35

sPECIFICATIONS 20

25 and 25 COM.

5200-5800 rpm 4500-5500 rpm . · · · · · · · · · · · · · · · 4500-5500 rpm ... . ... w· .. . j p. rt. Number 386891

Full throttle operating range · · · · · · · · · P. · · · N b 388880 Wheel Part Number 388880 .. · · · · hee a · 5300

POWER HEAD

Tank test ... ... .. . .... . ........... Wheel art um er . . . . . . 5200 rpm _r~m 4650 _rpm I 2 cvcle alternate tiring ... .. 2 cyl., 2 cycle, alternate tmng

Engine type ........ . . . .... . ...... 2 cyl., 2 cycle, alt~rnate f~r~~g .. ·7·6· io c~~ bar~ x 57 15 mm stroke .. 76,20 mm bore x 57,15 mm strok3 Bore and stroke .. .. ........... 76,20 mm bore x 57,1 m~2~t~om~:: .. : .......... . .. · . . . 521 cm3 ....... . . .. .. ........ 521 em

Piston displacement ...... . ............. · · · · : · · · · · · · Piston and ri ngs available standard and 76 mm overs1ze

~ Thickness of ring 2 286 2 273 2 286- 2 273 mm .... . . . ....... 2,286 -2 ,273 mm : ?;... Upper....... . ................ .. .. ... .. . ' 88. 1,562 mm .. . .... . . . . ·. :: 1,588-1:562 mm .... .. .. . ... .. 1,588- 1,562 mm

1 5 - mm... . . . ..... • 'I'X~ower ... . ..... . · · · · · · · · · · · · · · · · · · · · · · · ' ' dan~.~~~a~t size

31 775 _

31 788 mm ....... . .... 31 ,775 _ 31 ,788 mm .. . ......... 31,775-31,788 mm

TC~p:.:Jolllrnal ·~·......... .. ...... . 29,985-29,997 mm ...... . ..... 29,985.29,997 mm ... . .... .. .. 2294,998959-2295,909079 mm enter JOurna . . . : . · · · · · · · · · · · · · · · · · · · · ' ' 24 999 _ 25 009 mm . . . . . . . . . . . . . · , mm

Bottom journal .. .......... . ...... · ···· · · 24,999 · 25 •009 mm · · · · · · · · · · · · 30·043 30'030 mm 30 043-30 030 mm · · 30 043 30 030 mm - · · · · · · · · · · · · • ·

Connecting rod crank pin ... · · · · · · · · · · · · · · · · • · • . · · · · 6· ·2·1· · · · · ' _ 76 19'mm min ... 76,21 mm max.- 76,19 mm min. +Standard bore s1ze ..... . ....... 76,21 mm max. - 76,19 mm m1n ... 7 , mm max. ,

+To determine correct bore size for oversize piston, merely add oversize dimension for standard bore size . .:: 'X ~\~L Tr.:c\··..:. ~4C.:"'-..I ,

,•1 '7 ~ kJo ~o, ot) : 7 1(!), t 0;03 J

FUEL SYSTEM

Carburetion .......... . . . . . ....... Single barrel, float feed, fixed .. high speed, adjustable low­

speed, manual choke

L 6 ::J6 o ' ) j "(/ l1t:. I '1

. . Single barrel, float feed, fixed .. ... Single ~arre l, float feed, .fixed high speed, adjustable low· high speed, adjustab le lo -speed (under motor cover), speed (under motor cover),

manual choke manual choke

Float level setting . .... . ....... . Between steps on gauge no. 324891 . Between steps on gauge no. 324891 . Between steps on gauge no. 324891 F I oat drop setti ng ............... 28 - 41 mm from carburetor body .. 28 · 41 mm from carburetor body . . 28 - 41 mm from carburetor body lnletneedleseat .... . . . .......... .. ...... . .... 1,65-1,57mm............. 1,65-1,57mm .......... . ... . . 1,65-1,57mm Initial low speed needle sett ing ... .. .. . ............ 3/4 turn open .. . .. .. . . ..... . . 1-1 /2 turn open .. . ............. 1-1 / 4 turn open Idle speed . . . . . . . . . . . . . .. . ...... 650 rpm maximum ......... ... . 650 rpm maximum .... . .. . . . ... 650 rpm maximum Maximum neutral rpm .... . .. . . . ........ 2000- 3500 rpm . . . . . . . . . . . . . 2000- 3500 rpm . . .. . . . .... . ... 2000- 3500 rpm

LOWER UNIT Cooling system . . . . . . . . . . . . . . Combination positive displace- . .

ment and centrifugal pump Thermostatically and

pressure controlled Propeller gear ratio . . . . . . . . . . . . . . . . . . . . . 12:21 Propeller supplied with motor .... .. 3 blade, 9-1/ 4" dia. x 11" pitch.

Propeller options ..... . .... ........... 3 blade, 9" dia. x 9" pitch . . .

MISCELLANEOUS

3 blade, 9" dia . x 10" pitch

3 blade, 9-1 /4" dia. x 9" pitch SST

3 blade, 9-1 / 4 " dia. x 12" pitch SST

3 blade, 9-1 /4" dia. x 12" pitch

.... Combination positive displace- . . . . Combination positive displace-

ment and centrifugal pump ment and centrifugal pump Thermostatically and Thermostatica lly and

pressure control led pressure controlled .... . 12:21 ................. 14:27

3 blade, 9-1 / 4" dia. x 11 " pitch . ... . . . ... 3 b lade, 10" dia . x 13" pitci:J alum .

. 3 blade, 9" dia. x 9" pitch . .. ........ 3 blade, 11" dia. x 9" pitch alum.

3 blade, 1 0-1/2" dia. x 11" pitch alum.

3 blade, 10-1 /4" dia. x . 13" pitch SST

3 blade, 10-1 /2" dia. x 11" pitch SST

3 blade, 11" dia. x 9" pitch SST

3 blade, 9" dia. x 10::·pitch

3 blade, 9-1 / 4" dia. x 9" pitch SST

3 blade, 9-1 / 4" dia. x 12" pitch SST

3 blade, 9-1 /4" dia. x 12" pitch

Speed control ....... .. . . .......... . .. . On steering handle .. On steering handle (Manual start) Remote control available

(E lectric start)

On steering handle (Manual start) Remote contro l available

(Electric start) Forward, rfeutral and reverse Gear shift control . . . . . . . .. . .. Forward, neutral and reverse ...... Forward, neutral and reverse .

- Weight (without fuel tank, fuel tank weight 5 kg net.)

Standard length Manual start Electric start . ..

Long shaft Manual start ... . . . .... . ........ . ....... ... ... . Elect ric start ...... ...... . .. ..... .. . ..... .... .

Fuel capacity . . . . . . . . . . . . . . . . . . . . ... . .... . . . . .

ENGLISH

I~ I

45,8 kg ... . . . . .. .. . 47,2 kg .. . . . . .. . ... . . .... .. . 51,7 kg 51,4 kg." " " " "" . " " 53,1 kg

46,7 kg . 48,5 kg . . . . . . . . . . . . 53,5 kg 52,7 kg. . . ........... . 54,9 'kg

22,7 litres .... . . . . . . .... . 22,7 litres ... .. . . .. . ..... . .. .. 22,7 litres

1-7A

\ \

SPECIFICATIONS (CONT.) 20 25 and 25 COM. 35

ELECTRICAL SYSTEM

Generation

Electric start······ · · ·. · · .... .. . ... . . . ... .. ....... . .. .. . .... . .... 5 amp f lywheel alternator . . . . ... 5 amp f lywheel alternat or

Manual start . . ... ... .. . . ... 60 watts AC at 12V . .. 60 watts AC at 12V ..... . . . . . .. . 60 watts AC at 12V Starter amperage draw whi le crank ing ....... 100ampsmax .. . .. .. . . . . ...... 100 ampsmax .

IGNITION SYSTEM :gnition -f· · ·. · · · · · · · · · · · · · · · ........... Magneto breakerless C. D.. . . . . . . . Magneto breakerless C. D. . . . . . . . . Magneto breakerless C. D.

Sgpn~:~0~1u~mmg. : : : : :: : : : :: : : :: : : : : : C·h·a~~i~~- O LllJ4 -~r- L l7~J~ ·. · ... .. C·h·a-~pi~·n· OLllJ4-~r L7~j~: : : :: : C·h·a~~ i ~~-6 l_]]j4 -~r- L7~~~ +Alternate spark plugs . . . . . . . . . . . . . . Champ ion L78V, OL78V ... .. ... Champion L78V, QL78V ........ Champion L78V, QL78V

or AC-VOFFK or AC-VOF FK or AC-VOFFK Spark plug gap .. . . . . . . . . . . 1 ,0 mm . 1 ,0 mm . . . 1 ,0 mm Spark plug torque . . . 2,4 · 2,8 kg-m (24- 27 N-m) . . 2.4 - 2,8 kg-m (24 - 27 N-m) . . 2,4- 2,8 kg-m (24 - 27 N-m) Ignition co il ... . . . Part No. 582106.. ... Part No. 582106 .. . ..... . . Part No. 582106 (Coil Test page 4)

+Alternate spark plugs should be used when operat ing at high RP M for extended periods of t ime.

IGNITION COMPONENT TESTS

R esi~!ance Ground Test Output

Meter Setting Reading Meter Setting Reading Meter Setting Reading

Charge coil High ohms scale 575 ± 75 0 High ohms seal~ 00 H. 500 230

Sensor co il Low ohms sca le 4o ± 10 n Low ohms ~cale 00 S,5 0 .3

Power pack -- -- -- -- H. 500 180

CLEARANCE CHART

POWER HEAD

Piston ring gap . ... .. . . . ... . . . . . . ... .. . .. . . .. . . . .. .... . .. . . . .. . . . . . .. . .. .. . . . ... . . .. . ......... . .. . 0.43-0, 18mm Piston ring groove clearance, lower . . ........ . .. .. . . .. . .. . . .. . . . .. ......... . 0,102-0,038 mm Cylinder and piston. . .. . .. . . ....... . Crankshaft end play . . . . . . . . . ........... . .

LOWER UNIT

Propeller shaft in front gear bushing . ... . ... . ....... . . . ... . . . . . . . . . . . .. . . . .. . .. . . . ....... . ... . Rear reverse gear to rear bushing . . . . . . . ..... . . . .... . . Reverse gear bush ing to propeller shaft .. . .. . .. . . . .. . . . ..... . ..... . .. . . . . . . .. .. .. . . .. . ... . .... .

TORQUE CHART

POWER HEAD

. . .. .. . .. 0,165-0,089mm

. . .. ... . . . . 0.28 - 0,08 mm

0,051 -0,025 mm 0,051 -0,013 mm 0,038 - 0,013 mm

Flywheel nut ...... . .... . . • .. . .. . . 13- 14 kg·m (135 - 140 N-m) . . ... 13 - 14 kg ·m (135. 140 N-m) . . . .. 13 - 14 kg-m (135 - 140 N-m) Connecting rod screw ... . .... . . .. ... . 4,0- 4,2 kg -m (40- 42 N-m) . .... . 4,0-4,2 kg-m (40- 42 N-m) . ...... 4,0 4,2 kg-m (40- 42 N-m) Cylinder head screws .. ... .. . . . . .. . . . 2,5- 2,8 kg·m (24- 27 N-m) .. . ... 2 ,5-2,8 kg ·m (24. 27 N-m) . .. . .. 2,5 - 2,8 kg- m (24- 27 N-m) Crankcase to cylinder screws-

upper, center, and lower . . . .. . ...... 1,9-2,2 kg·m (19 - 22 N·m) ...... 1,9-2,2 kg·m (19 -22 N-m) .. . ... 1,9-2,2 kg·m (19 -22 N ·m) Powerhead to exhaust housing screws .. . ... . ................... . ...... . . . ... . ........ . . . .. . ..... .. 2.2 - 2,5 kg·m (22 - 24 N·m) Electric starter through bolts ..... . . . . . . ..... . . ...... ... . .. . ....... 0.7-1,0 kg·m (7 ,0 - 9,5 N·m) ..... 0.7 - 1,0 kg· m (7,0 · 9,5 N·m) Electric starter p inion nut ... .. . . .. . ... . . .... . ..... . .... .. . . . ...... 2,8- 3.4 kg ·m (27 - 34 N·m) .. . ... 2,8 - 3.4 kg·m (27- 34 N·m) Spark plug . ..... . . . ... .. . ...... . .. 2.4- 2,8 kg·m (24- 27 N·m) ..... . 2,4 - 2,8 kg·m (24- 27 N·m) . ..... 2,4- 2,8 kg·m (24 - 27 N·m) Manua l sta rterassemb lyscrew .. . . .. . . . 1) - 1.4 kg-m(11- 14N-m) .. . ... 1,1 - 1.4kg-m(11 - 14N-m) .. .... 1,1 - 1,4kg·m(1 1 - 14N·m) Power pack mounting screws .... . . . @)55- 0,69 kg·m (5 · 7 N·m) ...... 0,55 - 0,69 kg·m (5-7 N·m). . . 0,55 - 0,69 kg·m (5 · 7 N·m) Ignit ion co il mounting screws . . . . . 0;55.- 0,69 kg·m (5-7 N·m) . . . . 0,55- 0,69 kg·m (5-7 N·m) . . . 0,55 - 0 ,69 kg·m (5 · 7 N·m)

. ·;;.:~~·: •.

LOWER UNIT

Upper mounts .... . . . .. . ......... . 0.7 . 1,0 kg ·m (7 ,0 - 9,0 N-m) . . ... 0.7 - 1,0 kg·m (7 ,0- 9,0 N-m) .... . 0.7 · 1,0 kg ·m (7 ,0 · 9,0 N·m) Pilot shaft to steering . . ............. . . 1.4. 1,6 k-m (14 - 16 N-m) ...... 1.4 - 1,6 kg-m (14- 16 N-m) ...... 1.4 · 1,6 kg·m (14 - 16 N· m) * Pull at propeller shaft for tilt up ........ .. ... .. ... 13,6- 18,1 kg . ............... . 13,6- 18,1 kg ..... . . . .. · · · . .. · 13,6 · 18,1 kg

* Pull at propeller shaft to overcome reverse lock ........ . ... _: :. '\:\'_. . . . . . . . . 68 - 113 kg . . . . . . . . . . . . . . • . . . . 68 - 113 kg .. . · · · . · · · · · · · · · · · · 68 · 113 kg

*Standard length lower unit.

1-78

I :

LUBRICATION CHART - 20, 25 AND 25 COM., 35

FREQUENCY (PERIOD OF OPERATION

LUBRICATION POINT LUBRICANT FRESH WATER SALT WATERt

1. Throttle and Shaft Linkage, 60 days 30 days Rear Motor Cover Latch ,

0 Starter Neutral Lockout (Manual Start). See Figu re 1-21.

2. Throttle Shaft Bushings and

0 - 60 days 30 days Gears, Steering Handle and Bracket. See Figure 1-24.

3. Vertical Throttle Shaft and 0 60 days 30 days Gears. See Figure 1-22.

4. Carburetor, Choke Linkage , 0 60 days 30 days and Cam. See Figure 1-25.

5. Clamp Screws and Reverse

0 60 days 30 days Lock. See Figures 1-23 and 1-26.

6. Shift Lever Shaft and • 60 days 30 days

Swivel Bracket. See Figures 1-27 and 1-28.

7. Gearcase, Capacity - Change after first 20 hours of operation. Check every 50 hours of operation thereafter. 35 - 361 ml • Add lubricant if necessary . 20/25 - 246 ml See Figures 1-29 and 1-30. Drain and refill every 100 hours of operation or once each season, whichever occurs first .

8. Electric Starter Pinion • As required As required

Hel ix. See Figure 1-25.

t Some areas may require more frequent lubrication .

TYPES OF LUBRICANT Contact your DEALER for OMC Lubricants.

OMC OMC HI -V IS LUBRIPLATE TR IPLE·GUARD GEARCASE 777

GREASE LUBRICANT

\:1 .... l ~-

'

~ (,.~

......

~ """ ...... ~J!. -•"""' '

yrease ·-· ""

~ ~ d ~ --· ...:. r:.. · ·.....: v ~

TUBE GREASE GUN

0 • 0 0 LUBRICATION PICTURE SYMBOLS

1-17 ENGL.ISH

1-21

1-22

1-23

1-26

1-27

1-17

1-30

CARBURETOR RE M OVAL -9.9/ 10 AND 14 COM./ 15 Use Parts Catalog as reference (Carburetor Section).

a. Remove low speed knob.

b. 9 .9/ 15 - Remove air silencer cover. Remove air silencer base from carburetor (2 screws).

c. Remove choke knob detent. Disengage choke shaft f rom choke lever, and remove choke knob and shaft from lower motor cover.

d. Remove manual starter .

e. Remove cam follower shoulder screw and washer, and disengage lever from link and starter lockout pawl spring. Observe position of link in cam follower lever.

f. Remove nuts, carburetor, gasket and link as an assembly, from intake manifold. Observe position of link on lever.

l ~tJ&U N OTE ...

Link must be installed in throttle lever before re­installing carburetor on manifold, as manual starter lockout bracket prevents installation after carburetor is mounted on manifold.

g. Remove fuel hose t ie strap and disconnect fuel hose from carburetor.

LEAF PLATE REM OVAL

a. Remove six intake mani fold screws and re­move manifold . Remove leaf plate and gas­ket from crankcase.

REMOVAL. OF CARBU RETOR -20, 25, 2!5 COM. AND 35 J. Disconnect carburetor to fuel pump hose at

fuel pump.

b. Remove screw retaining choke lever to carburetor . Remove wave washer and spacer. Disengage choke lever from choke knob, and pull out of retainer in air silencer.

c. Remove pin from end of throttle control rod.

d. On Non-Commercial Models Remove locknut, three screws, and air silencer . See Figure 2-21 . Remove gaskets.

e. Disconnect throttle arm to cam follower link. See Figure 2-22 .

f. Remove electric sta rter if model is so equipped .

g. Remove carburetor to manifold nuts and remove carburetor.

REMOVAL OF LEAF PLATE ASSEM BLY a. Disconnect oil recirculation hose. See Figure

2-22A. Remove seven hex head screws and one slotted flat head screw. See Figure 2-22A. Remove intake manifold and gasket.

EN G L.ISH

b. Remove one slotted flat head screw and re­move leaf plate assembly and gasket.

REMOVAL OF CARBURETOR -40 COM.

a. Disconnect fuel line at carburetor. Remove choke link from choke lever. See Figure 2-228 .

UliiliU NOTE

If choke link screw is removed, manual choke must be readjusted so choke opens and closes fully.

~ ~flWioJ! I NOTE

Remove throttle cam link by pulling out of throttle arm bushing. If throttle arm adjustment screw is loosened and throttle arm removed, throttle cam adjustment must be made. See Figure 2-228.

2-13

b. Remove two nuts and lockwashers attaching carburetor to intake manifold. Remove carburetor and gasket from intake manifold .

c. Remove eleven screws attaching intake manifold to powerhead. See Figure 2-23. Remove intake manifold from powerhead.

d. Remove oil recirculation hose and screw attaching leaf plate to crankcase and remove leaf valve assembly, and gasket. See Figure 2-23 .

