINDER HEAD Measure the valve seat contact width.
If the measurement exceeds the service limit, replace the valve spring.
Valve Spring Preload Measure the valve spring preload.
1
1. Valve seat contact area
006045
Valve seat contact width: • IN / EX: 0.03 to 0.04 in. (0.8 to 1.0 mm) 006048
If measurement exceeds specification, repair valve seat. Clean and assemble the cylinder head and valve components.
IMPORTANT: Fill the intake and the exhaust ports with solvent in order to check for leaks between the valve seat and the valve. If any leaks occur, inspect the valve seat and the face for burrs or debris which could prevent the valve from sealing.
Valve Spring
Valve spring preload: • Standard – IN / EX: 8.05 to 9.24 lbs. (3.65 to 4.19 kg) for 0.6 in. (15 mm) • Service limit – IN / EX: 7.34 lbs. (3.3 kg) for 0.6 in. (15 mm) If the measurement exceeds the service limit, replace the valve spring.
Assembly Assembly is reverse order of disassembly with special attention to the following steps. Apply engine oil to the valve stem seals.
Measure the valve spring free length.
Install the valve stem seals to the valve guide.
1 006047
Valve spring free length: • Standard – IN / EX: 0.883 in. (22.42 mm) • Service limit – IN / EX: 0.847 in. (21.52 mm)
84
1. Valve stem seal (2)
006049
IMPORTANT: Do not re-use the removed valve stem seal. Always use a new stem seal.
POWERHEAD CYLINDER HEAD Apply engine oil to the valve guide bore and valve stem.
the retainer, and let it slide sidewise into the center hole.
Install the valves in the valve guides.
1 1
1. Side hole 1. Valve (2)
006050
Install the valve spring and the retainer.
2
006052
Make sure the retainers are properly seated in groove. Groove
6
1
006053 1. Valve spring 2. Retainer
006051
IMPORTANT: Do not re-use cylinder head gas-
IMPORTANT: Reassemble each valve spring to
ket. Always use a new gasket.
its original position.
Before installing cylinder head gasket, apply ThreeBond 1207B sealant to both surfaces of the shaded areas shown.
Push down the retainer with both thumbs so the valve stem can be inserted into the side hole of
006015
85
POWERHEAD CYLINDER HEAD
Installation
Install the push rods onto the cam rocker arms.
Insert the dowel pins and place a new cylinder head gasket into position on cylinder.
2
1 1 1
2 1. Push rod (2) 2. Cam rocker arms
1. Dowel pins 2. Gasket
006016
Position cylinder head assembly on cylinder.
006019 006020
Install the rocker arms and the rocker arm shaft. Adjust the valve clearance. Refer to VALVE CLEARANCE on p. 46.
Apply engine oil to cylinder head bolts. Lightly seat all cylinder head bolts. Tighten bolts in two steps according to tightening order. • First torque: 5.0 ft. lbs. (7 N·m) • Final torque: 9.5 ft. lbs. (13 N·m)
4
2
1 1. Rocker arm (2) 2. Rocker arm shaft
5 006017
4
1
2
3
Torque Sequence
86
006021
Install the cylinder head cover and the gasket, then tighten the four cylinder head cover bolts according to tightening order to torque of 5.0 ft. lbs. (7 N ·m).
3
2
Torque Sequence
1
006022
POWERHEAD CYLINDER/CRANKCASE/PISTON
CYLINDER/CRANKCASE/ PISTON
Remove the thrust washer.
1
Disassembly Remove the powerhead. Refer to REMOVAL on p. 77. Remove the cylinder head. Refer to CYLINDER HEAD on p. 78. Remove the bolt and the under oil seal plate.
1. Thrust washer
2
006056
Remove the cam rocker arm, washer, cam rocker arm, spring, washer, and shaft.
1
1
1. Bolt 2. Seal plate
6
5
3
006054
1
Remove the eight bolts and the crankcase.
2 4
1. 2. 3. 4. 5.
1
Cam rocker arm Washer Spring Washer Shaft
006057
Remove the oil pump shaft, camshaft, and shaft.
1 2 1. Crankcase
006055
3
1. Oil pump shaft 2. Camshaft 3. Shaft
006058
87
POWERHEAD CYLINDER/CRANKCASE/PISTON Remove the two connecting rod bolts and the connecting rod cap.
Remove the circlips, the piston pin, the connecting rod, and the piston rings from the piston.
1 5
2 2
4 1
1 3
1. Bolt (2) 2. Connecting rod cap
006059
Remove the piston with the connecting rod through the top of the cylinder bore.
1. 2. 3. 4. 5.
Circlips Piston pin Connecting rod Piston rings Piston
006062
Remove the screw and the oil pump outer plate.
1
2 006060
Remove the crankshaft from the cylinder block.
1. Screw 2. Plate
006063
Remove the inner rotor and the outer rotor.
2
1 1 1. Crankshaft
006061 1. Inner rotor 2. Outer rotor
88
006064
POWERHEAD CYLINDER/CRANKCASE/PISTON Remove the four bolts and the thermostat cover.
Remove a screw and the reed valve.
1
2 1
1. Thermostat cover
006065
Remove the thermostat.
1. Screw 2. Reed valve
006068
Inspection IMPORTANT: If excessive wear, crack, defective or other damage is found on any component, replace.
1
Camshaft Inspect the camshaft face for scratches and wear. Measure the camshaft height.
1. Thermostat
006066
Remove the three screws and the breather plate.
006069
1
1. Breather plate
006067
Cam height: • Standard – IN / EX: 1.1213 to 1.1291 in. (28.480 to 28.680 mm) • Service limit – IN / EX: 1.1094 in. (28.180 mm) If the measurement exceeds the service limit, replace the camshaft.
89
6
POWERHEAD CYLINDER/CRANKCASE/PISTON Inspect the camshaft gear for wear or other damage. Replace, if necessary.
Cylinder distortion:
• Service limit: 0.002 in. (0.05 mm) If the measurement exceeds the service limit, resurface or replace the cylinder.
006070
Cam Rocker Arm Inspect the cam rocker arm for wear or other damage. Replace, if necessary.
006073
IMPORTANT: The cylinder can be resurfaced, using a surface plate and a #400 grit wet sandpaper. Move the cylinder in a figure eight pattern when sanding. Water Jacket Inspect the water passages for clogs or obstructions. Clean, if necessary.
006071
Cylinder / Piston / Piston Ring Measure the gasket surface of the cylinder at locations shown.
006074
Cylinder Bore Inspect the cylinder wall for scratches, roughness, or ridges which indicate excessive wear. If the cylinder bore is very rough or deeply scratched or ridged, rebore the cylinder and use a oversize piston. 006072
90
POWERHEAD CYLINDER/CRANKCASE/PISTON Measure the cylinder bore in the thrust and axial directions at the three position depths.
Cylinder bore:
• 1.8898 to 1.8904 in. (48.000 to 48.015 mm) Piston skirt diameter:
• 1.8888 to 1.8894 in. (47.975 to 47.990 mm) Oversize piston and piston rings are marked as shown.
1 2
Piston 3
Oversize 0.50 mm
I.D. Mark 50
006075 006076
Check for the following: • Difference between the measurements at the three positions (taper). • Difference between the thrust and axial measurements (out-of-round).
6 Oversize Piston I.D. Mark
Cylinder bore wear (difference): • Service limit – 0.0039 in. (0.100 mm)
First and Second Ring
If the wear (difference) exceeds the service limit, rebore or replace the cylinder.
Oversize 0.50 mm
I.D. Mark 50
To check the piston to cylinder clearance, measure the following items: • Cylinder bore at 20 mm elevation from the gasket surface at a right angle to the crankshaft pin. • Piston skirt diameter at 5 mm elevation from the skirt end. Piston to cylinder clearance: • Standard – 0.0007 to 0.0013 in. (0.018 to 0.033 mm) • Service limit – 0.0039 in. (0.100 mm)
Oversize First and Second Ring I.D. Mark
006080
Oil Ring Oversize 0.50 mm
I.D. Mark Blue paint
If the clearance exceeds the service limit, replace the piston and/or the cylinder, or rebore cylinder.
Oversize Oil Ring I.D. Mark
006081
006078
91
POWERHEAD CYLINDER/CRANKCASE/PISTON IMPORTANT: The piston grooves must be clean, dry and free of carbon before checking clearance.
Measure the piston ring end gap with the piston ring in the lowest position of the cylinder bore.
Fit the piston ring into the piston groove, and measure the clearance between the ring and the ring groove using the thickness gauge. Piston ring to groove clearance: • Standard – First and Second Ring: 0.0008 to 0.0024 in. (0.020 to 0.060 mm) • Service limit – First and Second Ring: 0.0047 in. (0.120 mm)
1
1. Piston ring
Piston ring end gap:
• Standard – First and Second Ring: 0.006 to 1
0.014 in. (0.15 to 0.35 mm)
• Service limit – First and Second Ring: 0.020 in. (0.50 mm)
2 1. First ring 2. Second ring
006082 006083
If the measurement exceeds the service limit, replace the position ring. Measure the piston ring free end gap.
If the measurement exceeds the service limits, replace the piston and/or the piston ring. Piston ring groove width:
• Standard – First and Second Ring: 0.048 to 0.049 in. (1.21 to 1.23 mm)
• Standard – Oil: 0.059 to 0.060 in. (1.51 to 1.53 mm) Piston ring thickness:
• Standard – First and Second Ring: 0.046 to 0.047 in. (1.17 to 1.19 mm)
006085
Piston ring free end gap: Standard • First Ring: Approximately 0.24 in. (6.1 mm) • Standard – Second Ring: Approximately 0.22 in. (5.7 mm) Service limit • First Ring – 0.19 in. (4.9 mm) • Second Ring – 0.18 in. (4.6 mm) If the measurement exceeds the service limits, replace the piston ring.
