CONTENTS HOW TO USE THS MANUAL # C=O Co mowro usa Ta 2 Sane hile ky BOATING EQUPNENT (NOT REQUIRED AUT RECOMMENDED) 110 SAFETY INSERVICE te ‘TROUBLESHOOTING te SHOP EQUPMENT te Tools te FASTENERS, MEASUREMENT, AND CONVERSIONS te SPEGIFIGATIONS @ 7 GENERAL NFORMATON 22 De LUBRICATION SERVICE a ENGINE MAINTENANCE 26 BOAT NANTENANCE a TONEUP Fe “TN AND SYNCHRONIZATION ae STORAGE ay CLEARING A SUBMERGED NOTOR ba SPECIFICATIONS ai moe CARBURETED FUEL SYSTENS 2 FUEL TANK & UNES i CARBURETORS on UNDERSTANDING AND TROUBLESHOOTING eNO SIRs CUASMM Evectrical svsTEeNs a ieTiON SYSTEMS. ‘TROUBLESHOOTNG FLWIHEEL MAGNETO IGNTION SYSTEMS at LOW TENSION YVIHEELMAGNETOIGNITON SYSTEMS 4-21 ‘TYPE 1 CAPACITOR DISCHARGE (CD) IGNITION SYSTEM (Witt THER Base) a8 ‘TYPE Il CAPACITOR DISCHARGE (CD) IGNITION SYSTEM (Wm seNsOR CoM) am GENERATOR CHARGING citcuT ts CHARGING SYSTEMS BATTERY “8 STARTING SYSTEM ts ELECTRICAL ACCESSORIES (GAUGES, LIGHTS, HORNS AND swITCHES) 4a Secricknons tn WING DIAGRAMS tn LuBRIcaTION stsTews 52 pine Eee e le VARIABLE RATIO OILING (VRO) SYSTEM a [ACCUM (AUTOBLEND) OLING SYSTEM 5 GSouNG SYSTEM aCONTENTS SPECHIGATIONS Pc ee) A LOWER UNIT. GEARCASE BASICS 1 LOWER UNIT LOWER UNIT (NON-SHETING) rt LOWER UNIT (GHIFTW.NO-DISCONNECT) 5 LOWER UNT MECHANICAL SHIT, WSPLITGEARCASE, 6 HP & 95.25 HP) 78 LOWER UNIT (MECHANICAL SHIFT SOLID GEARCASE, (PROPELLER EXHAUST) Tat LOWER UNIT (MECHANICAL SHIFT, PROPELLER EXHAUST - CERTAIN 20-95 HP MODELS) Ts LOWER UNIT (MECHANICAL SHIFT SLIDING CLUTCH DOG) 7-94 TINT SYSTENS 82 esas 8 LATEMODEL MECHANICAL SHIFT REMOTE CONTROLS 9-20 HYDRO-ELECTRICMECHANICAL SHIFT REMOTE CONTROLS $2 REMOTE CONTROLS 9 HAND REWIND STARTER 102 HAND REWIND STARTER TYPE | STARTER - CYLINDER WIPINION GEAR (68 HP) 109 TPE IISTARTER- CYLINDER W PINION GEAR (95 HP) 108 ‘TYPE Il STARTER -COlL SPRING W SWING ARM VERTICAL MOUNT (VARIOUS 4/45 HP) STARTER. 10813 ‘TYPE IV STARTER COIL SPRING \W/ SLIDING GEAR ARMA HORIZONTAL MOUNT (8.915 HP) STARTER. 1017 ‘TYPE’ STARTER - MOUNTED ATOP FLYWHEEL WNO RETURN SPRINGS (1971-76 AND 1961-95 40 HP) 10.23 ‘TYPE Vi STARTER. MOUNTED ATOP FLYWHEEL WITH 110F 2 NYLON PAWLS (VARIOUS 235 HP MODELS) 10.28 ‘TYPE VISTARTER- MOUNTED ATOP FLYWHEEL WILARGE PAWL PLATE (1886-09 40 HP) STARTER 1022 SPECIFICATIONS 10m MASTER INDEX 10-95 aaa 4‘ACCUMIX (AUTOBLEND) OILING SYSTEM 56 TIMING 434 DESCRPTION & OPERATION. 56 TROUBLESHOOTING, 420, (GENERAL NAINTENANGE, 56 CAPACITOR DISCHARGE (CD) 16NTION (WiSENSOR COIL). OL RESERVOR CANISTER 56 “APMATURE PLATE ‘TROUBLESHOOTING, 56 CHARGE GR SENSOR COIL, ALTERNATOR CHARGING CIRCUIT. ‘ast DESCRIPTION & OPERATION. DESCRPTION & OPERATION. 451 FLYWHEEL DIODE 453 IDENTEICATION. (GENERAL INEORMATION 451 POWER PACK STATOR, 459 TIMING TROUBLESHOOTING 451 TROUBLESHOOTING. ANCHORS +10 CARBURETED FUEL S¥STENS ‘ANODES NGS} 27 DESCRIPTION & OPERATION, INSPECTION. 28 GENERAL INFORMATION SERVICING. 