Page 1 PNo. 003-21036-1 0509 NB 1000 Printrd in Japan...
Page 2 TABLE OF CONTENTS Service Safety General Service Information Fuel System Powerhead Midsection Gearcase Electrical System Power Trim/Tilt 3-/ 4-Cylinder...
Page 3: Table Of Contents
SECTION 1 SERVICE SAFETY TABLE OF CONTENTS Introduction ......................... 1-2 Safety Statements........................ 1-2 Safety Precautions ....................... 1-3 Workmanship Standards...................... 1-5 Test Tank Guidlines ......................1-7 3-/ 4-Cylinder...
Page 4: Introduction
SECTION 1 WARNING Inadequate knowledge of safe shop practices can result in severe injury or death. Review general safety procedures and speciﬁc safety information provided for each procedure prior to beginning any repairs. INTRODUCTION KC-5030 Marine manufacturers are required to comply with special regulations and standards to ensure their products are safe and reliable for the consumer.
Page 5: Safety Precautions
SERVICE SAFETY SAFETY PRECAUTIONS Handling Outboard Engines • Never disable the neutral switch start-in-gear prevention system to accommodate installation of a foot control or other option. Always test the neutral switch and emergency stop switch before returning an engine to the customer. •...
Page 6 SECTION 1 • Avoid running the engine at high RPM. Engine speed can easily increase to excessive RPM when under a no load condition. To avoid engine damage during testing, always use the correct test propeller and keep engine speed below 2000 RPM. •...
Page 7: Workmanship Standards
SERVICE SAFETY Hazardous Materials • Gasoline vapors are highly ﬂammable and can cause an explosion. Never smoke or allow sparks or ﬂames nearby when handling fuel. Always store gasoline in a shaded, well ventilated area in an approved safety container. •...
Page 8 SECTION 1 8. Keep all removed parts separated for ease of identiﬁcation during assem bly. 9. Locate alignment marks on components being disassembled. If marks are not present and should be, scribe or match mark them yourself to ensure the pieces are assembled properly. 10.
Page 9: Test Tank Guidlines
SERVICE SAFETY TEST TANK GUIDELINES When properly setup, test tanks provide a safe and controlled environment in which to perform outboard engine adjustment and testing procedures. Test tanks must be setup to the minimum dimensions shown. If multiple engines will be installed in the tank, secure partition plate (1) so that the minimum dimensions are maintained for each outboard engine installed.
Page 10 SECTION 2 GENERAL SERVICE INFORMATION TABLE OF CONTENTS General Precautions ......................2-2 Abbreviations and Symbols ....................2-3 Unit Conversions ......................... 2-4 Service Speciﬁcations ......................2-5 Engine Speciﬁcations ......................2-8 Lubrication Chart ......................2-11 Periodic Inspections ......................2-14 Break-In Procedure ......................2-18 Tune-Up Procedure ......................
Page 11: General Precautions
SECTION 2 GENERAL PRECAUTIONS Before performing any service work on the outboard engine, read and understand Section 1 - Service Safety. Use only genuine factory replacement parts with equivalent characteristics such as type, material, and strength. Failure to do so may result in product malfunction and injury to the operator or passengers.
Page 12: Abbreviations And Symbols
GENERAL SERVICE INFORMATION ABBREVIATIONS AND SYMBOLS Abbreviations liter ampere liter per hour alternating current L/hr pound ampere-hour milliliter approximately approx. millimeter American Petroleum Institute millivolt after top dead center ATDC newton before top dead center BTDC newton meter degree Celsius ˚C National Marine cold cranking amp...
Page 13: Unit Conversions
SECTION 2 UNIT CONVERSIONS Unit Preﬁxes Units of Torque Preﬁx Symbol Power mega x 1,000,000 ft-lb 1.3558 = N-m kilo x 1,000 ft-lb 0.1383 = kg-m centi x 0.01 in-lb 0.1130 = N-m milli x 0.001 in-lb 0.0115 = kg-m micro µ...
Page 14: Service Specifications
Powerhead Flywheel Puller Assembly Kit......... 3C7-72211-0 Plate, Flywheel Puller ......3B7-72783-0, 3C7-72783-0 Bolt, M8 x 25 mm (3 pcs) ..........3B7-72786-0 Bolt, M8 x 40 mm (3 pcs) ..........3B7-72785-0 Washer (3 pcs) ............940191-0800 Pressing Bolt .............3B7-72784-0 Powerhead Stand ............353-72247-1 Piston Pin Tool ........345-7221 5-0, 353-72215-0 Piston Ring Tool .............
Page 15 SECTION 2 Power Trim/Tilt Tilt Rod Guide Wrench ...........3C8-72791-0 Trim Rod Guide Wrench .........3B7-72792-0 General Equipment Required Water Pressure Gauge, 0 - 15 psi [0 - 103 kPa / 0 - 1 kg/cm Fuel Pressure Gauge, 0 - 15 psi [0 - 103 kPa / 0 - 1 kg/cm Torque Wrench, 0 - 150 in-lb [0 - 17 N⋅m / 0- 1.7 kg-m] Torque Wrench, 0 - 750 ft-lb [0 - 1000 N⋅m / 0 - 102 kg-m] Dial Gauge, minimum scale 0.0001 in [0.01 mm]...
Page 16 GENERAL SERVICE INFORMATION Consumables Required Threadlocker, Loctite ® Threadlocker, Loctite ® Gasket Dressing, Permatex Hylomar Aerosol High-Temp Gasket Dressing ® ® Gasket Sealant, Permatex High Tack Gasket Sealant ® Anaerobic Gasket Maker, Loctite ® Silicone Sealant, Permatex Hi-Temp RTV Silicone Gasket ®...
Page 17: Engine Specifications
............. 5000 - 5700 Piston Ring End Gap 50D ............5000 - 5700 40, 50 Top Ring ... 0.009 - 0.015 in [0.22 - 0.37 mm] ............. 5150 - 5850 60B, 70B ..........4900 - 5600 40, 50 2nd Ring .. 0.013 - 0.019 in [0.33 - 0.48 mm] 60C, 70C ..........
Page 18 80, 90 ........11.339 in [288 mm] Alternator 115, 120, 140 ......15.669 in [398 mm] 40, 50, 60, 70, 80, 90 ......12 V 130 W 115, 120, 140 ........12 V 330 W Gearcase Charging Performance (at 1500 RPM) Gear Ratio 40, 50, 60, 70, 80, 90 .........
Page 19 80, 90 ..........3.70 qt [3.5 L] Exciter Coil Output (Cranking) 115, 120, 140 ........6.34 qt [6.0 L] 40, 50, 60C, 70C, 80, 90, 115, 120, 140 ... 130 DVAMin 60B, 70B ..10-15 DVA (Brown/White to White/Yellow) Carburetor 100-200 DVA (White/Green to White/Yellow) 40, 50, 60, 70, 80, 90 .....3 butterﬂy valve type...
Page 20: Lubrication Chart
GENERAL SERVICE INFORMATION T1045 T1046 T1047 LUBRICATION CHART Frequency Type Fresh Salt Location Lubricant Water Water Advancer Arm, Throttle Cam, and Linkage Ball Joints Shitt Lever and Shift T1048 Guide Plate and Set Ring Starter Motor Pinion Every Every 50 hours 30 hours Throttle Cables (1 months)
Page 21 SECTION 2 T1054 T1055 T1056 Frequency Type Fresh Salt Location Lubricant Water Water Swivel Bracket Grease Fitting Clamp Screws Engine Cover T1057 Latches Every Every Propeller Shaft and 50 hours 30 hours Thrust Holder (3 month ) (1 month) Tilt Tube Grease Fittings Tilt Stopper Lever or Tilt...
Page 22 GENERAL SERVICE INFORMATION T1064 T1063 Frequency Type Fresh Salt Location Lubricant Water Water Lower Cylinder Pin Every Every Grease Fitting 50 hours 30 hours (3 month ) (1 month) Check level at time of Trim/Tilt Reservoir delivery, after ﬁrst 10 hours of operation, and every 100 hours (6 months).
Page 23: Periodic Inspections
SECTION 2 PERIODIC INSPECTIONS NOTE It is recommended that a complete engine overhaul be performed after 300 operating hours Item Inspection Remarks Fastener Check the following: • • Torque to Torque • Cylinder head bolts speciﬁcation. • Cylinder head cover bolts •...
Page 24 GENERAL SERVICE INFORMATION Item Inspection Remarks Fuel and • Clean and inspect. • Replace hoses Recirculation • Check all hose clips. every 2 years. Hoses • Engine • Check with compression gauge. Obtain normal Compression operating temperature and check at full throttle.
Page 25 SECTION 2 Item Inspection Remarks Electrical • Check for loose connections. • • Wiring • Inspect wires and insulation for damage. Ignition • Check and adjust timing. • • Timing and • Adjust linkage. Synchronization and Carburetor Linkage Adjustments Adjustments in this section.
