2 thru V6 Recreational Models

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PART NO 507508 LITHO U,S.A
 &SAFETY WARNING
This Service Manual will alert you to certain
procedures that should Ье done very carefully. If
you ignore this information, you could ...

• Injure yourself or bystanders

• Injure the boat operator, passengers or
bystanders
• Damage the outboard or its accessories
& This safety symbol appears next to
information that, if ignored, could result in
injury to you or others.
INotel Thisinformation symbol appears next to
information that, if ignored, could result in
damage to the outboard or its accessories.
This Service Manual tells you how to correctly
maintain and service the outboard and its
accessories. When correctly serviced, the
outboard and its accessories will Ье reliabIe and
safe to use.
When special service tools are called for, use
them. Special tools are а MUST to' do the job
correctly.
If you use service procedures or tools that are по!
recommended Ьу оме, YOU ALONE must
decide if your actions might injure people or
damage the outboard or its accessories.

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 оме
Recreationa l Outboard Service Manual
2 thru V-6 Models
Section 1 - General Information
ТаЫе of Contents
After Storing - Before Using .. .. ....... .. . 1-56
Arrangement of Service Manual ...... . . .. . . 1-6
Break-In ..... .... . . ...... . . . . ... ..... 1-47
Carburetor Orifice Plug Reference Chart .... 1-51
Checking Propeller Hub Slippage - 4
Deluxe thru 30 . .......... . .. .. . . ... .. 1-50
Drill Size Conversion Chart .......... ... . 1-53
Engine Fuel and Lubricant . . .......... ... 1-44
Gearcase Lubrication - 2 ............ . .... 1-25
Gearcase Lubrication - 4 thru V-6 .. . .. .... 1-25
General Specifications . ................. 1-24
Good Service Practice . ..... .... .. ... .. ... 1-6
Heli-Coil ® Inserts and Installers ....... . .. . 1-60
I ntroduction ...................... . . ... 1-6
Lubrication ........ ... . . ... ...... . . .. 1-24
Lubrication Chart - 2 and 4 . ....... .. . . .. 1-26
Lubrication Chart - 4 Deluxe, 4.5, 5,
6 and 8 . ... . . .. ... .. .. . .. . ......... . 1-28
Lubrication Chart - 9.9 and 15 . . . .... .. . . . 1-30
Lubrication Chart - 20, 25 and 30 ... . . . ... 1-32
Lubrication Chart - 40, 50 and 60 (Remote
Control Models) .. ... . . . .... . ..... . .. . 1-34
Lubrication Chart - 40 Rope, 40ТЕ эпd 50ТЕ,
45CR and 55CR ........ . . .. .... .. . . . . 1-36
Lubrication Chart - 70 and 75 ...... . . . . .. 1-38
Lu brication Chart - 90, 115 and V -6 ....... 1-40
Lu brication Chart - 120 and 140 .......... 1-42
New Motor Preparation . ......... . . ..... 1-62
Off-Season Storage ..................... 1-54
Outooard Models Covered in This Service
Manual ........... . .... ....... 1-2, 1-3, 1-4
Outboard Motor Nomenclature . . .. ...... . . 1-8
Parts Catalog ... .. . . ..... ....... ..... .. 1-7
Part No . 507508 ·1
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Power Trim and Tilt Reservoir ......... .. . 1-24
Propeller Selection .............. . ...... 1-48
Remote Control Warning Ногп Test
(At Control) .. . .... . .. .. .. .. . ...... .. ' -57
Replacement Parts and Product Reference ... . '-7
Selecting а Propeller . . . . . .. . . ..... . ..... 1-49
Service Policy ... . ..... . ... . . .. ... . .. . .. 1 ~ 7
Special Service Tools ....... . . ...... . . . . . 1-7
Spec ifications - 2 and 4 ..... . ...... 1-1 О, 1-11
Spec ifications - 4 Deluxe thru 8 ...... 1-12,1 -13
Specifications - 9.9 and 15 .......... 1-14,1-15
Specifications - 20 thru 30 . . . ..... ,. 1-16,1 -17
Specifications - 40 thru 75 . ...... . .. 1-18, 1-19
Specifications - 90, 115 and V-6 . . . . .. 1-20, 1-21
Specifications - 120 and 140 ...... .. 1-22, 1-23
Steering System Lubrication - Remote
Е lectric Models . .. .. . . ................ 1-25
Submerged Motors .... . .. . ...... . .. ... . 1-58
Synchronization and Linkage Adjustments -
2 thru 15 Models . .. . .. ... . ......... . . 1-64
Synchronization and Linkage Adjustments-
20 thru 30 Models . .. . . .. ..... . ... . ... 1-68
Synchronization and Linkage Adjustments-
40 and 50R and ТЕ Models ............. 1-70
Synchronization and Linkage Adjustments -
40Е thru V6 (Except 120, 140 Models) . ... 1-74
Synchronization and Linkage Adjustments-
120 and 140 Models ... . . ... ........ . .. 1-82
Testing Anti-Corrosion Anodes - AII Models .. 1-47
TroubIe Check Chart .......... 1-88' 1-89, 1-90
Tune-Up Procedure ... .. .. . . ... . ... .. . . 1-61
Weather, Altitude and Engine Performance " ' -63
 Outboard Models Covered in This Service Manual