219 PRESSURIZATION ARMATURE PLATE. SERVICE CAUTIONS (CD IGNITION SYSTEM (WSENSOR CoM) 442 TROUBLESHOOTING. FLYWHEEL MAGNETO IGNITION 417 CARBURETOR. TYPE | LOW TENSION FLYWHEEL MAGNETO ichTION 426 DISASSEMBLY & ASSEMBLY’ AVOIDING MISTAKES, ‘AVOIDING TROUBLE BAILING DEVICES: BASIC ELECTRICAL THEORY HOW DOES ELECTRICITY WORK OHMS LAW, WHERE TO START. BASIC OPERATING PRINCIPLES ‘COMBUSTION. UNDERSTANDING ENGINE OPERATION, STROKE MOTORS “4STROKE MOTORS BATTERY ‘CONSTRUCTION DUALBATTERY IISTALLATION AUNBER CABLES, Location. MAINTENANCE, MARINE RATINGS. SERVICE, STORAGE. TESTING BEFORE/AFTER EACH USE VISUALLY INSPECTING THE BOAT AND MOTOF BOAT MAINTENANCE : BATTERIES, FEEAGLASS HULL BOATING EQUIPMENT ‘ANCHORS. BAILING DEVICES COMPASS, FRSTAD Kir ‘OARIPADDLE: TOOLS & SPARE PARTS VHEEN RADIO. BOATING SAFETY ‘COURTESY MARINE EXANINNATIONS REGULATIONS FOR YOUR BOAT, REQUIRED SAFETY EQUIPMENT BOTTOM SEAL INSPECTION. REMOVAL & iiSTALLATION BREAKIN & THE VAO SYSTEM BREAKER PONTSICON DENSER FLYWHEEL MAGNETO IGNITION LOW TENSION FLYWHEEL MAGNETO iGhiTION BYPASS COVER, PEMOVAL & INSTALLATION caNYou Do Ir? ‘CAPACITOR DISCHARGE (6b) IGNITION (TIMER BASE} DESCRIPTION & OPERATION, IDENTFICATION POWER PACK. STATOR & CHARGE Coit TINER BASE & SENSOR ASSEMBLY. 432 REMOVAL, INSTALLATION & ADJUSTMENT (CARBURETOR. TYPE | (LATE NCDEL) 58 HP (1640) CLEANING & INSPECTION OVERHAUL, REMOVAL & STALLATION (CARBURETOR. TYPE It DISASSEMBLY & ASSEMBLY’ REMOVAL, INSTALLATION & ADJUSTHENT (CARBURETOR. TYPE I DISASSEMBLY & ASSEMBLY REMOVAL & INSTALLATION (CARBURETOR. TYPE WV. DISASSEMBLY & ASSEMBLY’ PEMOVAL, INSTALLATION &. ADJUSTMENT CARBURETOR INSTALLATIONS, TYPE! TYPE I TYPE I TPE. (CARBURETORS, ‘CARBURETOR INSTALLATIONS. 313 ELECTRIC FUEL PRINER, fava edd FUEL PUNP. 336 GENERAL INFORNATION, 313 MANUALFUELPRINER, 3.0 TYPE | CARBURETOR a TYPE | CARBURETORS (\ATE NGOEL) -58 HP (1840) 310 TYPE II CARBURETOR. 323 TYPE Il CARBURETOR. 337 TYPE IV CARBURETOR: 331 CENTERING PW, e2 REMOVAL. en CHARGE OA SENSOR COIL: TYPE i REMOVAL & INSTALLATION 449 CHARGING CIRCUIT (ALTERNATOR) SOs DESCRIPTION & OPERATION, 451 DIODE. 453, GENERAL INFORNATION 451 STATOR... aiaenincsni 4 TROUBLESHOOTING, 451 (CHARGING CIRCUTT (GENERATOR) cea DESCRIPTION & OPERATION, 445 GENERAL INFORMATION. 445 GENERATOR. 447 TROUBLESHOOTING. 448 VOLTAGE REGULATOR. 447 CHARGING SYSTEMS “ALTERNATOR GENERATOR CHEMICALS CLEANERS LUBRICANTS & PENETRANTS. SEALANTS TYPES OF CHEMICALS. (CHOKE CIRCUT, CLEARING A SUBHERGED MOTOR10-36 MASTER INDEX col. FLYWHEEL MAGNETO IGNITION 449 COMPASS. 140 INSTALLATION, tt PRECAUTIONS: tH SELECTION, 140 ‘COMPRESSION CHECK sive CONCEALED SIDE MOUNT REMOTE UNITS. 0.25 DISASSEMBLING & ASSENBLING THE HOUSING O28 OVERHAUL. 0.25 PLACING THE TRINTILT SWITCH. 0.5 ‘CONNECTING RODS eu CLEANING, INSPECTION & SERVICE e2 DISASSEMBLY & ASSEMBLY e18 EMOVAL & INSTALLATION eu CONTROL CABLES. 0.92 RIGGING, 022 COOLING SYSTEM DESCRIPTION & OPERATION 57 FLUSHING THE COOLING SYSTEM. 29 GENERAL INFORMATION 57 THERMOSTAT AND PRESSURE RELIEF VALVE}. 510 TROUBLESHOOTING, 53 WATER PUMP. : et (COOLING SYSTEN MAINTENANCE. 232 WATER PUMP CHECK 23 (COURTESY WARINE EXAMINATIONS 110 (CRANKCASE COVER. e13 REMOVAL & INSTALLATION e13 CRANKCASE SIDE BOLTS e12 ENOVAL & INSTALLATION 612 (CRANKSHAFT & BEARING 2 CLEANING & INSPECTION CRANKSHAFT & BEARING ASSEMBLY 62 INSTALLATION 624 FENOVAL & DISASSEMBLY 62 CYLINDER BLOCK 2 HONING PROCEDURES 62 SERVICE, 023 CYLINDER HEAD $5 REMOVAL & SERVICE. 