1. Throttle Control Rod 2 . Pin

2-20

1. Screw 2. Locknut 3. Air Silencer

2-21

1. Link

2-22

1. Hose

2-22A

1. Choke Link 2. Adjustment Screw 3. Cotter Pin 4. Link

2-228

1. Intake Manifold 2. Leaf Plate to Crankcase Screw

2 -23

2-20

2-22A

2-21 2-228

2-22 2-23

2-13

CARBURIETOR DISASSEMBLY

a. 2 . thru 35 - Remove packing nut and adJustable needle valves with adjusting knob.

b. 4 thru V-6 - Remove fixed jets with Tool No. 317002.

c. Remove float chamber and gasket. Remove hinge pin to permit removal of float and float arm assembly.

CLEANING, INSPECTION, AND REPAIR

GENERAL 11\ISTRUCTIONS

Clean all parts, except float and float valve, in solvent and blow dry with no more than 138 kPa of shop air. Do NOT dry parts with a cloth as lint

3Y cause trouble in the reassembled car­ouretor. Be sure all particles of gaskets are re­moved from gasket surfaces. Flush all passages in the carburetor body with solvent and remove any gummy deposits with OMC Engine Cleaner . Certain solvents will not remove this gum which accumulates, particularly in the f loat chamber and on needle valves.

l it·ffi!;"lil NOTE

Do not use OMC Engine Cleaner (OMC Engine Tuner) on rubber or similar parts.

FLOAT AND NEEDLE VALVE

a. Inspect float and arm for wear or damage . If the cork float has become oil-soaked, discard it and install a new one. Check float arm wear in the hinge pin and needle valve con­tact areas. l=leplace if necessary.

b . Inspect the inlet needle valve for grooves, nicks, or scratches. If any are found , replace float valve assembly. See Figure 2-30. DO NOT attempt to alter the shape of the needle valve.

c . Check the float with a magnifying glass; if the seat is nicked, scratched, or worn out-of ­round, it will not give satisfactory service. See Figure 2-31. The valve seat and valve are a matched set; if either is worn, both parts must be replaced. Use a new sealing washer when reinstalling the needle seat.

NEEDLE VALVES

a. Inspect the tapered end of the needle valves for grooves, nicks, or scratches; replace if necessary. See Figure 2-32.

b. DO NOT attempt to aher the shape of the low speed valve .

ENG LISH

CARBURETOR BODY

a. Clean out all the jets and passages, and the venturi making sure no gum or varnish deposits remain. Dry after cleaning with com ­pressed air. Keep clean for final reassembly .

b. Check all gasket surfaces for nicks, scratches. or distortion. Slight irreg ularities can be corrected with the use of a surface plate and emery cloth.

c. Check throttle and choke shafts for exces­sive play. Check operation of choke and throttle valves to be sure they correctly shut off air flow, yet move freely without binding. Replace carburetor if valves or shafts are excessive ly worn or damaged.

DNOTE

The threaded edges of the choke and throttle valve attaching screws are staked during car­buretor assembly to prevent loss during op­eration. Disassembly of these valves is possible, but replacement of the carburetor body is recommende d.

CORE PLUGS

a.

b.

c.

If necessa ry, remove core plug to clean out slow speed orifice holes. If leakage occurs at a core plug area, a smart tap with a hammer and flat end punch in the center of the core plug will normally correct this condition.

If leakage persists, drill a 3 mm hole through the center of t he core plug to a depth of not more than 1 ,5 mm below its surface. With a punch, carefully pry ou t t he core plug.

Inspect and clean the ca sting contact area . If nicks, scratches, or an out-of-round condi­tion exist, the casting will have to be replaced. If casting opening is normal, apply a bead of OMC Adhesive "M" to the outer edge of a new core plug. Place the new core plug in the casting opening, convex side up. Flatten to a tight fit with a flat end punch and hammer. Check f or leakage.

LEAD SHOTS

If leakage occurs at a lead shot area, follow these corrective measures:

a. If leakage is slight, a smart tap with a ham ­mer in the center of the lead shot will nor­mally correct this condition.

b. If 1 eakage sti II exists, remove the lead shot with an appropriate sharp tool.

c. Clean and inspect casting opening . If the casting opening is normal, install a new lead shot in casting opening and flatten out w1th

it, I ight hammer taps. Check for leakage.

ffi Safety Related

2-16

6332.4

2-30

@'-=-==) 63324

2-32

63324

2 -31

2-1 6

LEAF VALVES

a. Inspect the leaf plate assembly and dis­assemble if necessary. The leaf valves must be free from all varnish and gum, and the leaves must be perfectly flat and without dis­tortion so that they form a perfect seal with the leaf plate base.

b. DO NOT attempt to bend or repair a dam­aged leaf; replace the complete assembly if damaged. DO NOT under any circumstances bend or flex the leaves by hand .

c. Replace the leaf stop if any leaves are broken .

FUEL RECIRCULATING VALVE

When servicing the leaf valve assembly, remove the recirculation valve leaf and clean the hole in the plate and the leaf with OMC Engine Cleaner.

TESTING ELECTRIC CHOKE -50/60(70(75

For efficient operation, the plunger should be free from corrosion so that it can move freely in the solenoid housing. It is not necessary to lubri­cate the solenoid plunger since the oil film will only attract dust and cause sluggish plunger movement. Choke solenoid should test 2,0 ± 0,5 ohms between purple/ white stripe lead and black ground lead. See Figure 2-33.

PRIMER SYSTEM - V-4 AND V-6

For efficient operation, the solenoid plunger · should be free from dirt and corrosion so that it can move freely in the housing .

Primer solenoid should test 5.5 ± 1.5 ohms between purple/white stripe lead and black ground lead. See Figure 2-33.

To disassemble primer solenoid remove cover screws. See Figure 2-34. Lift off cover and gasket. Remove sea l. filter, plunger and spring. Clean or replace filter . When reassembling use new gasket and seal.

Replace any cracked or deteriorated primer hoses. Clean nipples in bypass covers with Special Tool Part No. 326623. See Figure 2-35 . If damaged replace bypass covers .

CARBURETOR REASSEMBLY

GENERAL INSTRUCTIONS

Reassemble the carburetor, paying particular attention to the following procedure. Keep all dust, dirt, and lint out of the carburetor during reassembly. Be sure that parts are clean and free from gum, varnish and corrosion when reas-

ENCiL. ISH

r..._ sembling them. Replace all gaskets and sealing ~washers. DO NOT attempt to use original

gaskets and washers, as leaks may develop after the engine is back in use.

CARBURETOR BODY

a. 2 thru 35 - Install low speed needle valve. Install orifice plugs. Replace float valve seat and gasket, float valve, float, and hinge pin.

b. To check position of float, turn carburetor body upside down, so that weight of the float closes float needle. Top of float should be be­tween steps on gauge no. 324891. See Fig ­ure 2-36.

c. Check for correct float drop dimension. See Figure 2-37. With carburetor body in normal running position, the float must drop open to dimension shown.

d. Using a new gasket, install the float cham­ber to the carburetor body.

e. V -4 and V -6 - Invert carburetor and place a small drop of Loctite Part No. 290 sealant to base of idle tube where idle tube comes out of casting . See Figure 2-38. Allow sealant to wick around tube but not run down tube or run down into idle air bleed orifices . Allow to dry.

2-17

1. Purple/white Lead 2. Lo Ohms Scale

2-33

1. Cover 2. Gasket 3 . Seal 4. Filler 5 . Plunger 6. Spring 7 . Solenoid Body 8. Plunger Valve

2-34

1. Gauge Number 324891 2. Top of Float Should be Between These

Two Steps

2 -36

1 . Base of Carburetor Body 2. Bend Float Lever Tang to

Achieve Proper .Dimension 3 . 2 thru 15 28-33 mm

20 thru 75 28-41 mm V -4 thru V -6 22-28 mm

2 -37

.&. Safety Related

2-36 803 1 39

2 -33

2

803406

2-37

803305

2 -34

8 0 3 4 0 7 803395

2-35 2-38

2-17

INSTALLATION OF CARBURETOR AND LEAF VALVES - 2 THRU 40

l'{\vr;: l NOTE

DO NOT use gasket sealer on leaf plate, mani­fold or carburetor gaskets.

a. 2 thru 4 - Place new gaskets between the leaf plate, intake man ifold, and crankcase, and attach to crankcase with four screws.

b. Using a new gasket, place carburetor in posi ­tion on manifold studs and fasten in place with nu ts.

c . Adjust throttle cam.

d. 2 - Install support bracket and air silencer.

e. Install integral fuel ta nk with two retainers .

f. Connect fuel hose to carburetor and install rew ind starter.

a. 4.5 thru 15 - Using new gaskets, install leaf valve assembly and intake manifold on crank­case . Install recirculation hoses.

b . Reconnect fuel line to carburetor using a new nylon hose strap.

c. Using a new gasket, place carburetor in posi ­tion on manifold studs and fasten in place w ith nuts.

d. Install cam follower and l ink.

e . Install manual starter.

f . Install choke, knob, pin , and cotter pin.

g. Install air silencer base and cover.

h. Push slow speed knob in place.

a. 20 thru 40 Com. - Using new gaskets, install leaf valve assembly and intake mani­fo ld on crankcase. Connect throttle control rod. Install rec ircu lat ion hoses .

b . Reconnect fuel line to carburetor using a new nylon hose strap.

c. Place a new carburetor gasket on intake manifold . Route fuel hose to fuel pump, and install carburetor. Connect cam follower link. Connect fuel hose to fuel pump using a new nylon hose strap.

d. Install electric starter if model is so equipped. See Section 7 .

e. Inst all air silencer with four screws and one locknut.

f. Push choke knob into place through retainer in air si lencer . Engage choke lever in choke knob and install choke lever w ith shoulder screw, wave washer, and spacer.

INSTALLATION OF INTAKE MANIFOLD AND CARBURETORS -50 THRU V-6

ENG !fiSH

E:] NOTE

DO NOT use gasket sealer on leaf p late, manifold or carburetor gaskets.

a. If removed and disassembled, attach the leaf segment, shims, and leaf stops to the leaf plates, then examine each leaf carefully. Shims go on the long side of the leaf pl ates (115 and 140 only). Each leaf must lie flat against the plate with no edges turned up or away from the plate. Replace any leaf valve assembly which shows any indication of dis ­tortion or damage of leaf stop.

b. Attach the leaf plate assemblies to the in­take manifold. Tighten screws to specified torque to avo id distortion of the leaf plates.

c. Apply OMC Screw Lock to intake manifold screws. Using a new gasket install intake manifold and leaf assembly to powerhead.

d. Connect recircu lation hoses using new tie straps.

e. Place new gaskets in position on studs on manifold. Connect fuel hoses between ca r­buretors using nylon tie straps . Place car­buretors on studs and fasten in place with nuts and lockwashers.

f . If necessary, install electric starter .

g. Connect choke and throttle linkages. See Figures 2-39, 2-40, 2 -24 or 2-26. Adjust link ­ages as descr ibed in Engine Synchronization and Adjustment, before installing air silencer . Throttle valves must close fully.

h . If removed, install fuel pumps with new gaskets.

1. 50 thru 75- Install choke soleno id and adjust as described in Choke Solenoid Adjustment -50 Thru 75 Models.

J. V-4 and V-6 models- Install primer soleno id.

INSTALLATION OF AIR SILENCER - 50 THRU V-6 a. Connect air silencer to manifold hose .

b . Install new gaskets and install air silencer base using OMC Screw Lock on new screws. Torque screws to specifications. See Section 1. Check that gasket surface on air silencer cover is not damaged or deformed. Install with new gasket.

1. Linkage Retainers (2) 2. Choke Solenoid Spring 3 . Fastener

5 . Throttle Link 6 . Throttle Shaft

Levers . 4 . Choke Links 7 . Screw

2-39

.~· 1. Link Retainer 2. Choke Solenoid Link

2 -40

2-18

2-39

2-40

2-18

CARBURETOR ADJUSTMENT THROTTLE CAM ADJUSTMENT - 2 THRU 15

a. Proper setting of the throttle pickup on the throttle cam is important for obtaining good overall running qualities together with the best possible fuel economy.

b . Advance speed control until center of roller is between marks on cam.

c. At this point the throttle should just begin to open. Sometimes though, it is difficult to tell when the carburetor's throttle shaft first begins to move. You can make a simple tool to exaggerate this movement from an alligator clip and a piece of stiff wire. See Figures 2-41 and 2-42 ·

i. Attach cl ip to end of throttle shaft opposite the cam follower linkage. The wire is bent upwards 90°.

e. Back out the cam follower "'adjustment screw with Special Tool Ballhex Driver Part No. 327622 until the throttle valve is closed com­pletely. Then advance the screw until the throttle shaft just begins to rotate.

f. Install starter.

LOW-SPEED NEEDLE - 2 THRU 40

a. Start engine.

rntm NOTE ~

Allow motor to reach normal operating tem­perature by running in a tank with test propeller in gear. at one-half throttle or slightly more before proceeding to next step.

b. With motor at operating temperature. run at slow speed (700 - 750 rpm) with test pro­peller in tank or on boat. Adjust low-speed knob until motor runs fastest and smoothest performance is obtained. Allow 15 seconds for motor to respond to adjustment.

c. Position low speed knob with pointer down, and replace on needle valve shaft without disturbing position of needle.

d. Adjust idle adjustment knob to allow motor to run at 650 rpm in gear. For neutral speed ad­justment.

ENGLISH

THROTTLE CAM ADJUSTMENT - 20 THRU 40

Advance throttle until marks on throttle cam are aligned with contact point of cam follower roller­on 20 and 25, at second mark to 6,34 mm past, on 35 and 40, between two marks. See Figure 2-43.

THROTTLE CONTROL ROD ADJUSTMENT -20 THRU 35

To adjust throttle control rod, shift lever must be in forward gear. Throttle lever must touch stop on cylinder. Push throttle control rod to full open, and adjust collar to touch nylon pivot block and tighten screw. See Figure 2-44.

THROTTLE AND CHOKE LINKAGE - 50 THRU V-4

a. Loosen carburetor throttle lever fastener screws to allow spring on throttle shafts to close throttle valves. Tighten screws. See Figure 2-45.

b. Loosen upper and lower choke lever retain­ing screws, and close choke valves, Tighten screws. See Figure 2-45. (50 thru 75 models.)

1. Stiff Wire and Alligator Clip

2-41

1 . Cam Follower 2. Mark on Cam 3. Throttle Cam 4. Cam Adjusting Screw

2 -42

·1. Cam Adjustment Screw 2. Cam Marks 3 . Cam Follower Roller

2-43

1 . Collar 2. Nylon Pivot Block

2-44

1 ) Upper Choke Lever Screw 2 .· Upper Throttle Lever Screw 3. Lower Choke Lever Screw 4 . Lower Throttle Lever Screw 5. Yoke

2-45

2 -44

2 -4 7

2-42

2-45

2-43

2-19 .

SECTION 3 IGNITION SYSTEM

.& SAFETY WARNING

• Perform all ignition coil tests on a wooden or insulated bench top to prevent leakage or shock hazards.

• To avoid possible shock hazards do not handle ignition coil or tester leads during output test.

• To prevent possible fire and explo­sion under the motor cover, make sure electrical wires are routed and clamped in original position; away from rotating parts which could cut or abrade wire insulation.

GENERAL INFORMATION

SPARK PLUG

The spark plugs should be removed and examined. If the electrodes are worn, or plug has a cracked insulator or shows other signs of damage, spark plug should be replaced . See Specifications. Section 1 .

SPARK TEST

a. Remove the high tension lead from each spark plug . To prevent damage to the spring terminal on the high tens ion lead, twist and pull on the cover . See Figure 3-1.

b. Adjust the air gap of the spark tester to spec­ifications - ~ee Table 1 and connect the tester leads to the high tension leads. Secure the other end of the spark tester to a clean engine ground.

li ~ ;~ NOTE

To prevent possible arcing of high voltage, position the tester leads at least 51 mm from any metal surface.

& SAFETY WARNING

To avoid possible shock hazards, do not handle ignition coil or tester leads during this test.

c. Crank the engine and observe the results at the spark tester .

If a spark jumps at all gaps alternately, the igni­tion system is OK. Check the spark plugs. and other engine systems.

If there is no spark, or only a spark at just one gap, continue the troubleshooting procedure .

ENG L.ISH

Table 1

Model Ignition System Spark Tester Gap

2 & 4 Magneto 6 mm

40 (Com.) Low Tension 11 mm

4.5 - V-4 C.D . 12 mm

V-6 C.D . 1 1 mm

FLYWHEEL REMOVAL

&a. To prevent accidental starting of motor, disconnect the four wire cable connector between the armature plate and power pack or disconnect spark plug leads.

~-1

b. Remove the flywheel nut using a strap wrench or other suitable tool to hold the fly­wheel. See Figure 3-2 .

c. To remove flywheel install the foll owing com­ponents from universal puller: (3) three screws Part No. 307641, (3) three washers Part No. 307639, Puller Body Part No. 307636 and Pressing Screw Part No. 307637. Install puller on flywheel with shoulder screws completely installed in fly­wheel, tighten center pressing screw while holding puller body with large screwdriver or handle Part No. 307638. See Figure 3-2.

~NOTE ~

The flywheel may not "pop" from the taper with only the force of the puller. In such a case, after applying tension with the pressing screw, pry up on the flywheel rim with a large screwdriver. and at the same time rap the pressing screw with a large brass hammer.

& SAFETY WARNING

Wear protective safety glasses before striking metal object with hammer to prevent accidental injury to eyes.

1. Spring 2. Cover 3. Hook 4. Wire 5. Spark Plug

3-1

& Safety Related

A~

3-1

l . ·-----.,

3-2

FLYWHEEL INSTALLATION

a. Clean the crankshaft and flywheel tapers with OIVIC Cleaning Solvent Part No. 390905 and blow dry with compressed air. These sur­faces must be clean and dry to allow proper locking of the tapers.

b. Install the flywheel and tighten the nut to the torque specified in Table 2.

Table 2

Flywheel Nut Torque

Model kg.m N.m

2 3,0 - 3,5 30 - 34

4 & 4.5 4,1 - 5,5 40 - 54

6/6 COM . & 7.5 5,5 - 6,1 54 - 60

9.9/10 & 6,1 -7,1. 60 - 70 14 COM./15

20, 25,25 COM., 13,8- 14,3 1 35 - 140 35 & 40 COM.

50, 55, 55 COM. , 11 ,2 - 11 '7 110 - 11 5 60

70, 75 , V-4 13,8- 14,3 1 35 - 140

V-6 19,3 - 20,4 190 - 200

ENG LISH 3-2

I

I

TROUBLESHOOTING THE C.D. SYSTEM - 4.5 THRU V-6

!he magneto capacitor discharge ignition system IS easy to t roubleshoot. Remember these tips to obtain fast, accurate test results :

a. Visual Inspection - Check wiring for broken , pmched, or loose leads. Connectors should be securely fastened and free from moisture or water accumulation .

b. Test Equipment Condition - Be sure testers are in working order. Many hours can be wasted by replacing working components needlessly.

c. Follow Procedure - Troubleshooting can seem difficult if you vary your technique for each problem. Many times items in the system are overlooked because you "thought" you tested them . By following the same procedure each time you troubleshoot, all items in the igni ­tion system are sure to be tested.

d. Test the Complete System - There may be occasions when more than one component is defective. If this condition is undetected, repeated ignition system failure may occur, or damage to replacement parts could result. Test everything.