2 thru V-6 Models

2 Models ~.
Е2АСО J2RCO
4 Models
Е4ВАСО Е4ВАНСО J4BRCO J4BRHCO
E4BRLCO E4BRHLCO J4BRLCO J4BRHLCO

4 Deluxe Models
E4RDCO E4RDHCO J4RDCO J4RDHCO
E4RDLCO E4RDHLCO J4RDLCO J4RDHLCO

5 Models

Е5АНСО J5RHCO
E5BFCO J5BFCO
E5BFLCO J5BFLCO
6 Models

Е6ВАСО Е6АСО J6BACO J6RCO

E6BALCO E6RLCO J6BALCO J6RLCO
E6BFCO E6SLCO J6BFCO J6SLCO
E6BFLCO J6BFLCO

8 Models

Е8АСО E8BALCO J8RCO J8BALCO

E8RLCO E8SRLCO J8RLCO J8SRLCO
Е8ВАСО J8BACO

9.9 Models

Е10АСО E10BALCO J10RCO J1OBALCO

E10RLCO E10SELCO J10RLCO J1OSELCO
Е10ВАСО Е10ЕСО J10BACO J1OECO
E1OELCO J10ELCO

15 Models

E15RCO E15ELCO J15RCO J15ELCO

E15RLCO Е15ВАСО J15RLCO J15BACO
Е15ЕСО E15BALCO J15ECO J15BALCO

20 Models

Е20САСО E25BFCO J20CRCO J25BFCO

E20CRLCO E25BFLCO J20CRLCO J25BFLCO
Е20ЕСО E20BICO J20ECO J20BICO
E20ELCO E20BILCO J20ELCO J20BfLCO
Е25ВЕСО J25BECO
E25BELCO J25BELCO
E20BFCO J20BFCO
E20BFLCO J20BFLCO
1-2 2· V6 А ее.

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 Outboard Models Covered in This Service Manual

2 thru V-6 Models

Е25АСО
•• Е25ТЕСО
25 Models
J25RCO
•
~
J25TECO
E25RLCO E25TELCO J25RLCO J25TELCO
Е25ВАСО Е25ЕСО J25BACO J25ECO
E25BALCO E25ELCO J25BALCO J25ELCO

30 Models
Е30АСО Е30ВАСО J30RCO J30BACO
E30RLCO E30BALCO J30RLCO J30BALCO
Е30ЕСО Е30ТЕСО J30ECO J30TECO
E30ELCO E30TELCO J30ELCO J30TELCO

40 Models
Е40АСО Е40ЕСО J40RCO J40ECO
E40RLCO E40ELCO J40RLCO J40ELCO
Е40ВАСО Е40ТЕСО J40BACO J40TECO
E40BALCO E40TELCO J40BALCO J40TELCO

50 Models
Е50ВЕСО E50TELCO J50BECO J50TELCO
E50BELCO E50TLCO J50BELCO J50TLCO

60 Models
Е60ЕСО J60ECO
E60ELCO J60ELCO
E60TLCO J60TLCO

70 Models
E70ELCO J70ELCO
E70TLCO J70TLCO

75 Models
E75ELCO J75ELCO
Е75ЕСО J75ECO
E75TLCO J75TLCO

1-3

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 Outboard Models Covered in This Service Manual

2 thru V-б Models

E90MLCO
E90TLCO
•• 90 Models
J90MLCO
J90TLCO
•
~
Е90ТХСО J90TXCO

115 Models
E115MLCO J115MLCO
E115TLCO J115TLCO

120 Models

E120TLCO J120TLCO
Е 120ТХСО J120TXCO

140 Models
E140TLCO J140TLCO
Е 140ТХСО J140TXCO

V-б Models
E150STLCO E235TLCO J150TLCO J235TLCO
E150TLCO Е235ТХСО J150TXCO J235TXCO
Е150ТХСО E235STLCO J150STLCO J235STLCO
E150ANCO J175TLCO
E175TLCO J175TXCO
Е175ТХСО J185TLCO
E185TLCO J185TXCO
Е185ТХСО

1-4 2-V6 Аес .

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 Introduction
This manual covers Service 1nformation оп а" current models
2 thru V-6. Much of the information also applies to previous
models.
Use this manual together with the ргорег Parts Catalog for part
numbers and for exploded views which аге а valuabIe aid to
disassembIy and reassembIy.
This manual presents the metric dimension first and the English
dimension in parentheses ( ). When referring to the metric dimen-
sion, а сотта is used to represent а decimal point which is
standard printing practice in Europe.

Good Service Practice

When repairing а component, the most reliabIe way to assure а
good job is to do а complete overhaul оп that component, rather
than just replacing the bad part. Wear not readily apparent оп
other parts could cause malfunction soon after the repair job.
Repair kits and overhau 1 kits contain а" the parts needed to
assure а complete repair, to eliminate guesswork, and to save time.
Repair time сап also Ье minimized Ьу the use of special tools.
ОМС special tools speed repair work so it сап Ье done within flat
rate time. 1n some cases the use of substitute tools сап actually
damage the part.
• То
prevent possibIe еуе injury always wear SAFETY
GLASSES while servicing motor.
• When testing ог adjusting а running engine with the
motor cover removed:
keep hands, hair, and clothing away from rotating
flywheel
do not touch electrical system parts. Reaction to
electrical shock could result in contact with rotating
flywheel.
• Refer to solvent manufacturer's caution lаЬеl regarding
ргорег use and storage of solvent.
fN=t;1 00 not operate motor out of water even momentarily.
~ If operated in test tank use рroрег test wheel. Failure to
do so сап result in damage to water pump and motor overheating.

Arrangement of Service
Manual
This Service Manual includes the specific information you will
need to service ОМС Outboards. А" general procedures аге
covered in abbreviated form mostly Ьу reference to procedural
illustrations. The specific procedures wh ich apply only, ог
primarily, to each motor аге covered in fully-illustrated, detailed,
step-by-step instructions as required.
The General Service Information section will help you diagnose
а malfunctioning outboard. It includes specifications and lubrica-
tion procedures. Clearances and torque values аге also included
for quick reference during servicing operations. Each of the
following sections, Fuel System, Ignition System, Powerhead,
Mid-Section, Gearcase, Manual Starter, Electrical System,
Remote Control and Power Trim and Tilt, gives detailed instruc-
tions for d isassembIy, inspection, reassembIy, and operating
adjustments of the components. These procedures will help you
service а specific system, ог completely overhaul the models.
&Safety Related 1-6 2·V6 Аес .