92
POWERHEAD CYLINDER/CRANKCASE/PISTON Piston Pin Clearance
Connecting Rod Big End Side Clearance
To check the clearance, measure: • Piston pin outside diameter in the thrust and axial directions. • Piston pin hole diameter in the thrust and axial directions.
Measure the clearance with the connecting rod installed on the crank pin as shown in the figure.
006089
Connecting rod big end side clearance: • Standard – 0.008 to 0.028 in. (0.20 to 0.70 mm) • Service limit – 0.039 in. (1.00 mm)
006086-8
Pin clearance in piston pin hole:
• Standard – 0.0001 to 0.0005 in. (0.002 to 0.013 mm) • Service limit – 0.0016 in. (0.040 mm) Pin clearance in connecting rod small end: • Standard – 0.0002 to 0.0007 in. (0.006 to 0.019 mm) • Service limit – 0.0020 in. (0.050 mm)
If the measurement exceeds the service limit, replace the connecting rod assembly and/or crankshaft. Connecting rod big end width:
• 0.689 to 0.701 in. (17.50 to 17.80 mm) Crank pin width:
• 0.709 to 0.717 in. (18.00 to 18.20 mm) Inspect the crank pin for uneven wear or damage. Measure the crank pin outside diameter for out-ofround or taper.
If the clearance exceeds the service limit, replace the piston, the piston pin and/or the connecting rod assembly. Piston pin outside diameter:
• Standard – 0.4722 to 0.4724 in. (11.995 to 12.000 mm) • Service limit – 0.4717 in. (11.980 mm) Piston pin hole diameter: • Standard – 0.4725 to 0.4728 in. (12.002 to 12.008 mm) • Service limit – 0.4736 in. (12.030 mm) Connecting rod small end inside diameter: • Standard – 0.4727 to 0.4730 in. (12.006 to 12.014 mm) • Service limit – 0.4740 in. (12.040 mm)
006090
• Out-of-round: A – B • Taper: a – b
93
6
POWERHEAD CYLINDER/CRANKCASE/PISTON Crank pin outside diameter difference (out-ofround and taper): • Service limit – 0.0004 in. (0.010 mm)
Remove the connecting rod and the connecting rod cap from the crank pin. Measure the clearance.
If the out-of-round or the taper exceeds the service limit, replace the crankshaft.
Connecting rod big end oil clearance: • Standard – 0.0006 to 0.0014 in. (0.15 to 0.035 mm) • Service limit – 0.0031 in. (0.080 mm)
Crank pin outside diameter:
• 0.7476 to 0.7480 in. (18.990 to 19.000 mm) Check the big end oil clearance. Clean the surface of the connecting rod, the connecting rod cap, and the crank pin. Place a piece of a plastigauge on the crank pin parallel to the crankshaft, avoiding the oil hole.
If the measurement exceeds the service limit, replace the connecting rod assembly and/or crankshaft. Connecting rod big end inside diameter:
• 0.7486 to 0.7490 in. (19.015 to 19.025 mm) Crankshaft Runout Measure the crankshaft runout.
006094
006091
Install the connecting rod and the connecting rod cap on the crank pin. Install the two connecting rod bolts and tighten the bolts in two steps: • First torque: 2.5 ft. lbs. (5 N·m) • Final torque: 5.0 ft. lbs. (7 N·m)
Crankshaft runout: • 0.002 in. (0.05 mm) If the measurement exceeds the service limit, replace the crankshaft.
Oil Seal and Bearing Visually check the oil seals installed in the cylinder block and crankcase for cuts, nicks, excessive wear, or other damage.
1 1. Bolt (2)
006092
IMPORTANT: Do not rotate the connecting rod with the plastigauge in place. 006095
94
POWERHEAD CYLINDER/CRANKCASE/PISTON Visually check the crankshaft upper bearing for pitting, roughness, or other damage.
Drive the oil seal down into position as shown.
1
Inside crankcase 1. Crankshaft upper oil seal
006099 006100
006096
1
If no damage is found on the oil seals or bearing, do not remove either.
6 2 Inside crankcase 1. Crankshaft lower oil seal 2. Driveshaft oil seal
Seals
006097 006098
IMPORTANT: Do not re-use the oil seal once
006101 006102
Oil Pump Inspect the outer rotor, the inner rotor and the rotor plate for excessive wear or other damage. Replace if necessary.
removed. Always use a new oil seal.
006103
95
POWERHEAD CYLINDER/CRANKCASE/PISTON
Assembly Assembly is reverse order of disassembly with special attention to the following steps.
Make sure that the connecting rod is installed in the direction shown. Install the circlips with a gap facing either up or down as shown.
If the original components are not replaced, each piston, piston pin, and connecting rod is to be assembled and installed in the original order and position.
Mark
IMPORTANT: Do not re-use gaskets, oil seals, O-rings, or circlips once removed. Always use new parts. Piston to Connecting Rod Apply engine oil to the piston pin, the piston pin bore, and the connecting rod. Gap
Fit the connecting rod to the piston as shown, and insert the piston pin through the piston and the connecting rod.
Gap
Install the piston pin circlips. 006105 006106
Piston Ring to Piston Oil Ring Apply engine oil to the piston rings. Install the spacer first, then the side rails.
2 1 1. 2. 3. 4.
Piston pin Connecting rod Piston Circlips
006104
2
1. Spacer 2. Side rail
96
006107
POWERHEAD CYLINDER/CRANKCASE/PISTON IMPORTANT: When installing the spacer, do not allow the ends to overlap in the groove.
Ring Gap Direction Position the piston rings so the ring gaps are staggered at approximately 90 degree angles.
incorrect
Mark
correct
006108 1. 2. 3. 4.
First Ring and Second Ring Apply engine oil to the piston rings. Install the second ring and the first ring to the piston with the “R” mark toward the piston head side.
First ring Second ring Oil ring lower side rail Oil ring upper side rail
006111
IMPORTANT: Failure to stagger the piston ring gaps may result in the crankcase oil dilution. Crankshaft and Piston to Cylinder
“R”
Apply engine oil to the crankshaft journals, crank pin, and bearing.
1 2 Mark
Apply Triple-Guard grease to the lip of the upper oil seal.
3
Install the crankshaft to the cylinder block.
1. First ring 2. Second ring 3. Oil ring
006109
IMPORTANT: The first ring differs from the second ring in shape. Distinguish the first ring from the second ring by referring to the figure.
1
1st ring 1st ring 1. Crankshaft
2nd ring
006115
Apply engine oil to the piston and cylinder wall.
2nd ring
006110
97
6
POWERHEAD CYLINDER/CRANKCASE/PISTON Insert the piston/connecting rod assembly into the cylinder bore from the cylinder head side using a piston ring compressor.
Install the connecting rod cap in the direction shown.
006119
006116
Position the “O” mark on the piston head to the flywheel side.
Apply engine oil lightly to the connecting rod bolts. Tighten the two connecting rod bolts in two steps: • First torque: 2.5 ft. lbs. (3.5 N·m) • Final torque: 5.0 ft. lbs. (7.0 N·m)
Flywheel side
1 1
006117
1. Bolt (2)
006120
Connecting Rod Cap
Camshaft
Apply engine oil to the crank pin, the connecting rod, and the connecting rod cap.
Apply engine oil to the shaft. Install the shaft in the cylinder block. Apply engine oil to the cam faces, the cam journals and the timing gear.
1
1 1. Connecting rod cap
006118 1. Camshaft
98
006121
POWERHEAD CYLINDER/CRANKCASE/PISTON While aligning each mark on the camshaft gear and the crankshaft gear, install the camshaft.
IMPORTANT: Be sure the cam rocker arms are positioned as shown.
Mark
Mark 006122
006125
Cam Rocker Arm
Oil Pump
Apply engine oil to the cam rocker arm shaft. Install the washer and the spring on the shaft as shown.
Apply engine oil to the inner rotor and the outer rotor. Install the inner rotor and the outer rotor in the crankcase as shown, with marks aligned.
2 1 3
1. Cam rocker arm shaft 2. Washer 3. Spring
1
2
006123
Install the cam rocker arm, washer, and cam rocker arm.
1
1. Inner rotor 2. Outer rotor
Install the outer plate. Apply Screw Lock to the screw. Install and tighten screw securely.
2
2
1. Cam rocker arm (2) 2. Washer
006124
006126
1
1. Outer plate 2. Screw
006127
99
6
POWERHEAD CYLINDER/CRANKCASE/PISTON Install the oil pump shaft.
Apply engine oil to the crankcase bearing, the crankshaft lower oil seal and the driveshaft oil seal.
1
1. Oil pump shaft
006128
Crankcase to Cylinder Clean the mating surfaces of the cylinder block and the crankcase. Install the two dowel pins and gasket.
006130 006131
Install crankcase on the cylinder block. Tighten the eight crankcase bolts to the specified torque: • 8.0 ft. lbs. (11 N·m)
Install the thrust washer on crankshaft. Torque bolts in the order indicated.
3 2
1
1. Dowel pin (2) 2. Gasket 3. Thrust washer
Apply engine oil to the crank journals.