Page 26 GENERAL SERVICE INFORMATION Item Inspection Remarks Operational Check function and condition of the • Checks following : • Water discharge from check ports • Tiller or remote steering controls • Power trim/tilt system • Manual or remote clutch engagement • Main switch key •...
Page 27: Break-In Procedure
SECTION 2 BREAK-IN PROCEDURE CAUTION Failure to follow the Break-In Procedure and special fuel mixture requirements for break-in may lead to serious engine damage and shortened engine life. To prevent serious engine damage and ensure long engine life, new engines, used engines with new powerhead, used engines with newly rebuilt powerhead, and engines coming out of storage must be run for a period of 10 hours in accordance with the break-in procedure.
Page 28 GENERAL SERVICE INFORMATION Next 50 Minutes • DO NOT operate the engine above 1/2 throttle (approx. 3000 RPM). • DO NOT maintain a constant throttle setting. Vary engine speed every 15 minutes. NOTE For boats which come onto plane easily, use full throttle to quickly accelerate onto plane;...
Page 29: Tune-Up Procedure
6. Check for proper clutch engagement and make shift cable adjustments as needed. Model Adjustment Part 40 /50 Shift lever stopper : Position onto Shift arm 60 / 70 F-type Shift lever stopper : Position onto Shift lever stopper plate...
Page 30: Emergency Stop Switch And Lanyard
GENERAL SERVICE INFORMATION 13. Run engine in test tank with proper test propeller and check for the following: • Abnormal engine noise. • Improper clutch operation. • Little or no cooling water discharge from check port and idle port. • Fuel leaks from mating surfaces of crankcase. •...
Page 31: Operator Alert Systems
SECTION 2 Function Test 1. Attach the lanyard lock clip to the stop switch. 2. Start the engine. 3. With engine running, pull the lanyard to disengage the lock clip. Engine should stop running. NOTE The stop switch is designed to also operate as a pushbutton switch with the lanyard left attached.
Page 32 GENERAL SERVICE INFORMATION 4. Disconnect the oil level sensor connection at the electrical box. T1066 5. Connect the main switch side of the bullet connector to a clean engine ground and verify the warning horn sounds. If the horn does not sound, but other electrical components are functioning properly, the horn or wiring may be faulty.
Page 33 SECTION 2 Pilot Lamp Test Models 40 and 50 EFGO, EFTO type are equipped with a pilot lamp mounted on the front surface of the lower engine cover. The pilot lamp illuminates to alert the operator of a low oil level in the oil automixing tank.
Page 34: Synchronization And Linkage Adjustments
GENERAL SERVICE INFORMATION SYNCHRONIZATION AND LINKAGE ADJUSTMENTS To ensure consistent engine idling and smooth operation throughout the full RPM range, it is important that each procedure be performed exactly as written and in the following sequence: • 1 st - Ignition Timing Adjustment •...
Page 35 SECTION 2 Ignition Timing Adjustment Models 40D / 50D 1. Pre-set ignition timing link (1) and throttle link (2) to speciﬁed lengths. Length (approximately) Model Ignition Timing Link Throttle Link T1069 5.04 in [129 mm] 3.86 in [99 mm] 5.04 in [129 mm] 3.86 in [99 mm] 2.
Page 36 GENERAL SERVICE INFORMATION Ignition Timing Adjustment Models 40D2 / 50D2 1. Adjust ignition timing link (1) and throttle link (2) to speciﬁed length. Length Model Ignition Timing Link Throttle Link T1069 40D2 3.98 in [101 mm] 4.53 in [115 mm] 50D2 3.86 in [98 mm] 4.53 in [115 mm]...
Page 37 SECTION 2 Ignition Timing Adjustment Models 60B / 70B 1. Pre-set ignition timing link (1), throttle link (2), and high speed side stopper (3) to speciﬁed length. Length (approximately) Ignition Timing Throttle High Speed Model Link Link Stopper T1074 5.24 in [133 mm] 5.00 in [127 mm] 0.28in [7 mm] 5.24 in [133 mm]...
Page 38 GENERAL SERVICE INFORMATION NOTE Align ﬂat surface (6) of crankcase mold boss with calibration marks on set ring. Perform the adjustment with set ring pushed slightly in the direction of arrow. 5. Return advancer arm (4) to the maximum speed position (wide open throttle) and adjust length of high speed side stopper (3) so it contacts the advancer arm.
Page 39 SECTION 2 NOTE Align ﬂat surface (6) of crankcase mold boss with calibration marks on set ring. 4. Place advancer arm (4) in the minimum speed position (throttle fully closed). Adjust throttle link (2) so ignition timing is ATDC 3˚ ± 1˚ when the advancer arm is in contact with low speed side stoooer (7).
Page 40 GENERAL SERVICE INFORMATION Ignition Timing Adjustment Models 80A / 90A 1. Adjust ignition timing link (1) and throttle link (2) to speciﬁcation : Length Model Ignition Timing Link Throttle Link T1081 4.88 in [124 mm] 5.18 in [131.5 mm] 4.88 in [124 mm] 5.18 in [131.5 mm] 2.
Page 41 SECTION 2 5. Place the advancer arm in the minimum speed position (throttle fully closed) and adjust stopper (6) (Pre-setting length = 12 mm) to obtain the speciﬁed ignition timing: Model Ignition Timing - Throttle Closed ATDC 5° ± 1˚ ATDC 5°...
Page 42 GENERAL SERVICE INFORMATION Ignition Timing Adjustment Models 115 / 120 / 140 1. Adjust ignition timing link (1) and throttle link (2) to speciﬁcation: Length Model Ignition Timing Link Throttle Link T1081 5.00 in [127 mm] 6.22 in [158 mm] 5.00 in [127 mm] 6.22 in [158 mm] 5.00 in [127 mm]...
Page 43 SECTION 2 6. Place the advancer arm in the minimum speed position (throttle fully closed) and adjust stopper (6) to obtain the speciﬁed ignition timing: Model Ignition Timing - Throttle Closed ATDC 10˚ ± 1˚ ATDC 10˚ ± 1˚ ATDC 10˚ ± 1˚ T1757 NOTE The rubber damper must be installed on stopper when...
Page 44 3. Adjust the length of each carburetor throttle link rod (5) to speciﬁcation : Length Model Link 40 / 50 3.54 in [90 mm] 60 / 70 3.81 in [97 mm] T1089 80 / 90 / 115 / 120 / 140 4.33 in [110 mm]...
Page 45 8. Turn throttle stop screw (7) until it touches throttle lever (8), then tighten the screw to the speciﬁed number of turns: Model Throttle Stop Screw Number of Turns 40 / 50 2-1/2 60 / 70 1-1/4 80 / 90 / 115 / 120 / 140 As needed so throttle valve is open 5˚...
Page 46 With an accurate tachometer installed, adjust the throttle stop screw to obtain the speciﬁed RPM at neutral idle and trolling speeds: Model Neutral Idle RPM Trolling RPM 40 / 50 60 / 70 80 / 90 115 / 120 / 140 Oil Pump Aperture Adjustment NOTE...
Page 47 SECTION 2 T1096 T1095 T1094 Throttle Model Position Aperture Setting Fully OPEN 40 / 50 Marks aligned. Fully CLOSED 60 / 70 Marks aligned. Fully OPEN* Marks aligned. T1097 90 / 115 / Fully CLOSED Marks aligned. 120 / 140...
Page 48: Anodes - Inspection And Testing
GENERAL SERVICE INFORMATION ANODES - INSPECTION AND TESTING Engines are equipped with several sacriﬁcial anodes to help protect metal parts from the effects of galvanic corrosion (electrolysis). Disintegration of the anodes indicates they are performing their function. An anode must be replaced when it has been reduced to 2/3 its original size (1/3 eroded).
Page 49 SECTION 3 FUEL SYSTEM TABLE OF CONTENTS General Precautions ......................3-2 Service Speciﬁcations ......................3-3 Fuel System Requirements ....................3-4 Troubleshooting ........................3-6 Description of Operation ..................... 3-8 Fuel Tank ........................... 3-11 Fuel Line and Primer ......................3-12 Fuel and Oil Filters ......................3-13 Fuel Pump .........................
Page 50: General Precautions
SECTION 3 GENERAL PRECAUTIONS WARNING Gasoline is extremely ﬂammable and can readily explode if mishandled. Before performing any service work on the fuel system, read and understand Section 1 - Service Safety. Before servicing the fuel system, disable the engine ignition system to prevent accidental starting of engine.
Page 51: Service Specifications
SERVICE SPECIFICATIONS Special Torque Values Torque in-Ib N·m kg-m Description Threadlocker Model 40 / 50 60 / 70 80 / 90 115 / 120 / 140 Carburetor 44 - 53 44 - 53 Mounting Bolt 5 - 6 5 - 6 ––...