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 Parts Catalog
The ОМС Parts Catalogs contain exploded views illustrating the
correct sequence of all parts as well as а complete listing of the
parts for replacement. This catalog сап Ье of considerabIe help as
а reference during disassembIy and reassembIy. Use the current
Parts Catalog for the specific model outboard you аге working оп
as you use this Service Manual.

Replacement Parts and

Product Reference
'" When replacement part5 are required, use genuine ОМС
ill parts or part5 with equivalent characteristic5 including
type, 5trength, and material. Failure to do 50 mау result in
product malfunction and p055ibIe injury to the operator and/or
passenger5.

When reference is made to а brand пате, product ог specific

tool, ап equivalent product тау Ье used in place of the referenced
product. Substitute products used must have equivalent charac-
teristics, including type, strength, and material. Incorrect substi-
tution тау result in product malfunction and possibIe injury to
the operator and/or passengers.

AII photographs and illustrations used тау not necessarily depict

actual models ог equipment, but аге intended only for reference.
Specifications used аге based оп the latest product information
availabIe at the time of pubIication.

Service Policy
Whether within ог following the warranty period, ОМС has а
constant interest in its products.

It is OMC's policy to provide dealers with service knowledge so

they сап give professional service demanded Ьу today's соп­
sumer. The ОМС Training Centers, frequent mailings of Service
Bulletins, Letters and Promotions, Special Tools and this Service
Manual represent OMC'S efforts to assist dealers in giving соп ­
sumers the best and most prompt service possibIe. The Service
Manual covers all phases of servicing motors. However, new sit-
uations sometimes arise in servicing а motor. 1f а service question
does not арреаг to Ье answered in this manual, you аге invited
to write to the Service Department for additional help. Always
Ье sure to give complete information, including motor model
number and serial number. Ве sure that you аге familiar with
the ОМС Warranty.

Special Service Tools

оме has specially-designed tools to simplify some of the dis-
assembIy and reassembIy operations. These tools аге illustrated in
this Service Manual, in тапу cases in actual use. Refer to the
оме Special Tool Catalog for а description and ordering instruc-
tions for these tools. 1ndividual purchasers of Service Manuals
must order Special Tools through ап authorized dealer.

&Safety Related 1-7 2-V6 Ae~ _

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 Outboard Motor Nomenclature
Sometimes the words "right" and "Ieft" аге very confusing when
referring to the sides of ап outboard motor. Therefore, the sides
аге referrea to as STARBOARD ог PORT sides. STARBOARD
means оп the right hand while facing the bow (F RОNТ) of the
boat; PORT means left hand.

Service required for ОМС motors is generally опе of three

kinds ...

1. Normal Саге and Maintenance - which includes putting а

new motor into operation, storing motors, lubrication, and саге
under special operating conditions such as salt water and cold
weather.

2. Operating Malfunctions - due to improper motor mounting,

propeller condition ог size, boat condition, ог the malfunction of
some раг! of the motor. This includes motor tune·up procedures
to keep the motor in prime operating condition.

3. Complete DisassembIy and Overhaul - such as inspecting а

motor that has Ьееп submerged, ог rebuilding trade·in units.

It is important to you as the service person to determine before

disassembIy just what the troubIe is, and how to correct it
quickly and with minimum expense to the owner.

1·8 2·V6 Аес .

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Specificati ons - 2 and 4

G eneral 2 4

Full Throttle Operating Range . . .... . . .... .. .. ........• . .. ... . ..... 4000 · 5000 грт . ... . .• . . . . . . • . . .. .. . . . .. 4500·5500 грт
Idle грт in Forward Gear with Ргорег Propeller .. .. .... . ... .. .. . ...... ... .. . 650 грт ... ... ..... . . .. . .. .. . .... . ... . . 600 грт
Test Wheel and грт . .... .. . .. . .. .. ..... . ..... . ... ....... .... . . . . Раг! No. 316021 ......................... Part No. 317738
(4-9/16" dia . х 5/8" wide) ' (5 -1/4" dia. х 11/16" wide)
3900 грт 4550 грт
Powerhead

80ге and Stroke .. . . . .. .... . .... .. . • . . ......... . .... . ..... . . . 39,8 тт х 34,9 тт ...... . ... . . .. ... . .... 39,7 тт х 34,9 тт
(1.567" 80ге х 1.374" Stroke) (1 .565" 80ге х 1.374" Stroke)
Piston Displacement . . ..... .. .. ... .. ..•.. .. .. . ... . . . . ... . .. ... 43 ст3 (2.64 си . in.) ... .. . ... ... . .. . . . .... 87 ст 3 (5.28 си. in.)
Crankshaft Size
Тор Journal ..... . ..........•... . ....... . .. 19,055 - 19.042 тт (0.7502" - 0.7497") ..... . 19,075 - 19,063 тт (0.751 О" - 0.7506")
Center Journal .... ... .......• .. ......• ... . . . . .. ..... ..... .. ..... .... .. ... . . ...... . 16,993 - 16,980 тт (0 .6690" - 0.6685")
Bottom Journal ..... .. . .. .. . . . .... . .... . . .. 19,055 - 19,042 тт (0.7502" - 0.7497") ... ... 19,055 - 19.045 тт (0.7502" - 0 .7498" )
Connecting Rod Crank Pin . . . . . .•. . . ... ... . • ... 17,018 - 17,005 тт (0.6700" - 0.6695") . . .... 17,018 - 17,005 тт (0 .6700" - 0.6695")
+Standard Воге Size ................ . ....... . . 39,815 - 39,797 тт (1 .5675" - 1.5668") .. . . . 39,751 - 39,733 тт (1.5650" - 1.5643")

+То determine соггес! Ьоге size for oversize pistons, add oversize dimension to standard Ьоге size.