65 DE-CARBONING THE PISTONS 22 DESCRIPTION & CPERATION "ACCUMDX SYSTEM 55 CARBURETORS 32 COOLING SYSTEM 57 FLYWHEEL MAGNETO IGNITION en LOWER UNT- ELECTRIC SHET, 2 SOLENOIDS 181 LQWER ONT HECHUMTA SET HYOPaUG RSS" 78 {OWERUNT MECHANICA SHEL PROPCLLER EUS. 2 IOWERUNT-MEGHAMCA SHEL Song CLUTCH DoS. at {OWERUNT MECHANICA SHEL SONG cLUTEN og. 734 LQWERUNT MECHANICAL SH SOLD GeARCASE. hort len DUAUST ra Ie UT ci i WU ARC CAN (Ei ios {WER UNT- Shr Wn Discos {Gencane syste PowWeR TAMIL FENOTE CONTROLS. EARLY NOBEL FENOTE cOnTROLS- LATE WooEE FENOTE CONTROLS. ELECTR GEAA BONES EVD 210 FENOTE cOMTROLS. SHIGE LEVER REMOTE COMBL SHET BOX 0413 STARTING SYSTEM: 45 BO SYSTEM 52 DIODE: +5 PEPLACENENT 4 DIRECTIONS & LOCATIONS 12 DDOUBLE-LEVER SHIFT BOX. 03 "ASSENELY & INSTALLATION 95 CLEANING & INSPECTION 95 PENOVAL & DISASSEMBLY 4 TROUBLESHOOTING, 93 DUAL HANDLE SURFACE NOUNT REMOTE (SINGLE MOTORS) ...0.25 OVERHAUL, 025 ELECTRIC FUEL PRINER 340 DISASSEMBLY & ASSEMBLY 343 REMOVAL & INSTALLATION 342 TESTING. 340 ELECTRIC GEAA BOXES (EVINRUDE). : 10 DESCRIPTION & OPERATION, 310 SHIFT SWITCH REMOVAL & INSTALLATION. 12 SHIFTER ADJUSTMENT 013 THROTTLE CABLE REMGWVAL & iNSTALLATION 12 TROUBLESHOOTING, 910 ELECTRIC GEAR BOXES & SiNGLELEVER CONTROLS (OuNSDY. 06 REMOTE CONTROL CABLE - INSTALLATION a0 ‘SHIFT BOX DISASSENBLY & ASSEMBLY 03 STARTER LOCKOUT SWITCH ADJUSTER 10 ‘TROUBLESHOOTING, 08 ELECTRIC STARTER NGTOR PINON 25 LUBRICATION, 25 RECOMMENDED LUBRICANT 25 ELECTRICAL ACCESSORIES (GAUGES, LiGHTS, HORNS AND SWITCHES), e 4s ‘CHOKE CIRCUIT é 470 FUEL GAUGE 38 (GENERAL INFORMATION 457 HORNS. 480 TACHONETER, 00 TEMPERATURE GAUGE ANDIOA WARNING LIGHT. 457 ELECTRICAL COMPONENTS #2 ‘GROUND. a Loap. “4 POWEA SOURCE. 2 PROTECTIVE DEVICES, a SWITCHES & RELAYS 4 WING & HARNESSES. “4 ELECTRONIC TOOLS. 123 BATTERY CHARGERS 123 BATTERY TESTERS, B GAUGES 2 NULTLMETERS (OVO) : ENGINE COVER LATCHES LUBRICATION, RECOMMENDED LUBRICANT ENGINE COVERS. REMOVAL & INSTALLATION ENGINE IDENTIFICATION ENGINE SERIAL NUMBERS ENGINE MAINTENANCE ‘ANODES NCS) (CCOLING sySTEM ENGINE COVERS, FUELFILTER, LOWER UNIT (GEARCASE) Oi PROPELLER, 2.STROKE ENGINE OIL. EXHAUST COVER, CLEANING... REMOVAL INSTALLATION EXPLODED VIEWS (POWERHEAD) ‘FCYLNDER AHP (OTL TF) 2.584 HP (1078 & LATER) 4.SHP (108085) & 75 HP (180.89) 630 6 HP (1071 & LATER) &8 HP (1084 & LATER) 63 9.SHP (1071-79, 633 S.QASHP (1974 & LATER)- CRANKSHAFT & PISTON oo 8.9015 HP (1074 & LATER). CYLINDER HEAD & CRANKCASE <1 6.34 9O/HP (1071-79, 1081 & LATER) CRANKSHAFT & PISTON. °° 1695 25 HP (1071 & LATER) &.5 HP (1076-64) 635 0 He (1071-76, 1961.82 636 40 HP (100 LATER), 46, 80 (107i & LATER), Ss (iané.&9) AND 60 HP (1980.85), 636 FASTENERS, MEASUREMENTS & CONVERSIONS ..-- 128 BOLTS, NUTS & OTHER THREADED RETAINERS‘STANDARD & METRIC: MEASUREMENTS 1-26 CHECKING THE COMNUTATOR BAR 449 TORGUE 125 CLEANING & INSPECTION 443 FIERGLASS HULL 221 REMOVAL & DISASSEMBLY 5 447 INSPECTION & CARE 2.21 TESTING THE ARMATURE 449 FIRE EXTINGUISHERS, 4 TESTING THE FIELD HOUSING «>. +0 449 ‘CARE AND TREATNENT 15 GENERATOR CHARGING CIRCUT «<7 4s CONTENTS OF EXTINGUISHERS 16 DESCRIPTION 8, OPERATION. 