TEST EQUIPMENT REQUIRED

a. Spark tester. See General Information.

b. Stevens or Electro-Specialties C.D. Volt­meter Tester. See Figure 3-35.

c. Ohmmeter - Capable of indicating low ohms (RX1) and high ohms (RX1 ,000).

d. Jumper Wires (4 required) . Jumper leads can be made as shown in Figure 3-36.

e. C.D. adapter available from Stevens or Electro Specialties.

CONNECTOR PLUGS

Two water-proof connectors, male and female plug-in type, are utilized in the ignition system. Each connector is secured by a retainer. The re­tainer must be removed to unplug the connector.

E NGLISH

CONNECTOR TERMINAL REMOVAL

I::'J&:w:l NoTE

Use the recommended lubricant for terminal re­moval. Substitutes may cause high resistance connections, short circuits between terminals, or have adverse effects on the connector material.

a. Apply isopropyl alcohol into the connector cavity at both ends to lubricate the terminal and connector .

b. Place the connector against the edge of a flat surface and allow clearance for the terminal to be removed .

c. Select - the proper removal tool for the ter­minal in the connector. See Figure 3-37.

d. Insert the removal tool onto the terminal and push the terminal from the connector . See Figure 3-38.

e. Pin and socket terminals may be replaced if damaged. Crimp new terminals onto the wire using OMC Crimping Pliers (Special Tool No. 322696). See Figure 3-37 for crimping loca­tion . If crimping pliers are not available, the terminals can be installed onto the wire using needle nose pliers, and then must be soldered to the wire to insure good electrical contact and security. No soldering is re­quired when using the OMC Crimping Pliers .

1 . Stevens CD-77 Tester 2. Electro-Specialties Model PRV-1 3. Stevens Adapter 4. Electro Specialties Adapter

3-35

1. No. 16 Wire, 200 mm Long 2. Pin (OMC Part No. 511469) 3. Socket (OMC Part No. 581656) 4. Tubing (OMC Part No. 51 0628) 25 mm Long

3-36

1. Insert Tool (OMC Part No. 322697) 2. Pin Remover (OMC Part No. 322698) 3 . Socket Remover (OMC Part No. 322699) 4. Pin Terminal 5. Socket Terminal 6. Crimp Termi nal Here

3-37

3-17

•'

0 3156

8 300 ,

3-35

' i

~ 0 I

CD

73 158

3-37

3-36

3-17 - ' ·------------···--~

CONNECTOR TERMINAL INSTALLATION

a. Connect both halves of the connector together.

U;l#31U N 0 TE

Do not use grease or oil. Clean out any grease or oil that may be present in cavities.

b. Apply isopropyl alcohol in to the connector cavity.

&sAFETY WARNING

To avoid personal injury, securely ho ld insert tool against shoulder of t erminal while installing t erminals into con­nector cavity.

c. Position the insert tool against the shoulder of the terminal. See Figure 3-39 .

d. Support the connector against a flat surface and push the terminal into the connector until the shoulder on the insert tool is at the end of the connector . See Figure 3-40.

e. Reinstall wire retainer on connector .

.GNITION COIL TESTS

A wide variety of ignition testers are available from various manufacturers. In addition, some automotive testers having the proper specifica­ti ons can be used .

Detailed instructions for the use of any tester are provided with the unit; therefore, only general in­formation is given here. See Coil Specifications, Section 1. ·

IGNITION COIL MUST BE REMOVED FROM POWERHEAD FOR POWER AND LEAKAGE TESTING.

& SAFETY WARNING

To avoid possible shock hazards and to prevent leal<age, perform all tests to the coil on a wooden or insulated bench top .

ENGL. I S H

POWER PACK REPLACEMENT -ALL MODELS

REMOVAL

a. Separate the connector between the power pack and ignition coils, and the connector be­tween the armature plate and power pack. See Figure 3-41.

l ;;,j~J;';i l NOTE

Remember the routing of the power pack leads and the location of clamps for proper lead posi­tioning during installation.

b. Unscrew the power pack mount screws and ground wire screw to remove the power pack.

INSTALLATION

bii!l NOTE

Unless otherwise specified, when installing lock­washers on electrical connectors, place the w asher on the engine side of the connector to provide a good ground.

a. Install the power pack ground wire and posi­tion the wire so there wi II be no pu II (stretch) when the power pack is installed. Excessive pull on the ground wire could result in igni­tion failure .

b. Mount the power pack and tighten the screws to 0,55 - 0,69 kg.m. ·

3-18

1. Insert Tool 2. Shoulder on Termina l 3 . Joined Connectors

3-39

1. Shoulder on Tool

3-40

1. Four Wire Connector - Charge Coils and Sensor Coils to Power Pack

2. Th ree Wire Connector - Power Pack to Ignition Co ils and Stop Switch

3 -41

93397

3-39

3-40

3-41

3-18

4.5 THRU 60 - C.D. IGNITION SYSTEMS

CONNECTOR PLUGS

A four wire conductor connects the charge coil and sensor coil leads to the power pack. The three wire connector connects the power pack leads to the ignition coils. See Figure 3-41.

STOP BUTTON ELIMINATION TEST

a. Separate the three wire connector between the power pack and ignition coils. See Fig ­ure 3-41.

b. Insert a jumper wire between the " B" terminals of the three wire connector . See Figure 3-43.

c. Insert a jumper wire between the "C" terminals of th e three wi re connector.

& SAFETY WARNING

To avoid possible shocl< hazards, do not handle ignition coil or tester leads dur­ing the test.

d. Crank eng ine and observe the results at th e spark tester. On electric starting models , crank the engine by hand using an emer ­gency starter rope .

e. If a spark jumps alternately at both gaps, th e problem is in the stop button circuit Refer to the stop button circuit test . If there is no spark, or a spark at only one gap, remove the jumper wires.

NOTE

Carefully align the connector halves during as­sembly to insure proper terminal contact.

f . Reconnect the three wire connector and con­tinue troubleshooting procedure .

STOP BUTTON CIRCUIT TEST - MANUAL START MODELS

a. Separate the three wire connector between t he power pack and ign ition co ils .

b. Calibrate the ohmmeter to high ohms scale. Connect the meter red lead(+) to the "A" ter­minal in the ignition coil end of the con­nector, and the meter black lead (-)to a clean engine ground . See Figure 3-42.

3-19

c. The meter should indicate open circuit (oo) . If there is any needle movement, replace the stop sw itch and lead assembly.

d. Push the stop button . The meter should indi­cate a closed circuit (0).

KEY SWITCH STOP CIRCU IT TEST ELECTRIC START MODELS

a. Perform steps a. and b. in STOP BUTION CIRCUIT TEST and separate the 4-wire con­nector.

b . Turn the key switch to "ON."

c . The meter should indicate an open circuit (oo). If there is any needle movement, re­move the blackjyellow stripe wire from the key switch " M " terminal with the ohmmeter still connected as shown in Figure 3-42.

d. If the meter indicates an open circuit (oo) with the wire removed from the key switch, replace the switch. If a closed circuit (o) is indicated, repair or replace the black/ yellow stripe lead between the key switch and igni­tion coil end of the three wire connector.

1. High Ohm Scale 2 . Red Meter Lead 3 . Black Meter Lead 4 . Stop Button or Key Switch 5. Key Switch "M" Terminal 6. Terminal "A"

3-42

1. Jumper Wires 2. Stop Button or Key Switch 3 . Terminal " B" 4 . Termina l "C"

3 -43

6

8 1 3034

3-42

813030

3-43

3-19

• · rr-~ -- - #'it

OHMMETER TESTS

Ohmmeter tests are necessary to determine if the sensor coil or charge coil have failed in a manner which could cause ignition failure.

Ui;j\t l NOTE

Resistance readings should be checked when the motor has completely cooled to ambient air tem­peratl!re. The higher temperature, caused by runnmg the motor, will increase the resistance reading and may result in unnecessary parts replacement.

Sensor Coil Test (Ohmmeter)

a. Separate the four wire connector between the armature plate and power pack See Fig­ure 3-41.

b. Insert a jumper wire to terminal "B" in the armature plate end of the connector. See Fig­ure 3-44.

c. Insert a jumper wire to terminal "C" in the armature plate end of the connector. See Fig­ure 3-44.

d. To test the resistance, connect an ohmmeter (calibrated on low ohm scale) between the two jumper wires. The sensor coil resistance is good if the meter indicates 40 ± 1 0 ohms (4 thru 60}, 45 ± 10 ohms (55 rope model) Replace the sensor coil if the resistance reading is not within this range. See Figure 3-44.

e. To test for shorts to ground , calibrate the ohmmeter to high ohm scale. Connect the black meter lead (-) to the armature plate (ground). Attach the red meter lead (+)to the " C" terminal jumper wire in the connector . See Figure 3-45. Any needle movement indicates the sensor coil or leads are shorted to ground. A shorted sensor must be re­placed, or the grounded lead repaired to remove the shorted condition.

f . Remove the jumper wires from the connector and continue the troubleshooting procedure.

Charge Coil Test (Ohmmeter)

a. Insert a jumper wire to terminal "A" in the armature plate end of the connector. See Figure 3-46.

b. Insert a jumper wire to terminal "D" in the armature plate end of the connector. See Fig ­ure 3-46.

ENGL.ISH

c. To test the resistance, connect an ohmmeter (calibrated to high ohm scale) between the two jumper wires. The charge coil resistance is good if the needle indicates 575 ± 75 ohms (manual start) or 475 ± 75 ohms (electric start). See Figure 3-46.

d. To test for shorts to ground, calibrate the ohmmeter to high ohm scale. Connect the black meter lead (-) to the armature plate (ground). Attach the red meter lead (+)to the "A" terminal jumper wire in the connector. See Figure 3-47. Any needle movement indi­cates the charge coil or leads are shorted to ground . A shorted charge coil must be re­placed, or the grounded lead repaired to re­move the shorted condition.

e. Do not remove the jumper wires from the connector, and continue the troubleshooting procedure.

1. Jumper Wires 2. Low Ohm Scale 3. Terminal "B" 4. Terminal "C"

3-44

1. High Ohm Scale 2. Black Meter Lead 3. Red Meter Lead 4. Jumper Wire 5. Armature Plate 6. Terminal "B" 7 . Terminal "C"

3-45

1. Jumper Wires 2. High Ohm Scale 3. Terminal "A" 4. Terminal "B" 5. Terminal "C" 6 . Terminal "D"

3-46

1. High Ohm Scale 2. Black Meter Lead 3. Armature Plate 4. Red Meter Lead 5. Jumper Wire 6. Terminal "A" 7. Terminal "B" 8. Terminal "C" 9. Terminal "D"

3-47

3-20

3-44

v (g;))

3-45

8340 1

4

83402

83399

3-46

3 83400

3-47

3-20

IGNITION SYSTEM TESTS USING C.D. VOLTMETER TESTER

ltil\%1'\i l N 0 TE

Before conducting these tests be sure to do the Spark Test and the Ohmmeter Tests.

CHARGE COIL TESTS

Set meter switches to Negative and 500. First, check for shorts to ground. Disconnect four wire connector. Insert red meter lead into cavity "A." Attach black meter lead to armature plate. See Figure 3-48. Crank engine and observe meter reading . Remove lead from cavity "A" and insert '"1to cavity "D." Crank engine and observe meter. Any reading on either test means charge coil is shorted to ground. Locate short and repair, or replace charge coil.

To check charge coil output, remove black lead from armature plate and insert probe into cavity "A" of connector. See Figure 3-48. Crank engine and observe meter reading.

a. If meter ,reads 230 or higher, go to Power Pack Output Test.

b. If meter reads below 230 replace charge coil.

SENSOR COIL TESTS

Set meter switches to "S" and 5. First, check for shorts to ground. Disconnect four wire con­nector. Insert red meter lead into cavity "C." Attach black meter lead to armature plate. See Figure 3-49. Crank engine and observe meter reading. Remove lead from cavity "C" and insert into cavity "B." Crank engine and observe meter. Any reading on either test means sensor coil is shorted to ground . Locate short and repair, or replace sensor coil.

To check sensor coil output, remove black lead from armature plate and insert probe into cavity "C" of connector. See Figure 3-49. CrC!nk engine and observe meter reading.

a. If meter reads 0.3 or higher, go to Power Pack Output Test.

b. If meter reads below 0.3, replace sensor coil.

ENCiLISH

1 , Term ina! " D" 2. Red Meter Lead 3. Black Meter Lead 4. Terminal "A" 5. Test for Short to Ground

3-48

1 , Term in a I "C" 2. Red Meter Lead 3. Black Meter Lead 4. Terminal "B" 5. Test for Short to Ground

3 -49

3-21

83403

3-48

2 ~--;r-t-----'

\

I 3

83404

3-49

3-21

.. ___________ , ______ -=------------------~~----------~~=

I i I

POWER PACK OUTPUT

Set meter switches to Negative and 500. Dis­connect three wire connector between power pack and ignition coils.

Insert jumper leads between "B" terminals of connectors and between "C" terminals. See Figure 3-50. Connect meter black lead to engine ground. Connect meter red lead to metal part of jumper lead coming from power pack cavity "B." Crank engine, observe meter reading. Connect meter red lead to metal part of jumper lead cavity "C." Crank engine, observe meter reading.

a. If meter reads 180 or higher, check ignition coil, or coils.

b. If meter does not read 180 or higher on one output, remove jumper lead from that cavity of connector from power pack. Insert meter red lead into that cavity. Crank engine: If meter reads 180 or higher, ignition coil is de­fective. If meter does not read 180 or higher, power pack is defective.

c. If meter does not read on both outputs, power pack is defective.

d. The power pack can be substituted with a known good pack. Be sure the power pack ground Lead is securely connected to the powerhead.

IGNITION COIL TESTS

OHMMETER TEST

Resistance tests may be performed while the ignition coil is still mounted to the powerhead.

a. Remove the high tension lead from the ignition coil.

b. Separate the three wire connector between the power pack and ignition coils.

c. Insert a jumper wire into the "B" terminal on the ignition coil end of the three wire con­nector. See Figure 3-51.

d. Calibrate an ohmmeter to low ohm scale, then connect the black meter lead (-) to a clean engine ground, and the red meter lead (+) to the "B" terminal jumper wire . See Figure 3-51.

e. Resistance of the primary winding should be 0,1 ± 0,05 ohms.

ENGL. ISH 3-22

f. Calibrate the ohmmeter to high ohm scale, then connect the meter red lead (+) to the "B" terminal jumper wire. Connect the meter black lead(-) to the high tension terminal of the coil. See Figure 3-52.

g. Resistance of the secondary winding should be 275 ± 50 ohms. Replace the ignition coil if the reading is other than specified .

h. To test No. 2 ignition coil, repeat the above procedure using terminal "C" in the three wire connector.

i. Test resistance of high tension leads on low ohms scale. Resistance should be near zero.

1 . Term in a I "B" 2. Terminal "C" 3. Red Meter Lead 4. Black Meter Lead

3-50

1. Jumper Wire 2. Low Ohm Scale 3 . Black Meter Lead 4. Red Meter Lead 5. Terminal "C" 6 . Terminal "B" 7 . Terminal "A" 8. Primary Resistance Test

~ 9. Secondary Resistance Test 10. High Ohm Scale

3-51 and 3 -52

j _

~ ®_ 50~

=-4

813039

3-50

2

8 813032 9 813033

3-51 3-52

I

3-22 :ll !l . I

IGNITION TIMING

It is possible for the ignition system to produce a good spark and yet the engine will not start . If the engine "pops" or "backfires" dur ing starting attempts, the ignition timing could be 180 degrees off. Check the following:

a . Sensor Wire Positioning - On the four wire connector between the armature plate and power pack be sure the white/ black stripe wire is located in the " 8" terminal of both connector halves.

b. Ignition Coil Wire Positioning - Check the three wire connector to be sure the No . 1 (TOP) ignition coil orange wire is in terminal "8 " of connector, and that it mates with the orange/blue stripe wire from the power pack.

4.5 thru 15 - No timing adjustments are nec­essary. Correct wire positioning in the three and four wi re connectors is all that is required to maintain proper ignition timing.

IGNITION TIMING ADJUSTMENT -20 THRU 60

a. Connect a timing light to the No. 1 cylinder. Start and run the engine at full throttle.

b. The timing mark must align with the mark on the flywheel grid. See Table 3 and Figure 3-53 .

c. Loosen the timing stop adjustment screw locknut, and turn the screw in or out as necessary to correct the timing . See Figure 3-54.

d. Tighten the locknut, and re-check the timing adustment.

Table 3

Model Timing

20 & 25, 34° ± 1° 25 COM.

35 30° ± 1 0

'-

50, 55, 19° ± 1 0

55 COM.

60 21 ° ± 1 0

IGNITION COIL REPLACEMENT

REMOVAL

a. Separate the three wire connector between the power pack and ignition coils.

b . Twist and pull on the cover to remove the high tension lead from the spark plug .

ENGl. I SH 3-25

c. Release the ign ition coil wires from the sup­port clamps, and remove the coil mounting screws.

d. Remove the ignition coil terminal from the three wire connector .

INSTALLATION

a. Reconnect the three wire connector, and se­cure with retainer.

I <it I NOTE

Carefully align the connector halves during assembly to provide proper terminal contact.

b. Insert the ignition coil terminal into the three w_ire connector. Secure with retainer.

c. Clean and prime screw threads with OMC Locquic Primer Part No. 384884. Apply OMC Screw Lock Part No. 384848 to mounting screws. Mount the ignition coil to the engine with the lockwasher between the ignition co il and ground wire connector. Torque screws to 7-9 N.m. See Figure 3-55 . Install the stop button or key switch ground wire with the lockwasher between the ignition coil and the ground wire connector.

d . Secure the high tension lead to the spark plug.

I ·:I NOTE

To insure proper ignition timing check the No. 1. (TOP) ignition coil orange lead to be sure it is i'7 the "8" terminal of the connector, and that 1t connects to the orange I blue stripe wire from the power pack.

A. 20, 25, 35 - Manual Start

B. 20, 25, 35 - Electric Start

C. 50, 55, 60

3-53

1. Locknut 2. Adjustment Screw 3 . Stop

3-54

1. Engine 2. Lockwasher 3. Electrical Connector 4 . W asher or "J" Clamp

3-55

3-53 B 13037

3-55

3-25

ARMATURE PLATE REMOVAL

a. 55 models - Remove manual starter .

b. Remove the flywheel . (Refer to Flywheel Removal .)

c. Remove the armature plate leads from the support clamps. On electric starting models remove three armature plate leads from the terminal board.

d. Loosen the screws attaching the armature plate to the retainer plate, and lift the arma­ture plate from the powerhead. See Figure 3-56, view A (manual start) and view B (electric start) .

e . The retainer plate and support plate may be removed (if necessary for servicing) by dis­connecting the throttle lever to armature plate link, then removing the screws from the support plate. See Figure 3-57.