Ignition Syste m

Ignition . . .... . .. .... ... . . . .•.... . ... . ... . ....... • . • ... ...... Flywheel magneto ...• .. . . .. . ... .. ........ Flywheel magneto
Spark Plug
Champion .. ... . . ...... . ... • . •. ..•.•...... . . . . . .... . . . . . . RJ6C ог J6C - 14 тт . .. .. . ..... .... .... RL86C ог L86C - 14 тт
Spark Plug Gap ..... .....• ........ ... ..... . . ... ..... . . ..... . .. . 0,76 тт (0.030" ) ....... .. .. . . . . .. .. ..... 0,76 тт (0 .030" )
Breaker Point Gap . ....... . . ......... .. . .. ... . . .... ... ...... .. . 0'51 тт (0.020") ... ..... ..... .. .... ..... 0,51 тт (0.020 " )
Condenser . .... ... .. . . . . .. . . .. . .. . ... ...... . . .. . Раг! No . 580321 - 0.18 - 0.22 Mfd ..... .. ..... Раг! No . 580321 - 0.18 - 0 .22 Mfd .
Ignition Coil .... ... ... . .. ........ .. •..... . . . • ... .... . . . . . ... .. . Раг! No. 582995 .. . • ... .... .. .. .. .... ... . Раг! No. 582995

Ignition Coil Test Specifications

Раг! No. 582995

Stevens Tester Model ST-75

Normal Polarity
(Switch Setting Standard) 1.8

Stevens Tester Model No. М.А. - 75 ог 80

Switch I ndex Adjustment

В 26

Мегс-О · Тгопiс

Primary Secondary Secondary

Operating Resistance Continuity Resistance
Amperage Min. Ма х. Min. Ма х. Min. Мах.

1.3 0.7 1.1 50 60 6500 9000

Graham Tester Model 51

Мах .
Maximum Maximum Coil Minimum Gap
Secondary Primary Index Coil Test Index
10.000 1.4 60 25 60

Coil Ohmmeter Test

Primary (Low Ohms) . . . . ........• .. .. • ... . ..• . . . ... . . 0.9!1 ± 0.2

Secondary (Н igh Ohms) ... . ..... . •. . . .•. . . ...• .. ..... 8000 !1 ± 300

1-1 О 2-V6 Аес .

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 2 4

Fuel System
Carburetion .. . ... . . . . .... . .. . . . .. .. ...•.. ... .. Single barrel float feed, with high and ... . ........ Single barrel float feed, fixed high
low speed adjustments, manual choke speed adjustabIe low speed, manual choke
Float Level Setting ..... . .. .. ... . . . .... . .... .. Between steps оп gauge Part No. 324891 . ..... Between steps оп gauge part No. 324891
Float Огор Setting ......... . .. . ..... ... . .. . .. . . . . . .... 28 · 38 тт (1 .125"·1 .500") ... .... . . . . .... 28 · 38 тт (1.125" · 1.500")

Clearance Chart
Powerhead

Piston Ring End Gap .... . .. .. . .. . . .. . . . . . .. . . ..•. . . . 0,64· 0,38 тт (0.025" · 0.015") ... . .... . .. . 0,38· 0,13 тт (0.015" ·0.005" )
Piston Ring Groove Side Clearance . . . . . .. .•..•... .. . . . . ... 0,10 тт Мах . (0.004" Мах.) . .. . ... . .. . .... 0, 10 тт Ма х . (0.004" Мах . )

Torque Chart
Powerhead

Flywheel Nut .. . .... .. . . .. . .. .. . ... . . ............ . . . .. 30·34 N'm (20·25 ft.lbs.) ... ... . . . . ... . .. 40 · 54 N 'm (30 · 40 ft . lbs.)
Connecting Rod Screws . ... .. ..... .. . ... . .. . . . •. .. .. . .. 7'0·7 '5 N'm (60·66 in.lbs.) . . . . . . .. . • ..... 7'0 · 7'5 N 'm (60 · 66 in . lbs.)
Cylinder Head Screws ... .. . . . ... . ..• ..• .. ... . . •. . . . .. .. 7,0 . 9,0 N 'm (60 · 80 in . Ibs.) . .. . . . .... . .. . . 7,0 · 9.0 N 'm (60 · 80 in . Ibs.)
Crankcase to Main Bearing Screws
Upper, Center, Lower . . . ... . .... ...... ... . . . . . . ..•... . .... . ... . . . ... .. .. . . . ..... . ... . . .. . ... 7,0 · 9.0 N 'm (60 · 80 in . Ibs.)
Bearing Housing to Cylinder Screws .... . . . . ... .. .. . . ... . . . 7,0·9.0 N'm (60 · 80 in . Ibs.)
Spark Plug . . .... . ....... . ...... . .......... . •.... . . . .. 24·27 N'm (18·21 ft. Ibs.) . . . . . . . . . . .... . . 24 · 27 N'm (18 · 21 ft . lbs.)
Gearcase Mounting Screws .... ... . . . . .. .. . . ... . .. . . .. . . . ... 7 · 9 N'm (60 · 80 in. Ibs.) .. ..... . . . .... ... . 7·9 N'm (60·80 in.lbs.)

1-11 2·V6 Rec.