Page 52: Fuel System Requirements
SECTION 3 Manufacturer Special Tools Required None General Equipment Required Fuel Pressure Gauge, 0 - 15 psi [0 - 103 kPa / 0 - 1 kg/cm Torque Wrench, 0 - 150 in-lb [0 - 17 N-m / 0 - 1.7kg-m] Digital Pulse Tachometer, 10 RPM, Electonic Specialties ®...
Page 53 FUEL SYSTEM Mix Ratios CAUTION In addition to oil in the oil tank, a 50:1 gasoline/oil mixture is required during engine break-in. Refer to Break-In Procedure in Section 2. Automixing The gasoline/oil mixing ratio varies automatically between 50:1 (2% oil) and 120:1 (0.8% oil) according to throttle opening and engine speed.
Page 54: Troubleshooting
SECTION 3 TROUBLESHOOTING The troubleshooting chart lists common engine symptoms related to problems with the fuel system. It also indicates speciﬁc malfunctions in the fuel system which may be causing the problem so it can be isolated more effectively. Before beginning major troubleshooting operations on the fuel system, perform the following operations: •...
Page 55 FUEL SYSTEM Symptom Checks OIL MIXTURE No oil in engine oil tank • • Mixture too rich (too much oil) • • Mixture too lean (not enough oil) • • • • • CARBURETOR Carburetor out of adjustment • • •...
Page 56: Description Of Operation
SECTION 3 T1001 DESCRIPTION OF OPERATION The following description of operation applies to fuel systems equipped with the oil automixing feature. Premix fuel systems operate in a similar manner but do not include a separate oil input circuit. Fuel Flow Upon engine startup, engine oil from oil tank (1) is drawn through oil ﬁlter (2) and into the oil pump.
Page 57 FUEL SYSTEM T1003 T1002 Oil Pump The oil pump is a plunger type mainly containing an internal worm gear driven by engine revolution, a spindle gear, and a cam shaft connected to engine throttle linkage. Fuel Pump The fuel pump is integral with the carburetor or mounted on the side of the crankcase and contains one or more internal diaphragms (1).
Page 58 SECTION 3 Pilot System The pilot system in the carburetor is a slow speed system consisting of the slow jet, slow air jet, pilot outlet, bypass, and pilot adjusting screw. At low throttle, mixed fuel (1) enters the carburetor and ﬂows from carburetor ﬂoat chamber (2) through passage (3) to slow jet (4).
Page 59: Fuel Tank
FUEL SYSTEM FUEL TANK Water or dirt in the fuel tank can cause fuel starvation and engine problems. Clean and inspect fuel tank once a year or after long time storage (more than 3 months). Cleaning 1. Disconnect fuel line from fuel tank. 2.
Page 60: Fuel Line And Primer
FUEL LINE AND PRIMER CAUTION Model 115, 120, and 140 fuel line assembly is not same model 90, 70, 60, 50 and 40 one. NOTE Before complete disassembly of fuel line and primer, check for damage or blockage of fuel line quick disconnects at engine and fuel tank.
Page 61: Fuel And Oil Filters
FUEL SYSTEM 4. Reassemble all components. NOTE Install primer so arrow points in direction of fuel ﬂow. Use pliers to compress hose clamps to proper shape. FUEL AND OIL FILTERS The fuel and oil ﬁlter assemblies should be removed from the engine and serviced after engine break-in and after every 50 hours of operation (3 months).
Page 62: Fuel Pump
Disassembly NOTE T1008 Models 40 and 50 are equipped with carburetor mounted fuel pump. Disconnect fuel hoses from pump, loosen the four mounting screws and remove pump. Gently separate the pump components and continue with Cleaning and Inspection procedures.
Page 63 1. Clean all pump components with mild solvent or isopropyl alcohol. 2. Clean pump mounting surface on carburetor with isopropyl alcohol (models 40 and 50). 3. Dry all components with low pressure compressed air. Ensure all passages are completely dry.
Page 64 SECTION 3 5. Inspect gasket between crankcase and fuel pump for dryness (crankcase-mounted pumps). 6. Verify pre-drilled pressure intake hole (1) exists in rear pump cover. Hole diameter must be 0.079 in [2 mm] (crankcase-mounted pumps) (115-140 only). Assembly 1. Install all check valves in pump body. 2.
Page 65: Automixing System
FUEL SYSTEM AUTOMIXING SYSTEM Routine inspection of the oil automixing system should be performed once a season. Inspection 1. Inspect entire automixing circuit for leaks. Check all hose connections, clamps must be tight. Check for leakage from pump and between surface of pump and crankcase.
Page 66 T1026 60 / 70 0.8 - 0.9 [23 - 28] 80 / 90 1.1 - 1.4 [33 - 40] 115 / 120 / 140 1.7 - 2.1 [51 - 62] Function Test - Oil Level Sensor 1. Disconnect the oil level sensor leads at the electrical box and remove sensor from tank.
Page 67 • Oil level indicator on tachometer illuminates and warning horn sounds when ﬂoat makes contact with sensor switch. Models 40 / 50 with remote control: • Oil level indicator on tachometer illuminates and warning horn sounds when ﬂoat makes contact with sensor switch.
Page 68: Carburetor
5. Remove carburetors and discard the carburetor base gaskets. Disassembly NOTE Bottom carburetor on models 40 and 50 is equipped with integral fuel pump. To ensure proper cleaning of the carburetor, remove and service the fuel pump at this time. Refer to Fuel Pump, this section.
Page 69 FUEL SYSTEM 1. Clean all metal components using a mild aerosol solvent or isopropyl alcohol. Use a soft bristle brush to remove gummy deposits. Clean plastic parts with warm soapy water. 2. Dry all components with low pressure compressed air. When drying passages, direct the ﬂow of air opposite the direction of fuel ﬂow.
Page 70 Before proceeding, be sure all components are completely clean and dry and all replacement parts match the originals. NOTE Fully assemble bottom carburetor on models 40 and 50 before installing the fuel pump. 1. During assembly, replace all serviceable gaskets (1) and plugs (2) as illustrated.
Page 71 NOTE If ﬂoat height is not correct, remove the ﬂoat valve assembly and make minor adjustments by slightly bending the tabs on the ﬂoat hinge clip. Models 40 T1037 and 50 cannot be adjusted. 4. Install new gasket on ﬂoat chamber.
Page 72: Intake Manifold
SECTION 3 Installation 1. Clean the carburetor mounting surfaces on the intake manifold with isopropyl alcohol. 2. Install new carburetor base gaskets dry. 3. Mount carburetors to intake manifold and torque to speciﬁcation. 4. Install all fuel hoses and clamps. 5.
Page 73 0.25 - 0.26 [6.5 - 6.7] 0.36 - 0.37 [9.3 - 9.5] 60 / 70 / 80 / 90 0.39 - 0.40 [10.0 - 10.2] 115 / 120 / 140 0.36 - 0.37 [9.3 - 9.5] Inspect entire valve assembly for corrosion.
Page 74 SECTION 3 Assembly Components must be clean and all serviceable gaskets must be replaced. 1. Assemble the intake manifold components as illustrated: • Apply Loctite 242 to threads of reed valve assembly screws (1). • Install all gaskets dry. • Torque manifold bolts (2) evenly to speciﬁcation. 2.
Page 75 SECTION 4 POWERHEAD TABLE OF CONTENTS General Precautions ......................4-2 Service Speciﬁcations ......................4-3 Troubleshooting ........................4-7 Description of Operation ..................... 4-8 Cylinder Compression Test ....................4-9 RPM Performance Test ..................... 4-10 Overheat Sensor ....................... 4-11 Water Pressure Sensor ..................... 4-12 Thermostat ........................
Page 76: General Precautions
SECTION 4 GENERAL PRECAUTIONS Before performing any service work on the powerhead, read and understand the Service Safety section at the beginning of this manual. Use the manufacturer special tools as indicated during servicing of the powerhead. Use caution when performing tests with the engine cover removed. Do not wear loose clothing or jewelry.
Page 77: Service Specifications
SERVICE SPECIFICATIONS Special Torque Values Torque in-lb (ft-lb) N·m kg-m Description Threadlocker Model 40 / 50 60 / 70 80 / 90 115 / 120 / 140 44 - 53 44 - 53 44 - 53 44 - 53 Thermostat Cap...
Page 78 SECTION 4 Torque in-Ib N·m kg-m Description Threadlocker Model 40 / 50 60 / 70 80 / 90 115 / 120 / 140 44 - 53 27 - 35 44 - 53 44 - 53 Air Silencer Bolt 5 - 6...
Page 79 POWERHEAD T1157 T1158 T1159 Figure Description Unit 40 / 50 60 / 70 80 / 90 115 / 120 /140 Cylinder 2.677 2.913 3.386 3.465 Bore 68.0 74.0 86.0 88.0 (Standard) Piston 0.0012 - 0.0028 0.0016 - 0.0031 0.0031 - 0.0051 0.0039 - 0.0055...