100
006129 Torque Sequence
006132
POWERHEAD THERMOSTAT Breather Plate and Thermostat Install the reed valve on the cylinder block and secure with a screw.
THERMOSTAT Removal Remove the recoil starter assembly. Refer to MANUAL STARTER on p. 139. Remove the four bolts and thermostat cover.
1 1 1. Reed valve
006133
2
Install the gasket and breather plate on the cylinder block and secure with the three screws. 1. Thermostat cover 2. Bolt (4)
006137
Remove the thermostat.
1
1. Breather plate
1 006134
Install the thermostat. Refer to THERMOSTAT on p. 101. 1. Thermostat
006066
Inspection If salt deposits, corrosion, wear, or other damage is found, clean or replace the thermostat.
Thermostat
006140
101
6
POWERHEAD THERMOSTAT Insert a length of thread between the thermostat valve/body and suspend the thermostat in a container filled with water.
Apply silicone sealant to both surfaces of thermostat cover gasket (as shown in shaded areas).
Place the thermometer in the container and heat water. Observe water temperature when the thermostat valve opens and releases the thread. Thermostat operating temperature: • 118 to 126°F (48 to 52°C) 006143
Install the gasket and the thermostat cover to the cylinder block and secure with the four bolts.
006142
2
Installation Installation is reverse order of removal with special attention to the following steps. Install the thermostat.
1
1. Thermostat
102
1
006066
1. Thermostat cover 2. Bolt (4)
006137
POWERHEAD INSTALLATION
INSTALLATION Installation is reverse order of removal with special attention to the following steps.
Secure the powerhead to the lower cover and tighten the four bolts to the specified torque: • 6.0 ft. lbs. (8 N·m)
Install the two dowel pins and gasket on the driveshaft housing.
1 2
1. Bolt (4)
1
006007
Install the powerhead/lower cover assembly onto the driveshaft housing. 1. Dowel pin (2) 2. Gasket
006005
IMPORTANT: Do not re-use the gasket once removed. Always use new parts.
Apply silicone seal to the four powerhead mounting bolts and tighten the bolts to the specified torque: • 7.0 ft. lbs. (10 N·m)
Apply Moly Lube grease to driveshaft splines. Apply Triple-Guard grease to the seal lips of driveshaft oil seal. Install the oil seal protector and tighten the bolt after applying Nut Lock to the bolt.
1
1
1. Oil seal protector
006006
1. Bolt (4)
006002 006001
103
6
POWERHEAD INSTALLATION
Flywheel
Final Assembly Check
Install the flywheel magneto. Refer to Flywheel on p. 60.
Perform the following checks in order to ensure proper and safe operation of the outboard. • All parts removed have been returned to the original positions. • Midsection gear engagement is properly adjusted. Refer to GEAR SHIMMING AND ADJUSTMENT on p. 135. • All fuel hoses and wirings are correctly routed. Refer to WIRE/HOSE ROUTING on p. 145. • No water leakage is evident during final test running. • No fuel leakage is evident.
Tighten the flywheel nut to the specified torque: • 32.5 ft. lbs. (45 N·m)
WARNING
006008
Igniter Unit Install the igniter unit with an air gap of 0.5 mm between the both core ends and the flywheel. • Air gap: 0.02 in. (0.5 mm)
1 2
1. Igniter unit 2. Air gap
104
006009
Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.
POWERHEAD WATER COOLING SYSTEM
WATER COOLING SYSTEM The water cooling system consists of the water pump (in the midsection), the water tube (between the midsection and the powerhead) and the thermostat (in the cylinder). This system cools both the powerhead and the exhaust. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build-up or damage. Thermostat When open
Cylinder
Cylinder head
6
Exhaust water jacket
Driveshaft housing
Exhaust release hole
Driveshaft housing Water tube
Water pump
Exhaust outlet
Water intake
[WATER]
105
POWERHEAD ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM A camshaft driven trochoid-type pump provides lubrication to all required powerhead components.
Crankshaft upper bearing
Cylinder head
Cylinder block 路 Connecting rod 路 Piston 路 Timing gear 路 Lower bearing Oil pump
ENGINE OIL
106
Lower crankcase (Oil pan)
Valve train
MIDSECTION
MIDSECTION TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWIVEL BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TILLER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWIVEL BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TILLER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 110 111 111 112 114 115 115 116 117 117
7
107
MIDSECTION SERVICE CHART
SERVICE CHART TILLER HANDLE AND DRIVESHAFT HOUSING
A
A
F
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Handle, tiller Grip, throttle Spacer, tiller handle Bushing, tiller handle Mount, tiller handle Washer, tiller handle Bolt, handle pivot Knob, throttle adjust Nut, throttle adjust knob Case, throttle upper Case, throttle lower Cable assembly, throttle Screw, throttle cable Clamp, throttle cable Screw, throttle cable Tube, throttle cable Protector, throttle cable Decal, handle grip
A Triple-Guard Grease F Blue Nut Lock
108
1. 2. 3. 4. 5. 6.
Housing, driveshaft Gasket, driveshaft Bolt, driveshaft housing Driveshaft housing, knock Stopper, reverse thrust Bolt, stopper reverse thrust
004235 004221
MIDSECTION SERVICE CHART
SERVICE CHART STERN BRACKET AND SWIVEL BRACKET A
A
A A F
A
7 1. 2. 3. 4. 5. 6. 7. 8.
Bracket, clamp Handle, clamp Plate, clamp Cap, clamp screw Spacer, tilt lock Bolt, tilt lock Nut, tilt lock wing Pin, tilt lock
A Triple-Guard Grease F Blue Nut Lock
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Bracket, swivel port Bracket, swivel starboard Bushing, steering upper Bolt, swivel bracket Bolt, swivel shaft Nut, swivel shaft Washer, swivel shaft Washer, tilt friction Block, thrust Mount, lower thrust Bracket, stopper Shaft, stopper Spring, stopper Plate, steering adjuster Rubber, steering adjuster Bolt, steering adjuster Spring, steering adjuster Lever, tilt lock Bolt, tilt lock lever Spacer, tilt lock lever Spring, tilt lock
004232 004233
109
MIDSECTION REMOVAL
REMOVAL
Remove the swivel shaft nut and swivel shaft washer.
Remove the powerhead. Refer to POWERHEAD on p. 73. Remove the gearcase. Refer to GEARCASE on p. 119.
2
Remove the water tube with the grommet upside.
1
1
1. Nut 2. Washer
006148
Remove the port side clamp bracket and tilt friction washer.
1. Water tube
006146
Remove the spring pin and the tilt lock wing nut. Remove the tilt lock spacer.
2 1
3 2 1. Side clamp bracket – port 2. Washer
1
006149
Remove the tilt lock bolt and the thrust block with the lower thrust mount. 1. Spring pin 2. Nut 3. Spacer
006147
1
2
1. Tilt lock bolt 2. Lower thrust mount
110
006150
MIDSECTION REMOVAL Remove the starboard side clamp bracket, the tilt friction washer and the swivel shaft bolt.
Take out the steering adjuster plate with the steering adjuster rubber.
2 1 1 3
1. Side clamp bracket – starboard 2. Washer 3. Bolt
006162
2
1. Adjuster plate 2. Adjuster rubber
006165
Remove the stopper bracket.
Clamp Bracket
1
Remove the two swivel bracket bolts.
7 1 1. Stopper bracket
1. Bolt (2)
006163
Swivel Bracket Remove the starboard side swivel bracket.
Remove the port side swivel bracket.
1
1
1. Swivel bracket – starboard 1. Swivel bracket – port
006166
006167
006164
111
MIDSECTION REMOVAL Take out the upper steering bushings from the driveshaft housing.
Remove the igniter unit bolt and ground lead of the emergency/engine stop switch. Remove the plus lead of the emergency/engine stop switch from the igniter unit.
1 1
1
1. Upper steering bushing (2)
006168
Tiller Handle
2
3 1. Bolt 2. Emergency stop switch ground (–) 3. Emergency stop switch positive (+)
Remove the three bolts and the recoil starter.
006188
Remove the throttle cable clamps.
1
1 1. Bolt (3)
006186
Remove the throttle cable from the carburetor. Loosen the lock nuts and remove the throttle cable from the throttle cable holder.
1
1. Throttle cable clamp (2)
006189
Remove the handle pivot bolt and tiller handle washer. Remove the tiller handle.
3
1 2 3 1. Throttle cable 2. Lock nut 3. Throttle cable holder
112
2
006187 1. Bolt 2. Washer 3. Tiller handle
006190
MIDSECTION REMOVAL Remove the washer, two tiller handle bushings, tiller handle mount, and tiller handle spacer from the tiller handle.
2
Take out the throttle lower case and the throttle upper case from the tiller handle.
3
2 2
1 4
1 1. 2. 3. 4.
006191
Washer Bushing (2) Mount Spacer
1. Lower case 2. Upper case
006194
Remove throttle cable end from the tiller handle.
Remove the throttle adjust knob.
7 1
006195
1. Throttle adjust knob
006192
Remove the throttle grip from the tiller handle.
Remove the throttle cable screw and the cable stopper. Remove the two throttle cable screws.
3 1
1. Throttle grip
2 1. Screw 2. Stopper 3. Throttle cable screw (2)
006196
1 006193
113
MIDSECTION INSPECTION
INSPECTION
Steering Upper Bushing
IMPORTANT: If excessive wear, crack, defec-
Inspect the upper bushings.
tive or other damage is found on any component, replace.
Driveshaft Housing If crack or other damage is found, replace.