ARMATURE PLATE INSTALLATION

a. If removed for servicing, install the retainer plate on the crankcase. Next. position the support plate over the retainer plate and align the holes between the plate and crank­case. Install the screws and torque to specifi­cations in Section 1. Reconnect the throttle lever to armature plate link. See Figure 3-57.

b. Apply OMC Moly Lube to the crankcase boss (pilot for armature plate) . See Figure 3-58.

Lubricate the armature plate bearing with a light coat of OMC outboard lubricant.

d. Insert needle nose pliers into the slots pro­vided, and hold the armature plate bearing compressed while guiding the armature plate into position. See Figure 3-58.

e. Position the armature plate with the center of the charge coil in line with the stop on the retainer plate, and tighten the screws to the torque specified in Section 1. See Figure 3-56, view A. On electric starting models, position the cut-outs in the armature plate assembly as shown in Figure 3-56, view B.

ENGL..ISH

[]NOTE

To provide adequate movement of the armature plate and to prevent damage to the wires, route the armature plate lead so the dots on the sleeve are located inside the forward support clamp.

f. Secure the armature plate lead in the support clamps so that the lead has sufficient slack at full advance. On electric starting models, route the stator assembly lead behind the starboard bracket, and connect the three wires to the terminal board . Match the wire colors from the stator lead with those from the rectifier .

g. Install the flywheel. (Refer to Flywheel Installation).

h. Install the manual starter assembly.

View A - Manual Start

1. Armature Plate Link

View 8 - Electric Start

1. Armature Plate Cut-Outs

3-56

1. Crankcase Boss 2. Throttle Cam

3-58

3-26

VIEW A

I r .ij

li ~

VIEW B i 3-60

73023

3-59

3-61

3-27

II CHARGE COIL OR SENSOR COIL REPLACEMENT (STATOR ASSEMBLY REPLACEMENT)

REMOVAL

ilia. To prevent accidental st arting of motor dis­connect cha rge coil connection (4 wire connector).

b. Remove the flywheel. (Refer to Flywheel Removal. )

c. Remove the armature plate as described in Armature Plate Removal.

d. If repla cing the charge coil, terminals " A " and "D" must be removed from the arma­ture plate end of the four wire connector. To replace the sensor coil, remove terminals "B " and "C" from the armature plate end of the four wire connector. On electric starting models, remove all four terminals from the connector .

e. Remove the cover from the bottom of the armature plate. See Figure 3-59.

f. Next, remove the clamp on top of the arma­ture plate retaining the leads. See Figure 3-60.

g. With the screws secur ing the charge coil or sensor co il removed, pull the coi l and lead assembly from the insu lation sleeve and armature plate. On electr ic starting models , re move the screws from the stator assembly and pull the sta tor from the insulation sleeve and armature plate.

INSTALLATION

a. Lubricate the insulation sleeve with iso­propyl alcohol, and insert the coil leads through the armature plate and sleeve to the four wire connector.

b . Install the terminals into the connector .

c. Position the charge coi l or sensor coil on the armatu re plate, and insert the mount screws just finger tight. On electric starting models, position the stator assembly on the armature plate and install the mounting screws to the torque specified in Section 1, then proceed to step e.

ill Safety Related

ENGL. ISH 3-27

d . Correct locating of the coi l assembly is governed by machined mounting surfaces on the armature plate. The outside edge of the charge coil and sensor coil must be flush with the machined surfaces on the armature plate to prevent contact with the flywheel magnet and provide maximum output from the coils. See Figure 3-60, view A. A lig n­ment of the charge coil and sensor coil will be simplified when using the OMC Coil Locating Ring (Spec ial Tool No. 317001) ma­chined to fit over the armature plate bosses. See Figure 3-61 . With the Coil Locating Ring in position over the armature plate bosses, push the ring toward the coil while pulling the coil toward the ring, and tighten the coil mounting screws to the torque specified in Section 1 .

e . Instal l the c lamp on top of the armature plate to position the charge co il and sensor coil leads. See Figure 3-60, view A or B.

f. Slide the insulation sleeve to the armature plate to protect the coil leads, and install the cover on the bottom of the armature plate . Line up the notch in the plate with the notch on the cover during installation . See Figure 3-59 .

g. Install the armature plate . Refer to Armature Plate Installation procedures.

h . Reconnect charge coil connection.

1. Notch in Cove r

3-59

VI EW A - MANUAL START

1. Outside Edge of Charge Coil 2. Machined Boss 3. Clamp

VIEW B - ELECTRIC START

1. Armature Plate 2. Clamp 3. Stator Assembly Mount Screws

3-60

KEY SWITCH ELIMINATION TEST

a. Separate t he four wire connector that connects the power pack to the ignition coils and key switch. See Figure 3-66.

b. Insert a jumper wire between the "A" ter­minals of the four wire connector . See Figure 3 -66.

c. Insert a jumper wire between the "8" ter­minals of the four wire connector. See Figure 3-66.

d. Insert a jumper wire between the "C" ter­minals of the four wire connector. See Figure 3-66.

& SAFETY WARNING

To avoid possible shock hazards, do not handle ignition coil or tester leads during this test.

e. Crank engine and observe ·the results at the spark tester.

f . If a spark jumps alternately at all gaps, the problem is in the key switch circuit. Refer to the key switch stop circuit test . If there is no spark, or a spark at only one gap, remove the jumper wires .

r;::'01 NOTE ~

Carefully align the connector halves during as­sembly to insure proper terminal contact.

g. Reconnect the four wire connector and con­tinue troubleshooting procedure.

EN GLISH 3-29

KEY SWITCH STOP CIRCUIT TEST

a. Separate the four wire connector between the power pack and ignition coils.

b. Calibrate the ohmmeter to high ohms scale. Connect the meter red lead (+) to the "D" ter­minal in the ignition coil end of the con­nector, and the meter black lead(-) to a clean engine ground. See Figure 3-67.

c. Turn the key switch to "ON ."

d. The meter should indicate an open circuit (DO}. If there is any needle movement, re­move the black/ yellow stripe wire from the key switch "M" terminal with the ohmmeter still connected as shown in Figure 3-67 .

e. If the ·meter indicates an open circuit (oo) with the wire removed from the key switch, replace the switch. If a closed circuit (o) is indicated, repair or replace the black/ yellow stripe lead between the key switch and igni­tion coil end of the four wire connector.

f . Turn key switch to "OFF" position. Meter should indicate a closed circuit.

g. If meter does not indicate closed circuit, check key switch, key switch ground lead and black/ yellow stripe lead for open circuit . Repair circuit.

h . If engine does not stop when key switch is turned to "OFF" position, and stop circuit checks out ok, replace power pack.

1. Terminal "A" 2 . Terminal "8" 3. Terminal "C" 4. Spark Gap Checker

3-66

1. Ohmmeter 2. High Ohms Scale 3 . Red Meter Lead 4. Terminal "D" 5. Black Meter Lead 6. Key Switch

3-67

4

r

I I I

~ I I - I

L-~---J 3-66

3-67

3-29

81304 1

OHMMETER TESTS

Ohmmeter tests are necessary to determine if t he sensor coil or charge coil have failed in a manner which could cause ignition failure .

lrsi\r l NOTE

Resistance readings should be checked when the m otor has completely cooled to ambient air tem­perature. The higher temperature, caused by running the motor, will increase the resistance reading and may result in unnecessary parts replacement.

Sensor Coil Test (Ohmmeter)

a. Separate the four wire connector between the t imer base and power pack. See Figures 3-62, 3-63 and 3-64.

b. Insert a jumper wire in "A" terminal of the t imer base end. See Figure 3-68.

c. Insert a jumper wire in terminal " B" in the timer base end of the connector . See Figure 3-68.

d. Insert a jumper into "C" terminal.

e. Insert a jumper into "D " terminal.

f . To test t he res istance, connect an ohmmeter (calibrated on low ohm scale) between the "A" and " D" terminal jumper wires, then the "B" and "D" terminals, and then the " C" and "D" termi nals . The sensor coil resistance is good if the meter indicates 17 ± 5 ohms. Replace the sensor coil if the resistance read ing is not with in this range . See Figure 3-68.

g. To test for shorts to ground, calibrate the ohmmeter to high ohm scale. Connect the black meter lead (-) to the timer base (ground). Attach the red meter lead (+)to the " A" terminal, then "B," then "C," then "D," jumper wire in the connector . See Figure 3-69. Any needle movement indicates the sensor coil or leads are shorted to ground. A shorted sensor must be replaced, or the grounded lead repaired to remove the shorted condition .

h. Remove the jumper wires from the connector and continue the troubleshooting procedure.

Charge Coil Test (Ohmmeter)

a. Separate two wire connector (CHARGE COIL).

b. Insert a jumper wire to terminal "A" in the stator end of the 2 wire connector. See Figure 3-70.

c. Insert a jumper w ire to terminal "B" in the stator end of the connector. See Figure 3-70.

ENG L.I S H 3-30

d. To test the resistance, connect an ohmmeter (calibrated to high ohm scale) between the two jumper wires . The charge coil resistance should be 550 ± 75 ohms .

e. To test for shorts to ground,calibrate the ohmmeter to high ohm scale. Connect the black meter lead (-) to the timer base (ground) . Attach the red meter lead (+) to the " A" terminal jumper wire in the connector . See Figure 3-71 . Observe the meter. Then move red lead to "B" terminal. Any needle movement indicates the charge coil or leads are shorted to ground. A shorted charge coil must be replaced, or the grounded lead repaired to remove the shorted condition .

f. Do not remove the jumper wires from the connector, and continue the troubleshooting procedure.

1. Jumper Wires 2 . Low Ohm Scale 3 . Terminal " A" 4 . Terminal "B" 5. Terminal "C" 6. Terminal "D" 7. Stator 8 . Timer Base

3-68

1. High Ohm Scale 2. Black Meter Lead 3. Red Meter Lead 4. Jumper Wire 5 . Timer Base 6. Terminal "A" 7. Terminal "B" 8. Terminal " C" 9. Terminal "D"

3-69

1. Jumper Wires 2. High Ohm Scale 3 . Terminal "A" 4. Terminal " B"

3-70

1. High Ohm Scale 2. Black Meter Lead 3 . Timer Base 4. Red Meter Lead 5. Jumper Wire 6. Terminal "A" 7 . Terminal "B"

3-71

I ' I '

'

3-68

3-69

83275

3-70

3-71

3-30

83277

83278

I {

I I. !

\1 ! i I

II IGNITION SYSTEM TESTS USING C.D. VOLTMETER TESTER

I i!i l N OTE

Before conducting these tests be sure to do the Key Switch Elimination Test and the Ohmmeter Tests.

CHARGE COIL OUTPUT

a. Set meter switches to negative and 500.

b. Disconnect two wire connector between stator and power pack.

c. To test for shorts to ground, set meter switches to (-) 500 scale. Connect the black meter lead (- ) to the timer base (ground) . Attach the red meter lead (+) to the " A " terminal jumper wire in t he connector . See Figure 3-73. Observe the meter . Then move red lead to " B" terminal.

d . Any needle movement indicates the charge coil or leads are shorted to ground . A shorted cha.rge coil must be replaced, or the grounded lead repa ired to remove the shorted condition·.

e. Insert meter black lead probe into cavity " A " of connector from stator . Insert meter red lead probe into cavity " B" of connector. See Figure 3-72.

f . Crank engine and observe reading .

g. If meter reading is 220 or higher, go to Sensor Coi l Output Test .

h. If low or no reading, check resistance of charge coi l. If resistance does not meet spec ifications, replace charge coil.

SENSOR COIL OUTPUT TEST

a. Set meter switches to "S" and 5. Separate four w ire connector between timer base and power pack. To test for shorts to ground, connect the black meter lead (-) to the timer base (ground). Attach the red meter lead (+) to the "A" terminal. then "B," then "C," then " D," jumper w ire in the connector . See Figure 3-74. Any needle movement indicates t he sensor coi I or leads are shorted to ground . A shorted sensor must be replaced, or the grounded lead repaired to remove the shorted condition .

b. To test sensor coil output, insert meter black lead probe into cavity "D" of four wire con ­nector from timer base.

ENG L. ISH 3-31

c. Insert meter red lead probe into cavity " A " of four wire connector from timer base. See Figure 3-74.

d. Crank engine and observe meter reading.

e. Move meter red lead from cavity " A" to cavity " B" of the connector .

f . Crank engine and observe meter reading .

g. Move meter red lead from cavity " B" to cavity "C" of the connector .

h. Crank engine and observe meter reading .

i . Meter should read 0.4 or higher. If it does not, sensor coil may be bad. Engine rpm may be too low or sensor magnet may be weak.

1. C.D. Voltmeter Tester 2 . Meter Red Lead 3 . Meter Black Lead 4. Stator 5 . Terminal " A" 6 . Terminal "B"

3-72

1. C.D . Vo ltmeter Tester 2 . Meter Red Lead 3. Meter Black Lead 4 . Stator 5 . Terminal "A " 6 . Terminal "B " 7 . Short to Ground Test

3-73

1. CD Voltmeter Tester 2 . Black Meter Lead 3 . Red Meter Lead 4 . Terminal "A" 5. Term inal "B" 6. Terminal "C" 7. Terminal "D" 8. Jumper Wire 9. Timer Base

1 0 . Short to Ground Test

3-74

81 304 2

3-72

93433

3-74

3-31

93432

3-73 I 'I

II POWER PACK OUTPUT

a . Set meter switches to negative and 500.

b. Disconnect four wire connector between power pack and ignition coils.

c . Insert jumper leads between "A" terminals of connectors. See Figure 3-75.

d. Insert jumper leads between "B" terminals of connectors.

e. Insert j umper leads between "C" terminals of connectors. Connect meter black lead to en­gin e ground.

f . Connect meter red lead to metal part of jumper lead coming from power pack cavity "A." Crank engine and observe meter reading .

g. Connect meter red lead to metal part of jumper lead coming from power pack cav ity " B." Crank engine and observe meter reading .

h. Connect meter red lead to metal part of jumper lead cavity " C." Crank engine and ob­serve meter reading.

1. If meter reads 230 or higher, check ignition coil or coils.

J. If meter does not read 230 or higher on one output, remove jumper lead from that cavity of connector from power pack. Insert meter red lead into that cavity. Crank engine . If meter reads 230 or higher, ignition coil is defective. If meter does not read 230 or higher, power pack is defective.

IGNITION COIL TESTS

OH MMETER TEST

Resistance tests may be performed while the ignition coil is still mounted to the powerhead .

a . Remove the high tension lead from the ignition coil.

b. Separate the four wire connector between the power pack and ignition coils.

c . Insert a jumper wire into the "A" terminal on the ignition coil end of the connector. See Figure 3-76.

d. Calibrate an ohmmeter to low ohm scale, then connect the black meter lead (-) to a clean engine ground, and the red meter lead (+) to the "A " term inal jumper w ire. See Figure 3 -76.

ENG L.. I SH

e. Resistance of the primary wind ing should be 0 ,1 ± 0 ,05 ohms.

f. Calibrate the ohmmeter to high ohm scale, then connect the meter red lead (+) to the " B" terminal jumper wire . Connect the meter black lead(-) to the the high tension terminal of the coil. See Figure 3-77.

g. Resistance of the secondary winding should be 275 ±50 ohms. Replace the ignition coil if the reading is other than specified .

h. To test all ignition coils, repeat the above procedure using terminals "B" and " C" in the four wire connector.

i . Test resistance of high tension leads on low ohms scale . Resistance should be near zero . See Figure 3-75A.

1 . Terminal " A " 2. Terminal " B" 3 . Terminal "C" 4 . Terminal " D" 5 . Red Meter Lead 6 . Jumper Lead 7. Black Meter Lead

3 -75

1. Jumper Wire 2 . Low Ohm Scale 3 . Black Meter Lead 4. Red Meter Lead 5 . Terminal "A" No. 1 6 . Terminal " B" No. 2 7 . Terminal "C" No. 3 8 . Engine Ground

3 -76

1 . High Ohm Scale 2 . Red Meter Lead 3. Black Meter Lead 4. Terminal "A" No. 1 5 . Termina l "B" No. 2 6. Terminal "C" No. 3

3-77

3-32

EEJ @ ® - 500

8 1 3044

3-75

813301

3-75A

8 1 3 046

8 1 3045

3-76 3-77

3-32

SECTION 4 POWER HEAD

& SAFETY WARNING

• To prevent possible damage to eyes and irritation of skin, always wear eye protection and rubber gloves or other non-porous hand protection while working with Gel Seal and Gasket Remover Compounds.

• To prevent possible fire and ex­plosion, after reassembly of any motor, always:

Check fuel system for leaks. Make sure electrical leads are routed and clamped securely in original position away from rotating parts which may damage insulation and make electrical sparks.

• To prevent sudden movement of the boat when starting the motor and possible man-overboard situations, after reassembly of motors equipped with a start-in-gear-pro­tection system, test the shift/throttle interlock systems for proper operation before returning the motor to the field.

CLEAI\IING, INSPECTION, AND REPAIR - ALL MODELS

CYLINDER BLOCK AND CRANKCASE

Check cylinder walls for excessive wear and check cylinder ports for carbon accumulation. Cylinder walls wear in various degrees, depend­ing on lubrication and conditions under which the motor is operated. Major portion of wear is in the port area and the area covered by ring travel.

Check cylinder for size and wall straightness by using an inside micrometer. Replace cylinder block, or rebore block for overs ize pistons if wear is in excess of 0,05 mm. See the chart below for maximum tolerance.

Model Maximum Tolerance

2 thru 6 0,05 mm

9.9 thru 60 0,08 mm

70!75 0,76 mm

V-4/V-6 0,10 mm

ENCL.ISH 4-1

Oversize pistons and ring sets are available.

Carbon accumulation in the exhaust ports restricts the flow of exhaust gases and has con­siderable effect on performance of the motor. Carefully scrape carbon from cylinder heads and exhaust ports with scraper or other blunt instru­ment. Exhaust ports and all exhaust passages must be free from carbon deposits to insure maximum performance. Avoid getting carbon in water jackets.

If equipped, check recirculation orifice in crank­case. Clean as required . Also, clean nipples in by-pass covers with Nipple Cleaning Tool Part No. 326623.

55 Model - Be sure compress ion relief holes in cylinders are clear.

With continued operation of the motor, the cyl­inder walls will take on a glaze which reduces the effectiveness of the seal between the piston rings and the cylinder walls. The result will be reduced compression and a decrease in perform­ance of the motor. Before reinstalling the pistons, break the glaze by using a f ine cylinder hone to refinish cylinder walls. Use low rpm on drill with rapid up and down movement to obta in a good cross-hatch pattern for good oil retention . Use hone with medium stone (220 grit). Blow out all oil passages and drains. See Figure 4 -1.

: I I I I

4-1

4-1

GASKET SURFACES

Remove all traces of dried cement, using OMC Gel Seal and Gasket Remover Part No. 390928. In using Gel Seal and Gasket Remover, spray the area to be cleaned and let stand for 5-10 min­utes before cleaning off the remover. Care should be taken to prevent overspray of Gel Seal and Gasket Remover on painted surfaces as the paint may be removed .