Page 80 SECTION 4 Manufacturer Special Tools Required Flywheel Puller Assembly, 3B7-72214-0, 3C7-72211-0 Plate, Flywheel Puller, 3B7-72781 -2, 3C7-72783-0 Bolt, M8 x 25 mm, 3B7-72786-0 Bolt, M8 x 40 mm, 3B7-72785-0 Washer, 940191-0800 Pressing Bolt, 3B7-72784-0 Powerhead Stand, 353-72247-0, 353-7247-1 Shackle, 353-01512-0...
Page 81: Troubleshooting
POWERHEAD TROUBLESHOOTING The troubleshooting chart lists common engine symptoms related to problems with the powerhead. It also indicates speciﬁc component failures which may be causing the problem so it can be isolated more effectively. Symptom Checks Poor crankcase seal • Ignition timing or throttle linkage out of •...
Page 82: Description Of Operation
SECTION 4 T1160 T1161 DESCRIPTION OF OPERATION The power head of this outboard motor is a two- stroke engine (or two-stroke cycle engine). The engine completes its one cycle operation including gas mixture suction, compression, explosion and exhaust while the crankshaft rotates once i. e. the piston moves upward and then downward (two strokes).
Page 83: Cylinder Compression Test
Take reading for each cylinder and verify speciﬁed pressure is obtained: Cylinder Compression* Model psi [kPa / kg/cm 40 / 50 117 [800 / 8.2] ± 13 % 60 / 70 121 [830 / 8.5] ± 13 % 80 / 90 117 [810 / 8.2] ±...
Page 84: Rpm Performance Test
SECTION 4 RPM PERFORMANCE TEST NOTE Engines are equipped with RPM limiting function. If full throttle RPM values cannot be obtained, see RPM Limitation Test in Section 7. CAUTION Do not perform RPM test if engine shows signs of overheating. T1170 Perform this test with correct test propeller installed and with the engine in a test tank.
Page 85: Overheat Sensor
NOTE T1164 The overheat sensor is not standard equipment on model 40 prior to 1994 but is available as an option. Function Test 1. Disconnect the overheat sensor bullet connector at the electrical box and the ground wire.
Page 86: Water Pressure Sensor
SECTION 4 WATER PRESSURE SENSOR The water pressure sensor is a pressure-sensitive switch installed on the powerhead to monitor the forced water cooling system. The sensor is connected in series with the warning horn. If the sensor detects low water pressure at a predetermined RPM, contacts close and cause the warning horn to emit a continuous tone.
Page 87 POWERHEAD If tester indicates no continuity (switch open), loosen adjustment screw (4) just enough so the switch button does not make contact with the diaphragm pressure button. If still no continuity, replace the sensor assembly. 4. Disconnect the INPUT hose from the sensor ﬁtting. Using a T-ﬁtting (obtain locally), install a water pressure gauge between the sensor and the hose.
Page 88: Thermostat
SECTION 4 THERMOSTAT Removal 1. Remove thermostat cap screws. Gently tap thermostat cap with rubber mallet to loosen and remove cap and gasket. Discard gasket. 2. Remove and inspect thermostat. NOTE Earlier 90, 115, 120 and 140 engines had a ﬂat metal T1166 bypass valve with a spring and retainer.
Page 89: Recoil Starter
RECOIL STARTER WARNING T1176 F-type of 40/50 engines have neutral start mechanism (start-in-gear protection) attached to the recoil starter. This feature disables the engine from starting wheel in gear (forward or reverse).
Page 90 SECTION 4 T1179 T1180 T1181 2. Place recoil starter top side down on bench. Pull out approximately 24 in [60 cm] of starter rope and hold the reel tightly to prevent it from rewinding. 3. Hold reel tightly at all times so it does not suddenly rewind while completing the following steps: •...
Page 91: Powerhead
POWERHEAD 8. Carefully turn over recoil starter on bench so spring is facing down. Firmly hold starter housing against bench and lightly tap housing with rubber mallet to dislodge the starter spring. Remove the spring. 9. Turn recoil starter over and remove sliding plate (7) and bushing (8).
Page 92 SECTION 4 T1190 T1191 T1189 3. Wind starter rewind spring (4) into starter housing. 4. Thread starter rope through rope hole in reel (6). Knot the rope and pull it tight in the reel. Route the remaining rope through the rope guide and attach the handle. 5.
Page 93 POWERHEAD 8. Place sliding plate (3) on friction plate (11) and install friction spring (12). Position the assembly on the reel so key hole in friction plate is properly aligned. Install mounting bolt. 9. With the rope hooked in the reel notch and aligned with the rope guide, rotate the reel counterclockwise 5 times to tighten the rewind spring.
Page 94 Number Number 3C7-72211-1 40 / 50 / 60 / 70 / 80 / 90 / 115 / 120 / 140 Flywheel Puller 3B7-72786-0 40 / 50 / 60 / 70 / 80 / 90 / 115 / 120 / 140...
Page 95 POWERHEAD T1193 T1194 T1195 Removal WARNING Ignition system must be disabled to prevent accidental engine startup during removal of the ﬂywheel. 1. Remove recoil starter and starter pulley or remove the ﬂywheel cover as required. 2. Determine the direction of rotation for removing ﬂywheel nut by running your thumbnail along the threads of the crankshaft.
Page 96 5.Install recoil starter or ﬂywheel cover as required. Flywheel Nut Torque ft-lb Model N·m T1199 kg-m 65.1 - 79.5 40 / 50 88.2 - 107.8 9.0 - 11.0 101.2 - 115.7 60 / 70 / 80 / 90 137.2 - 156.8 14.0 - 16.0 181.0 - 195.0 115 / 120 / 140 245.0 - 264.6...
Page 97 POWERHEAD POWERHEAD Typical 3-Cylinder T1200 4-23 3-/ 4-Cylinder...
Page 98 SECTION 4 Typical 4-Cylinder T1201 4-24 3-/ 4-Cylinder...
Page 99 POWERHEAD Removal WARNING Ignition system must be disabled to prevent accidental engine startup during removal of the powerhead. NOTE If service work requires ﬂywheel to be removed, remove ﬂywheel before lifting powerhead from the rest of the engine. See Flywheel, this section. T1202 NOTE Mark the mounting location of all clamps so they can...
Page 100 Powerhead Applicability T1206 Stand Part Model Number — 40 / 50 353-72247-1 60 / 70 / 80 / 90 / 115 / 120 / 140 Disassembly Preliminary 1. Remove all carburetion, ignition, and electrical components from the powerhead. T1207 2.
Page 101 Remove the bolts in order from highest embossed number to lowest. Crankcase and Crankshaft NOTE Crankshaft on models 40 and 50 is equipped with bearing thrust plates (5) and crankshaft thrust plates (6). Mark these parts so they can be returned to their original positions during assembly.
Page 102 SECTION 4 T1215 T1216 T1217 9. Remove the crankcase bolts and separate the crankcase from the cylinder block. NOTE Remove the smallest size bolts ﬁrst. Start with the bolts farthest from the center of the crankcase and work inward. 10. Lift the crankshaft and pistons from the cylinder block and place on bench for disassembly.
Page 103 Applicability Part Number Model 345-72215-0 40 / 50 353-72215-0 60 / 70 / 80 / 90 / 115 / 120 / 140 15. Remove the piston, bearing washers (16) (models 80, 90, 115, 120 and 140), and bearing (17) from the connecting rod.
Page 104 SECTION 4 4. Wipe off all traces of oil and thoroughly wash the cylinder block and crankcase with warm, soapy water. Air dry the cylinder block and crankcase. Dry all holes and passages with low pressure compressed air. 5. Coat the cylinder walls with genuine engine oil or certiﬁed TC-W3 oil to protect them from corrosion.
Page 105 • Dimension 3 : Distance between the outside edges of the ﬁrst and last crankshaft webs. If any dimension is not within speciﬁcation, replace the crankshaft assembly. Figure Description Unit 40 / 50 60 / 70 80 / 90 115 / 120 / 140 - 0.008 2.087 2.362 2.677...
Page 106 T1832 Standard Bore Diameter Piston Clearance Model in [mm] in [mm] 2.677 0.0012 - 0.0028 40 / 50 [68.0] [0.03 - 0.07] 2.913 0.0016 - 0.0031 60 / 70 [74.0] [0.04 - 0.08] 3.386 0.0031 - 0.0051 80 / 90 [86.0]...
Page 107 Ring End Gap in [mm] Model STD Value Repair Limit Top Ring: 0.009 - 0.015 0.032 [0.22 - 0.37] [0.8] 40 / 50 2nd Ring 0.013 - 0.019 0.032 [0.33 - 0.48] [0.8] T1159 0.009 - 0.015 0.032 60 / 70 [0.22 - 0.37]...
Page 108 • Install new oil seal (4) in upper main bearing and new o-ring (5). 2. Coat the rotating surfaces of the crankshaft and connecting rod bearings, bearing washers, and bearing thrust plates (models 40 and 50) with genuine engine oil or TC-W3 oil.