006171
Stopper Bracket/Stopper Spring Inspect the stopper bracket and the stopper spring. 006169
Clamp Bracket/Swivel Bracket Inspect the clamp brackets and swivel bracket.
006172
Thrust Block/Lower Thrust Mount Inspect the thrust block and the lower thrust mount. 006170
006173
114
MIDSECTION ASSEMBLY
ASSEMBLY
Swivel Shaft Bolt Inspect the swivel shaft bolt.
Reassembly is reverse order of disassembly with special attention to the following steps.
Swivel Bracket After completing reassembly of the midsection, apply Triple-Guard grease through grease nipple. Apply Triple-Guard grease to the following parts: • Inside and outside surfaces of the bushings. • Inside surface of the lower thrust mount • Steering adjuster 006174
Install the upper steering bushings in position.
Water Tube Inspect the water tube.
1
1. Upper steering bushing (2)
006175
If clog, obstruction, or other damage is found, clean or replace.
1
006168
Install the starboard swivel bracket. Install the stopper bracket.
2
1 1. Swivel bracket – starboard 2. Stopper bracket
006177
115
7
MIDSECTION ASSEMBLY Install the steering adjuster rubber with the steering adjuster plate.
Install the thrust block with the lower thrust mount and the tilt lock bolt.
2
1
2 1
1. Adjuster rubber 2. Adjuster plate
006178
Install the swivel port bracket. Install the two swivel bracket bolts and tighten to a torque of 6.0 ft. lbs. (8 N·m).
1. Thrust block 2. Bolt
006181
Install the tilt friction washer and the clamp bracket port side.
1 1
1. Bolt (2)
2
006179 1. Washer 2. Clamp bracket – port
Clamp Bracket Apply Triple-Guard grease to the clamp bracket through swivel shaft bolt hole. Install the clamp bracket starboard side, the tilt friction washer and the swivel shaft bolt.
2
006182
Install the tilt friction washer and the swivel shaft nut. Apply Nut Lock to the swivel shaft nut, and torque the nut to 7.0 ft. lbs. (10 N·m).
1 2
3 1 1. Clamp bracket – starboard 2. Washer 3. Bolt
116
006183
1. Washer 2. Nut
006183
MIDSECTION ASSEMBLY Install the tilt lock spacer and the tilt lock wing nut. Install the tilt lock pin to the tilt lock bolt.
3
1
Install the throttle handle spacer and the throttle handle bushings.
2
2 1 1. Spacer 2. Wing nut 3. Lock pin
006184
1. Spacer 2. Bushing (2)
006198
Lubrication
Install the tiller handle washers and the handle pivot bolt.
After completing reassembly of the midsection, apply Triple-Guard grease through grease nipple.
Apply Nut Lock to the handle pivot bolt.
Tiller Handle
7
Reassembly is reverse order of disassembly with special attention to the following steps. Apply Triple-Guard grease to the throttle handle mount.
2 1
Install the throttle handle mount in position.
1. Washer (2) 2. Pivot bolt
1
006199
Tighten the tiller handle pivot bolt to a torque of 12.5 ft. lbs. (17 N¡m).
1. Throttle handle mount
006197
1
1. Pivot bolt
006200
117
MIDSECTION ASSEMBLY Install throttle cable to the throttle cable holder. Install throttle cable to the carburetor.
3
1 2 1. 2. 3. 4. 5.
5 4
Throttle cable Holder Carburetor Choke rod connector Choke rod
006201
Check that the throttle control operates smoothly from the fully closed position to the fully opened position. Install the choke rod connector to the carburetor. Install the choke rod to the choke rod connector. Check that the choke control operates smoothly from the fully closed position to the fully opened position.
118
GEARCASE
GEARCASE TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR SHIMMING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD GEAR/PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT THRUST PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120 122 122 122 122 122 122 123 123 124 126 127 127 131 131 132 133 134 135 135 136 137 138
119
8
GEARCASE SERVICE CHART
SERVICE CHART GEARS / GEARCASE
D 1. 2. 3. 4. . . . . 5. 6. 7.
8. 9. 10. 11. 12. 13.
A
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Case, gear (white) Bolt (6X35) Anode, protection Bolt, anode protection Gasket, drain plug Plug, drain Seal, drive shaft oil Housing, prop shaft bearing O-ring, prop shaft bearing housing Seal, prop shaft oil Bolt, prop shaft bearing housing (6X15) Propeller (3X188X135) Propeller (3X188X115) 13. Pin, shear 14. Pin, cotter
B A
A A
A
A B C D
120
Shaft, drive Bush, Drive shaft Pinion Shim (10X16X1.8) Shim (10X16X1.9) Shim (10X16X2.0) Shim (10X16X2.1) Shim (10X16X2.2) E-ring, pinion Gear, forward Shim (17X23X0.3) Shim (17X23X0.4) Shim (17X23X0.5) Shim (17X23X0.6) Shaft, propeller Shifter, clutch dog Spring, return Circlip, propeller shaft Rod, push Washer (10X14X1.6) Washer (10X14X1.7) Washer (10X16X1.8) Washer (10X16X1.9) Washer (10X16X2.0)
Triple-Guard Grease Gasket Sealing Compound ThreeBond Moly Lube
F Blue Nut Lock R DPL Penetrating Lube W HPF XR Gear Oil EPC4237 EPC4238
GEARCASE SERVICE CHART
SERVICE CHART WATER PUMP
B
A A
8 C 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
A Triple-Guard Grease B Gasket Sealing Compound C ThreeBond
Case, water pump Seal, water pump case Sleeve, water pump case Grommet, water pump case Impeller, water pump Pin, pump case impeller Panel, pump case under Gasket, pump case panel Tube, water Grommet, water tube upper Bolt (6X30)
D Moly Lube F Blue Nut Lock R DPL Penetrating Lube
004359
121
GEARCASE PROPELLER
PROPELLER
LUBRICANT
Inspection
Draining
Carefully check the propeller and outboard for the following conditions: • Damaged blades and signs of propeller cavitation • Spun or overheated inner hub • Inadequate lubricant • Damage to outer hub area • Correct size • Check for bent or damaged propeller shaft
Installation
WARNING Gearcase lubricant may be under pressure and/or hot. If plug is removed from a recently operated outboard, take precautions to avoid injury. Remove the lubricant level plug, then the lubricant drain/fill plug, and drain the lube from the gearcase into a container. Inspect the lubricant for metal chips.
Refer to Propeller Hardware Installation on p. 36.
WARNING When servicing the propeller, always shift the outboard to NEUTRAL and twist and remove all spark plug leads so the engine cannot be started accidentally.
TYPICAL 1. Lubricant level plug (upper) 2. Lubricant drain/fill plug (lower)
004362
The presence of metal fuzz can indicate normal wear of the gears, bearings, or shafts within the gearcase. Metal chips can indicate extensive internal damage.
122
GEARCASE LEAK TEST
Inspection
LEAK TEST
Inspect the lubricant for water contamination. Water in the lubricant can cause a milky appearance, however normal aeration can also cause the same appearance.
Check for leakage of the oil seals and O-ring when applying the specified pressure inside of the gearcase.
To check for water contamination, drain lubricant into a suitable glass container. Allow the drained oil to settle for a minimum of one hour to determine if there is an abnormal amount of water in the oil. Some gearcase lubricants are designed to mix with a small amount of water from normal water vapor condensation within the gearcase.
Install leakage tester into the oil level hole. Connect an air pump to leakage tester. Rotate the driveshaft and the propeller shaft clockwise several times and then apply the specified pressure for the test.
Refer to LEAK TEST on p. 123. Overheated lubricant will give the lubricant a black color and burned odor. Internal gearcase inspection is recommended when lubricant is contaminated or shows signs of failure.
Filling 006262
Secure the gearcase in a vertical position. Remove the lubricant level plug and the lubricant drain/fill plug.
Apply low initial pressure of 2.8 to 5.7 psi (20 to 40 kPa) first, then apply the specified pressure.
Using Gearcase Fill/Drain Adapter, P/N 5037486, slowly fill the gearcase with HPF XR gearcase lube through the drain/fill hole until it appears at the oil level hole. Filling the gearcase too quickly can cause air pockets and the gearcase may not fill completely. Clean plug seal area and install the lubricant level plug and new seal, then the lubricant drain/fill plug and new seal. Tighten them to a torque of 114 in. lbs. (13 N¡m).
Leakage test pressure: • 100 kPa (1.0 kg/cm2, 14.2 psi)
IMPORTANT: Do not exceed pressure of 15.6 psi (110 kPa) or damage to oil seals will result. Once stabilized, the pressure should remain steady for at least five minutes. If the pressure does not fall, sealing performance is correct. Drain lubricant before testing.
004363
123
8
GEARCASE REMOVAL
REMOVAL
Remove the two bolts. Separate the gearcase assembly from the driveshaft housing.
WARNING To prevent accidental starting while servicing, twist and remove all spark plug leads.
1
During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service. Remove the four engine mounting bolts. Detach the powerhead with the lower cover. Refer to POWERHEAD on p. 73.
1. Bolt (2)
006205
Remove the gear oil drain plug before the gear oil level plug and drain the gear oil.
Remove the spring.
2 1 1
1. Lubricant drain/fill plug (lower) 2. Lubricant level plug (upper) 1. Spring
006206
006203
Remove the E-ring. Take out the shift rod from the clutch rod arm.
Remove the cotter pin then detach the propeller. Remove the shear pin.