& Wear eye protection and rubber gloves or other non-porous hand protection while working with Gel Seal and Gasket Remover.

Check all gasket faces for flatness. Under certain conditions, gasket faces may warp or spring, particularly where thin sections or flanges are employed and are subject to temperature changes.

To check for flatness, lay a sheet of No. 120 emery cloth on a surface plate or piece of plate glass. Place the part to be surfaced on the emery cloth and move slowly .. back and forth several times in a figure 8 motion, exerting evenly dis­tributed, light pressure. Lift part from surface plate to observe results. See Figure 4-2.

If the surface is actually warped or sprung, high spots making contact with the surface plate will take on. a dull polish, while the low areas will have retained their original state. To insure flatness over the entire surface, continue sur­facing until the entire gasket surface has been polished to a dull luster . Finish surfacing with No. 180 emery cloth .

r;&;l l.ii!!ll N 0 T E

DO NOT scratch cylinder head gasket surface of cylinder. Use surface plate to surface this area.

& Safety Related

ENG LI S H 4-2

4-2

4-2

A

4 -77A

4-778

4-77

4-25

THE USE OF GEL SEAL -4 THRU V-6

Utili NOTE

On motors that use neoprene "spaghetti" seal. Do not use OMC Gel Seal in place of OMC Ad­hesive M.

SURFACE PREPARATION:

1. Remove all traces of old Gel Seal (crankcase sealer) by using OMC Gel Seal and Gasket Remover Part No. 390928. In using Gel Seal and Gasket Remover, spray the area to be cleaned and let stand for 5-10 minutes before cleaning off the remover .

~ a=:! NOTE

Care should be taken to prevent over-spray of Gel Seal and Gasket Remover on painted surfaces as the paint ma~ be removed.

& Wear eye protection and rubber gloves or other non-porous hand protection while working with Gel Seal and Gasket Remover.

2. Use OMC Cleaning Solvent Part No. 390905 to remove all traces of Gel Seal and Gasket Remover. See Figure 4-8. Use a black light to check for any remaining Gel Seal. The black light should be used in a darkened room. Hold black light at an angle to the power­head being inspected.

APPLYING GEL SEAL:

Iii) NOTE

Be sure your hands are clean and free of oil or grease before applying Gel Seal.

1. Apply a small amount of OMC Needle Bearing Grease Part No. 378642 to the crankcase and cylinder block labynnth seals to prevent engine "lock-up" from excess Gel Seal. Again use Cleaning Solvent to remove any oil or grease on flanges from assembly. Oil or grease on flanges will cause leaks.

2. Squeeze out a ball of Gel Seal, 5 mm on 140-

40 models, 6 mm on 50-60 models and mm on 70 - V-6 models, and dab it along one flange of the crankcase .

3 . Dab the Gel Seal over one crankcase fla1nge

from end to end, being sure to apply sea ant inside all bolt holes. Avoid getting closer than 6 mm to the labyrinth seals. Repeat for the other crankcase . flange.

& Safety Related

4-4

4. On 50 - V-6 models, add additional dabs of Gel Seal to areas of crankcase flanges where they narrow down. See Figure 4-9 .

If the motor is to be run the same day, the surface opposite the one Gel Seal is applied to should be sprayed with OMC locquic Primer Pa rt No. 384884. Wait several hours before running to allow Gel Seal to cure. If Locquic Primer is not used, the assembly should sit overnight before being run.

If excess Gel Seal has caused the motor to "lock­up," it may be loosened by turning the flywheel with a wrench. The motor may then be started and run with no detrimental effects.

Since Gel Seal begins curing as soon as it is confined (especially on those motors where Locquic Primer has been used), the assembly should be completed and all screws torqued promptly after assembly.

lit;i(J;![i l NOTE

If Gel Seal is allowed to set up before drawing down and torquing screws, Gel Seal may act as a shim. This may cause bearing misalignment, improper bearing location, and tight armature plate bearings.

1. Add Additional Dabs of Gel Seal

4-9

co 3162

4-8

5 0/ 55/60 co 1 548

4-9

4-4

I I -·- l_.- - ----CHECKING MOTOR TEMPERATURE - ALL MODELS

The Markal Thermomelt Stik, a heat sensitive stick similar to a crayon which melts on contact w ith a surface at a specific temperature, is used to measure powerhead temperature.

The motor is best checked when operating on a boat. If this is not possible, run the motor in a test tank for at least five minutes at a maximum speed of 3000 rpm. Mark the cylinder water jacket with the St ik. The mark will appear dull and chalky. When the surface temperature reaches the temperature rating of the Stik, the mark will melt becoming liquid and glossy in appearance. On some painted surfaces on which the Stik will not leave a mark, it will be neces­sary to hold the Stik against the surface. See Figure 4-10.

2 thru 4.!5 - Using a 73° C Thermomelt Stik , mark the side of the cylinder .

Ui®mwl NorE

DO NOT use the Stik on the cylinder head The center of the cylinder head on the motor will nor­ma//y run slightly hotter than 73° C.

The mark wi_ll appear dull and chalky. If the mark melts and appears glossy, the powerhead is over­heating. Check fo r a worn water pump or a clogged or leaky cooling system.

6 thru V-6 - Two Thermomelt Stiks are necessary to check motor - a 52° C Stik and a 73 ° C Stik . With the engine at operating temperature, the 52° C mark should melt and the 73° C mark should not melt .

If the 52° C mark does not melt after a rea­sonable length of time, the thermostat is stuck open and the motor is running too cold . If the 73° C mark also melts, the cooling system is not functioning properly allowing the motor to over­heat. Check for a worn pump assembly, leaky water system, or restrictions in the cooling system.

TESTING TEMPERATURE SWITCHES - REMOTE CONTROL MODELS

Temperature switches, installed in each cylinder head, are in series with a "HOT" warning horn in the remote control box. Should an irregularity develop in the cooling system and cause ab­normal water jacket temperatures, the switches close the warning circuit.

ENGl..ISH 4-5

A switch may be checked by submerging it in hot oil. Use a test light to check the contacts and a thermometer to check oil temperature. The contacts should close at a temperature of 99° C ± 3° and open at 79 ° C ± 4 ° See Figure 4-11.

To remove switches for testing, pull back insulating sleeves and open knife terminal con­nections. Remove cylinder head cover(s) and switch(es). See Figure 4-12. On installation, clean gasket surface thoroughly Apply OMC Gasket Sealing Compound lightly to gasket surface(s). Also apply the same sealing com­pound to top surface of heat switch grommet and again after cover has been installed . Install cyli nder head cover using a new gasket. Re­connect temperature switch leads and slide insulating sleeves over connections.

REMOVAL OF UPPER CRANKCASE SEAL - 2 THRU 15

The presence of oil under the flywheel indicates a leaking upper crankcase seal. The upper main bearing seal can be replaced without disas­sembly of crankcase . Remove flywheel. Use Seal Remover Special Tool No. 319060 to remove and install the seal. See Figure 4 -13 .

Use tip " A " on 4 and 4.5 models, tip " B" on 6 , 6 Com. and 7.5 models , and tip "C" on 2, 9.9 , 10 and 14 Com. and 15 models.

To remove seal, install tip into remover/ installer body. Thread remover/ installer body with tip into seal to engage metal case.

While holding remover/ installer body, turn pressing screw and remove seal.

To install, apply OMC Gasket Sealing Compound to metal casing of a new seal. Position seal on powerhead with lip facing down.

Using a mallet and remover/ installer body, install seal in powerhead.

A. Removal of Seal B. Install New Seal-Lip of Seal Facing Down

1. Pressing Screw 2. Removal/Installer Body 3. Tip

4-13

I

4-10

4-12

536 2 I

4-11

4-5

REMOVAL OF POWERHEAD - 20, 25, 25 COM. AND 35

NOTE

If only replacing upper main bearing seal, per­form steps (f) through (j). Use Seal Remover Too( Part No. 387780 to remove seal, and Installer Tool Part No. 321539 to install seal. See Figure 4-77.

a. Disengage throttle arm spring from throttle arm . Remove pin from end of throttle control rod, and remove two screws and clamp retaining vertical throttle shaft. Lift vertical throHie shaft from throttle gear. See Figure 4-77A.

b. Remove three screws, manual starter, starter lockout lever, and spring .

c. Remove screw retaining choke lever to car­buretor. Remove wave washer and spacer. Disengage choke lever from choke knob and pull knob out of retainer in air silencer.

d. Remove three air silencer screws and lock­nut and remove air silencer. Disconnect throttle arm to cam follower link. See Figure 4-778.

e. Disconnect carburetor to fuel pump hose at fuel pump. Disconnect overboard water hose.

f. Remove two carburet_or nuts. Remove car­buretor . Discard gaskets.

g. Remove flywheel nut using a suitable tool to "'' hold flywheel. Remove f lywheel using OMC

puller tool No. 378103 .

h. Loosen five armature plate screws. Remove port and sta rboard sta rter mounting brackets (manual start) or starboard bracket (electric start ).

i. Disconnect 4-wire connector from armature plate . Remove coils from cylinder head. Ob­serve location of coil ground leads for correct reassembly.

J. Lift armature plate from powerhead.

k. Remove four screws and armature plate sup­port and retainer plates.

I. Remove shifter lock lever and bracket from powerhead .

m. Remove two screws, fuel pump, and gasket.

n. Remove hose from intake man ifo ld. Remove screws and nuts retaining intake manifold. Remove intake manifold and gasket, and re­move one screw and leaf valve assembly.

ENGL ISH 4-25

o. Remove four screws retaining powerhead to exhaust housing.

p. Using a 1/ 2 inch offset box wrench (Special Tool No. 322700), remove port and starboard nuts retaining powerhead to exhaust housing.

q. Remove cotter pin and disconnect shift link. See Figure 4-77C.

r. Lift powerhead from exhaust housing, and place on work bench .

A

1. Seal Remover Part No. 387780 2. Seal Installer Part No . 321539

B

1. Sea l Remover Part No. 387780

c

1. Seal Installer Part No. 321539

4-77

1. Throttle Control Rod 2. Pi n 3. Spring 4. Clamp

4-77A

1. Link

4-778

POWERHEAD DISASSEMBLY -20, 25, 25 COM . AND 35

li!)NOTE

To simplify reassembly and wiring installation, lay out the various screws and clamps in order of their proper location.

a. Remove screws and inner exhaust tube. Re­move and discard gasket.

b. Remove water tube guide from inner ex­haust tube by pressing in on tab while pulling guide from exhaust tube. Remove and discard rubber grommet in exhaust tube. See Figure 4-78.

c. Remove three screws and lower main bearing seal housing. Remove and discard 0-ring on seal housing and inside of crank­shaft. See Figure 4-79. Seal inside of seal housing can be removed by driving it out with a punch and hammer.

NOTE

If only replacing lower main bearing seal, coat outside metal case of new seal with OMC Gasket Sealing Compound and press into housing using OMC installer tool no. 321515 and an arbor press. Press seal into housing with lip facing up. See Figums 4-79 and 4 -80. Press until tool is seated on face of seal housing.

d. Remove screws, cylinder head, and gasket.

e. Remove screws and cylinder head cover. Re­move and discard gasket. Remove thermostat and seal. Discard seal. See Figure 4-81.

f. Remove screws and exhaust cover. Remove inner e><haust cover, and discard inner and outer gaskets.

g. Remove screws and intake bypass cover . Discard gasket.

h. Using a punch and hammer, remove taper pin, punching from back to front of crank­case. See Figure 4-82 .

E N G LISH 4-26

1. Inner Exhaust Tube 2. Grommet 3. Tab 4. Guide

4-78

1. 0-Ring 2. Seal Lip Faces Up 3. Internal 0-ring 4. Lower Main Bearing

4-79

1. Tool No. 321515

4 -80

1. Thermostat 2. Seal 3. Gasket 4. Cylinder Head Cover

4-81

4-79

63249

4-80

4-26

POWERHEAD DISASSEMBLY - 20, 25, 25 COM. AND 35 (Continued)

1. Remove crankcase screws. See Figure 4 -83.

J. Tap crankshaft with soft mallet to break seal between crankcase and cylinder. See Figure 4-84. Remove crankcase from cy linder block.

k. Remove rod caps and bearing retainers.

Pistons, connecting rods, bearings, and caps are matched parts and seat with the operation of the motor. Because of this it is essential to maintain their original positions at reassembly.

M ark each connecting rod and cap, piston, and bear ing component to assure correct mating when they are reassembled. Also mark the cylinder from which piston assemblies are removed.

I. Remove lower half of center main bearing, needles and retainer .

m. Lift crankshaft from cylinder block. See Fig­ure 4··85. Reinstall matched caps on con­nect ing rods and remove pistons and rods from cy linders.

n. The top main bearing slides off. If necessary to remove the bottom main bearing, remove Truarc r ing and use an appropriate bearing puller . See Figure 4-86. Remove remaining center main bearing components . Remove 0-ring from inside of crankshaft lower main bearing journal. See Figu re 4-79.

o. Remove the rings from the pistons by prying the ends loose enough to grip them with pliers and then breaking them away from the piston . DO NOT try to save the rings. Install a complete set of new rings on every power­head service job.

p. If necessary to remove piston from con­necting rod, remove wrist pin retaining rings. Use piston cradle (Special Tool No. 326573) and wrist pin pressing pin (Special Tool No. 321434). With piston skirt flush with cradle, press out pin using an arbor press.

REASSEMBLY OF POWER ­HEAD - 20, 25, 25 COM. AND 35

Proceed slowly. Make no forced assemblies unless press fits are called for , and make no "dry" assemblies. Be sure all parts to be as­sembled are clean and free from dirt and grit . Perfectly good cylinder walls, pistons, and rings can be ruined in a few minutes of operation unless all forms of grit are removed before assembly. Work in clean surroundings and with reasonably clean hands. Coat all bearing surfaces, cylinder walls , etc., with clean oil before assembly. Where the use of oil is specified, we recommend 50/ 1 Outboard Lubricant.

[J NOTE

Alw ays use new gaskets throughout when re ­assembling the powerhead. Coat gaskets with OMC Gasket Sealing Compound No. 317201. Do not use sealer if so stated on gasket.

Make sure water deflectors are in place . See Figure 4-87.

1. Upper Main Bearing Locator Hole 2. Seal 3. Bearing 4. Bearing 5. Bearing

4-85

1 . Locator Pin 2. Locator Hole 3. Seal 4 . Upper Main Needle Bearing 5 . Needle Bearing 6. Ball Bearing 7. Retaining Ring

4-86

4-27

63203

4-83 4-85

. I I I PISTONS, WR IST PINS, AND CONNECTING RODS

a. The relative positions of pistons and con­necting rods must be considered when as­sembling pistons to rod . Pistons must be in­stalled in cylinders with intake side of deflector toward intake port. See Figure 4-87. Oil hole in connecting rod must be toward top of motor.

b. Apply a coat of oil to wrist pin, making sure surface is clean. Place a drop or two of oil in each pin hole in the piston.

c. Insert wrist pin through hole in piston. Oil wrist pin bearing in connecting rod . Place con necting rod in position, then proceed to install the wrist pin using Piston Cradle Special Tool Part No. 326573 and Wrist Pin Pressing Pin Part No. 321434.

d. Replace retaining rings using Special Tools Part No. 318600 and 318599. See Figure 4-87A. Make certain rings come to rest securely in the groove provided for this purpose.

e. Check piston with micrometer to determine whether piston has been distorted during as­sembly. Replace the piston if variation in diameter at the bottom of the piston skirt is greater than 0,08 mm.

PISTON RINGS

Install the piston rings on each piston. Spread each ring with a ring expander just enough to slip it over the head of the piston and down into place. Be sure the rings fit freely in the piston r ing grooves. The ring grooves are pinned to secure the position of the rings, primarily to prevent ends of the rings from catching on the edges of the ports in the cylinders, but also to assure staggering of the ring gaps.

ENGLISH

PISTON AND CONNECTING ROD INSTALLATION

Coat pistons and cylinder bores with oil and install piston and connecting rod assemblie!?. being sure to match each assembly with the cylinder it was removed from. The intake side oft he piston deflector must be placed toward the intake port. The piston rings must be compressed before the pistons can be replaced in the cylinders. Makecertainthatthe rings are correctly positioned in their grooves with respect to the groove pins . Damaged pistons and broken piston rings may result from imperfect alignment of the ring gap and the piston dowel pins.

The use of automotive type ring compressing tools should be avoided, as these frequently cause damaged pistons and broken piston rings through imperfect alignment of the ring gap and piston dowel pin. The use of Special Tool No. 326591 is recommended . See Figure 4-88 . Using one hand to push the piston into the cylinder, use the free hand to guide the connecting rod into place.

1. Intake Side of Deflector 2. Intake Side of Cylinder 3. Exhaust Side of Cylinder 4. Exhaust Side of Deflector 5 . Water Deflectors

4-87

1. Start Retaining Ring in Tapered End of Cone 2 . Cone Part No. 318600 3. Driver Part No. 318599

4-87A

1. Special Tool No. 326591

4-88

4-28

6321 a

4-87

"t

63217

4-88

22183

4-87A

4-28

I• I' ;,

CRANKSHAFT

a. Oil crankshaft bearing surfaces. Replace main bearings and upper main oil seal on crankshaft.

b. Remove rod caps from connecting rods. Place one retainer half and bearings on each rod. See Figure 4-89.

c. Place center bearing shell with locator in block. Be sure raised portion seats into hole in block. See Figure 4-89. Be sure pointed end of bearing shell is on intake side of engine.

d. Place crankshaft in position on cylinder block, upper main bearing dowel pin with dowel pin hole in cylinder block and center main bearing dowel pin hole with dowel pin in cylinder block. See Figure 4-90.

e. Place other retainer halves and bearings on crankpins.

f. Install connecting rod caps, but do nottorquethe screws at this time.

min NOTE 1.:!!.1 One side of connecting rod and cap has raised dots, and the corners are also chamfered for alignment of rod and cap. Connecting rod caps are not inter­changeable with those of other rods, nor can they be turned end for end.

Draw a pencil over the chamfered corners on both sides of rod to make certain that cap and rod are aligned at this point. If misaligned, the chamfered corners can be felt with the pencil point. See Figure 4-91. If misaligned, tap lightly with a punch and hammer.

g. Tighten connecting rod screws to torque specified in Section 1, using a torque wrench. Rods and bearings should float on crankpins.

h. Install crankcase half of center main bearing rollers and shell, matching dovetail ends. See Figure 4-92.

ENGL.ISH

1. Center Main Bearing Locator 2. Rollers and Retainer 3. Upper Main Bearing Locator Hole

4-89

1. Upper Main Bearing Locator Hole 2. Seal 3. Bearing 4. Bearing 5. Bearing

4-90

1. Chamfered Corners

4-91

1. Exhaust Side of Engine

4-92

4-29

I

4 -91

83255

4-89

4-92

4-90

-4-29

CRANKCASE AND CYLINDER

& a. Refer to The Use of Gel Seal at the be­ginning of this section.

b. Position crackcase on cylinder block, and in­stall screws finger tight. Replace crankcase taper pin, driving in carefully with a ham­mer.

c. Tighten all crankcase screws to torque speci ­fied in Section 1.

d. Place a new 0-ring in groove on lower main bearing seal housing. Install seal housing with screws dipped in OMC Gasket Sealing Compound. Torque screws to specifications given in Section 1. Place a new 0-ring inside crankshaft. See Figure 4-93.

e. Check for binding between the crankshaft and the bearings or connecting rods by rotating the crankshaft with the flywheel.

f. Install cylinder head, .using a new gasket coated lightly with OMC Gasket Sealing Compound. Do not use sealer if so stated on the gasket. Tighten cylinder head bolts to spec if ied torque, following the sequence shown in Figure 4-93A.