Page 109 POWERHEAD 4. If oil pump drive gear (8) and lower main bearing (9) were removed, coat lower end of crankshaft with genuine engine oil or TC-W3 oil and install the lower crankshaft components in order, press ﬁtting the gear and bearing onto the crankshaft. Make sure snap ring (10) is properly seated.
Page 110 ﬂange of the cylinder block for proper alignment with the crankcase. • Oil pump drive gear on crankshaft is meshed with the oil pump driven gear. • Bearing washers or thrust plates (models 40 and 50) are seated properly in the cylinder block. 4-36 3-/ 4-Cylinder...
Page 111 NOTE Apply light coat of dielectric lubricant to sensor before installation. NOTE On models 40 and 50, torque the cylinder head M6 bolts ﬁrst, starting with those nearest the center of the cylinder head and working outward. Torque the T1247 M8 bolts in order from lowest embossed number to highest.
Page 112 SECTION 4 Exhaust Cover 15. Lightly coat both sides of new inner and outer exhaust cover gaskets with gasket sealant. Install gaskets and mount exhaust covers to cylinder block. Torque exhaust cover bolts to speciﬁcation from lowest embossed number to highest. Final Assembly 16.
Page 113 POWERHEAD T1253 T1252 T1254 18. Install all carburetion, ignition, and electrical components on the powerhead using the following guidelines. Assemble as much as possible before mounting powerhead to engine midsection. • Follow all relevant procedures and wiring diagrams in other sections of this manual.
Page 114 11. Purge all air from the oil automixing system. See Automixing T1256 System in Section 3. 12. Perform all tune-up operations. See Tune-Up Procedure in Section 2. 13. Test and inspect all safety features of the engine. 4-40 3-/ 4-Cylinder...
Page 115 SECTION 5 MIDSECTION TABLE OF CONTENTS General Precautions ......................5-2 Service Speciﬁcations ......................5-3 Tiller Steering Handle ......................5-5 Lower Engine Cover ......................5-9 Driveshaft Housing ......................5-10 Stern and Swivel Brackets ....................5-16 3-/ 4-Cylinder...
Page 116: General Precautions
SECTION 5 GENERAL PRECAUTIONS Before performing any service work on the midsection, read and understand the Service Safety section at the beginning of this manual. Replace locking fasteners when their locking feature becomes weak. Use only factory replacement parts. When using compressed air to clean ordry parts, make sure air supply is regulated not to exceed 25 psi [172 kPa / 1.76 kg/cm Always inspect and test the start-in-gear prevention system before returning engine to customer.
Page 117: Service Specifications
Special Torque Values Torque in-lb (ft-lb) N·m kg-m Description Thread locker Model 40 / 50 60 / 70 80 / 90 115 / 120 / 140 (14 - 15) (14 - 15) (17 - 19) (25 - 30) Engine Mounting Bolt...
Page 118 SECTION 5 Consumable Supplies Required Threadlocker, Loctite ® Threadlocker, Loctite ® Gasket Dressing, Permate Hylomai Aerosol High-Temp Gasket Dressing ® ® Silicone Sealant, Permatex Hi-Temp RTV Silicone Gasket ® Super Bond Adhesive, Permatex Super Glue Gel ® Cleaning Pads, Scotch-Brite Abrasive Pads ®...
Page 119: Tiller Steering Handle
MIDSECTION TILLER STEERING HANDLE NOTE Reference the following illustrations for all procedures. Models 40 and 50 T1257 Models 60 / 70 / 80 / 90 T1258 3-/ 4-Cylinder...
Page 120 SECTION 5 Removal 1. Disconnect throttle cables from advancer arm and remove cables from lower engine cover. 2. Remove the tiller steering assembly from steering shaft (1) and place on bench for disassembly. Disassembly 1. Remove grip (2). 2. Disconnect throttle cables (3) from throttle shaft (4). Remove the throttle shaft.
Page 121 MIDSECTION Assembly NOTE Apply genuine grease or equivalent friction surface marine grease to bushings (11), spacer (12), throttle shaft roller (13), and the grip portion of steering handle (7) before assembly. DO NOT lubricate friction piece (5). 1. Apply spray lubricant to the throttle cables. Work the cables back and forth to ensure full coverage under the protective covering.
Page 122 SECTION 5 T1259 T1260 2. Route throttle cables through lower engine cover, clamp in place, and connect cables to advancer arm. 3-/ 4-Cylinder...
Page 123: Lower Engine Cover
MIDSECTION T1262 T1261 T1263 3. Adjust the throttle cable length at adjusting nut (14) so grip (2) contacts stop screw (15) when the grip is in the fully open position (models 60, 70, 80 and 90). Return grip to fully closed position and conﬁrm sufﬁcient freeplay between grip and stop screw.
Page 124: Driveshaft Housing
SECTION 5 T1336 T1266 Installation Installation is done in the reverse order of Removal. Use Loctite 242 on shift lever shaft holder bolts (1) if removed. DRIVESHAFT HOUSING Removal 1. Remove powerhead as described in Section 4. 2. Remove tiller steering handle if equipped, this section. T1267 3.
Page 125 MIDSECTION T1270 T1271 T1272 Disassembly 1. Remove and disassemble the upper and lower rubber mounts. 2. Remove upper rubber mount damper (1) if equipped, from engine base. 3. Remove bolts securing engine base (2) to driveshaft housing (3). Use rubber mallet to break seal between base and housing.
Page 126 SECTION 5 T1276 Cleaning and Inspection All worn, damaged, or missing parts must be replaced. 1. Before cleaning, examine the following rubber parts as applicable and remove if damaged, dry, or brittle: • Exhaust housing grommet (1). • Idle port grommet (2). •...
Page 127 MIDSECTION 2. Thoroughly clean all parts including fasteners with solvent and dry with low pressure compressed air. Verify all carbon deposits, gasket adhesives, and threadlocker residue have been removed. 3. Inspect water pipe (7) for kinks or obstruction, reverse gas passage (8) for signs of deterioration. Replace as needed.
Page 128 SECTION 5 T1281 T1282 T1283 T1284 T1285 3. Mount new exhaust housing gasket (2) and exhaust pipe gasket (3) on engine base. Apply high temperature gasket dressing to both sides of gaskets. 4. Install exhaust pipe and exhaust housing. 5. Apply genuine grease or equivalent friction surface marine grease to water pipe seal (4).
Page 129 MIDSECTION T1288 T1289 T1290 T1291 T1292 T1266 Installation 1. Assemble the upper rubber mount components. 2. Apply Loctite 242 to bolt threads and install upper rubber mounts on steering shaft. Torque to speciﬁcation. 3. Install the upper rubber mount damper if equipped, in engine base.
Page 130: Stern And Swivel Brackets
Section 8. Models 40 and 50 (for Manual Tilt) Models 40 and 50 (for Gas Assist Tilt and PT/T) Models 60 and 70 (for Manual Tilt) Models 60 / 70 / 80 / 90 (for Gas Assist Tilt and Old PT/T)
Page 131 MIDSECTION T1296 T1297 5-17 3-/ 4-Cylinder...
Page 132 SECTION 5 T1298 Removal 1. Remove powerhead as described in Section 4. 2. Remove tiller steering handle if equipped, this section. 3. Remove lower engine cover, this section. 4. Remove gearcase as described in Section 6. 5. Remove driveshaft housing, this section. 5-18 3-/ 4-Cylinder...
Page 133 MIDSECTION T1299 Disassembly NOTE Disconnect all bracket ground wires before disassembly. 1. Remove snap ring (1) from steering shaft. Discard the snap ring. T1300 5-19 3-/ 4-Cylinder...
Page 134 Refer to Section 8 for servicing power trim/tilt. Models 40 and 50 - Manual Tilt Models 40 and 50 - Gas Assist Tilt Models 60 and 70 - Manual Tilt T1302 Models 60 / 70 / 80 / 90 - Gas Assist Tilt...
Page 135 MIDSECTION T1307 T1306 5-21 3-/ 4-Cylinder...
Page 136 SECTION 5 T1308 Assembly NOTE Before proceeding, make sure all components have been thoroughly cleaned with solvent and allowed to dry. Inspect all parts, especially bushings, thrust washers, and upper and lower engine mounts for damage and deterioration. Replace all seals and o-rings. NOTE Improper arrangement of bushings and thrust washers may not prevent full assembly of the bracket...
Page 137 MIDSECTION T1309 T1310 T1311 1. Mount the stern brackets on engine stand. 2. Fully assemble and install the manual tilt or gas assist tilt components as illustrated in the Disassembly procedure or install the power trim/tilt unit at this time as described in Section 8. 3.
Page 138 SECTION 6 GEARCASE TABLE OF CONTENTS General Precautions ......................6-2 Service Speciﬁcations ......................6-3 Water Pump ........................6-4 Gearcase ..........................6-9 Backlash - Shim Adjustment Table ................... 6-29 Gearcase Repair Procedures .................... 6-30 3-/ 4-Cylinder...