3 2 2 1 1 1. E-ring 2. Shift rod 3. Clutch rod arm
124
006204
1. Cotter pin 2. Shear pin
006207 006208
GEARCASE REMOVAL Pull out the shift rod.
1
Remove the two bolts securing the propeller shaft bearing housing.
1
1. Shift rod
006209 1. Bolt (2)
006212
Remove four pump case bolts and pump case. Remove the propeller shaft bearing housing.
2
1
1
1. Bolt (4) 2. Pump case
8
006210 1. Bearing housing
Remove the water pump impeller, key, and pump under panel.
006213
Remove the E-ring.
1
1
2 3 1. E-ring 1. Impeller 2. Key 3. Under panel
006214
006211
125
GEARCASE REMOVAL
Propeller Shaft
Pull out the driveshaft.
Separate the following parts: • Bearing housing • Washer • Propeller shaft assembly
3 1
006215
Remove the pinion gear and pinion gear backup shim.
2
1. Bearing housing 2. Washer 3. Propeller shaft assembly
2
006218
Remove the clutch dog.
1 1
1. Pinion gear 2. Pinion gear backup shim
006216
Remove the forward gear and forward gear backup shim. 1. Clutch dog
2
006219
Remove the spring and circlip.
1 1 2
1. Forward gear 2. Forward gear backup shim
006217
1. Spring 2. Circlip
126
006220
GEARCASE INSPECTION
Water Pump
INSPECTION
Separate the following parts: • Water pump case seal • Water pump case sleeve • Water pump case • O-ring
IMPORTANT: If excessive wear, crack, defective or other damage is found on any component, replace. Propeller Inspect the propeller. If bend, chip or other damage is found on the blades, replace or repair the propeller.
3 4
2
1. 2. 3. 4.
Seal Sleeve Case O-ring
Inspect the shear pin. If bend or other damage is found, replace the shear pin.
1
006221
006222
Gearcase Housing Inspect the gearcase. If crack or other damage is found, replace the gearcase. Visually check the forward gear bearing. If pitting, noisy, rough or other damage is found, replace the bearing. Visually check the driveshaft bushing. If excessive wear, pitting or other damage is found, replace the bushing.
006223 006224
127
8
GEARCASE INSPECTION Pinion Gear Inspect the teeth of the forward gear and pinion gear. If excessive wear, chip or other damage is found, replace.
Inspect the return spring. If excessive wear or other damage is found, replace.
006227
006225
Inspect the propeller shaft. If excessive wear, twist or other damage is found, replace.
Inspect the engaging dogs of the forward gear. If excessive wear, chip or other damage is found, replace.
006228
Shift Rod and Shift Cam 006226
Propeller Shaft
Inspect the “stepped� surfaces of the shift cam. If excessive wear, chip or other damage is found, replace the cam.
Inspect the push rod. If excessive wear or other damage is found, replace. Inspect the clutch dog shifter. If excessive wear, crack, chip or other damage is found, replace.
006229 006230
128
GEARCASE INSPECTION Propeller Shaft Bearing Housing Inspect the housing. If crack or other damage is found, replace the housing.
When replacing the propeller shaft bearing housing oil seal, use a screwdriver to remove oil seals.
Visually check the oil seal and O-ring. If cut, nick, excessive wear or other damage is found, replace the oil seal.
006233
Apply Triple-Guard grease to the outer circumference of the oil seal. 006231
IMPORTANT: Do not re-use the oil seal or the O-ring once removed. Always use new parts.
Drive the oil seals down into the housing with the lipped portion toward the propeller. (one at a time) Apply Triple-Guard grease to the seal lips.
8
006232
006234 006235
129
GEARCASE INSPECTION Water Pump
Driveshaft Oil Seals
Inspect the impeller. If cut, tear or excessive wear is found, replace the impeller.
Visually check the oil seals. If cut, nick, excessive wear or other damage is found, replace the oil seal.
Inspect the pump case, the inner sleeve and the under panel. If wear, crack, distortion or corrosion is found, replace. Inspect the impeller pin. If excessive wear or other damage is found, replace the pin.
006238
Replacement Remove the oil seal using a bearing remover and sliding hammer. 006236
Inspect the seal and the O-ring. If cut, excessive wear or other damage is found, replace.
IMPORTANT: Do not re-use the seal or O-ring once removed. Always use new parts.
006239
Apply Triple-Guard grease to outer circumference of the oil seal.
006237
130
Drive the oil seals down into the housing with lipped portion toward the water pump case. (one at a time)
GEARCASE ASSEMBLY
ASSEMBLY
Apply Triple-Guard grease to the seal lips.
Reassembly and installation is reverse of removal and disassembly with special attention to the following steps.
IMPORTANT: • Make sure that all parts used in assembly are clean and lubricated.
• After assembly, check the parts for tightness
006240
Driveshaft Inspect the driveshaft. If wear, twist or other damage is found on the splines, replace the driveshaft.
and smoothness of operation. • Before final assembly, be absolutely certain that all gear contact, shim adjustments and tolerances are correct. • Failure to correctly adjust these areas will result in gearcase damage. • Do not re-use the gasket, the O-ring and the cotter pin once removed. Always use new parts. Refer to GEAR SHIMMING AND ADJUSTMENT on p. 135.
Lubrication Forward Gear 006241
Apply gear lubricant to the following parts: • Forward gear backup shim • Forward gear
8
1
2
1. Forward gear backup shim 2. Forward gear
006242
IMPORTANT: The forward gear has the bushing and the dents at the side of the dog bosses.
131
GEARCASE ASSEMBLY Pinion Gear
Install the driveshaft.
Apply gear lubricant to the following parts: • Pinion gear backup shim • Pinion gear
1
1
1. Driveshaft
006247
Install the E-ring.
2
1
1. Forward gear backup shim 2. Pinion gear
006243 006244
1. E-ring
006248 006249
Driveshaft
Propeller Shaft
Apply Triple-Guard grease to the oil seal lips.
Install the circlip to the propeller shaft. Insert the return spring and the clutch dog to the propeller shaft.
Apply gear lubricant to the bushing in the housing.
3
2 1
006245 006246
132
1. Circlip 2. Spring 3. Clutch dog
006250
GEARCASE ASSEMBLY Insert push rod into the propeller shaft.
Install the propeller shaft/housing assembly to the gearcase and tighten the two bolts to torque of 6.0 ft. lbs. (8 N¡m).
1 1
1. Push rod
006251
Propeller Shaft Assembly and Bearing Housing
1. Bolt (2)
Insert the thrust washer and the bearing housing to the propeller shaft.
Water Pump
Apply Triple-Guard grease to the O-ring and the oil seals of the bearing housing.
006254
Apply ThreeBond 1207B sealant evenly to both sides of under panel gasket. Place gasket on gearcase assembly.
2 1
8 1 3 1. Thrust washer 2. Bearing housing 3. O-ring
006252
1. Gasket
006255
Install the under panel, impeller pin, and impeller.
3 2
1
1. Under panel 2. Impeller pin 3. Impeller
006256
133
GEARCASE ASSEMBLY Apply ThreeBond 1207B sealant on the outer surface of water pump sleeve. Install the water pump sleeve into the water pump case by confirming the boss on the sleeve should be meeting with the groove on the pump case.
Install the water pump case while rotating the driveshaft clockwise in order to flex the impeller vanes in the correct direction. Tighten the water pump case bolts to torque of 3.5 ft. lbs. (5 N¡m).
1 1
1. Bolt (4) 1. Sleeve
006257
Install the water pump case seal. Apply TripleGuard grease to O-ring and install the O-ring.
006259
Shift Rod Install the shift rod.
1
1
2 1. Shift rod 1. Seal 2. O-ring
006261
006258
The stepped section of the shift cam must be positioned toward the propeller shaft.
1 1. Shift cam, stepped section
134
006260
GEARCASE INSTALLATION
INSTALLATION Apply Moly Lube to the driveshaft splines.
GEAR SHIMMING AND ADJUSTMENT
Install the gearcase assembly. Apply Gasket Sealing Compound to the gearcase retaining bolts and tighten the bolts to a torque of 6.0 ft. lbs. (8 N¡m).
If the gearcase has been rebuilt or has had components replaced, shimming for correct gear contact and backlash will have to be adjusted in order to ensure smooth, reliable operation of gears.
1
Shim/Washer and Mounting position Numerical index/item
1. Bolt (2)
006266
Available thickness (mm)
Design specification thickness (mm)
1
Pinion gear backup shim
1.8, 1.9, 2.0, 2.1, 2.2
2.0
2
Forward gear backup shim
0.3, 0.4, 0.5, 0.6
0.5
Propeller
1.6, 1.7, 1.8, 1.9, 2.0
3 shaft thrust
0.2 (Thrust play)
washer
Install the shift rod to the clutch rod arm. Install the E-ring. Install the clutch notch spring. Shift the clutch lever from neutral and forward to check operation.
8 4 1
3
1. 2. 3. 4.
Shift rod Clutch rod arm E-ring Spring
2
006267
Fill the gearcase with gearcase lubricant. Refer to Filling on p. 123. 006268
135
GEARCASE GEAR SHIMMING AND ADJUSTMENT
Forward Gear/Pinion Gear
Push the propeller shaft inward and hold in position.
Backlash Adjustment To check the gear backlash of the pinion and forward gear, hold the pinion gear by hand, then gently rock forward gear back and forth by hand. Gear backlash: • 0.004 to 0.008 in. (0.10 to 0.20 mm) If backlash is larger than specified, the thickness of the forward gear backup shim must be increased. If backlash is smaller, the thickness of the backup shim must be decreased.