IIRI NOTE

Re-torque cylinder head screws after motor test has been completed and motor has cooled com­fortable to touch.

g. Reinstall thermostat. Install cylinder head cover, using a new gasket.

h. Install inner and outer exhaust covers using new gaskets. Tighten all screws to specified torque.

i.. Apply OMC Adhesive "M" t o outside of water tube grommet. Install grommet in inner ex­haust tube. Be sure none of the sealant is inside the grommet . Insert water tube guide into inner exhaust housing.

j . Make sure the gasket surfaces of the power­head are clean. Apply OMC Gasket Sealing Compound to powerhead and inner exhaust tube surfaces. Place a new gasket on the powerhead and install the inner exhaust tube.

k. Attach oil recirculation hoses to crankcase . Longer hose connects by-pass cover to fitting on intake manifold. See Figure 4-938.

& Safety Related

ENGLISH 4-30

1. 0-Ring In Crankshaft Groove

4-93

1. Longer Hose

4-938

' '

8 p

1

'

4-93

,... • " 11 ,.,..--- ...... ,

' ' 5 4 I ' '

~': ;~ I

I

' " 3 -~ I

/

6

....... ___ ,._ ... /

4-93A

A ~ ~Dt

"

~ .,

/" ,LJ

4-938

4-30

63226

9

I .. .:

0 10

' ,I

i I I ii

\: \ P' !I: 'l

53629

I' !\' ,.

11.

!I:\ :p, I! •I[

. ., I' r ~

I I

l l

~ I

INSTALLATION OF POWERHEAD 20, 25, 25 COM . AND 35

a. Coat driveshaft splines with OMC Moly Lube. Do not coat top surface of driveshaft as lubri­cant here may prevent seating of driveshaft in crankshaft.

b . Apply OMC Gasket Sealing Compound to ex­haust housing surface. Apply liquid hand soap to top of water t ube. Assemble power­head to exhaust housing making sure water tube enters inner exhaust tube guide . Rotate powerhead slightly back and forth to align crankshaft and driveshaft splines.

c. Apply OMC Nut Lock to port and starboard powerhead to exhaust housing studs. Install nuts. Torque to Specifications in Section 1.

d. Install four exhaust housing to powerhead screws with OMC Screw Lock. Torque screws to Specifications in Section 1 .

e. Install leaf plate assembly using a new gas­ket . Tighten flat head screw to Specifications in Section 1.

f . Install intake manifold using a new gasket. Flat head screw goes into port hole. Torque screws to Specifications in Section 1. Con­nect oil recirculation hose.

g . Install shifter lock lever with screw and bush­ings, and install spring . Install fuel pump.

h . Apply OMC Nut Lock to threads and install armature retainer and support plates aligning holes as shown in Figure 4-94. Torque screws to Specifications in Section 1.

1. Using new gaskets install carburetor, choke bracket, and choke shaft while engaging choke lever in slot in choke shaft .

j . Connect carburetor to fuel pump hose and secure with hose strap. Install starter mount­ing brackets .

k. If flywheel key has been removed, reas­semble to crankshaft with outer edge parallel to centerline crankshaft.

l!tii£1 NOTE

Be sure that the single upset mark on the side of the key is facing down.

1. Apply OMC Moly Lube around crankcase boss (armature plate pilot). Oil groove of plast ic armature plate bearing with OMC out­board lubricant. Install ring over edge of re­tainer plate. Position support plate on crank­case. Place retainer plate over support plate aligning holes with crankcase. Attach plate. Torque screws to specifications given in Sec-

tion 1. Install armature plate over crank­shaft. Using a needle nose pliers in slots in armature plate bearing, compress ring , and locate armature plate over Delrin ring. Align holes in armature plate and support plate. Tighten screws and torque to specifications given in Section 1. Install ignition coils by locating upper coil to upper cylinder . Upper coil is identified by a band marked No. 1, around coil lead . Reconnect all leads, con­nectors, and linkages. Coil ground leads and star washers are located below lamination in upper screw hole. Clamp armature plate wires .

m. Connect throttle arm to throttle cam follower link. Install vertical throttle shaft and con­nect throttle link to vertical throttle shaft arm with pin . Offset on pivot must face forward. Adjust throttle control rod and throttle cam synchronization. Install manual starter with 3 screws, and install starter lockout cable, or electric starter.

n. Coat air silencer screws with OMC Screw Lock. Install air silencer with three screws and a locknut. Use OMC Adhesive "M" on gaskets to hold them in place during as­sembly . Two rods placed in threaded holes in carburetor will align bracket and gaskets. Re­move one and install screw. Remove remaining rod and install other screw. Lubri­cate linkages . Test engine in test tank with appropriate test wheel (see Section 1 ), or on a boat . Adjust carburetor. Check idle, slow speed, and full throttle performance. Check engine temperature . Check starting inner lock system to be sure engine cranks in neutral only.

BREAK-IN - 20, 25, 25 COM. AND 35

Be sure that when the engine is returned to ser­vice after an overhaul, the owner is advised to follow break-in procedures. See Break-In Section ..

1. On Reassembly, Locate This Screw First

4 -94

& Safety Related

4-94

4-31

GEARCASE PRESSUR E AN D VACUUM TESTS - ALL MODELS

To test all gearcases for correct sealing, proceed as follows:

l i:&i')'~ ' NOTE

A ll gearcases must be completely empty of gear ­case lube before performing pressure or vacuum tests.

a. Remove drain plug and screw in a pressure test gauge. See Figure 5-1. Stevens Experi ­mental pressure test gauge illustrated .

b . Pump pressure up to 3-6 psi (21-42 kPa). If pressure gauge indicates leakage, submerge gearcase in water to determine source of leakage as evidenced by bubbles. If gearcase pressure gauge does not indicate leakage, in­crease pressure to 16- 1'8 psi (11 0-124 kPa) . If pressure does not hold, submerge gear­case in water and check for source of leak­age. Make necessary repairs and repeat test.

c . Screw in vacuum tester . Pump out to 76-127 mm of mercury and see if vacuum holds. Then pump out to 381 mm of mercury and check. If gearcase fails to hold on either test. put oil around suspected seal. If leak then stops or oil is drawn in, that seal is defec­tive . When gearcase checks out OK, refill with lubricant. See Section 1 Lubrication Chart.

FILLING GEARCASE

a. 2 models - lay motor on side with fill hole facing up.

4 thru V-6 - gearcase must be in an upright position.

b. Remove oil level and oil fill/drain plugs.

c. Fill gearcase with OMC HI-VIS Gearcase Lube until lubricant appears at oil level hole . See Figure 5-2. Insert and tighten oil level plug first . Invert gearcase and remove oil fill hose. Install fill/drain plug and tighten.

d. Inspect gearcase oil level after motor test.

1. Gearcase Pressure Test

5-1 ···.:.."'~

1. Oil Level Plug

{,\___ ./ --~\:_ '-.!.;------=:.:..___-- -7- ~ --· ...

635 12

5-2

5-1

5-8

GEARCASE REMOVAL - 35

It is possible to remove the lower gearcase as­sembly without removing the powerhead from the motor. However, if disassembly of the ex­haust housing is required, it is necessary first to remove the powerhead. See Section 4 for instructions.

The gearcase assembly may be removed from the exhaust housing as follows:

,& a. Remove upper motor cover . To prevent acci­dental starting of motor, disconnect the charge coil connector.

b. Remove both port and starboard water intake screens. See Figure 5-141. With two wrenches, hold lower shift rod and turn upper shift rod connector . See Figure 5-142 . Remove plastic keeper on shift rod. The upper connector cannot be removed at this time. The connector will fall off when the gearcase is removed from the exhaust housing. See Figure 5-143.

c. Remove screws and nut attaching gearcase to exhaust housing . See Figure 5-141.

d. Remove gearcase assembly from exhaust housing, taking care to avoid damaging drive­shaft, which extends upward to the power­head ..

e. Place gearcase in a suitable stand for disas­sembly.

GEABCASE DISASSEMBLY - 35

a. Remove oil level and drain plugs, and drain gearcase .

b. Remove cotter key, nut, spacer, propeller, and thrust bushing.

c. Remove pump housing screws, driveshaft, and water pump assembly from gearcase. Remove impeller plate. See Figure 5-145. Driveshaft sleeve, seals and bearing are visible.

d. Remove two propeller shaft bearing head screws using a 5/16 inch deep thinwall socket. Using puller tool No. 378103 and two long 1/ 4 -20 screws, pull housing from gear­case . See Figures 5-146 and 5-147.

.& Safety Related

ENGL.ISH 5-47

1. Water Intake Screws -Two Each Port and Starboard

2. Nut and Lockwasher 3. Screws - Two Each Port and Starboard

5-141

1. Upper Shift Rod Connector 2. Lower Shift Rod Connector

5-142

1. Keeper 2. Upper Connector

5 - 143

1. Water Tube 2. Driveshaft 3. Grommet 4. Water Pump Screws 5. Water Pump

5-144

1. Impeller Housing 2. Impeller 3. Impeller Pin 4. Impeller Plate 5 . Scraper - Bushing

5-145

1. Puller Tool No. 378103 2 . Long Screws 1/4"-20

5-146

1. 0 -Ring

5-147

813101

5-47

GEAR CASE DISASSEMBLY - 35 (Cont.)

e. Using retammg ring pliers No. 303859, remove retaining ring . See Figure 5-148. Re­move retainer plate. See Figure 5-149.

& SAFETY WARNING

Retaining rings are under extreme pres­sures during removal and installation. Wear safety glasses and proceed with care to avoid unsnapping ring from pliers .

f. Unscrew lower shift rod from yoke. Using a needle nose pliers, remove yoke from gear­case. See Figure 5-150.

g. Remove pivot pin with a Phillips screwdriver. See Figure 5-1 51. Pull propeller shaft, thrust washers, clutch dog, cradle, and reverse gear from gearcase. See Figure 5-152.

h. Remove shifting lever from gearcase. See Figure 5-153 . Remove pinion gear, thrust bearing, forward gear, a.rd bearing from gearcase. See Figure 5-154.

ENG~JSH 5-48

1. Retaining Ring Pliers No. 303859 2. Retaining Ring

5-148

1. Forward Bearing 2. Forward Gear 3. Thrust Washer 4 . Thrust Bearing 5. Pinion Gear 6. Lower Thrust Washer 7 . Upper Thrust Washer

5- 154

~ ' '

5-151

813103

5-48

1~. ·~.~ I i

5-153

5-154

GEARCASE DISASSEMBLY - 35 (Cont.)

1. If dr iveshaft upper bearing seals and bearing are worn, use a Two Jaw Puller No. 391010 or Sea l Remover Part No. 391259. Pull drive­shaft seals from gearcase. See Figure 5-155. To remove driveshaft bearing, drive out using OMC Special Tool Part No. 326570. See Fig ­ure 5-156. Remove bearing sleeve us ing Slide Hammer Special Tool Part No. 391008 and Two Jaw Puller Part No. 391010. Invert gearcase and driveshaft bearings will fall out .

J. If pinion bearing is worn , assemble com­ponents from Pinion Remover/ Installer Special Tool Part No. 391257. See Figure 5-157. Drive bearing out of gearcase.

k. If shift rod bushing and 0-ring are worn, use Slide Hammer with adapter (Special Tool No. 391 008) and a 1/4-20 or 1/4-28 nut with corners ground to clear casting. Remove shift rod washer, 0-r ing and bushing . See Figure 5-158 . .,

I. If forward roller bearing and cup are worn or pitted, use OMC Special Tool No. 391010, and Slide Hammer No. 391008 to remove forward bearing cup . See Figure 5-159. Space is provided in gearcase to allow jaws of tool to engage cup.

m . If bearing housing seals and bearings are worn , use OMC Special Tool No. 321259 to remove gearcase bear ing housing seals (pro­peller end). See Figure 5-1 60. Using OMC Specia l Tool No. 391008 and Two Jaw Puller 391010, remove front bearing .

ENG L.I SH 5-49

1. Two Jaw Puller No. 391010

5-155

1. 1/4-20 x 1/ 2 Screw 2. Washer No. 326587 3. Plate No. 326583 4. Gearcase 5 . Rod No. 326582 6. Remover/I nstaller No. 326577 7. Screw 1/4-20 x 1-1 /4"

5 - 157

1. Sl ide Hammer No. 391 008 2 . Adapter 3. Bushing 4 . 0-Ring 5 . Washer 6 . Rounded 1/4 Inch Nut

5-158

1. Two Jaw Puller No. 391010 with Slide Hammer No . 391 008

5-759

1. Puller No. 321259

5-760

5-155

2005

5-156

6 1 3 11 7

5-157

5-49

I

l.

,.l , I

I

~~·.· .. :. t ·'

' I

' I

5-158

5-159

co 3 4 5 2

5-160

GEARCASE REASSEMB LY - 35

U!i!li;];f NOTE

Use OMC Gasket Sealing Compound Part No. 31720 1 in bores or around met a/ case of all pressed in seals in gearcase bearing housing and impeller housing.

Make no dry assemblies. Lubricate bearings, 0-rings, shafts and gears with OMC HI-VIS Gear­case Lube. Use OMC Needle Bearing Grease to hold detent spring and balls in propeller shaft.

a. If removed, install new rear bearing in pro­peller shaft bearing housing using installer tool No. 321429 and an arbor press. See Fig­ure 5- 161. Press until tool is seated on hous­ing . Install new oil seals, one lip in, one lip out, using Seal Installer Part No. 326546. Use OMC Triple-Guard Grease between seals. See Figure 5-162. Install new front bearing using installer tool No. 321428 and an arbor press. See Figure 5-163.

b. If removed, install propeller shaft front bear­ing cup using installer .\ool No. 319929 and drive handle No. 311880. See Figure 5-164.

c. If removed, install shift rod bushing, 0-ring, and washer using installer tool No. 304515. See Figure 5-165. Use OMC Gasket Sealing Compound on bushing.

d. If removed, install new pinion bearing using Remover- Installer Part No. 391257. Assem­ble as shown in Figure 5-164. Apply a little needle bearing grease to end of tool and slide bearing on tool lettered side up. Insert tool in gearcase, and drive bearing in until plate is seated on face of gearcase. See Figure 5-166.

~I

ENG L.JSH

5-50

1. Bearing Installer No. 321429

5-161

1. Seal Installer No. 326546

5-162

1. Bearing Installer No. 321428

5-163

1. Bearing Cup Installer No. 319929 2. Drive Handle No. 311880

5 - 164

1. Bushing Installer No. 304515 2. Bushing 3. 0-Ring

5-165

1. Screw 1/4-20 x 1/ 2" 2. Washer No. 326587 3. Spacer No. 326585 4. Plate No. 326583 5. Gearcase 6. Rod No. 326582 7. Remover-Installer No. 326577 8. Screw 1/4-20 x 1-1 /4"

5-166

t

l

5 -161

2002

5-162

5-163

803455

6 3 272

5 -164

5-165

8 1 3 117

5 - 166

5-50

GEARCASE REASSEMBLY - 35 (Cont.)

e. Using Installer Part No. 322923 and an arbor press, press a new driveshaft bearing into the housing. Press u nti I the bearing is flush. See Figure 5- 167. Press housing in gear­case using the same tool. See Figure 5-168. Press housing in until seated. See Figure 5-169. Install seals back to back. Drive both seals in with installer tool No. 326552. See Figure 5-170. Apply OMC Triple-Guard Grease between lips of seals . If removed, apply OMC Gasket Sealing Compound to threads of gearcase stud, and thread into gearcase until seated . Use two nuts tightened together to turn in stud. Install• bushing on stud. See Figure 5-169.

f . Oil and install forward bearing in cup. Swab inside of gearcase with gearcase oil.

g. Oil and install pinion, lower thrust washer, thrust bearing, and upper thrust washer in gearcase. Chamfer in lower thrust washer must face pinion. See Figure 5-170A.

EN GL ISH 5-51

1. Driveshaft Bearing 2. Bearing Housing 3. Bearing Installer No. 322923

5-167

1. Bearing Installer No. 322923 2. Plate No. 318122 3. Screw 1/2-13

5-168

1. Plate Flush With Gearcase 2. Gearcase Stud

5-169

1. Seal Installer No. 326522

2. Installing Inner Seal 3. Installing Outer Seal

5-170

1 . Chamfered Edges of Thrust 2. Thrust Washer

5-170A

5-167

5-170

5 -168

803051

5-170A

5-169

5-51

GEARCASE REASSEMBLY - 35 {Cont.}

h. Install forward gear and thrust washer.

i. Assemble cradle to clutch dog with OMC Needle Bearing Grease. Place shift lever on cradle as shown in Figure 5-171. Note that groove on dog is facing forward.

j. Rotate clutch dog so that upon installation dog will be OUT OF engagement with for­ward gear. See Figure 5-1 72. Insert as­sembly into gearcase keeping all parts to­gether as shown in Figure 5-171. Install pivot pin . See Figure 5-173.

k. Assemble detent balls and spring on prop shaft. Sl ide Special Tool No. 321519 onto propeller shaft. Align holes in sleeve with detent balls and slide sleeve over balls until balls are visible thru holes in sleeve. See Figure 5-174.

I. Position shaft and sleeve .f!ssembly in gear­case so that slots in sleeve match up with clutch dog. DO NOT disturb clutch dog posi­tion. If splines do not match up, rotate shaft 180°. When splines match up and sleeve seats on clutch dog, push propeller shaft into place. Remove sleeve. If correctly done clutch dog will be retained on shaft by detent balls. Check for detent balls that may have popped out of position. Slide the thrust washer, and reverse gear down the propeller shaft.

ENGLISH

1. Engaged 2. Out of Engagement

5-172

5-52

5-171

CD

5-172

5 -173

5-52

_/<""\ r '1

83132

GEARCASE REASSEMBLY - 35 (Cont.)

m . Position the yoke in gearcase and engage the shifting lever clevis pin. See Figure 5-175. Thread lower shift rod into yoke until rod bot­toms in yoke .

n. Slide reverse gear bushing onto propeller shaft. Use sleeve, OMC Special Tool No. 321519 to press bushing into gear. See Fig­ure 5-176.

o. Posi t ion retainer plate in gearcase.

&sAFETY WARNING

Retaini ng rings are under extreme pres­sures during removal and installation. Wear safety glasses and proceed with care to avoid unsnapping ring from pliers.

p. Using retaining ring pliers OMC Special Tool No . 303859, install · retaining ring in gearcase.

q . Oil and place a new 0-ring in groove on pro­peller shaft bearing head. See Figure 5-177. Apply OMC Needle Bearing Grease to thrust washer, and place thrust washer in propeller shaft bearing head. See Figure 5-177.