Page 139: General Precautions
SECTION 6 GENERAL PRECAUTIONS Before performing any service work on the gearcase, read and understand the Service Safety section at the beginning of this manual. Full servicing of the gearcase requires manufacturer special tools. Follow all special tool requirements as speciﬁed. Substituting special tools with those not provided by the manufacturer may result in severe personal injury, equipment or engine damage, or faulty service work.
Page 140: Service Specifications
Special Torque Values Torque in-lb (ft-lb) N·m kg-m Description Thread locker Model 40 / 50 60 / 70 80 / 90 115 / 120 / 140 (22 - 29) (22 - 29) (22 - 29) (22 - 29) Propeller Nut...
Page 141: Water Pump
SECTION 6 General Equipment Required Torque Wrench, 0 - 150 in-lb [0 - 17 N·m/0 - 1.7 kg-m] Torque Wrench, 0 -750 ft-lb [0 - 1000 N·m/0 - 100 kg-m] Dial Gauge, minimum scale 0.0001 in [0.01 mm] Gearcase Pressure Tester, Stevens S-34 or equivalent ®...
Page 142: Gearcase
GEARCASE T1341 T1342 T1343 Disassembly and Assembly 1. Disassemble the water pump components as illustrated and verify the kit parts match the originals before discarding old parts. NOTE Lower pump case dowel pins are difﬁcult to remove and should only be pulled out if replacement is necessary.
Page 143 SECTION 6 T1347 T1348 T1349 5. Apply anaerobic gasket maker to seating surface of water pipe lower seal (2). 6. Install seal in upper pump case so locking tabs (3) align with holes (4). 7. Slide pump case liner (5) partially into upper pump case housing so locking tab (6) is aligned with notch in housing.
Page 144 GEARCASE T1354 T1353 T1355 11. Apply gasket sealant to guide plate side of upper pump case gasket (11). Mount gasket on guide plate. NOTE Models 115, 120, and 140 are equipped with special shaped pump case o-ring seal (12) instead of gasket. Apply a thin bead of anaerobic gasket maker in the upper pump case seal groove and install o-ring seal in groove.
Page 145 SECTION 6 5. Lubricate the impeller ﬁns with soapy water and slide upper pump case down driveshaft. Hold pump case securely and push downward while rotating driveshaft clockwise to seat the impeller. CAUTION Do not rotate driveshaft counterclockwise. Doing so will bend impeller ﬁns in wrong direction and may weaken or damage the impeller.
Page 146 GEARCASE GEARCASE Typical Gearcase T1360 3-/ 4-Cylinder...
Page 147 SECTION 6 T1361 T1362 T1363 Removal WARNING Ignition system must be disabled to prevent accidental engine start-up during removal of the gearcase. 1. Place engine in FORWARD gear so shift rod joint (1) is accessible. If necessary, use shift rod joint puller (2) (Part No.
Page 148 GEARCASE T1367 T1368 T1369 Disassembly CAUTION Gearcase must be secured in a suitable holding ﬁxture during disassembly. 1. Drain all gearcase oil into a container and inspect the oil for metal chips. NOTE Small metal fragments may indicate normal wear of gears, bearings, and shafts.
Page 149 8. Lift the driveshaft from the gearcase and set it aside. 9. Using a piece of wire or other hooking device, remove driveshaft spring guide (8). NOTE Models 40 and 50 are not equipped with removable driveshaft spring guide. T1376 10. Reach inside gearcase and remove roller bearing (9) and bevel gear A (10).
Page 150 GEARCASE T1378 T1379 14. Insert screwdriver under one end of clutch pin snap spring (17). Remove spring from groove by unwrapping it from clutch. Discard the spring. CAUTION DO NOT reuse clutch pin snap spring (17), it must be replaced. Reusing clutch pin snap spring may cause severe damage to gears and other components.
Page 151 SECTION 6 Propeller and Shaft • Verify the propeller is true and free of nicks, chips, and other damage that will affect performance. Inspect the thrust washer and mounting hardware for damage. • Check the propeller shaft threads and splines for wear and damage.
Page 152 5. Install the driveshaft through the drive shaft housing. Make sure driveshaft bearing outer race is fully seated against the bearing. NOTE Models 40 and 50 are not equipped with bearing outer race. T1384 6. Apply Loctite 242 to bevel gear B nut (5). Slide bevel gear B (6) onto driveshaft (7) as shown from propeller shaft side of gearcase.
Page 153 SECTION 6 T1388 T1389 T1390 10. Install bevel gear A (10) so tapered roller bearing (11) is seated in outer race and the gear teeth are properly meshed with bevel gear B. 11. Replace cam rod bushing internal o-rings (12) and external o-ring (13).
Page 154 GEARCASE T1394 T1395 T1396 16. Insert detent ball (20). Install clutch push rod (21) so tapered end faces bevel gear A. 17. Compress the clutch spring by applying pressure to push rod (21). Align the holes of the clutch and spring holder and insert clutch pin (22).
Page 155 23. Move the cam rod to each position and rotate the driveshaft to test gearcase function in all gears. Check the propeller shaft for looseness in the forward and reverse directions. If looseness exceeds 0.016 in [0.40 mm], replace bevel gear C washer (28) with one of correct thickness. NOTE Refer to current Parts Catalog for washer availability.
Page 156 GEARCASE • Pump vacuum tester until gauge indicates 3 - 5 in [76 - 127 mm] of mercury. If loss of vacuum occurs, apply oil around suspected seal. If leak stops or oil is drawn in, the seal is defective and must be replaced.
Page 157 2. Insert speciﬁed shimming gauge (3) into gearcase. Tool Part Number Model Shimming Gauge 3C8-72250-0 40 / 50 / 60B / 70B 60C / 70C / 80 / 90 / Shimming Gauge 3B7-72250-0 115 / 120 / 140 NOTE Correct positioning of the shimming gauge in the gearcase is critical.
Page 158 GEARCASE 3. Eliminate all looseness between driveshaft and gearcase using one of the following methods: • Lift driveshaft upward and tap down on gearcase with rubber mallet. • Slide a compression spring (obtain locally) over driveshaft and seat onto lower pump case. Install backlash measuring tool clamp assembly (Part No.
Page 159 40 / 50 / 60B / 60C / 70B / 70C / 80 / 3B7-72720-0 Measuring Tool 90 / 115 / 120 / 140 40 / 50 / 60B / 60C / 70B / 70C / 80 / 90/ 115 / Dial Gauge Plate 3B7-72729-0 120 / 140...
Page 160 6. Assemble the following backlash tool components. Note the correct quantity and orientation of conedisk spring washers: Models 40 and 50 - Assemble three conedisk spring washers (10), o-ring (11), and collar (12). Models 60B and 70B - Assemble four conedisk spring washers (13), set piece A (14), and o-ring (15).
Page 161 Adjustment Table, this section. See Gearcase Repair Procedures in this section for removal and installation of the bevel gear A roller bearing. Acceptable Dial Gauge Reading Model 40 / 50 0.0122 - 0.0244 0.31 - 0.62 60B / 70B 0.0094 - 0.0319 0.29 - 0.58...
Page 162 GEARCASE Backlash Adjustment - Bevel Gears B and C NOTE Obtain backlash measuring tool kit. Reference the following speciﬁcation table for Backlash Adjustment special tool requirements: Tool Part Number Model Backlash Measuring Tool Kit 3A3-72255-0 60B / 70B 930191-0800 60B / 70B Washer 940191-0800 60B / 70B...
Page 163 • Install set piece B (37) and attach retainer (36) to shaft groove shown. • Slide plate (39) onto shaft and attach washer (40) and nut (41). 16. Insert the assembly into the gearcase and rotate the driveshaft to ensure bevel gears B and C are properly meshed.
Page 164: Backlash - Shim Adjustment Table
C (44) and propeller shaft housing bearing (45) in accordance with the Backlash - Shim Adjustment Table, this section. Acceptable Dial Gauge Reading Model 40 / 50 0.0122 - 0.0244 0.31 - 0.62 60B / 70B 0.0094 - 0.0319 0.29 - 0.58...
Page 165 SECTION 6 T1417 T1420 T1421 Installation WARNING Ignition system must be disabled to prevent accidental engine start-up during installation of the gearcase. 1. Lightly coat the driveshaft splines with genuine engine oil or TC-W3 oil and apply silicone spray lubricant to water pipe lower seal (1).
Page 166 GEARCASE 6-29 3-/ 4-Cylinder...
Page 167: Gearcase Repair Procedures
SECTION 6 GEARCASE REPAIR PROCEDURES CAUTION DO NOT attempt gearcase repairs without proper manufacturer special tools. Use this section when service work requires disassembly or replacement of the following gearcase components: • Driveshaft roller bearings. • Gearcase needle bearing. • Propeller shaft housing needle bearing. •...