006271
Rotate the driveshaft clockwise five to six times.
006270 006273 006272
Tooth Contact Pattern To check and adjust the tooth contact pattern of the pinion and forward gear, apply a light coat of Prussian Blue on the convex surface of the forward gear. Install the propeller shaft and the housing assembly. Do not install the push rod.
IMPORTANT: Securing the propeller housing with the bolts is not required.
Carefully pull out propeller shaft and housing to check tooth contact pattern. Concave side
Tooth width
Convex side Heel
shaft
Toe Tooth top Tooth bottom
TOOTH CONTACT PATTERN 006274
136
GEARCASE GEAR SHIMMING AND ADJUSTMENT A shim adjustment may be necessary in order to obtain the optimum tooth contact pattern.
Approx. 1/3 of tooth width Approx. 1 mm HEEL
Correction measures: • Increase the thickness of the forward gear shim. • Slightly decrease the pinion gear shim thickness.
IMPORTANT: Do not set tooth contact in the bottom side toe contact position. Chipping of the pinion gear may result.
Propeller Shaft Thrust Play TOE Convex side Optimum Tooth Contact
006275
After adjusting all gear positions, measure the propeller shaft thrust play. Propeller shaft thrust play: • 0.008 to 0.016 in. (0.20 to 0.40 mm)
IMPORTANT: The backlash of the gear should be checked when increasing or decreasing the thickness of the shim to adjust tooth contact. Example
Heel
Toe
INCORRECT Top Side Toe Contact
006276
Correction measures: • Decrease the thickness of the forward gear shim. • Slightly increase the pinion gear shim thickness.
IMPORTANT: Do not set tooth contact in the
006278
Measurement Push the propeller shaft inward. Hold the propeller shaft in and set the dial gauge pointer to zero.
top side toe contact position. Damage and chipping of the forward and pinion gear may result.
Slowly pull the propeller shaft outward and read the maximum thrust play on the dial.
Example
If the measurement is more than the specification, increase the propeller shaft thrust washer thickness.
Heel
Toe
If the measurement is less than the specification, reduce the propeller shaft thrust washer thickness.
INCORRECT Bottom Side Toe Contact
137
8
GEARCASE NOTES
NOTES Technician’s Notes
Related Documents Bulletins
Instruction Sheets
Other
138
MANUAL STARTER
MANUAL STARTER TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140 141 142 143 143
9
139
MANUAL STARTER SERVICE CHART
SERVICE CHART 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Starter assembly, recoil Reel Ratchet set Spring, spiral Grip set Rope Pulley, starter Bolt Bolt Decal, S.I.G.P.
A
A Triple-Guard Grease F Blue Nut Lock
140
EPC4222
MANUAL STARTER REMOVAL
REMOVAL
Remove the knot from grip holder. Remove the grip holder and starter grip. Completely remove the motor cover.
WARNING Avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Wear safety glasses while disassembling and assembling manual starters to avoid personal injury caused by rewind spring tension. Remove the motor cover.
1. Grip holder 2. Starter grip
006282
Install the starter grip and the grip holder to the end of the rope. Loosen the knot previously tied in the rope.
006280
Tie a knot in the rope inside of the motor cover to prevent the rope from rewinding onto the recoil reel when the starter grip is removed.
9 006283
Remove the three bolts and the recoil starter assembly.
006281
1 1. Bolt (3)
006284
141
MANUAL STARTER DISASSEMBLY
DISASSEMBLY
Remove the spring and the ratchet.
1
WARNING Because of the coiled tension in the recoil spring, wear safety glasses and hand protection when winding or unwinding this component.
2
Turn the reel clockwise in order to release the coiled tension in the recoil spring. 1. Spring 2. Ratchet
006287
Slowly remove the reel with the recoil spring from the recoil case.
1
1
1. Reel
006285
Remove the screw and the friction plate.
IMPORTANT: The screw is a left-hand thread. 1. Reel
006288
Remove the recoil spring from the reel.
1
1. Screw 2. Friction plate
2 1 006286
1. Recoil spring
006289
IMPORTANT: Do not remove the recoil spring unless replacement is necessary. Inspect the spring in the assembled position. Remove the rope from the reel.
142
MANUAL STARTER INSPECTION
INSPECTION IMPORTANT: If excessive wear, crack, defective or other damage is found on any component, replace. Inspect the ratchet and the all springs. If excessive wear or other damage is found, replace. Inspect the reel and the recoil case. If crack or other damage is found, replace.
ASSEMBLY AND INSTALLATION Reassembly is the reverse order of disassembly with special attention to the following steps. Secure the outer end of the recoil spring on the boss in the reel and wind the spring toward the center of the reel in a counterclockwise direction.
1
006290
1. Recoil spring
Inspect the recoil rope. If wear or fraying is found, replace. Inspect the recoil spring. If crack, deformation or excessive curve is found, replace.
006292
WARNING Because of the coiled tension in the recoil spring, wear safety glasses and hand protection when winding or unwinding this component. Apply Triple-Guard grease to the recoil spring. Install the rope with knot secured in the reel fitting.
006291
1
1. Rope
006293
143
9
MANUAL STARTER ASSEMBLY AND INSTALLATION Install the reel and the recoil spring to the recoil case aligning the inner end of the spring with the boss cutaway on the case.
Install the friction plate. Apply Screw Lock to threads of screw then tighten the screw.
1
2
1. Reel
006294
1
1. Friction plate 2. Screw
006286
IMPORTANT: Screw is a left-hand thread.
Install the ratchet and the spring.
Rotate the reel approximately four turns counterclockwise until the recoil spring is tensioned.
2
1
1. Ratchet 2. Spring
006295
006297
144
WIRE/HOSE ROUTING
WIRE/HOSE ROUTING TABLE OF CONTENTS WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 WIRE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 FUEL HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
10
145
WIRE/HOSE ROUTING WIRING DIAGRAM
WIRING DIAGRAM
Igniter unit
Spark plug
Flywheel Magneto
Wire color B: Black EMERGENCY STOP SWITCH Emergency stop switch: Lock plate IN → RUN Lock plate OUT → STOP Button PUSHED → STOP
006298
146
Emergency stop switch
Clamp
Emergency stop switch
Igniter unit
WIRE/HOSE ROUTING WIRE ROUTING
WIRE ROUTING
10
006299
147
WIRE/HOSE ROUTING FUEL HOSE ROUTING
FUEL HOSE ROUTING
Fuel tank
Fuel cock
Breather hose
Do not over-bend (kink) or twist hoses when installing. When installing hose clips, position tabs to avoid contact with other parts. Check that hoses do not contact rods and levers during either engine operation or standstill. Extreme care should be taken not to cut, abrade or cause any other damage on hoses. Care should be taken not to cause hoses to be compressed excessively by any clamp when fitted.
Fuel hose
• • • • •
006300
148
SAFETY
SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM . . . . . . . . . . . . . . . . . . . . . S–3 OUTBOARD SHIFT SYSTEMS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–4 OUTBOARD SPEED CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–5 OUTBOARD STEERING CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–6 OUTBOARD FUEL, ELECTRICAL SYSTEM, AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–8 OUTBOARD MOUNTING SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–11 IF WEAKENED, PARTS COULD FAIL LATER ON THE WATER, WHEN NOT EXPECTED . . . . . . . . . . . . . S–12 OUTBOARD HYDRAULIC TILT/TRIM SHOCK ABSORPTION SYSTEM AND SAFETY . . . . . . . . . . . . . . . . S–13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–14 SUMMING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–16 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM . . . . . . . . . . . . . . . . . . . . . S–17 HANDLING OUTBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–17 HANDLING LEAD/ACID BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–21 GASOLINE – HANDLE WITH CARE! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–22 HAZARDOUS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–23 SAFETY AWARENESS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–24
S–1
S–2
SAFETY
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that service boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so not only to protect yourself, but also to protect the people around you. It is impossible for this manual to cover every potentially hazardous situation you may encounter. However, your understanding and adherence to the recommendations contained in this manual and use of good judgment when servicing outboards will help promote safety. Always be alert and careful: a good foundation for safety. Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are careful to make sure:
• Product user is informed; and • Products are safe and reliable. It is up to you, the people who...
• Rig boats; • Fix machinery; and • Maintain equipment ...to keep the products safe and reliable. This section talks about safe boating and how you can help make it safe. Some of these safety issues you will know, others you may not.
First! A word about parts... Plain parts; special parts; all parts!
DO NOT SUBSTITUTE PARTS “They look the same, but are they the same?”
• • • •
Same size? Same strength? Same material? Same type?
Don’t substitute unless you know they are the same in all characteristics.
Second! • Special locking bolts and nuts are often used to hold steering, shift, and throttle remote control cables to the outboard.
• When you take any outboard off a boat, keep track of special nuts and bolts. Do not mix with other parts. Store them on the outboard, then they are there when you need them.
• When the outboard is returned to the boat, use only the special nuts and bolts to hold remote steering, shift, and throttle cables to the outboard.
S–3
SAFETY
Outboard Shift Systems and Safety The outboard Shift System starts here at the remote control lever...
...and ends here at the propeller.
When control lever is in FORWARD, NEUTRAL or REVERSE...
What is most important?
...shift linkage must match control lever position.
What could happen? IF...
IF... NEUTRAL
...propeller still powered (turning) unknown to operator, or outboard will START in gear, and boat will move suddenly.
FORWARD or REVERSE
FORWARD
...boat will move opposite to direction wanted by operator.