45 FRE EXTINGUISHER APPROVAL 16 GENERAL INFORMATION 45 LEGAL REQUIRENENTS FOR EXTINGUISHERS 16 GENERATOR “7 USING A FIRE EXTINGUISHER 16 TROUBLESHOOTING, 146 FIRST AID KIT +40 VOLTAGE REGULATOR. 47 FLYWHEEL HAND REWIND STARTER ¢ 102 CCD IGNITION sySTEM jwsENSOR COM) 442 EMERGENCY STARTING. 102 FLYWHEEL MAGNETO IGNITION 19 GENERAL INFORMATION 102 LOW TENSION FLYWHEEL MAGNETO IGNITION. 425 DESIGN! 102 FLYWHEEL MAGNETO IGNITION SYSTEMS on DESIGN 2. 102 ‘ARMATURE PLATE. “7 DESIGNS 102 BREAKER PONTSICONDENSER, 515 OPERATION 102 COLL. £19 HAND TOOLS +40 DESCAIPT GN & GPERATION on BREAKER BARS +20 FLYWHEEL a9 HAMMERS, 122 IDENTIFGATICN, on PLERS rat TOP SEAL, 8 SCREWDAWERS rt TROUBLESHOOTING, on SOCKET SETS +40 wick. 21 TORQUE WRENCHES +20 FUELFILTER, 24 WRENCHES 121 SERVICING. 215 HORNS 460 FUEL GAUGE 68 HOW TO USE THis MANUAL - 2 HOOKUP. 65 "AVOIDING THE MOST COMMON MISTAKES. n TROUBLESHOOTING 8 ‘AVOIDING TROUBLE. 2 FUELLINES & FITTINGS: ot (CAN YOU Do Ir? 12 SERVICE, 312 DIRECTIONS & LOCATIONS. 2 TESTING on MANTENANCE OR REPAIR 2 FUELPRMER PROFESSIONAL HELP, 1B ELECTRIC 3.40 PURCHASING PARTS, 8 MANUAL te) WHERE TO BEGIN 12 FUELPUNP. 3-36 NGNITION & ELECTRICAL SYSTEM MANVTENANCE. 230 ‘OVERHAUL. 238 INSPECTION. REMOVAL & iNSTALLATION ‘337 IGNITION SYSTEMS, TESTING 336 CAPACITOR DISCHARGE (Ci) WiSENSGA CCl. rr FUELSYSTEM MAINTENANCE... 20 CAPACITOR DISCHARGE (CD) - WITIMER BASE. 428 ‘CARBURETOR ADJUSTHENTS 200 COIL POLARITY CHECK 40 FUEL & FUEL TANKS 232 FLYWHEEL MAGNETO. in FUEL PUMPS 2.32 IGNITION VIFING HAFWESS 49 FUEL SYSTEM PAESSLAIZATION a4 INTRODUCTION a IDENTIFICATION 48 PRESSURING THE FUEL SYSTEM: CHECKING FOR LEAKS »...24 LOW TENSION FLYWHEEL MAGNETO 421 FUEL SYSTEM SERVICE CAUTIONS. 34 SPARK PLUG EVALUATION. 48 FUEL SYSTEM TROUBLESHOOTING, 35 TROUBLESHOOTING, 40 ‘CHOKE PROBLEMS. 36 LINKAGE, CABLES AND SHAFTS (SHIFT, CARBURETOR ANDCR IGINE SURGE 38 THROTTLE SHAFT) EXCESSIVE FUEL CONSUMPTION 38 LUBRICATION. FUELLINE TESTING a7 PECOMMENDED LUBRICANT FUEL PROBLENS., 35 LOW TENSION FLYWHEEL MAGNETO iGiiTION SvSTENS FUEL PUMP TESTING 37 "ARMATURE PLATE. POUGHENGINE IDLE 38 BREAKER PONTSICONDENSER/DAIVEA GOI. TROUBLESHOOTING, 38 DESCRIPTION & OPERATION. FUELTANK 30 FLYWHEEL SERVICE, 0 IDENTIFICATION: FUEL TANK 1 LINES 39 TOP SEAL FUEL LINES & FITTINGS: oH TROUBLESHOOTING, FUEL TANK, 39 © LOWER UNIT GENERAL INEORMATION 30 ELECTAIC SHIT, 2 SOLENOIDS GENERAL INFORMATION (WHAT EVERYONE SHOULD GEARCASE BASICS. KNOW ABOUT MAINTENANCE)........ 22 MECHANICAL SHIFT, HVORADLIG ASSIST BEFORE/AFTER EACH USE 23 MECHANCAL SHIFT, HYDRAULIC ASSIST ENGINE IDENTIFICATION 22 MECHANICAL SHIFT PROPELLER EXHAUST. MANTENANCE COVERAGE IN THiS NANUAL. 22 MECHANCAL SHIFT, SLIDING CLUTCH DOS. MAINTENANCE EQUALS SAFETY 22 MECHANICAL SHIFT, SOLID GEARCASE, PACPELLEA EXHAUST. CCUTBOAADS ON SAL BOATS 22 MECHANICAL SHIFT, WISPLIT GEARCASE (6 HP & 05.95 HP) GEARCASE OL. 78 MECHANGAL SHIFT, WISPLIT GEARCASE (EARLY 40 HP). ‘CHECKING OIL LEVEL & CONDITION 78 NON-SHETING. DRAINING & FILLING, 7210 SHIT WNO.DISCONNECT: lL RECOMMENDATIONS, 7.8 LONER UNIT (GEARCASE) GL GENERATOR. ‘ear ‘CHECKING OIL LEVEL & CONDITION. 