Page 168 60B / 70B Plate, Needle Bearing Puller 3B7-72701-0 60C / 70C / 80 / 90 Washer, 13-21-2.5 346-72707-0 40 / 50 / 60B / 60C / 70B / 70C / 80 / 90 Nut, 12P1.25 346-72706-0 40 / 50 Nut, 12P1.5 3B7-72735-0...
Page 169 Make sure retainer is fully seated in groove with raised surface facing bearing: Models 40 and 50 - groove (3). Models 60B / 60C / 70B / 70C / 80 / 90 - groove (4). 3. Slide guide (5) onto shaft from water pump side of gearcase.
Page 170 3. Attach retainer (3) from propeller shaft side of gearcase to speciﬁed shaft groove. Make sure retainer is fully seated in groove with raised surface facing bearing: Models 40 and 50 - groove (4). Models 60B / 60C / 70B / 70C / 80 /90 - groove (5). T1428 4.
Page 171 SECTION 6 Gearcase Needle Bearing - Models 115 / 120 / 140 NOTE Reference the following speciﬁcation table for gearcase needle bearing Removal and Installation special tool requirements : Tool Part Number Model Needle Bearng Press Kit 3C7-72900-1 115 / 120 / 140 Pressing Bolt, Needle 3C7-72766-0 115 / 120 / 140...
Page 172 GEARCASE T1433 T1434 T1435 2. Install o-ring (9) on press B (8). Place washer (3) on bolt (10) and insert bolt through hole closest to shoulder (12). 3. Attach press B (8) to pressing rod (6) by tightening bolt (10) into threaded portion of rod. 4.
Page 173 The needle bearing is fully seated in housing when stopper (14) on pressing rod contacts bearing outer pressing guide (7). T1438 Propeller Shaft Housing Needle Bearing - Models 40 and 50 19 20 NOTE Obtain needle roller bearing puller kit. Reference the following speciﬁcation table for propeller shaft...
Page 174 GEARCASE Removal 1. Remove oil seal from propeller shaft housing. 2. Remove roller bearing from propeller shaft housing by heating the housing with a heat gun. 3. Place shaft (1) through needle bearing. 4. Attach retainer A (2) to shaft groove (G) with raised surface of retainer facing bearing.
Page 175 SECTION 6 Propeller Shaft Housing Needle Bearing - Models 60B and 70B 21 22 NOTE Obtain needle roller bearing puller kit. Reference the following speciﬁcation table for propeller shaft housing needle bearing Removal and Installation special tool requirements : Tool Part Number Model Shaft, Needle Bearing Puller...
Page 176 GEARCASE Installation 1. Attach retainer (2) to shaft groove (G) with raised surface of retainer facing bearing. 2. Coat new needle bearing with gear oil. Slide bearing onto shaft so bearing stamped surface faces retainer (2). CAUTION Stamped surface of needle bearing must face retainer or bearing could be damaged during installation.
Page 177 4. Slide stopper (9) and plate (5) onto shaft and secure with washer (6) and nut (7). 5. Tighten nut (7) until stopper (9) contacts plate (5). 6. Remove tools and verify needle bearing is fully seated in housing. T1445 6-40 3-/ 4-Cylinder...
Page 178 (3B7-72224-0) 90 / 115 / 120 / 140 Bearing Outer Press Kit 3B7-72739-0 40 / 50 / 60 / 70 / 80 / 90 / 115 / 120 / 140 Guide, Bearing Outer Pressing 346-72733-0 40 / 50 60B / 60C / 70B / 70C / 80 /...
Page 179 Tool Part Number Model Set Tool, Bevel Gear A Bearing 3C8-72719-0 40 / 50 / 60B / 70B Set Tool, Bevel Gear A Bearing 3B7-72224-0 60C / 70C / 80 / 90 / 115 / 120 / 140 6-42 3-/ 4-Cylinder...
Page 180 SECTION 7 ELECTRICAL SYSTEM TABLE OF CONTENTS General Precautions ......................7-2 Service Speciﬁcations ......................7-3 Electrical Servicing Standards .................... 7-7 Troubleshooting ......................... 7-11 Description of Operation ....................7-13 Battery Care and Maintenance ..................7-17 Ignition System ......................... 7-22 RPM Limitation Test ......................7-47 Ignition System Repair Procedures ...................
Page 181: General Precautions
SECTION 7 GENERAL PRECAUTIONS Before performing any service work on the electrical system, read and understand the Service Safety section at the beginning of this manual. Use the manufacturer and special tools as indicated during servicing of the electrical system. Avoid electrical shock: •...
Page 182: Service Specifications
SERVICE SPECIFICATIONS Special Torque Values Torque in-lb (ft-lb) N·m kg-m Description Threadlocker Model 40 and 50 60 and 70 80 and 90 115 / 120 / 140 4 - 9 4 - 9 26 - 43 Electrical Box –– 0.5 - 1.0 0.5 - 1.0...
Page 183 SECTION 7 General Equipment Required Analog Multimeter, Electronic Specialties Model M-530 or equivalent ® Digital Multimeter, Electronic Specialties Model KD 3200 or equivalent ® Spark Gap Tester, Stevens S-13C, S-48, or equivalent ® Digital Pulse Tachometer, 10 - 6000 RPM, Electronic Specialties Model 321 or equivalent ®...
Page 184 40, 50, 60, 70, 80, 90 : 3 A 115, 120, 140 : 12 A At 5500 RPM 40, 50, 60, 70, 80, 90 : 9 - 11 A 115, 120, 140 : 24.5 - 27.5 A Number of Tachometer-to-Alternator Coil Impulses...
Page 185 3.6 - 4.8 kΩ 115, 120, 140: 2.7 - 3.7 kΩ CD Unit Output (Cranking) 40, 50, 60, 70, 80, 90, 115, 120, 140: 198 - 220 DVA Exciter Coil Output (Cranking) 40, 50, 60C, 70C, 80, 90, 115, 120, 140:...
Page 186: Electrical Servicing Standards
ELECTRICAL SYSTEM ELECTRICAL SERVICING STANDARDS Electrical Connectors When you replace electrical components or perform diagnostic tests, you must disconnect electrical connectors in many instances. The following discussion will help you recognize connectors in electrical drawings and show you how to disconnect and connect them.
Page 187 SECTION 7 T1477 T1479 T1465 Special cases are the connectors used to test components located on the coil plate assembly. For testing purposes, the ﬁrst connector is located at the far end of the cable (away from the coil plate assembly) and usually found inside of the electrical box. Bullet Connectors NOTE Bullet connectors (1) are shown like this in electrical...
Page 188 ELECTRICAL SYSTEM Connecting Bullet Connectors Grasp the ﬁxed end (1) of the connector and carefully push the removable end (2) into it without twisting or bending the connector. Rectangular and Triangular Multi-Conductor Connectors NOTE Multiple-conductor connectors may be shown like this (1) or this (2) in electrical drawings.
Page 189 SECTION 7 Round Multi-Conductor Cable Connectors NOTE Multiple-conductor connectors may be shown like this (1) or this (2) in electrical drawings. These types of connectors are held closed with a lock ring. SQUEEZE both ridged locks (1) and at the same time carefully pull the connector apart without twisting or bending it.
Page 190: Troubleshooting
ELECTRICAL SYSTEM Electrical Drawings All electrical drawings shown in this manual have been simpliﬁed to clarify the circuit that is being tested. They represent typical conﬁgurations and may not look exactly like the electrical wiring for your engine. Complete electrical schematics are provided in the Outboard Motors Service Data publication.
Page 191 SECTION 7 Ignition System Will not Poor accel- SYMPTOM Starts but Engine will Cranks but start Low or high eration, low stops not shut will not start and pops or speed miss top end immediately CHECKS backﬁres Faulty stop circuit - see Test 2 - ¡...
Page 192: Description Of Operation
ELECTRICAL SYSTEM Charging System SYMPTOM Battery does not maintain charge or overcharges CHECKS ¡ Blown fuse ¡ Shorted or faulty alternator coil ¡ Faulty recitier/regulator T1453 ¡ Faulty charge circuit wiring DESCRIPTION OF OPERATION Ignition System The ignition system consists of the magneto (1), Capacitive Discharge (CD) unit (2), ignition coils (3), main key switch (4) and emergency stop switch (5).
Page 193 SECTION 7 Magneto For models 40 / 50 / 60 / 70 / 80 / 90 : The magneto consists of a cover (1), ﬂywheel (2), and coil plate assembly (3), guide plate (4), shim (5), and set ring (6).
Page 194 Through mutual induction, the ignition coil transforms the output from the CD Unit to as much as 40,000 volts to ﬁre the spark plug. • 3 cylinder models - Three ignition coils are provided, one per cylinder.
Page 195 SECTION 7 T1460 T1458 T1459 T1461 • 4 cylinder models - Four ignition coils are provided, one per cylinder. Main Key Switch and Emergency Stop Switch The main key switch and emergency stop switch are connected to the CD Unit through an engine wiring harness. When the main key switch is in the OFF position, or the lanyard is removed from the emergency start switch, an input to the CD Unit is grounded.