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Specifications - 4 Deluxe thru 8

General 4 Oel uxe alld 4.5 5,6 and В

Full Throttle Operating Range ... . .. .. ... . .. . ... . ... . .. ... . .... ... . 4500 · 5500 грт . . . . ..• .. . ...•... 5 and 6 - 4500 . 5500 грт
В - 5000 . 6000 грт
Idle грт in Forward Gear with Ргорег Propeller . .... ...... . ... . ........ .. .. . 600 грт . ..... • .... . ....... ... ..... . . .. 650 грт
Test Wheel and грт . . .... . . ... . ....... . . .... .. .. •. .. . . ... . .. . ... Раг! No. 390123 ... . .. • .. . . • .•. .. . . . .. .. . Раг! No . 390239
(5·3/4" dia . х 5/В" wide) (5·3/4" dia . х 1·1 / 8" wide)
5100 грт 4900 ГРПI

Powerhead
Вог еand Stroke .. . .. . . . . .. . .. . . . . . . .... . . . . • .. ..... .. .. .. 39,69 тт х 34,93 тт .. . . .... . . ...... ... . 49,21 mm х 43,18 тт
(1 .5625" Воге х 1.375 " Stroke) (1 .9375 " Воге х 1.700" Stroke)
Piston Oisplacement . .. .. .. . ..... . .• . . . . . . . .... . .. .. ...... . . . . 87 ст 3 (5 . 2В cu. in .) .. ... ....... ... . . .. . . 164 ст 3 (10 .0 cu . in .)
Crankshah Size
Тор Journal . . . .. . . ....... . . . ... ... ...• . . . . 19,075· 19,063 тт (0.751 О " · 0 .7505") .. . . 22,282·22,155 mm (0.87725" · 0.87225")
Center Journal .. .. .. ..... ... • . .. .... .. . . ... 16,993 · 16,980 тт (0.6690" · 0 .6685") . .. . . 20,712 · 20,585 тт (0.81545" ·0.8104")
80Нот Journal .. . . .. .. .. . • .. • .... . ... . ... . 19.055·19,045 тт (0.7502" · 0 .7498") . . ... . 19,207·19 ,045 mm (0 .7562" ·0.7498")
Connecting Rod Crank Pin . . .. . ... . ...... . .... . 17,018· 17,005 тт (0.6700" · 0.6695") ... ... 17,018· 17,005 mm (0.6700 " . 0.6695")
+Standard Воге Size ..... . ... . . .. .. ..... ..... . 39'751·39,733 mm (1.5650" · 1.5643 " ) ... . . . 49'225 · 49' 207 mm (1 .9380" · 1.9373")

+То determine соггес! Ьогс size for oversize pistons, add oversiz e dimension to standard Ьоге size.

Ignition System
Ignition .................... . ... . . . . . ... . . ... .. Flywh eel magneto, breakerless С . О . .... . ... . , Flywh eel magneto. breakerless С . О .
Spark Plug (Champion)
Sustained Low Speed Operation .. . ......... . .. . . .. ...... . .. . ............. GL77J4 ....•. .. . . . . .. . . • . . .. . .... . ..... GL77J4
Alternate ... . .. .... ..... . .. . . . ... . . ... .... .. . . . ... . . . . . ..... . .... . . L77J4 . .......... .. ..... . .. . .... . ... . . . L77J4
Gap Setting .. . .............. .. . .. . .. . . . ....... . .... . ....... 1,0 тт (0.040") . . .. . ..... . . .. . . .. . ...... 1.0 mm (0.040")
Sustained High Speed Operation .... . .•.... . ....• . ... . .. . .•..... . . . . .. ... GL78v . ... . ...... ... . . • .... . ........ . . GL78V
Alternate .... . . . ..... . . . ..... . ...... . .. . ... . . .... ..... . .. . .. ........ L78V ..... .. •. .. . ..•.. . ........ . ..... . . L78V
Gap Setting ... .. . .. . . . . ... . . . . . .. .. . .. ...... . .... . . . .. . .. . Gap Is Р е гтапеп! . .. ....... . ... • ... . •. . .. Gap Is Р е гтапеп!
Ignition Coil ..... . ..... . ............. .. . . ... ... . . .. . . . . .. ..... . Раг! No. 582508 .. . . . .... ... . . ... . . .. . ... Раг! No. 582508
RPM Limiter Powerpack . . . ..... .. .•. .. . •...... . . . .. ... . . .. ...... .. . .. .. .... ....... . .... .. . ... . .. . . . . .. . .. . 8 · 6200 грт
Electrical System
Alternator 5ystem
Electric 5tart ... ... . . . . ...... . .... . ...... . .. .. ... .... .. . .. ... ..... ... . . .. . . . . ..... .... . . . . . . . 4 amp flywheel alteгnator
Manual Start (АС Model) . .. .. . ... . . . .. ... . . . .• .. . . . . . ... .... . 60 watt АС а! 12 V . .. ..... . ...... ... . . ... 60 watt АС at 12 V

Ignition Coil Test Specifications - Part No. 582508

Merc·O·Tronic 9800
Stevens Model 5Т · 75
ог 98 with Adapter Model 55-980

Ма х imum Operating Amperage

(Reverse Polarity · Switch Setting : СО) ... . ....... 1.1 Amp s Max imum Operating Amperage
(R everse Polarity) .. . . . ... . ..... . . . . . . .. .... .. 1.5 Amps
Stevens Tester Model М . А. · 75 ог М . А. - 80 Primary Resistance ..... .. .. . • . . .... . . . . . .. . . ........ 0. 1
Second ary Continu ity .. .. . . . . . .. ... . . .. . . . . . . .. 5 а рргох .
Switch .. .. . . .. А (U se Model СО-1 Adapter - Reverse Polari ty)

Index Adjustment .. .. . . . . .. .. .... .... .. .... . . .. . ... 20

Igni t ioll СОП1ропепt Tests - 4 Deluxe thru В

Resistance Ground Test Cranking Output

Meter Setting Reading Meter 5etting Reading Meter 5etting Reading
Charge coil Н igh ohms scale 575 ± 25 О High ohms scale 00 Н , 500 230
Sensor coil Low ohms scale 40 ± 10п Low ohms scale 00 5,5 2.0
Power pack Н , 500 200
Ignition coil Low ohms scale 0,1 ± 0,050
primary
5econdary High ohms scale 275 ± 50 О

1-12 2-V6 Аес .