REVERSE
How can loss of shift control be minimized? Read, understand, and follow manufacturer’s instructions • Follow warnings marked “ ” closely. When • Assemble parts carefully. rigging • Make adjustments carefully. or after • Test your work. Do not guess. Make sure propeller does just what the operator wants servicing and nothing else. • Do not shift gears on a stopped outboard. Adjustments can be lost and parts weakened.
S–4
SAFETY
Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead.
What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL... Powerhead speed must slow down to allow operator to shift into NEUTRAL. Operator must be able to STOP propeller.
What could happen? If Operator cannot slow down the outboard or shift into NEUTRAL gear (stop propeller), Operator could panic and lose control of boat.
How can loss of speed control be minimized? Read, understand, and follow manufacturer’s instructions • Follow warnings marked “ ” closely. When • Assemble parts carefully. rigging • Make adjustments carefully. or after • Test your work. Do not guess. Make sure speed control system does just what the operservicing ator wants and nothing else. • Make sure full throttle can be obtained so Operator will not overload parts.
S–5
SAFETY
Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel...
...and ends here at the trim tab on the outboard.
What is most important? The steering system: • Must not come apart; • Must not jam; and • Must not be sloppy or loose.
What could happen? • If steering system comes apart, boat might turn suddenly and circle. Persons thrown into the water could be hit.
• If steering jams, operator may not be able to avoid obstacles. Operator could panic.
• If steering is loose, boat may weave while operator tries to steer a straight course. With some rigs (at high speed), loose steering could lead to loss of boat control.
S–6
SAFETY
How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets • When • rigging • or after • servicing • •
Marine Industry Safety Standards (ABYC). Read, understand, and follow manufacturer’s instructions Follow warnings marked “ ” closely. Assemble parts carefully. Make adjustments carefully. Keep parts moving freely. Lubricate parts as shown in manual. Use the bolts, nuts and washers supplied with steering attachment kits—they are a special locking type that will not loosen, rust, or weaken.
Transom Mounted Steering Systems – Check to Uncover Possible Trouble! Tilt outboard into boat, then turn it. During this procedure, steering parts: • Must not bind; and • Must not touch other boat, outboard, or accessory parts in transom area.
transom mounted steerer
Why? A hard blow to the outboard’s gearcase can result in damage to steering parts. stop
to
stop
Be aware that raising or lowering outboard on transom can change a set-up which was OK earlier. If moved up or down even one-half inch, run test again to make sure steering parts are free and clear. Check for damaged parts. Blows to the outboard like this
or this can put heavy loads on steering parts. Look for: • Cracked parts, including steering parts, swivel brackets, and transom brackets; • Bent parts; and • Loose nuts and bolts. Replace damaged parts. If weakened, parts could fail later on the water when least expected.
S–7
SAFETY
Outboard Fuel, Electrical System, and Safety
The electrical system begins here at the battery...
The fuel system starts here at the fuel tank... ...and ends here at the fuel injector.
...and ends here on the powerhead.
What is most important? • Fuel leakage must be eliminated. • Stray electric sparks must be avoided.
What could happen? • When not boating, fuel leaking in car trunk or van, or place where portable tank is stored (basement or cottage), could be ignited by any open flame or spark (furnace pilot light, etc.).
• When boating, fuel leaking under the engine cover could be ignited by a damaged or deteriorated electrical part or loose wire connection making stray sparks.
How Can Fire and Explosion Be Minimized? • Read, understand, and follow manufacturer’s instructions • Follow warnings marked “ ” closely. • Do not substitute fuel or electrical systems parts with other parts which may look the same. Some electrical parts, like starter motors, are of special design to prevent stray sparks outside their cases. • Replace wires, sleeves, and boots which are cracked or torn or look in poor condition. GA
S
When mixing and refueling, always mix gas and oil outside...
Always fill the tank outside the boat
GA
S
Fumes are hard to control. They collect and hide in the bottom of the boat.
Remember: Do not use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling. If you use a funnel, it has to be metal to ground the spout to the tank.
S–8
To avoid those static electric sparks, ground (touch) the spout against the tank.
SAFETY
If electrical parts are replaced or even removed from the outboard, check the following:
Wire and high voltage lead routing • As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads Sleeves, boots, shields • In position (to avoid shock hazard) • Not torn or cracked Metal Clamps – Tie Straps • Position as shown in manual Screws, Nuts, Washers • Tighten firmly–these keep clamps in position and ends of wires from sparking • Where lock washers are called for, use them
Spark Plug Boots • Not torn or cracked • Fully pushed onto spark plug
Spark Plugs • Avoid rough handling that could crack ceramic part of plug. (Sparks may jump across outside of plug.) In transom area:
All Connections • Clean • Tight (Prevents sparks)
Electric Cable • Not rubbing on sharp objects • Enough slack to allow full turning without pull loads on cable (prevents sparks)
Batteries • Secure in approved battery box or battery tray
• Battery terminals insulated • No strain on cables
S–9
SAFETY
After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard
Check for leaks under engine cover
GASOLINE
GASOLINE
If tank cap has an air vent valve, make sure it is closed.
If gasoline tank is stored indoors, do not put it in a room having an appliance with a pilot light or where electrical appliances or switches (which may spark) will be used.
Whenever possible, remove hose from outboard and from tank. Store hose around ears of tank. This way, gasoline is trapped in tank and not in the hose, where it might leak onto the floor if the hose deteriorates.
When Running: Carburetor air intake silencer will catch and hold fuel which may flood into engine if carburetor float sticks.
• Make sure silencer and its gaskets are on engine and drain hose is in place. • Air silencer mounting screws are special lock screws. Use only the special screws. S–10
SAFETY
Outboard Mounting System and Safety
The mounting system includes:
• outboard parts • bolts, nuts, and washers • boat’s transom
What is most important? • Outboard must stay in position on boat’s transom. What could happen? Outboard may
Outboard may S...L...I...D...E on transom Boat may turn and be hard to steer.
T...I...L...T on transom Boat may turn and be hard to steer.
• If outboard hits something solid and does not stay on the transom, boat occupants may be injured from the outboard or its parts entering the boat. Boat’s transom could break away.
Outboard may be lost overboard. Boat may SINK.
How Can Loss of Mounting Be Minimized? • Read, understand, and follow manufacturer’s instructions. • Follow warnings marked “ ” closely.
S–11
SAFETY
If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. If transom is curved, outboard may come loose.
Mount on flat surface only. Use shims to make surface flat.
Use bolts, nuts, and washers supplied with outboard. They are usually special, and will not rust or weaken.
If owner tells you “I hit something really hard...”
Check for a high speed blow to the lower unit.
OR...
“I was backing up and I think the outboard may have hit a tree or something.” Check for a slow, heavy squash to the outboard.
• Look for damaged parts and loosened nuts and bolts in both the steering and mounting systems. Replace damaged parts.
S–12
SAFETY
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? • Shock absorption system must always be ready to absorb some blows to the lower parts of the outboard. • Outboard must not trim in too far suddenly.
What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat. Transom could break away and outboard may be lost overboard.
Boat may SINK.
At high speeds, sudden trimming in too far may dive boat under water or spin it around.
How can possible conditions be minimized? • Read, understand, and • • • •
follow manufacturer’s instructions. Follow warnings marked “ ” closely. Test your work whenever possible. If oil leaks are seen in service areas, determine source. Keep reservoir filled. If outboard is hydraulic tilt/ trim model, always return rod to hole position determined by boat operator and make sure angle adjusting rod retain is in locked position.
Make sure manual release valve is closed tight. Torque to 45 to 55 in. lbs. (5.1 to 6.2 N·m). If left open, outboard has no shock protection. Trimming “in” too far can happen when angle adjusting rod is not in the right hole or is not in any hole (lost).
S–13
SAFETY
Outboard Emergency Stop System and Safety
The emergency system begins here at the clip and lanyard...
...and ends here in the ignition system on the powerhead.
What is most important? • The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop / key switch.
What could happen? If switch fails...
...engine will keep running when clip is pulled from the switch If lanyard is caught... ...engine will keep running.
S–14
SAFETY
What could happen?
If lanyard is cut or frayed...
...lanyard or clip may break when pulled...
If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway. Operator may drown and boat WILL run into something.
How can failure of the emergency stop system be minimized? • • When • rigging •
Read, understand, and follow manufacturer’s instructions Follow warnings marked “ ” closely. Assemble parts carefully. Inspect lanyard for cuts or fraying; clip for wear. Replace with original parts. Do not or after substitute. servicing • Locate control box and other items in area to keep lanyard from being caught. • ALWAYS TEST EMERGENCY STOP SYSTEM. PULL LANYARD. ENGINE MUST STOP. IF IT DOES NOT, REPAIR BEFORE NEXT USE.
S–15
SAFETY
Summing up Now you know some things that can take the joy out of boating.
No doubt about it—proper safety takes time! • Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments • Testing your work And making sure
• Worn or damaged parts are replaced • Replaced parts are like originals in every way • Customer is told of things which need attention But, do you really want the alternative?
S–16
SAFETY
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while:
• • • •
Rigging boats Troubleshooting problems Fixing components Testing their work
Some of these safety issues you will know, others you may not.
Handling Outboards When lifting outboards Some outboards have a fixed lift bracket bolted to the powerhead. Because outboard will want to hang like this when off the floor...
Center of gravity Stand Clear! It might hit you as it swings.