Install propeller shaft bearing housing with " UP" mark up. See Figure 5-178.

r . Apply OMC Gasket Sealing Compound to screws and tighten to torque specified in Section 1.

s. Install water pump. See Water Pump Service.

t. Install oil level and drain and refill plugs in gearcase. If removed, slide gearcase stud bushing over stud. See F1gure 5-179.

u. Perform gearcase and vacuum pressure tests .

ENGLISH 5-53

1. Yoke 2. Hook Engages Shifting

Lever Clevis Pin

5-175

1. OMC Special Tool No. 321519 2. Bushing

5-176

1. Thrust Washer 2. 0-Ring 3. Bearing Head

5-177

1. Stud 2. Bushing 3. Water Tube

5-179

6328 0

5-775 5-178

5-179

5-176

5-177

5-53

GEARCASE INSTALLATION - 35

a. If powerhead was removed, remove inner exhaust tube f rom powerhead. Clean surfaces of powerhead and inner exhaust t ube and outer exhaust housing . Apply OMC Gasket Sealing Compound to these surfaces. Place a new gasket on powerhead and re­install inner exhaust tube.

b. Lubricate upper outside diameter of water tube. Insert water tube into exhaust tube guide. Coat driveshaft splines with OMC Moly Lube. Do not coat top surface of shaft as lubricant here may prevent seating of driveshaft in crankshaft. Lubricate lower end of shift rod and water t ube.

c. Install upper sh ift rod connector into lower shift rod . Inspect upper shift rod for burrs . Remove with file or sandpaper. Apply motor oil to shift rod to minimize damage to shift rod 0-rings in pump housing .

N OTE.

Damage to shift rod 0-rings could allow exhaust gasses to enter cooling system resulting m engine overheat causing permanent damage.

d. Bring gearcase into position beneath ex ­haust housing . Guide shift rod into position . Carefully guide water tube into the water pump grommet (See Figure 5- 144) whil e aligning the driveshaft and crankshaft splines by rocking the f lywheel.

e. Attach gearcase to exhaust housing with screws, nut and lockwasher dipped in OMC Gasket Sealing Compound No. 317201 and tighten to torque specified in Section 1.

f. Move shift lever to forward gear. Slide con­nector onto shift rod and install keeper into shift rod groove. See Figures 5-142 and 5-143. Move shift lever back to neutral and tighten connector. Do not turn lower shift rod while tightening upper shift rod connector . See Figure 5-141.

g. Coat propeller shaft splines with OMC Gasket Sealing Compound . Place thrust bushing in propeller and then slide assembly onto propeller shaft. Install thrust washer on shaft spline. Install and tighten propeller nut finger t ight and then tighten to align next cotter pin hole. Install cotter pin (use new pin if nec­essary). bending ends over nut. Fill gearcase wi th OMC HI-VIS Gearcase Lube.

FUN CTI ON TEST OF GEARCASE

a. Run motor in test tank and check cooling system operation as indicated by spray from idle relief holes.

ffi Saf ety Related

EN CiL.I S H

b . Shift to forward, then reverse, propell er should turn .

In neutral position. propeller should not turn .

ADJUSTMENTS

SHIFT HANDLE ADJUSTMENT -20, 25, 35

If removed or replaced, check shift ha ndle register with REVERSE, NEUTRAL, FORWARD, on lower motor cover.

a. Place gearshift in neutral. Propeller should turn freely. The roller on the shift lever should be centered on the neutral detent on t he shifter lock lever. When shifted into for­ward gear, you should feel a slight shifter dog drag when turning propeller shaft back and forth. This indicates full engagement be­tween clutch dog and forward gear.

b. If out of adjustment, shift gearcase linkage into neutral. Propeller shaft should turn freely. Loosen shift lever clamp screw and adjustment screw.

c. Move shift lever into neutral detent on shifter lock. Tighten both screws. Shift into forward gear and feel for slight shifter dog drag . If you do not feel the drag, then readjust shift lever slightly toward reverse position and tighten screws. Recheck for drag . This drag in fo rward gear assures that the shifter dog and gear are in full engagement.

ST EER ING FRICTION ADJUSTMENT

Adjust steering friction with motor mounted to boat by simply loosening or tightening screw with screwdriver as shown. Steering friction should be adjusted so that a slight drag is fe lt when turning . This will allow smooth steering. Minimum friction is required when remote steer­ing is used. See Figure 5-182 or 5-183.

& SAFETY WARNING

The steering friction screw is not intended to allow "hands off " steering .

IDLE SPEED ADJUSTMENT

If disturbed, adjust idle speed knob . Turning clockwise on the knob increases idle speed. turning counterclockwise decreases idle speed. Make certain that throttle is in slow position and the motor is at normal operating temperature before making the idle speed adjustment. s~e Figure 5-184. Motor should idle at 650 rpm m gear.

5-54

20 & 25 21056

5-182

35 61361

5-183

5-184

5-54

REMOVAL OF MOTOR FROM SWIVEL BRACKET -20, 25, 35

a. Place motor on a suitable stand .

b. Remove f ront upper mount nut. See Figure 5-185.

c. Remove lower side mount screws. Loosen lower thrust mount screws. See Figure 5-186.

d. Remove lower mount covers. See Figure 5-187.

e. Remove port and starboard upper side mount nuts. See Figure 5- 188.

f . Using a hoist, l ift motor from swivel bracket . See Figure 5- 189. Place motor in a con­venient place resting on the lower motor cover and on tip of ant i-ventilation plate.

1. Upper Thrust Mount Nut and Flat Washer

5-185

1. Remove Lower Side Mount Cover Screws 2. Loosen Lower Thrust Mount Screws 3 . Lower Mount Covers

5 - 186

1. Lower Thrust Mount 2. Lower Side Mount - Port and Starboard 3. Port Side Cover 4. Screw and Washer 5. Starboard Side Cover 6. Screws Pass Thru These Holes 7 . Bumper

5 - 187

1. Lower Motor Cover 2. A nti-Ventilat ion Plate 3. Pivot Shaft 4. Swivel Bracket 5. Stern Bracket 6. Steering Ha ndle - Rope Start

5-189

II ; ' Hi 'll

JA tl kl!i .. 4

'-.--------~~.~~::;.-_·,~y /''' ,.~ I

• • 5-185

5-188

63230

5-189

5-55

80 3 30 2

, I I i i

DISASSEMB LY OF STERN AND SWIVE L BRACKETS -20, 25, 35 a. Figure 5-190 shows the tilt and reverse lock

components that are replaceable if necessary.

b. Upper front rubber mount can be replaced if necessary by removing nut and washer. See Figure 5-191 .

c. If necessary steering bracket can be re­moved from pivot shaft by removing four screws. See Figure 5-1 91 .

d. Pivot shaft can be removed from pivot bracket . See Figure 5-192.

STEERIN G HAND LE AND THROTILE GEAR S (ROPE START)

a. Remove handle grip screw, handle grip, fric­tion block, spring, and throttle control plate.

b. Remove the three screw holding the steer­ing handle halves togeth~_r.

c. To remove long shaft and gear from port side half of handle, remove groove pin and washer. Pull shaft out.

d. To remove throttle control gear, loosen screw holding pinion gear to short throttle shaft and gear assembly, and withdraw shaft . Lift thrott le control gear from bushing in steer ­ing bracket. Bushing can be pressed out if servicing is required .

REASSEM BLY OF STER N AND SVVIVEL BRACKETS -20, 25, 35 a. If pivot shaft has been removed, lubricate

t hrust washer and liner with OMC Triple­Guard Grease. Place thrust washer and liner on pivot shaft.

b. If removed , place co-pilot plate and spacer in swivel bracket. Slide pivot shaft into swivel bracket. Lubricat e pivot shaft bushing, 0-ring, and lower thrust washer with OMC Triple­Guard Grease and install on pivot shaft.

c. If disassembled, reassemble stern brackets. Assemble stern brackets to swivel bracket with tilt t ube and nuts.

d . Coat t he steering bracket screw threads with OMC Screw Lock. Assemble steering bracket to pivot shaft and tighten the four screws to torque specified in Section 1. Install upper thrust mount, if removed, and tighten nut and washer securely. See Figure 5-193.

e. Lubricate and position th rottle gear bushing in steering bracket and install throttle con­trol gear.

ENG L. I S H

f . Lubricate and install the two throttle shaft bushings in steering bracket. Install the short gear and shaft. Position the throttle control pinion on the short shaft meshed with the control gear, as shown in Figure 5-193, and tighten the screw.

g. Lubricate and insert the bushing in the steer­ing handle half. Install the long shaft and gear, and insert groove pin.

h. Assemble the handle halves to the steering bracket, positioning the spacer between the two flat washers. See Figure 5-194. Be sure that the throttle gears are properly meshed. See Figure 5-194. Tighten the two screws securely, and torque to specifications in Sec­tion 1.

i. Place the throttle control plate (SLOW SHIFT START FAST) on the steering handle. Lubri­cale the spring and friction block with OMC Triple-Guard Grease and slide onto throttle shaft. Place grip spring washer on shaft. Place handle grip on shaft and insert screw and t ighten. Advance throttle to fast posi­tion. Throttle and pinion gears should rotate freely from slow to fast.

1. Clamp Screws, Buttons and Retainers 2. Stern Brackets 3 . Shallow Water Drive Bracket 4. Swivel Bracket 5 . Reverse Lock Springs 6. Tilt Tube 7. 35 Model Shown

5-190

1. Steering Bracket to Pivot Shaft Screws 2 . Nut and Flat Washer 3. Steering Bracket 4. Upper Thrust Mount

5-191

1. Thrust Washer 2. Liner 3. Pivot Shaft 4. Swivel Bracket 5 . Thrust Washer 6. 0-Ring 7 . Bushing

5-792

1. Screw 2. Control Gear 3. Pinion 4. Upper Thrust Mount 5. Nut and Washer 6 . Screws

5-193

1. Washers

5-194

5-56

63254

5 -190

5-193

I"<

53253

5 -191

5-192

5-56

INSTALLATION OF MOTOR TO SWIVEL BRACKET - 20, 25, 35

a. Clamp stern and swivel brackets to a motor stand. Using a hoist, position motor on swivel bracket. See Figure 5-189.

b. Place port and starboard side lower mount housings in position on exhaust housing and pivot shaft . Insert the two lower side mount cover screws, but do not tighten. Be sure screws pass t hru holes in pivot shaft, see Figure 5-186.

c. Make sure upper side mount and thrust mount st uds are correct ly located in slots in steeri ng bracket . Install washers and nuts. Tighten all hardware to torque specified in Section 1. See Figure 5-188.

d. Lubr icate all lube points with OMC Triple­Guard Grease as described in Section 1.

REMOVAL OF EXHAU ST HOUSING

a. Remove wire from end of throttle control rod . Unhook armature plate link to vertical throttle arm spring . Remove two screws and clamps.

b. Remove vertical throttle shaft . See Section 2.

c. Remove locknut, three screws, and remove ai r si lencer. Disengage choke shaft from car­buretor choke lever. See Section 2.

d. Cut hose strap at fuel connector and dis­connect fuel hose.

e. Remove port side powerhead to exhaust housing stud nut. See Section 4 .

f . If necessary, remove hardware attaching starboard electrical components bracket (electr ic start model), and swing aside . Re­move starboard powerhead to exhaust housing stud nut. See Section 4.

g. Remove four screws retaining powerhead to exhaust housing . Disconnect ground wire be­tween powerhead and lower motor cover . Disconnect cooling indicator hose. Lift power­head from exhaust housing .

h. Remove four rubber mount screws, shift lever, and lower motor cover. See Figure 5-195. Avoid loss of washers.

ENG LI SH 5-57

i. Remove two screws and exhaust housing cover plate to expose shift rod connector. Re­move lower screw. Remove four screws, one nut and lockwasher. Carefully remove gearcase.

J. Remove upper thrust mount nut and flat washer . See Figure 5-197. Remove upper port and starboard side mount nuts, and f lat washers. See Figure 5-198.

k. Remove two lower side mount cover screws. Loosen two lower thrust mount screws. See Figure 5- 198. Remove lower mount covers . Remove exhaust housing from swivel bracket. See Figure 5 -197.

1. Lower Motor Cover Support 2 . Screws 3 . Screw 4 . Shift Rod Lever 5 . Seal 6. Exhaust Housing 7 . Steering Bracket 8. Shift Lever and Shaft

5-196

1. Exhaust Housing 2. Upper Side Mount (Port and Starboard) 3 . Lower Thrust Mount 4. Lower Side Mount (Port and Starboard) 5 . Screw - Thrust Mount 6. 35 Model Shown

5-197

I

5- 195

8 1 3 1 77

5-197

co 1 699

5-198

5-196

5-57

INSTAILlATION OF EXHAUST HOUSING - 20, 25, 35

a.

b.

c.

d.

e.

f.

g .

If removed, install a new exhaust housing to lower motor cover seal, using OMC Ad­hesive "M." Lubricate shift lever shaft and install thru exhaust housing and upper shift rod lever. Shaft has a f lat spot for retaining screw. Tighten screw to torque given in Sect ion 1. Install lower motor cover front bracket and torque screws to specifications in Section 1.

If removed, install upper and lower rubber mounts, and lower thrust mount. See Figure 5-197. Apply OMC Gasket Sealing Compound to threads.

Place exhaust housing in swivel bracket. Install nuts and flat washers loosely. See Figures 5-195 and 5- 196.

Position lower mount covers on pivot shaft and exhaust housing. Insert the two lower side mount cover screws thru the port side cover, pivot shaft, and thread into starboard cover. Tighten all screws and nuts to torque specified in Section 1. See Figure 5-198.

Install gearcase with screws dipped in OMC Gasket Sealing Compound, making sure lower shift rod enters connector . Apply same to threads of stud and install lockwasher and nut. Torque to specifications in Section 1. In ­stall cover with screws dipped in OMC Gasket Sealing Compound.

Remove inner exhaust tube from power­head. Clean surfaces of powerhead and inner exhaust tube to remove old cement and gasket material. Apply OMC Gasket Sealing Compound to these surfaces. Position a new gasket on powerhead and reinstall inner ex­haust tube.

Oil and install a new 0-ring in crankshaft. Coat driveshaft splines with OMC Moly Lube. Do not coat top surface of shaft as lubricant here may prevent seating of driveshaft in crankshaft.

h . Install powerhead on exhaust housing while rotating slightly back and forth to engage driveshaft and crankshaft splmes. Be sure water tube enters water tube guide.

I.

j .

Install exhaust housing to powerhead screws and nuts. Torque to specifications in Section 1 .

Install vertical throttle shaft, aligning nylon pin with slot in control gear . Attach clamp with two screws, secure throttle control rod with wire, and connect throttle shaft arm to armature plate link with spring.

ENGLISH

k. Coat threads of air silencer screws with OMC Screw Lock. Engage choke shaft with car­buretor choke lever. Using two pins in air silencer thread holes in carburetor as a guide, install air silencer . Hold air silencer against carburetor, remove pin and thread screw into carburetor. Remove other pin, and thread screw into carburetor. Attach re ­maining screw and locknut.

REMOVAL OF EXHAUST HOUSING, STEERING AND STERN BRACKETS - 40 COM.

a.

b.

c.

d.

e.

f .

g.

h .

Remove powerhead as described in Section 4 .

Remove four nuts and lockwashers attach ­ing lower motor cover to exhaust housing. Remove lower motor cover, powerhead plate, and gaskets.

Remove gearcase, and gearcase extension if used.

Remove screws and nuts attaching lower mount housing to exhaust tube assembly. See Figure 5-198. Remove both lower mount housings.

Remove nuts and washers from upper side mounts. Remove nut attaching exhaust tube assembly to upper front mount. Loosen steer­ing friction adjustment screw. Lift exhaust housing from steering bracket. See Figure 5-121.

Remove and discard any rubber mounts which are cracked or otherwise deteriorated.

To remove throttle control, loosen screw at­taching throttle control pinion to shaft . Re­move throttle control pinion, shaft, and gear. Press throttle control bushing from bracket, if worn .

Lift steering bracket from swivel bracket as­sembly. Stern bracket assembly may be d1s- . assembled by removing nut from tilting shaft bolt and removing stern bracket strap.

SEE GENERAL CLEANING, INSPECTION, AND REPAIR

5-58

REMOVAL OF STARTER FROM POWERHEAD - 20/25/35, 25 COM. AND 40 COM.

On Non-Commercial Models - A locking lever linked to the gearshift lockout lever prevents manual starter engagement while the motor is in gear. See Figure 6-43 .

.&a. 40 Commercial - Twist high tension lead counterclockwise and pull off from spark plug.

b. Remove three screws and lift starter from powerhead.

&a. 20/25/35 and 25 Commercial - Disconnect electrical connector between armature plate and power pack to avoid accidentally starting motor.

b. Remove starter housing screws.

c. Use a screwdriver to disengage cable con­nector from starter hou.sing. See Figure 6-43A.

d. To remove lockout lever from motor, remove two bottom fuel pump screws and move fuel pump aside.

e. Remove screw on cable bracket. See Figure 6-43A.

f. Disconnect cable from lockout lever and lift off cable assembly.

& Safety Related

ENGLISH

1 . Upper Lockout Lever 2. Lower Lockout Lever 3. Adjustment Screw 4. Locknut 5. Spring

6 -43

6-11

6-43A

~ \

6- i i

DISASSEMBLY OF STARTER -20/ 25/ 35, 25 COM. AND 40 COM.

& SAFETY WARNING

We recommend w earing safety glasses while disassembling and reassembling manual starters because of tension re­tained in rewind spring.

a. Pull the starter rope out far enough to tie a slip knot in the rope. Pry t he rope anchor out of the handle. Remove the handle, release the knot, and ease the starter pulley back until the starter drum is fully unwound.

b. Remove retaining ring and lift off pawl with links and spring as an assembly.

c. Remove nut. screw, and washer from spindle . Hold pulley in housing while turning starter over, legs down. Hold fingers clear of pulley and jar housing against bench top to dislodge spr ing and pulley.

CLEANING, INSPECTION , AND REPAIR a. Wash metal components in solvent and dry

with compressed air .

b . Inspect spring for broken end loops and weak tension .

c. Examin e pawl for wear.

d. Inspect f r iction spring, spindle, and links.

e. Inspect rope and discard if frayed . Be sure to replace with starter rope cut to a length of 174 em.

f . Examine pulley and housing . Look for sharp edges and rough surfaces that cou ld fray rope. File and polish to remove .

q. Examine starter interlock parts. Replace any worn or damaged parts.