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 4 Delu xe ar1d 4.5 5,6 and 8

Fuel System
Carburetion ... ... . . ... . . . .. . . . .. . .....•. . . . . . .. . .. . . . ... Single barrel, float feed, ... . ... . . . ......... Single barгel , float feed,
fixed high speed adjustabIe fixed high speed adjustabIe
low speed, manual choke low speed, manual choke
Float Level Setting ..... .. . . .. . ....... . .. . .... Between steps оп gauge Part No. 324891 . .... . Between steps оп gauge Раг! No . 324891
Float Огор Setting ........... . ..... . ... .. .. . . .. .. .. ... 28 · 32 тт (1 .125" - 1.500") . ........... . .. 28 - 32 тт (1 .125" - 1.500")

Clearance Chart
Piston Ring End Gap ........ . .........•..• . ...•... 0,38 - 0,127 тт (0.015" . 0.005" ) .. .. .... . .. 0,38 · 0,127 тт (0.015" · 0.005")
Piston Ring Groove Side Clearance . . .. ... . . .. . .... . ....... 0,10 тт Мах . (0.004" Мах.) ... . . . .. . ...... 0,10 тт Мах . (0.004" Ма х. )

Torque Chart
Powerhead

Flywheel Nut . .. . ... .. . .. .. .. .. .. . , .. .. ... .. ... , . .. . . . 40 - 54 N 'm
Connecting Rod Screws . . ... .......... . . . .... ... ... . ... 7.0 - 8,0 N 'm
Cylinder Head Screws .... .. .. . .. ... . .. . . . • .. . ... .•. .... 7,0 - 9,0 N 'm
Crankcase to Main Bearing Screws
Upper, Center, Lower ....... . ..... . . ..... . . .. ... ..... 7'0 - 9,0 N 'm
Spark Plugs .. . .. . . . ... ... .. . .. .. .. . . .. ......... . ... . .. 24 · 27 N 'm
Power Pack Mounting Screws ........ _ . _ . ... . . . . . . . . _....... 7 - 9 N·m
Ignition Coil Mounting Screws ... ... . . . . .. . . .. .. . ...... . . .. . 7 - 9 N·m
(30 - 40 ft . Ibs.) ... . ..... . ...... 54 - 67 N'm (40 - 50 ft . Ibs.)
(60 - 66 in . lbs.) ..... . .. . ...... 7'0 - 8,0 N'm (60 - 66 in . lbs. )
(60 - 80 in . lbs.) . ..•.. . .. . ... 16,0 - 19,0 N'm (12 - 14 ft . Ibs.)
(60 - 80 in. Ibs.) .. . . . . . ... . .. 16,0 - 19,0 N'm (12 - 14 ft . Ibs.)
(18 · 21 ft . lbs.) . .. • ............ 24 - 27 N 'm (18 - 21 ft . lbs.)
(60 - 84 in. Ibs.) ......... . ........ 7 - 9 N·m (60 - 84 in. Ibs.)
(60 - 84 in . Ibs.) ..... . ... . .. . . . ... 7 · 9 N·m (БО - 84 in. Ibs.)

Gearcase

Gearcase Mounting Screws

Front Screws . ......... . ............ • ... . . . .. ... . . ... 14 - 1б N 'm (10 - 12 ft . lbs.) ... ..... .. . ..... 14 - lб N 'm (10 - 12 ft.lbs .)
Аеаг Screws .... . . . .... . ' .' .. . .. . .. . . .. . ... .. . . .. . .. .. . . 7 - 9 N 'm (БО - 80 in. Ibs.) . . .. .. . . . . • ..... .. 7 - 9 N'm (БО - 80 in. Ibs.)

1-13 2-V6 Аес .

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 Specifications - 9.9 and 15

General 9 .9 and 15

Full Throttle Operating Range ................. .. .•............. . ...... •. .. . •.. . ... ... .. ... ........ . ... 9.9·5000 - 6000 грт
15·5500 . 7000 грт
Idle грт in Forward Gear with Ргорег Propeller . .. . .•........ • .. .. . ....•......... .. ... .......... . •.. . . • .•... . ....... 650 грт
Test Wheel and грт . . ....... .. .... . ...... . ... . ..... . ....... . .. . ...•...... . .... : .... • .... .... ...• .. ..... Part No. 386537
(7" dia. х 1" wide)
9 .9-5500 грт
15-6200 грт

Powerhead
Воге and 5troke ........... . . ....• . . ... . .•... . ........•... . ... . ..... .. . .. 55,58 тт х 44,70 тт (2.188 " Воге х 1.760" 5troke)
Piston Oisplacement . . .. ............... . ........ . . .... ..... . ........ ............... ........ ........ 216 ст 3 (13.20 cu . in .)
Crankshaft 5ize
Тор Journal ..... . . ...• ..... . .. . ................. ....... . .... • .................... 22,255 · 22,243 тт (0.8762" -0.8757")
Center Journal ............. .. .................. . . • .. ....... . . • ...•......•. . . . ..... 20,638-20,625 тт (0.8125" - 0 .8120")
Bottom Journal ..... .. ........... ........•....... ...... ... ..... . .............. ... . 19,200 - 19,990 тт (0.7874" - 0.7870")
Connecting Rod Crankpin .. . ... ... .... . . . . .. ...... . . . ...... . ..... . •.. .. .... . . .. . .. .. . 20,638 - 20,625 тт (0.8125"- 0.8120")
+5tandard Воге Size .. ..... ............ . ...... . ... ... .... .. ... .. . .... ..... .. .......... 55,582 - 55,562 тт (2. 1883" · 2.1875)

+То determine correct Ьоге size for oversize pistons, add oversize dimension to standard Ьоге size.