212,78 ‘ASSEMBLY & WSTALLATION +0 DRAINING & FILLING 213, 7-1010-38 MASTER INDEX GENERAL INFORMATION OIL RECOMMENDATIONS LOWER UNT- GEARCASE BASICS (GENERAL INFORMATION, LOWER UNIT (GEARCASE) OiL MAINTENANCE & SERVICE PROPELLER, LOWER UNT- ELECTRIC SHIFT, 2 SOLENOIDS. DESCRIPTION & OPERATION LOWER UNT ‘ASSEMBLY. CLEANING i NSPECTION: DISASSEMBLY ENOVAL & INSTALLATION. TROUBLESHOOTING, WATER PUMP. FENOVAL & WSTALLATION. LOWER UNT- MECHANICAL SHIFT, HYDRAULIC ASSIST DESCRIPTION & OPERATION LOWER UNIT ‘ASSEMBLY. (CLEANING & NSPECTION: DISASSEMBLY ENOVAL & INSTALLATION: TROUBLESHOOTING, WATER PUMP. ENOVAL & INSTALLATION. LOWER UNT- MECHANICAL SHIFT, PROPELLER EXHAUST. DESCRIPTION & OPERATION LOWER UNT ‘ASSEMBLY. CLEANING & iNSPECTION: DISASSEMBLY ENOVAL & INSTALLATION: TROUBLESHOOTING, WATER PUMP. ENOVAL & NSTALLATION. LOWER UNT- MECHANICAL SHIFT, SLIDING CLUTCH DOG DESCRIPTION & OPERATION, LOWER UNT "ASSEMBLY. (CLEANING & INSPECTION: DISASSEMBLY ENOVAL & INSTALLATION. TROUBLESHOOTING, WATER PUMP. FENOVAL & WSTALLATION. LOWER UNTT- MECHANICAL SHIFT, SOLID GEARCASE, PROPELLER EXHAUST... DESCRIPTION & OPERATION. LOWER UNT CLEANING & iNSPECTION: ASSEMBLY. DISASSEMBLY’ ENOVAL & INSTALLATION: TROUBLESHOOTING, WATER PUMP. FENOVAL & WSTALLATION. LOWER UNT.- MECHANICAL SHIFT, WiSPLIT GEARCASE (GHPR9S25H0) LOWER UNTT ‘CLEANING & INSPECTION: DISASSEMBLY & ASSEMBLY. ENOVAL & INSTALLATION. SHEET ROD DISCONNECT. TROUBLESHOOTING, WATER PUMP. FENOVAL & WSTALLATION. LOWER UNT- MECHANICAL SHIFT, WISPLIT GEARCASE (EARLY 40 HP) ‘i DESCRIPTION & OPERATION LOWER UNT ‘CLEANING & iNSPECTION. DISASSEMBLY & ASSEMBLY. EMOVAL & INSTALLATION. an 242.73 v2 12 78 12 73 trer 787 780 178 1% 72 7 78 70 770 TROUBLESHOOTING, WATER PUNE. REMOVAL & iNSTALLATION. LOWER UNIT. NON-SHIFTING DESCRIPTION & OPERATION, LOWER UNIT CLEANING INSPECTION: DISASSEMBLY & ASSENBLY ENOVAL & INSTALLATION TROUBLESHOOTING, WATER PUMP. ENOVAL & STALLATION, LOWER UN. SHIFT WINO DISCONNECT: DESCRIPTION & OPERATION, LOWER UNIT ‘ASSEMBLY, CLEANING INSPECTION: DISASSEMBLY ENOVAL & INSTALLATION ‘TROUBLESHOOTING, WATER PUMP. ENOVAL & INSTALLATION. LUBRICATION SERVICE... ELECTRIC STARTER MOTOR PINION ENGINE COVER LATCHES. (GENERAL NFORMATION LINKAGE, CABLES AND SHAFTS (SHIFT, CARBURETOR ANDOR THROTTLE SHAFT, POWER TAMTLT RESERVOF STEERING ARM (CABLE RANTLLER AFI). ‘SWIVEL BRACKET AND TILT SUPPORT TILTTUBE ASSENBLY LUBRICATION SYSTEMS | DESCRIPTION & OPERATION, MAIN BEARING BOLTS REMOVAL & INSTALLATION MAINTENANCE COVERAGE Wi THis MANUAL MAINTENANCE EQUALS SAFETY MAINTENANCE OR REPAIR? MANUAL FUEL PRIMER, [ASSEMBLY & INSTALLATION (CLEANING & INSPECTION (GENERAL INFORMATION REMOVAL & DISASSENBLY TESTING. MEASURING TOOLS ‘CALIPERS. DEPTH GAUGES DIALINDIGATORS MICROMETERS TELESCOPING GAUGES, OARIPADDLE: OL RESERVOIR CANISTER SERVICE, OTHER COMMON TOOLS ‘OUTBOAADS ON SAILBOATS PERSONAL FLOTATION DEVICES ‘CARE OF LIFE JACKETS, GENERAL CONSIDERATIONS, LEGAL REQUIREMENTS TYPE | PFDS. TYPE IPEDS: TYPE ll PFOS, TYPE IV PFDS TPE PFDS PISTONS & PINGS, CLEANING, INSPECTION & SERVICE DISASSEMBLY & ASSENELY RENOVAL & INSTALLATION POWER PACK CCD IGNITION sYSTEM (WISENSOR GOL) (CD IGNITION SYSTEM (WITIMER BASE). POWER TRIMTLT RESERVOIR FLUID LEVELICONDITION RECOMMENDED LUBRICANT.MASTER INDEX _ 10-39 POWERHEAD INTRODUCTION. REBUILDINGTIPS THEORY OF OPERATION POWERHEAD BREAKIN, POWERHEAD OVERHAUL BOTTON SEAL. BYPASS COVEA, ‘CENTERING PI. ‘CONNECTING RODS. (CRANKCASE COVER (CRANKCASE SIDE acs (CRANKSHAFT & BEARING (CYLINDER BLOCK. (CYLINDER HEAD EXHAUST COVER MAN BEAFING BOLTS PISTONS. PRELIMINARY WORK PEED VALVES. RINGS. TOP SEAL POWERHEAD REBUILDING - PRELIMINARY WORK. PREAWIRED BINVACLE MOUNT REMOTE UNITS. OVERHAUL. PRESSURE RELIEF VALVE. REMOVAL & INSTALLATION TESTING PROFESSIONAL HELP, PROPELLER (CLEARING THE FISH LINE TRAP FROZEN PROPELLER INSPECTION. PEMOVAL & INSTALLATION ‘CASTELLATED NUT RETAINED BAOPS KEEPER RETAINED PROPS SHEAR PIN PROPS PURCHASING PARTS E-COMMISSIONING. REMOVAL FROM STORAGE EBUILDING TPS FEED VALVES, ‘AGTUAL OPERATION ADUSTNENT. BROKEN REED, CLEANING & SERVICING DESCRIPTION & OPERATION REED BOK INSTALLATION PEED DESIGNS REED STOPS REED-TOREED BOXGIHECK. \V-TYPEREED BOXES EGULATIONS FOR YOUR BOAT ‘CAPACITY INFORMATION (CERTIFICATE OF COMPLIANCE: DOCUMENTING OF VESSELS HULL IDENTFIGATION NUMBER LENGTH OF Boars, NUMBERING OF VESSELS. REGISTRATION OF BOATS, SALES & TRANSFERS. VENTILATION VENTILATION SvsTElUS, FENOTE CONTROLS. ‘CONCEALED SIDE MOUNT REMOTE UNITS DOUBLE-LEVER SHFTBOX. 62 62 62 30, en ee eM 13 12 SERREES Bisa, 8 0-26 03 DUAL HANDLE SURFACE MOUNT REMOTE (SNGLE NOTORS)..035 ELECTRIC GEAR BOXES (EVINRUDE) ELECTRIC GEAR BOXES & SINGLE LEVER CONTROLS cogs PRE-WIRED BINNACLE MOUNT REMOTE UNITS, SINGLE LEVER REMOTE CONTROL SHIFT BOX ‘SMALL MOTOR STANDARD SURFACE REMOTE UiNiTs) STANDARD SUAFACE MOUNT PEMOTE UNITS, of 2h 0.21 EMOTE CONTROLS - HYDRO-ELECTRICMECHANICAL SHIFT... 2 DESCRIPTION & OPERATION. 02 DOUBLELEVER SHIFT BOX. 03 HECTRC GEAR BoKES & Sil [EVER CONTE oihscinas ELECTRIC GEAR BOXES (EVINRUDE) GENERAL INFORMATION “oe SHFTTHROTTLE CABLES, oe SINGLE LEVER RENOTE CONTROL SHIFT BOX O13 REMOTE CONTROLS LATE-MODEL MECHANICAL SHIFT... $-20 ‘CONCEALED SIDE MOUNT REMOTE UNITS 0.25, DESCRIPTION & OPERATION, a 920 DUAL HANDLE SURFACE MOUNT REMOTE UNITS FOR SINGLE NOTORS 0.25 INTRODUCTION 9.20, PRE-WIRED BINNACLE MOUNT RENOTE UNITS. 0.28 SMALL MOTOR STANDARD SURFACE REMOTE UNITS 0.24 STANDARD SURFACE MOUNT REMOTE UNITS, 0.21 REQUIRED SAFETY EQUIPMENT. 45 FIRE EXTINGUISHERS 16 MINIMUM BEQUIREMENTS: 45 PERSONAL FLOTATION DEVICES 7 ‘SOUND PRODUCING DEVICES 18 TYPES OF FIRES. 1 VISUAL DISTRESS SIGNALS 18 WARNING SYSTEM 7 ‘SAFETY IN SERVICE He DONTS: 1 Dos . He SAFETY TOOLS 146 EYE & EAR PROTECTION +46 WORK CLOTHES “7 WORK GLOVES. 146 SHIT CABLES. os FITTING CABLES TO THE MOTOR (ALLEXC. SINGLE LEVER REMOTE) INSTALLING THE SHIFT CABLE END. NSTALING TE THROTTLE CABLE Eid ‘SHOP EQUIPMENT. SAFETY TOOLS CHEMICALS SINGLE LEVER REMOTE CONTAOL SHIFT BOK DESCRIPTION &. OPEFATION, SHIFT BOX DISASSEMBLY & ASSENBLY SHETTHROTTLE CABLE REMOVAL & INSTALLATION TROUBLESHOOTING, ‘SMALL MOTOR STANDARD SURFACE REMOTE UNITS ‘OVERHAUL, ‘SPARK PLUG WIRES REMOVAL & INSTALLATION TESTING SPARK PLUGS HEAT RANGE INSPECTION & CAPPING PEADING PLUGS REMOVAL & INSTALLATION ‘SPECIAL TOOLS. +23 ‘SPECIFICATIONS = 2a ‘CONDENSER an ‘CONVERS IGN FACTORS: 127 GENERATOR: 470 GEARCASE Olt CAPACITIES 248 GENERAL ENGINE & TUNE-UP eat GENERAL ENGINE & TUNE-UP NOTES. 