REASSEMBLY OF STARTER a. Clamp Spring Winder base (Special Tool Part

No. 392093) in a vise . When rewinding 25 and 40 model spring, insert adapter release plate into base. See Figure 6-43B .

b. Place inner loop of spring inside cup . Locate crank and pin assembly into winder base installing crank retainer screw. See Figure 6-43C.

c. Rotate crank and pin assembly in direction of arrow shown on handle. Wind spring into base until loose loop end contacts base. See Figure 6-430.

d. Remove crank retainer screw and crank as­sembly. See Figure 6 -43.E~

e. Remove adapter releas-e:· 'plate from base. Install spring into starter housing, locating pin into spring loop. See Figure 6-44.

f. Press down through holes of base to transfer spring into starter housing.

g. Bend inside loop end of spring in toward center of housing to align with pin in pulley. Lubricate spring with Lubriplate 777. Install pulley being sure to engage pin with inside spring loop. See Figure 6 -45.

h. Apply a light coat of Lubriplate 777 to spindle and install in housing with spindle screw, washer, and nut.

i. With housing upside down on bench, wind pulley counterclockwise until spring is tight. Back off about 1/ 2 to 1 turn and align hole in pulley with hole in housing. Lock pulley by inserting a nail , small pin or drill thru holes in pulley and housing. See Figure 6-46.

j. Cut new rope to a length of 174 em . Using a match or cigarette lighter, fuse nylon strands at each end for about 13 mm . Rope ends must be stiff to hold in pulley and rope anchor. Tie knot in end of rope and thread through pulley and housing. See Figure 6 -47.

k. Apply Lubriplate 777 to handle end of rope. Using Starter Rope Threading Tool (Special Tool No. 378774), thread rope through handle. Press rope into channel in rope anchor, with end of rope butting firmly against end of channel. Press anchor into handle .

I. Tug on end of rope to seat the knot against the pulley. Remove locking pin and allow rope to wind slowly onto the pulley.

m. Apply a light coat of Lubriplate 777 to pawl pin, and install pawl with spring and links. Secure pawl with retaining ring .

n. Check operation of pawl when rope is pulled out. Pawl should extend when rope is pulled and retract when rope recoils .

o. Pull starter rope out a few times, then check timing. When the starter is properly timed, an arrow on the housing will align within the limits of a box marked on the pulley.

NOTE A new rope, being stiff, may cause timing marks to misalign slightly. This condition normally cor­rects itself after using starter a few times.

6-12

1. Adapter Release Plate 6-438

1. Loop Over Pin In Housing 6-44

1. Pin 2 . Inside Loop 6-45

1. Locking Pin 2. Retaining Ring 6-46

1 . Punch 4. Grommet 2. Rope Knot 5. Retaining Ring 3 . Seat Rope Knot Here

6-47

-~~~ .. ~~~~ ·:?~·

'·1

6-438 6-44

6-43£ 6-47

6-12

REASSEMBLY OF STARTER TO POWERHEAD - 20/25/35 AND 25 COM.

a. 20/ 25/ 35 housing.

Snap lockout cable into starter

b. Align starter with powerhead, and attach with three housing screws.

To install lockout cable to powerhead:

a. Hook end of cable into lockout lever.

b. Connect cable bracket to powerhead with screw. See Figure 6-48.

c. Reinstall fuel pump.

~d. If equipped, check operation of starter interlock. Manual starter must not function when throttle is advanced beyond the "START" position.

~ Safety Related

1. Cable Bracket Screw

6-48

6-13

6-48

I ! .

SECTION 7 ELECTRICAL SYSTEM

SAFETY WARNING

To prevent sparks which may result in fire and explosion, make sure all elec­trical connections are tight, insulator boots and sleeves are in place and elec­trical wires are routed and clamped in the original position before returning motor to owner.

STARTER SYSTEM TROUBLE ISOLATION CHART

PROBLEM: STARTER DOES NOT CRANK ENGINE

a. If checking starter system on a boat. place remote control lever in neutral.

b. Inspect battery condition. Battery must be fully charged .

c. Inspect cables and leads for worn insulation. Check connections . They must be clean, tight. and free of corrosion .

d. Check 20 amp fuse in lead between solenoid and key switch.

STARTER SYSTEM VOLTAGE D ROP TEST

a. By making a systematic check from the positive battery terminal, through the starting circuit and back to the negative battery terminal, any component or electrical con­nection having excessive resistance, thus causing high voltage drop and subsequent hard starting, can be located below.

b. Disconnect four wire connector between armature plate and power pack so that engine can be cranked without firing. Connect voltmeter and turn ignition switch to START to crank engine. See Figure 7-1 .

..., NOTE ~

By placing voltmeter leads against battery, solenoid. and starter motor terminals rather than against connecting cable ends, each connection can be tested for high resistance along w1th component.

c. Clean and retighten, or replace, any connec­tion, cable, or component having greater than specif ied voltage drop.

ENGL.ISH 7-1

STARTER SYSTEM VOLTAGE DROP TEST

(See Figure 7 -1.)

a. Connect voltmeter pos1t1ve lead to battery positive post. Connect voltmeter negative lead to starter solenoid positive terminal. Turn key switch to start to crank engine. Voltage reading should not exceed 0.3 volts.

b. Connect voltmeter (only while engine is cranking) positive lead to starter solenoid positive terminal. Connect voltmeter nega­tive lead to starter solenoid starter lead terminal. Turn key switch to start engine. Voltage reading should not exceed 0.2 volts.

c. Connect voltmeter positive lead to starter solenoid, starter lead terminal. Connect volt­meter negative lead to starter motor terminal. Turn key switch to start engine. Voltage reading should not exceed 0.2 volts.

d. Connect voltmeter positive lead to battery negative lead common powerhead ground screw. Connect voltmeter negative lead to battery negative post. Turn key switch to start engine. Voltage reading should not exceed 0.3 volts.

1. Common Engine Ground 2. Starter Motor 3. Solenoid Switch 4. 12 Volt Battery 5. 0.3 Volts Maximum 6. 0 .2 Volts Maximum

7-1

a.

b.

c.

d.

I

:G) : I L ______ .J

I

f.\ I I \V I I I L------.J

I f.\ I

I \V I I I L ______ _j

~ @ ,,

CD

73228

7-1

i .. i

! ;,

7-1

a STEP

Check voltage between ground and

point(}.

..6sAFETY WARNING

Steps 1 thru 6 - Remove starter to solenoid cable from check

point 0 to prevent starter

engagement whi le making checks.

Check voltage between ground and

point0.

0NOTE

In STEPS 2 thru 6 turn key to "off" position before discon­necting and connecting meter. Turn key to "start" position after making connection where required.

EJ Check voltage between ground -and

point@.

II Check voltage between ground ond

point 0.

IJ Check voltage between ground and

point 0. Check voltage be­

tween ground and point 0 .

1':1 Check val tage between ground and

point0.

fJ Check voltage between ground and

point 0·

ENGLISH

1. Place Voltmeter Lead to Each Check point

2. Common Engine Ground 3. Common Engine Ground

PROCEDURE

Remove white lead from safety switch

at check point 0. Connect volt­

meter between point 0 and com­

mon engine ground. Turn key switch to start position. Vo ltmeter should show 12 vo lts (battery voltage).

Connect meter at 0 . Turn key

switch to "start" position.

Connect meter at 0 . Turn key

switch to "start" position.

Connect meter at 0 . Turn key

switch to "stort" position.

Connect meter at 0. Turn key

sw itch to "off" position.

Connect voltmeter at point 0. Turn key to "start" position.

Reconnect starter to solenoid cab I e

at check point 0. Connect

meter at point 0. Turn key to

"start" position.

4. Starter Motor 5. Solenoid Switch

RESULT

a. If meter does not read any val tage, pro­ceed to STEP 2.

b. If meter reads 12 volts (battery voltage) reconnect white lead to safety switch and proceed to STEP 6.

a. If meter reads 12 volts (battery vo ltage),

lead is open between 0& 0. b. If no reading, proceed to STEP 3.

a. If meter reads 12 volts (battery voltage), solenoid switch is faulty.

b. If no reading, proceed to STEP 4.

a. If meter reads 12 volts (battery voltage),

I ead is open between VJ & 0. b. If no reading, proceed to STEP 5.

a. If meter reads 12 val ts (battery voltage), check key switch.

b. If no reading at 0 check for open

I ead or fuse between 0 and 0 • c . Connect meter at point@. If no

reading ot 0, check for open lead

between 0 and battery positive

terminal. If reading at 0 1 proceed •

to STEP?.

a. If no reading, solenoid is faulty.

b. If meter reads 12 va l ts (battery val tage - click should be heard in solenoid), proceed to STEP 7 .

a. If meter reads 12 val ts (battery vol a nd starter motor does not turn, check starter motor.

b. If no reading, check for broken cable or poor connection.

8. Fuse 9. Ignition Switch

6 . Common Engine Ground 10. Yellow/Red 11 . Safety Switch 7. 12 Volt Battery

7-1A

7-2

I+ I

: CD I I I 1....--- _j ---

83107

7-1A

7-2

KEY SWITCH CHECK

(With Test Light or Ohmmeter)

(See Figure 7-1 B.)

a. Disconnect battery leads.

b. With key switch in " OFF" position, connect a continuity light or meter leads between key switch " BATT" and "A" terminals. Light or meter should not show continuity.

c. Turn key switch to "ON" position. Light or meter should show continuity.

d. Turn key switch to "START" position. Light or meter should still show continuity.

e. W it h key held in "START" position, transfer lead f rom "A" terminal to "S" terminal. Light or meter should still show continuity.

f . Tra nsfer leads to "M" terminals. Light or meter should not show continuity in " START" or " ON" positions.

J. Turn key switch to " OFF" position . Light or meter should show continuity .

h. Transfer leads to "B" and "C" terminals. Turn key switch to "ON" position and push in key. Light or meter should show continuity when key is pushed in.

i. Turn key switch to "START" position and push in key. Light or meter should show con­t inuity when key is pushed in .

KEY SWITCH CHECK (With Leakage Tester)

In some conditions, the key switch may be shorting (some leakage) to the other terminals in t he key switch, but will not show up with a test I ight or an ohmmeter. This condition may be found by using a condenser tester (leakage test) w here a voltage of approximately 500 volts is ap­p li ed t o t he key switch terminals . '3 . With all leads disconnected and the key

switch in the off position, connect the black lead of t he tester to one of the "M" ter­minals of the key switch. See Figure 7-1C.

b . Attach t he red lead of the tester to the "B" terminal CD and apply leakage test .

c . Repeat t est by moving the red lead to each of the term inals and applying the leakage test. The meter will indicate if leakage is present.

d . When app ly ing test to other "M " terminal ~ turn key to the on position.

REMOVAL OF STARTER

Due to the construction of the starter motor , maintenance operations are generally limited to periodic checking for looseness of mounting. Unless it is certa in that the starter motor re­quires attention, do not remove it for overhaul. A thorough check should be made of the battery. cables, starting solenoid, and switch.

E N G L.ISH 7-3

25 AND 35

Uliiill NOTE

Disconnect battery cables at battery.

a. Remove vertical throttle shaft clamp screws and clamp. See Figure 7-3.

b. Remove the upper and lower screws retammg the starter bracket to the power­head. See Figure 7-3 . Observe that the ground lead attaches to the lower screw.

c. Disconnect all leads from the solenoid. See Figure 7-3 .

d. Remove one locknut and three screws attaching air silencer to powerhead. Remove air silencer .

e. Remove starter bracket front screw and place starter and bracket assembly on a bench for disassembly. See Figure 7-3.

50 THRU V-6

l ,ki~I!IU N 0 TE

Disconnect battery cables at battery.

a. Disconnect lead f rom starter motor .

b. Remove air silencer as described in Section 2.

c. Remove three starter mounting screws. See Figure 7-2.

1. Battery 2. Off 3. On 4. Start 5. Choke Start

7-18

a. Leakage Tester b . Black Lead c . Red Lead d . Red Lead with Key in "ON" Position

7-1C

1. Starter Mounting Screws

7-2 1. Screws 2. Clamp 3. Vertical Throttle Shaft 4. Starter Bracket Screws 5. Starter Pinion Gear 6. Ground Lead 7. Solenoid Leads 8. Starter Solenoid

7-3

7-1 c

~ S M

M 8

0 7-2

7-18

7-3

7-3

ALTERNATOR STATOR TEST -25 THRU 60

~ Ji\\!~ 1 NOTE

Set ohmmeter on Low Ohms scale.

a. Connect black ohmmeter lead to the yellow I ead of stator .

Connect red ohmmeter lead to the yellow/ grey lead of the stator. See Figures 7-17 and 7-17A. Ohmmeter should read 0,35 ± 0,1 ohm.

b. Disconnect ohmmeter red lead from the stator yellow/grey lead. (Leave ohmmeter black lead connected to yellow lead.)

Connect the ohmmeter's red lead to the stator's yellow with blue st ripe lead . Ohmmeter should read 0,2 ± 0, 1 ohm. See Figures 7-17 and 7-17 A.

Disconnect red ohmmeter lead from the stator's yellow with blue stripe lead (leaving the ohmmeter 's black lead connected to the yellow I ead of stator).

Set ohmmeter scale to Hi Ohms.

Connect the ohmmeter's red lead to ground. Ohmmeter should show open circuit (infinity) . If ohmmeter shows any reading, stator is shorting to ground. See Figu re 7-17B.

RECTIFIER DIODE TEST - 25 THRU 60

a. Connect one lead of ohmmeter to rectifier case (ground) and other lead to yellow/ grey stripe lead of rectifier. Note reading. See Figures 7-18 and 7 -18A. Reverse ohmmeter leads or press polarity button . Note readmg. Reading on one check and no reading (infinity) on the other check - diode is good; both readings zero, diode is shorted .

OHMMETER LEADS MUST BE REVERSED FOR EACH TEST OR PRESS POLARITY BUTION

b. Repeat above test using yellow rectifier lead.

C.

Reading on one check and no readmg (In­finity) on the other check - d1ode IS good; both readings high, diode is open; both read­ings zero, diode is shorted .

Repeat above test using yellow/blue stripe lead. Reading on one check and no readmg (infinity) on the other check - diode is good; both readings high, diode is open; both read­ings zero, diode is shorted.

ENG L.I SH 7 -8

d. Repeat test procedure with ohmmeter be ­tween red lead of rectifier and yellow/ grey stripe lead of rectifier. Reading on one check and no reading (infinity) on the other check -diode is good; both readings high, diode is open; both readings zero, diode is shorted .

e. Repeat test between red and yellow lead of rectifier. Reading on one check and no read­ing (infinity) on the other check - diode is good; both readings high, diode is open; both readings zero, diode is shorted.

f. Repeat test between red and yellow/ blue stripe lead of rectifier. Reading on one check and no reading (infinity) on the other check -diode is good; both readings high, diode is open; both readings zero, diode is shorted .

1. Ohmmeter 2. Steps <D and @ 3. Step @ Hi Ohms 4. Red 5 . Yellow 6. Yellow/ Grey 7 . Yellow/ Blue 8 . 5 Amp Stator 9 . Terminal Block

10. Black

7-17

Lo Ohms Scale Scale

1 . Ohmmeter Red Lead 2. Stator Yellow Lead 3. Stator Yellow/ Grey Lead 4. Ohmmeter Black Lead 5 . Stator Yellow/Blue Lead

7-17A

1. Ohmmeter Black Lead 2. Stator Yellow/ Grey Lead 3. Ground 4. Ohmmeter Red Lead

7-178

1. Rectifier Yellow/ Grey Lead 2. Meter Black Lead 3. Meter Red Lead 4. Ground

7-18 and 7-18A

83082

8 1 311 1

7-17A 7-18

8 1 3 1 1 2

7-178 7-TBA

CONTROL CABLES INSTALLATION ON MOTOR

a.

b.

c.

d.

Identify the throttle cable from the shift cable at the engine end of cables by lifting fast idle lever. The throttle cable will move.

Lubricate the shift and throttle cable ends with OMC Triple-Guard Grease.

& SAFETY WARNING

To prevent accidental starting of engine always remove ignition key from start switch. Accidental starting of engine could cause possible injury to the in­staller and/ or bystanders.

Remove rubber grommet from front of lower motor cover. Open cable retainers . See Figure 8-6 or 8-7.

Move control lever on remote control box to neutral position . Move fast idle lever down to "run" position.

·-& SAFETY WARNING

Before connecting shift control cable to engine. insme that the remote control is in neutral and the engine shift lever is in neutral. Failure to make this adjust­ment can result in the engine starting in gear and/or the control "locking" in gear. Operator may become confused and temporarily lose control of boat.

e. Place shift lever on engine in neutral posi­tion (propeller shaft will turn freely when in neutral). Note amount of free play in shift lever, and position lever in center of this travel.

• Determine mid-point of shift cable backlash by first pushing cable and trunnion nut toward each other. and then pulling them apart.

• Position backlash at mid-point. Then place trunnion adjustment nut of shift cable into trunnion pocket of anchor block which aligns with the shift lever . See Figure 8-20.

• Turn the trunnion adjustment nut until hole in cable is in line with pin on shift lever.

• Attach cable to pin using washer and lock­nut supplied with engine.

f. Move throttle lever on engine so that idle stop screw is against its stop.

g. Grasp throttle cable and trunnion nut. Pull firmly on cable while pushing on trunnion nut to remove backlash from cable and remote control.

ENGLI SH

U±l£1 NOTE

Unless backlash is removed (as in step "g" above) before adjusting and connecting throttle cable. engine may not return to a consistent idle speed.

h. Position throttle cable in notch in anchor block. Turn trunnion adjustment nut until hole in cable is in line with pin on throttle lever. Attach cable to pin using washer and locknut supplied with engine. See Figure 8-21.

& The throttle cable must be adjusted just tight enough to insure that the engine throttle lever returns to its idle stop . If this cable is too loose. the engine idle speed will be high and incon­sistent. causing difficulty shifting out of gear.

If it is too tight. the control will feel stiff through the shifting range, and the warm-up lever will tend to move up when shifting to neutral.

&i. Slip rubber grommet onto control cables. and press grommet into groove in lower motor cover. Snap cable retainers shut. See Figure 8-6 or 8-7.

8-7

J. Test operation. See Function Testing of Controls.

•> '?,

1. Locknut and Washer 2 . Shift Control Cable 3. Anchor Block 4 . Shift Trunnion Adjustment Nut

8-20

1. Locknut and Washer 2. Throttle Cable 3. Throttle Trunnion Adjustment Nut 4. Throttle Lever

8-21

.ffi Safety Related

8-20

8-7

/

COMBINATION THERMOSTAT AN D PRESSURE RELIEF

25 GEARCAS E

\ \ \ \I

\ \ ~~ ~I ~~ v~ 1

~ ~~! I I - II

20/25 COMMERCIAL/25-35 WATER FLOW DIAGRAM

20/25/35

35 GEARCASE

93·

SENSOR COIL

(A) BROWN

---

WIRING DIAGRAM C.D. 2 4.5 THRU 55 MANUAL START

CHARGE COIL

SHORTING SWITCH ASSY.

21:~::{ ---------J ------------------------~ lANGE/BLUE

lANG E

.ACK/YELLOW

8 1 3276

BLACI} --

POWER PACK CD 2

£ ~::-'Z.... __________ __. L----,---

SENSOf

~?5Zl (B) ORANGE/BLUE

~{C)ORANGE (A) BLACK/YELLOW

35 ELECTRIC START

CONTROL BOX

CABLE CONNE CTOR VACANT

YELLOW/ RED 16 GA.

RED/ PURPLE

STR IPE

VACANT--- ,

PURPLE

VACANT

VACANT

RED/ PURPLE STRIPE

BLACK/ YELLOW

PURPLE

RED

MOTOR CABLE

CONNECTOR

MOLDED

ARROW~

YELLOW/ RED 16 GA.

VACANT

63110