Ignition System
Ignition ............... . .......... . ........ .. . . . .. . . . . ... .. ......... ....... ... . .. . . ... Flywheel magneto, breakeriess ё . i5 .
Spark Plug (Champion)
Sustained Low Speed Operation .... . ....•....•......•............................ ... ... .•....•.......... . . .... . . OL77J4
Alternate .. ...... .. . .... . ...... . . . .... ......... .. . ..... . ... ..... .......... .......... . ................... .. L77J4
Gap Setting ... ....... ..... ...... .. ... . ....... . ..•... .. ............ .. ......... . . . ..... . . . .... ... ... 1,0 тт (0.040")
Sustained High Speed Operation ...•................•....•...... . . .. ...•........... . ....•... . .. . .............. .. OL78V
Alternate ........ . ....... ...•........ .. . ... . . ... . ...... . ........•.....................•.................... L78V
Gap Setting .. . .. . . . .............. . .... . ...... .. ............ . .... ......... . . . .. . . .... . . .. ......... Gap Is Регтапеп!
Ignition Coil ......... . . . . . .. . ... . .. . . . .... . .... . . .. .. ... ... . ... . .......... .. .. . .. ... ... ............. .. Part No. 582508

Ignition Coil Test Specifications - Part No. 582508

Merc·O·Tronic 9800
Stevens Model ST·75
ог 98 with Adapter Model 55·980

Maximum Operating Amperage

(Reverse Polarity . Switch Setting : СО) .. . . ....... 1.1 Amps Мах imum Operating Amperage
(Reverse Pol arity) ........... . . .. .. ..... . .. ... 1.5 Amps
S tevens Tester Model М . А. · 75 ог М . А. - 80 Primary Resistance ..... .. . .. .... . . . ................. 0.1
Secondary Continuity ...... . .. . ............ . ... 5 арргох.
Switch ........ А \Use Model СО - 1 Adapter · Reverse Polarity)

Index Adjustment . . . ... ...... ...... . . ...... . ....... 20

Ignition СОl11ропе ,н Tests - 9.9 апи 15

Resistance Ground Test Cranking Output
Meter 5etting Reading Meter Setting Reading Meter Setting Reading
Charge coil High ohms scale 575 ± 25 n High ohms scale 00 Н,500 230
Sensor coil Low ohms scale 40 ± 10 n Low ohms scale 00 5,5 2.0
Power pack Н,500 200
Ignition coil
Low ohms scale 0,1 ± О, О5П
primary
Secondary High ohms scale 275 ± 50 П .

1-14 2-V6 Аес.

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 9.9and15

Electrica l Sy stem

Alternator System
Electric Start .. . . .. .... . .. . . . .............. .... ... .. .... .. . . .... . . . .... . . .. . •... . .. •... ..• ... 4 атр flywheel alteгnator
Мапиа' Start (АС Model) .. ..... .. . . . . .... . .. .. . .... . . ... . .. . •.. . ... ... .• . .. .•. . .... . ....... ... .. ... . 60 watt АС at 12 V

Fuel System
Carbuгetion . .. .. . .... . ...... . .. . ... . ... .. . .... . ..... .. Single barrel, float feed, fixed high speed adjustabIe low speed, тапиаl choke
Float Level Setting .......... . ... . . . ... .. • .... .. . • ..... .. . . .... . . .. . .... . ....... .... . Between steps оп gauge Part No. 324891
Float Огор Setting . ... . .. .. . ..• . .. . . .. .. .. .. . .. . • .. ... . ... ... . . . . .... . ... . ... .•.... ... .... .. . 28·32 тт (1.125" . 1.500")

Cl earance Ch art
Powerhead

Piston Ring End Gap ... .. ..... ... . .. . .. .... . . . . . ... . ..... ... ... .. . . . ..... . . .. ... . . .. ...... 0,38 - 0, 13 тт (0.015" - 0.005 " )
Piston Ring Groove Side Clearance, Lower ..... . . .. . . ... .. .. . .. .. . . . . • _. . .. _. . . _. . _.... ... . . . . .. .. . 0,10 тт Мах . (0.004" Мах . )

Torq ue Chart
Powerhead

Flywheel Nut ... .. .... . .. . ... . ... ... . . ... . .. . .... . ... •....... _... _• . _. . . .. ... _... ... ... .... .. 60 - 70 N'm (45 - 50 ft. Ibs.)
Connecting Rod Screws ... ...... . . . . . .• .. . .. ... . _. _. . . .. .. _... ... _. __ .. . ... _•. .. . _. ...... . . ... 5,0 - 7,0 N'm (48 - 60 in. Ibs.)
Cylinder Head Screws .... . _.. ... .. _• _. . _. . .• .. _. _.. ..• . • .. . . . . . .. .. .. _. _. ___ • ... _. . • _... . ..... _ 24·27 N'm (18 - 20 ft. Ibs.)
Crankcase to Main Bearing Screws
Upper, Center, Bottom .... . .. . ... . . ... . . . ..... . _. . .. ___ . • ... __ . . __. .... .... .. . ... . .. . . _. .. . .. 16 - 19 N'm (12 - 14 ft.lbs.)
Spark Plug _.... .. . .. ..... .. ..• ..... • . . _. _.. . . .. _• . _. _.. . .. __ . . . . .. .. .. . .. . .. _.. . _..... _..... 24 - 27 N -m (18 - 21 ft. Ibs.)
Electric Start Thru-Bolts .. _. ....... . ... .. _.. . _• ... .. . _. • . .. . . .. . . ..... . _. _... ..... .. ........ . ... _ 4 - 5 N -m (30 - 40 in . Ibs.)
Starter Motor Pinion Nut ... . .. . ... . ... • .. .. ... • ... .. _.... . .... .. .. _. . . _. _. ..... _. . . . __ ... . __ _ 17 -19 N -m (150 -170 in.lbs.)
Power Pack Mounting Screws . .. . ... ... • .. _...... ..... ... . ... . ... . . _. ... ... . .. _. . .... _.. .. . .. . .. . .. 7 - 9 N-m (60 - 84 in. Ibs.)
Ignition Coil Mounting Screws ..... . . . ..... . ... .. . . . . . _. ..... • . .... ... . . . . .. ....• .... .... •. _.... __ . 7 - 9 N·m (60 - 84 in. Ibs.)
Мапиа' Staгter AssembIy Screw .. . .. .. . . . .... .. . ... . . . . . . . .... .. • . ...... . . .• .. . .. _ . _... •.• . ..•.. . 32 - 36 N·m (24 - 26 ft . Ibs.)