248 GENERATOR 470 LUBRICATION CHAE 250 MAINTENANCE INTERVALS 250 COILFUEL MOCTURE RATIOS. 249 POWERHEAD REBUILDING ea7 REGULATOR 470 SPARK PLUG DIAGNOSIS 240 STARTER NOTOA 470 STARTER POPE joa TORQUE 4 TORQUE 28 TORGUE SPECIFICATIONS & TYPICAL TORQUE VALUES 11°... 1-28 ‘STANDARD SURFACE MOUNT REMOTE UNIS. 921 ‘OVERHAUL, 02110-40 MASTER INDEX ‘STARTER (TYPE!)- CYLINDER W PINION GEAR (68 HP) STARTER ASSEMBLY & INSTALLATION CLEANING & INSPECTION REMOVAL & DISASSEMBLY STARTER ROPE, REPLACEMENT... ‘STARTER (TYPE) - CYLINDER Wi PINION GEAR STARTER ASSEMBLY & INSTALLATION CLEANING & INSPECTION EMOVAL & DISASSEMBLY STARTER ROPE, EPLACENENT STARTER (TYPE Il) - COIL SPRING Wi SWING AF VERTICAL MOUNT. STARTER ADAUSTAIENT ASSEMBLY & NSTALATION CLEANING & INSPECTION. REMOVAL & DISASSEMBLY ‘STARTER (TYPE!) = COIL SPRING W SLIDING (GEAR ARM HORIZONTAL MOUMT. STARTER i ‘ADJUSTMENT. DISASSEMBLY # ASSEMBLY REMOVAL & INSTALLATION STARTER ROPE, REPLACENENT STARTER (TYPE V) WOUNTED ATO FLYWHEEL \WINO RETURN SPRINGS .. STARTER ASSEMBLY & INSTALLATION CLEANING & INSPECTION. EMMOVAL & DISASSEMBLY ROPE INSTALLATION ‘STARTER (TYPE VI) = MOUNTED ATOP FLIWhiEEL WITH1 OR 2NYLON PAWLS. HAND STARTER TIMING. STARTER ‘ASSEMBLY & INSTALLATION CLEANING & INSPECTION. REMOVAL & DISASSEMBLY ‘STARTER (TYPE Vi) « MOUNTED ATOP FLYWHEEL WILARGE PAWL PLATE... STARTER CLEANING & INSPECTION. ASSEMBLY & INSTALLATION REMOVAL & DISASSEMBLY STARTER WOTOR "ARMATURE TESTING CLEANING i INSPECTION DISASSEMBLY & ASSEMBLY DRIVE GEAR REPLACEMENT. ENOVAL & INSTALLATION TESTING, ‘STARTING SYSTEM, "7 DESCRIPTION & OPERATION STARTER NOTOR TROUBLESHOOTING. STATOR. REPLACEMENT STATOR & CHARGE COIL” TYPE | REPLACEMENT STEERING ARM (CABLE RAWTILIER AFI) LUBRICATION. ECOMNENDED LUBRICANT ‘STORAGE (WHAT To DO BEFORE AND AFTER). PE-COMNISSIONING, WINTERIZATION, ‘SWIVEL BRACKET & TT SUPPORT. LUBRICATION FECONNENDED LUrIGANT SYNCHRONZATION (ALL MOTORS) PRINARY PICK-UP ADIUSTMENTS & LOCATIONS TACHOMETER TEMPERATURE GAUGE ANDIOR WARNING LIGHT (CHECKING THERMOMELT STICKS WARNING LISHTS TEST EQUIPHENT. JUMPER WIRES. MULTIMETERS TESTLGHTS TROUBLESHOOTING, THEORY OF OPERATION ‘ACTUAL OPERATION, (CROSS FUEL FLOW PANGIPLE INTAKEEXHAUST LOOP SCAVENGING LUBRICATION: POWER STROKE PHYSICAL LAWS SUNMARY. TINING THERMOSTAT. REMOVAL & INSTALLATION TESTING, THROTTLE CABLES, : FITTING GABLES TO THE WOTOR (ALLEXG. SINGLE LEVER REMOTE). INSTALLING THE SHIFT CABLE END INSTALLING THE THROTTLE CABLE END. TILT TUBE ASSEMBLY LUBRICATION: RECOMMENDED LUBRICANT TIMER BASE & SENSOR ASSEMBLY - TYPE. REPLACEMENT TIMING & SYNCHRONIZATION: © ‘GENERAL INFORMATION 'SYNCHFONZATION TIMING Toots. ELECTAONIG TOOLS. HAND TOOLS NEASURING TOOLS OTHER COMMON TOOLS: SPECIAL TOOLS. TOOLS & SPARE PARTS TOP SEAL FLYWHEEL MAGNETO IGNITION LOW TENSION FLYWHEEL MAGNETO IGWiTICN TOP SEAL REMOVAL & INSTALLATION