If engine does not have fixed lifting bracket and you use Universal Puller, P/N 378103, and Lifting Eye, P/N 321537, or Lifting Eye and Adapter Assembly, P/N 396748... ...use only the special hardened screws and washers from the set. Outboard can drop suddenly if hoist or engine stand are in poor shape, or too small for the job.
300 lbs. (136.1 kg)
Regular screws are not strong enough. Screws may break and outboard may drop suddenly.
V6 455 lbs. (206.4 kg)
• Make sure shop aids have extra capacity, and keep them in good repair.
S–17
SAFETY
Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock you and may cause you to recoil into the rotating flywheel.
• Two people working together on a live outboard must look out for each other. Never, ever, use the key to start the outboard before signaling your partner. He may be leaning over the outboard with hands on the flywheel, handling a “hot” electrical part, or near the propeller.
Outboard starting at the wrong time When you do things that turn the flywheel like: • Off-season storage fogging (oiling) of outboard; • Removing propeller with a powered tool; • Electrical system checks; • Servicing the flywheel; or • Any other actions ALWAYS...
1) Turn key switch OFF 3) Shift to NEUTRAL
2) Twist and remove ALL spark plug leads
Check prop shaft. Is outboard really in NEUTRAL? NO SPARK
S–18
NO START
NO SURPRISES
SAFETY
Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily. Wear eye protectors.
2) Running with the wrong test wheel... Use the right test wheel.
This may happen if outboard runs too fast.
Running outboards: Exhaust fumes DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.
• Whenever running the engine, assure there is proper ventilation to avoid the accumulation of carbon monoxide (CO), which is odorless, colorless, and tasteless, and can lead to unconsciousness, brain damage, or death if inhaled in sufficient concentrations. CO accumulation can occur while docked, anchored, or underway, and in many confined areas such as the boat cabin, cockpit, swim platform, and heads. It can be worsened or caused by weather, mooring and operating conditions, and other boats. Avoid exhaust fumes from the engine or other boats, provide proper ventilation, shut off the engine when not needed, and be aware of the risk of backdrafting and conditions that create CO accumulation. In high concentrations, CO can be fatal within minutes. Lower concentrations are just as lethal over long periods of time.
S–19
SAFETY
Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Always shut off the engine when near people in the water.
Eye protection Eyes need protection when:
• Grinding
• Spraying cleaners and paints
• Chiseling Tip: When steel on steel, use plastic- or brass-type hammers. They don’t chip off as easily as steel hammers.
Wear Safety Glasses Protect eyes from:
S–20
• Acid
• Ends of cables
SAFETY
Handling Lead/Acid Batteries Strong acid solution (sulfuric acid)
If spilled or splashed on any part of body...
If solution gets into eyes, wash and contact a doctor immediately.
Wash with lots of water.
Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket. (This prevents shocks if charger is defective.) 2) Observe correct polarity when connecting these larger leads. 3) Always charge in a well ventilated area. Charging causes acid solution to give off hydrogen gas through the vents in the caps. Make sure vents are open. If clogged, pressure inside may build. Battery may EXPLODE.
Battery gas is explosive! While charging or discharging, remember: • No smoking • No flames • No sparks
DO NOT check battery charge by placing metal objects across posts. You will make sparks and serious burns are possible.
Never remove charger cables from battery posts. It is a sure way to make a lot of sparks in an area surrounded by battery gas.
After charging: • Shut off charger • Pull charger plug out of 110 V outlet • Take charger cables off battery posts
S–21
SAFETY
Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when mixed as shown...
1 Part Gasoline
20 Parts Air When you smell ANY odor of gasoline, explosion is possible.
Gasoline fumes are heavy and will sink to the lowest point in the boat or room and will STAY there, WAITING...
By Volume
Gas Fumes If the air around you is calm, the pilot light in the heater could ignite the heavy fumes before your nose ever smells the fumes.
What can you do?
Store gasoline in sturdy, approved, sealed gas can and keep outside.
• • • •
Always store gasoline outside in a safe can (flame arrester and pressure relief valve in pour spout). Fill portable tanks outside of boat. Spillage will collect in bottom of boat. Use fuel as fuel ONLY, not for a cleaner or degreaser. If fumes are smelled in shop, basement, or garage, immediately: – Put out open flames, cigarettes, sparking devices; – Wipe up spill or leak; – Get towels and rags outside fast; – Open doors and windows; and – Check lowest area for fumes.
Be aware of items in and around repair area which can ignite fumes. Control them if fumes are smelled. Matches, cigarettes, blow torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights or electric ignitors (furnace, dryer, water heaters) Loose wires on running outboards Other variables which may ignite fumes
• • • • • • •
How many of these are in your repair area?
S–22
SAFETY
Hazardous Products
Know how items in the shop can hurt people...
READ • “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an emergency arise • “How to dispose of can” It’s all on the back of the can or bottle label. And remember: Little children are very curious and will try to taste everything so keep containers away from children!
S–23
SAFETY
Safety Awareness Test The Technician’s Safety Awareness Test.... 1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and procedures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual? 4) Will you follow all safety warnings, precautions, instructions and recommendations outlined in this service manual? 5) Do you understand that the service manual as a whole and this Safety section, in particular, contain essential information to help prevent personal injury and damage to equipment and your customers? 6) Have you received training related to common shop safety practices to protect yourself and others around you? 7) When replacement parts are required, will you use Evinrude ®/Johnson ® Genuine Parts or parts with equivalent characteristics, including type, strength and material? 8) Are you ready to follow the recommendations in this service manual before you service any boat or outboard? 9) Do you understand that safety-related accidents can be caused by carelessness, fatigue, overload, preoccupation, unfamiliarity of operator with the product, drugs and alcohol, just to name a few?
S–24
INDEX
INDEX A
Abbreviations 12 Adjustment Backlash 136 Gear Shimming 135 Propeller Shaft 137 Throttle 69 Adjustments Idle Speed 48 Ignition Timing 49 Valve Clearance 47 Anode Anti-Corrosion 40 Continuity Check 41
B
Bearing Propeller Shaft Bearing Housing 129 Break-In Procedure 33, 51
C
Camshaft Assembly 98 Inspection 89 Removal 87 Carburetor Cleaning and Inspection 66 Disassembly 65 Inspection 43 Installation 68 Reassembly 67 Removal 64 Clamp Bracket Assembly 116 Removal 111 Compression Testing 76 Cooling System Description 42 Diagram 105 Flushing 42 Inspection 42
Operating Temperature 17, 34 Turbulence 28 Corrosion Anodes 40 Exterior Finishes 41 Internal Engine Treatment 50 Metallic Components 41 Winter Storage 50 Crankcase Assembly 100 Disassembly 87 Crankshaft Assembly 97 Inspection 89, 94 Removal 88 Cylinder Bore 16, 75 Cylinder Head Assembly 84 Cleaning and Inspection 80 Disassembly 78 Installation 86
D
Driveshaft Housing Assembly 115 Inspection 114 Removal 110
E
Emergency Stop Switch 34 Engine Specifications 16 Exterior Finish Protection 41
F
Flushing, Cooling System 42 Fuel Additives 16 Minimum Octane 16 Requirements 16 Treatment 50
Index–1
INDEX
Fuel System Carburetor 65 Fuel Cock 64 Fuel Requirements 31 Minimum Octane 31 Storage 50
G
Idle Adjustment 48 RPM 16 Ignition Operation 55 Servicing 59 Tests 58 Wire Routing 147 Wiring Diagrams 146 Inspection Schedule 38
L
Lubrication Engine Oil 16 Gearcase 17, 44, 122 Schedule 38
M
Neutral Start Protection 34
Hoses Routing 148
I
N
Gearcase Assembly 131 Inspection 127 Installation 135 Leak Test 123 Lubricant 17, 44, 122 Lubrication 131 Removal 124 Water Pump 133
H
Removal 141 Minimum Octane 16 Model Number Location 6 Mounting the Engine 30
Maintenance Schedule 38 Manual Starter Assembly and Installation 143 Disassembly 142 Inspection 143 Index–2
O
Oiling System Engine Lubricant 32 Requirements 32 Operating Temperature 34
P
Pinion Gear Installation 132 Removal 126 Piston Assembly 96 Inspection 90 Removal 87 Powerhead Assembly 96 Cleaning and Inspection 80 Disassembly 78 Installation 103 Removal 77 Specifications 74 Pre-Season Service 51 Propeller Installation 36, 122 Safety 122 Selection 35 Propeller Shaft Bearing Housing Inspection 129 Installation 132 Removal 125
R
Running Checks Emergency Stop Switch 34 Neutral Start Protection 34 Operating Temperature 34 Water Pump Overboard Indicator 34
INDEX
S
Safety S–1 Serial Number Location 6 Shimming 135 Spark Plugs Recommended 17, 46 Replacement Schedule 39 Specifications 16 Powerhead 74 Starter Assembly and Installation 143 Disassembly 142 Inspection 143 Removal 141 Stop Circuit 34 Storing the Engine 50 Submerged Engines 51 Swivel Bracket Assembly 115 Removal 111
T
V
Valve Clearance Adjustment 47
W
Water Intake Screen 42 Water Pump Overboard Indicator 34 Winterizing 50
Technical Data 16 Ten Hour Inspection 40 Thermostat Operating Temperature 17, 34 Tiller Handle Assembly 117 Removal 112 Timing Adjustment 49 Tools Lifting Eye, P/N 321537 17 Universal Puller Set, P/N 378103 17 Torque Specifications, Standard 18 Troubleshooting Ignition 57
Index–3