Mid·Section

Upper Mounts .. . . ... ..... . . .... ..... ....... . ....•.. .... .. ...•..• _.. . • ... .. . . ..... . . •... ... . ... 7 - 9 N'm (60 - 80 in . Ibs.)
Pilot Shaft to Steering Bracket Screws .. . ___ . . ..•.. __ • . _. . .. •.. .. . . ___ • . . ... .. __ . _. .... . •.... . . . .... 11 - 15 N 'm (8 . 1О ft . Ibs.)

IGearcase

Gearcase Mounting Screws _..... • .. .. . . .... • . ... . . .......... .. .. .... • . .... . . . __ . _. . ..... _... .. .. . 8 - 11 N·m (72 - 96 in. Ibs.)

1-15 2-V6 Аес .

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Specifications - 20 thru зо

General 20 thru 30

Full Throttle Operating Range .. .... ... .. ............•.. . .•... . . .• ...... . .... . ........ . . .. ......... . .... . . 4500 · 5500 грт
Idle грт in Fo!Ward Gear with Ргор е г Propell er .. . . . .............. . ...... . .•.... . .•... .• .... . ......... . .. ...... .... 650 грт
Test Wheel and грт . .................. .. ..... .. . . ........... . .. . ... . .•...... • ... . ....... ... ........ 20 - Раг! No. 386891
25 and 30 - Раг! No. 394145
20 - 4550 min. грт
25 _. 4800 min . грт
30 - 5400 min. грт

Powerhead
Воге and Stroke ... ...... . .. . . .... . . .. . .... . .. . .... . . .... .. . .. . .. . . . .. . .. . ......... . ..... . ... ..... 76.20 тт х 57, 15 тт
(3.000" Воге х 2.250" Stroke)
Piston Displacement .. . .... . . .... .. . .. ...... . ... ...•. .. .•.... . . . ...... . . . .. ....... ...... .. .. .. .. .... 521 ст 3 (31 .8 cu. in.)
Crankshaft Size
Тор Journal .. ... . . .. . ....... . . .... ...... .... . .. . . . . .... . .... . ..... . . . ... .... . . .. 31 ,775·31,788 тт (1 .2510" · 1.2515")
Center Journal ..... . ....•..•. .. ...... . . ..... . . ... . ......... . . . . . ..... . .. .. ... .. .. 30,056·30,069 тт (] .1833" . 1.1838")
Bottom Journal ... ......... .. . • .... . . ... ... ...... •... . ..•.... •. . . ..... . . •. . . . • ... 24,999 . 25,009 тт (0.9842" . 0.9846")
Connecting Rod Crankpin .. . ... . ... ... .. .•. . .. . .. .. ......... . .. . . • . . . . .. . ...... . ..... 30,043 · 30,030 тт (1 .1828" . 1.1823")
+Standard Воге Size .. ..... . .. ........ . . . ..... . ..... . ...... . .......... ...... ......... 76,213 · 76,187 тт (3.0005" . 2.9995" )

+То determine соггес! Ьоге size for oversize pistons, add oversize dimension to standard Ьоге size.

Ignition System
Ignition .......... ...... . . . . .. . ........... ... . .. . . . . . ... .. . . . . ... ... .. . .. . . . .... ... . .. Flywheel magneto, breakerless C.D.
Spark Plug (Champion)
Sustained Low Speed Operation ... ... ..• ... .•..•. .. .. . .. . ... .. ..• . . . .. ...• . . . . .....• .... . . . ... . .. . .... . . . .. .. ... QL77J4
Alternate ....... . .. . ... . . .. . . . . .... .. .. . .... .... . . .. ... . ... ... .. . ...... . .. .. • ....•... . . .... .. .... ... . . . ... L77J4
Gap Setting ......... . .... .. .. .... .. .. . ... . .. . ..... . .... . . . ... . .... . ... .... . .. . ..... ... . .. . .... . .. . 1,0 тт (0.040")
Sustained High Speed Operation ... • ...... . .. . . .. ... . . .. .... . .•. .. .. .... .. .... .. ... .. .. . • .. . ... • . . .......... ... . QL78V
Alternate ... ........... .. . . ....... . .. . .. . .. . .. . . . . ... . . . .. .... . . .. ... . ..... . ... . ..... .. ... . .. . .. . ........ . . L78V
Gap Setting ....... . . . . .. . ... . ..... . . . . .... .. . .. . . . ..... .. . . . ..... .. .. ... .. . .. . . . . ... ...... . .. . . .. Gap Is Регтап еп!
Ignition Coil .... . . .. . . ... . . ..... . . .. ..... . .. . . . .... .......... . ........ . .. .. • . .. .. .. . . .. ... ... . .. • . .. .. Раг! No. 582508

Ignition Coil Test Specifications - Part No. 582508

Merc·O·Tronic 9800
Stevens Model ST·75
ог 98 with Adapter Model 55·980

Maximum Operating Amperage

(R everse Polarity . Switch Setting: CD) . ..... .. . .. 1. 1 Amps Maximum Operating Amperage
(Reverse Polarity) ............ . ...... . . . . . .... 1.5 Amps
Stevens Tester Model М . А .· 75 ог М . А .· 80 Primary Resistance ........ .. ... . .................... 0. 1
Second ary Continuity ..... .... . . .. . .. . . .... . ... 5 арргох .
Switch .. .... . . А (Use Model CD· 1 Adapter · Reverse Polarity)

Index Adjustment ........ . . ...... .... ... . . . . .. . . .. . 20

1-16 2·V6 Аес .

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