TAIMTILT ASSEMBLY REMOVAL & INSTALLATION TRIMTILT MOTOR, ASSEMBLY CLEANING & INSPECTION 'BPUSH REPLACEMENT (CHECKING END HEAD BUSHINGS (CHECKING FELD COILS. (CHECKING FORA GROUNDED AANATURE CHECKING FORA SHORTED ARMATURE. DISASSEMBLY TESTING. TRIMTILT SYSTENS DESCRIPTION & OPERATION. POWER TANUTLT RESERVOR TAINMTILT ASSENBLY TAIMTILT MOTOR TROUBLESHOOTING, ‘TROUBLESHOOTING ‘ACCUM (AUTOBLEND) OILING SYSTEM ALTERNATOR BASIC OPERATING PRINCIPLES (CARBURETOR CCD IGNITION SYSTEM (WiSENCA coil) (OD IGNITION SYSTEM (W/TIMER BASE) ‘COOLING SYSTEM 490 457 467 fe Ey SeRpeerereer hats 113MASTER INDEX _ 10-41 ELECTRICAL SYSTEMS, FLYWHEEL MAGNETO IGNITION FUEL GAUGE FUEL SYSTEN GENERATOR, IGNITION SYSTEM, LOW TENSION FLYWHEEL MAGNETO IGNITION. LOWER UNIT- ELECTRIC SHIFT, 2 SOLENOIDS LOWER UNIT- NECHANICAL SHIFT, HYDRAULIC ASSIST LOWER UNIT - MECHANICAL SHIFT, PROPELLER EXHAUST. LOWER UNIT- MECHANICAL SHIT, SLIDING CLUTCH Dos. LOWER UNIT - MECHANICAL SHIFT, SLIDING CLUTCH Dos. LOWER UNIT - MECHANICAL SHIFT, SOLID GEARCASE, PROPELLER EXHAUST. LOWER UNIT- MECHANICAL SHET, WISPLIT GEARCASE (GHP.RO525 HP) LOWER UNIT - MECHANICAL SHIFT, WISPLIT GEARCASE (EARLY 40 HP) LOWER UNIT - Now SHETiN, LOWEA UNIT - SHET WN DISCONNECT. EMOTE CONTROLS - SINGLE LEVER REMOTE CONTROL SHIFT BOX. PEED VALVES. REMOTE CONTROLS - DOUBLE-LEVER SHIFT Bax. EMOTE CONTROLS - ELECTRIC GEAR BOXES (EVINRUDE) REMOTE CONTROLS - ELECTRIC GEAR BOXES & SINGLE LEVER CONTROLS (JOHNSON). ‘STARTING SYSTEM. TEST EQUPNENT. TANATIT RO SYSTEM UNEP, ‘COMPRESSION CHECK (COOLING SYSTEM MAINTENANCE: DE-CARBONING THE PISTONS FUEL SYSTEM MAINTENANCE, IGNITION & ELECTRICAL SYSTEM MAINTENANCE: INTRODUCTION. ‘SPARK PLUG WIRES. ‘SPARK PLUGS. TUNE-UP SEQUENCE TTUNE-UP SEQUENCE UNDERSTANDING & TROUBLESHOOTING ELECTRICAL SYSTEMS BASIC ELECTRICAL THEORY ELECTRICAL CONPONENTS ELECTRICAL TESTING PRECAUTIONS. TEST EQUPNENT. TROUBLESHOOTING, WIRE & CONNECTOR REPAIR, \ARIABLE RATIO OILING (VRO) SYSTEM BREAKIN AND THE VRO SYSTEM CHECKING & SERVICING DESCRIPTION TROUBLESHOOTING, \VHEEM RADIO. VOLTAGE REGULATOR GENERATOR RO SERVICE, CHECKING FUEL & Olt CIRCUITS CLEANING THE VACUUM PULSE HOSE. ENGINE MOUNTED FUEL FILTER FUELLLINE VAGUUM TEST VAGUUMHOSE CHECK. RO PUNP SERVICE, WARNING HORN CHECK WATER PUNP FEMOVAL. INSPECTION & OVERHAUL INSTALLATION ELECTRIC, HYDRAULIC & MECHANICAL SHIET GEAR CASES (GDHP & LARGER MOTORS AND 1976 & LATER 40 HP} MANUAL SHIFT GEAR CASES (1971-70 60 HP, 1971-73 9.520 HP, 1071-85 25 HP. MANUAL SHIFT GEAR CASES (40 HP TO 676) NO SHIFT GEAR CASES PROPELLER EXHAUST MECHANICAL SHIFT GEAA GASES (19748 LATER 9.015 HP) PROPELLER EXHAUST MECHANICAL SHIFT GEA CASES (0081 & LATER 2020 H, 1006 & LATER 25 HP & 1076-84 25H SHIFT, NO DISCONNECT GEAR CASES. wick REPLAGENENT WINTERZATON. PREPPING FOR STORAGE: STORAGE CHECKLIST (PREPARING THE BOAT AND WGTOR) WHERE TO STORE YOUR BOAT AND MOTOR WIRE & CONNECTOR REPAIR WIRING DIAGRAMS. INDEX ZINCS (ANDES) INSPECTION: SERVING, 2.STROKE ENGINE OIL. FILING FUELOIL RATIO. OILINECTION: COL RECONMENDATIONS PREM. 52 52 52 52 52 1-40 513 5 421 421 237 2a7 238 237 48 in 472 247 248 240 240 240 240 on 210 2