Page 196: Battery Care And Maintenance
AC voltage into direct current (DC) voltage. Regulator output is about 15 volts DC with a current rating of 9 - 11 A [models 40 / 50 / 60 / 70 / 80 / 90] or 24.5 - 27.5 A [models 115 / 120 / 140] at 5,500 RPM.
Page 197 SECTION 7 Cleaning Follow this procedure to clean the battery: 1. Disconnect cables and remove battery. 2. Prepare a solution of one part baking soda to four parts of water. Clean battery, terminals, cable connectors, battery mounting, and battery box. NOTE Keep cleaning solution out of battery cells.
Page 198 ELECTRICAL SYSTEM 2. Insert the hydrometer tube into the battery cell and use the bulb to withdraw ﬂuid until the ﬂoat is free. 3. View the hydrometer with your eye at the same level as the ﬂuid. 4. Note the temperature of the battery ﬂuid or ambient air. 5.
Page 199 SECTION 7 2. Test the speciﬁc gravity of the battery. See the Speciﬁc Gravity Test previously discussed in this section. 3. Find the Battery Charge Percent using the Speciﬁc Gravity/ Battery Charge Relationship Chart. 4. Calculate the amount of discharge in ampere hours using this formula: Amount of Discharge (AH) = Rated Ampere Hours x Battery Charge Percent x 0.01...
Page 200 ELECTRICAL SYSTEM 10. As soon as the charging process has completed, measure the battery voltage and speciﬁc gravity. The voltage should be 15 to 16 volts and the speciﬁc gravity should be 1.260 (corrected for temperature). If either of these conditions are not met, replace the battery.
Page 201: Ignition System
SECTION 7 IGNITION SYSTEM CAUTION All cranking output tests must be performed with spark plugs installed and torqued in the cylinder head. If necessary to remove the spark plugs, be sure to keep the spark gap tester away from open spark plug holes. CAUTION Avoid electrical shock: •...
Page 202 ELECTRICAL SYSTEM Ignition System Performance Testing Ignition Performance Testing is divided into two sections. The ﬁrst section consists of a ﬂow chart. This chart presents the correct sequence of performing ignition system performance tests to effectively and efﬁciently check for problems in starting and running the engine.
Page 203 SECTION 7 Ignition System Performance Testing Flow Chart T1557 7-24 3-/ 4-Cylinder...
Page 204 ELECTRICAL SYSTEM Test 1 - Spark Test NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure. Check for continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coils before conducting the following procedure.
Page 205 SECTION 7 Test 2 - Stop Circuit Test Stop circuit malfunction can cause the engine not to start or prevent it from stopping. Several component failures can cause the stop circuit to malfunction. Use this ﬂow chart to isolate and repair all component failures.
Page 206 ELECTRICAL SYSTEM Test 2a - Stop Circuit Main Key Switch Test This test is used to determine whether the main key switch and connecting wiring are functioning normally. NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure.
Page 207 SECTION 7 6. Disconnect CD Unit (8) terminals (5) and (6). 7. Connect one meter lead to terminal (6) and the other to terminal (2) and check continuity. If the meter does not show continuity, replace the cable. 8. Connect one meter lead to terminal (6) and the other to a clean engine ground.
Page 208 ELECTRICAL SYSTEM 1. Remove negative lead from battery. 2. Disconnect emergency stop switch terminals (1), (2), (3) and (4). 3. Set analog multimeter to check continuity. Connect one meter lead to terminal (1) and the other to terminal (3). 4. Attach lanyard (5) to emergency stop switch (6), meter must not show continuity.
Page 209 The pulser and alternator coils have been removed from both illustrations for clarity. - Figure 1 - models 40 / 50 / 60C / 70C 80 / 90 / 115 / 120 / 140. - Figure 2 - models 60B / 70B.
Page 210 DVA, from the exciter coil (1), located on the coil plate assembly (2) [models 40 / 50 / 60 / 70 / 80 / 90] or the alternator assembly (2) [models 115 / 120 / 140] to the CD Unit (3) while you are cranking the engine.
Page 211 3. The meter should indicate the following resistance: Engine Models Results 530 - 720 Ω ± 25% 40 and 50 Test 1: 216 - 324Ω ± 25% 60B and 70B Test 2: 16 - 24Ω ± 25% 220 - 330 Ω ± 25% 60C and 70C 174 - 236 Ω...
Page 212 ELECTRICAL SYSTEM T1479 5. For models 40 / 50 / 60C / 70C / 80 / 90 / 115 / 120 / 140: Set the analog multimeter to “400” on the “DVA” scale. Connect the RED tester lead to terminal (6) and BLACK tester lead to terminal (4).
Page 213 8. At cranking RPM, the tester should show the following results: Engine Models Test Results 40 / 50 / 60 / 70 / 80 / 130 DVA Minimum 90 / 115 / 120 / 140 Test 1 - 10 - 15 DVA Test 2 - 100 - 200 DVA 9.
Page 214 The exciter and alternator coils have been removed from both illustrations for clarity. - Figure 2 - models 40 / 50 / 60B / 70B / 60C / 70C / 80 / 90. - Figure 3 - models 115 / 120 / 140.
Page 215 120 / 140], to the CD Unit (3) while you are cranking the engine. 1. Disconnect the following terminals: Engine Models Disconnect Terminals 40 / 50 / 60B / 70B / 4, 5, 6, 7, 8, 9, 10, and 11 60C / 70C / 80 / 90 4,5, 6, 7, 8, 9, 10,...
Page 216 Engine Models Results 160 - 220 Ω ± 25% 40 / 50 / 60 / 70 / 80 / 90 187 - 253 Ω ± 25% 115 / 120 / 140 4. If the resistance is not within the indicated range, replace the pulser coil set.
Page 217 SECTION 7 T1481 5. Set the analog multimeter to “20” on the “DVA” scale. 6. Insert the banana plug of the RED tester lead into the meter connection labeled “DVA” and the banana plug of the BLACK tester lead into the meter connection labeled “-COM”. •...
Page 218 (one terminal at a time) to check the output voltage (DVA) of each pulser coil at cranking speed: Engine Models Black Lead Red Lead • Terminal 6 40 / 50 / 60B / 70B / 60C / 70C • Terminal 4 • Terminal 8 / 80 / 90 • Terminal 10 •...
Page 219 Reference the following electrical drawings for the CD Unit Output Test - Cranking RPM: - Figure 4 - models 40 / 50 / 60B / 70B / 60C / 70C / 80 / 90. - Figure 5 - models 115 / 120 / 140.
Page 220 ELECTRICAL SYSTEM The CD Unit Output Test - Cranking RPM is used to 22 23 determine the output voltage, in DVA, from the CD Unit (1), to each ignition coil (2) while you are cranking the engine. 1. Remove all spark plug caps. 2.
Page 221 SECTION 7 NOTE To prevent possible arcing of high voltage, route tester leads at least 2 in [51 mm] from any metal surface. Ground unused test leads to a clean engine ground. 5. Set the tester to “400” on the “DVA” scale. 6.
Page 222 ELECTRICAL SYSTEM NOTE DO NOT disconnect the CD Unit output 25 26 connector [terminals (4) and (5)]. Damage to the CD Unit may result. Repeat for each CD Unit output connector. 9. Attach lanyard to emergency stop switch. 10. Crank engine. 11.
Page 223 Repeat readings for each ignition coil: Engine Models Results 2.7 - 3.7 K Ω ± 25% 40 and 50, 60 / 70C 2.7 - 3.7 K Ω ± 25% 60B / 70B 3.6 - 4.8 K Ω ± 25% 80 / 90 2.7 - 3.7 K Ω...
Page 224 ELECTRICAL SYSTEM 9. If secondary winding for any ignition coil is not within the acceptable range, replace the ignition coil. See Ignition System Repair Procedures - Ignition Coil. After repairs are made, return to Ignition System Performance Testing Flow Chart. 10.
Page 225 SECTION 7 Output Tests - Engine Running - Flow chart T1559 7-46 3-/ 4-Cylinder...
Page 226: Rpm Limitation Test
ELECTRICAL SYSTEM RPM LIMITATION TEST CAUTION The following tests must be performed with correct test propeller and with the engine in a test tank. Note that some performance problems cannot be duplicated in a test tank, in these cases the tests must be conducted with the engine mounted on a boat with the correct propeller installed and operated in open water.
Page 227 Depending upon the model of the engine, one, two or all three sensors are provided. Description of Operation for models 40 / 50 / 60 / 70 / 80 / 90 Engines In these engines, the water pressure sensor (1) and overheat sensor (2) control the half-maximum RPM limitation input [terminal (9)] to the CD Unit (4).
Page 228 3500 ± 400 RPM Sensor 70 (optional) / 80 / 90 40 / 50 / 60 / Oil Level Sensor 70 / 80 / 90 Description of Operation for 115/1 20/140 Engines In these engines, the water pressure sensor (1) and lower oil level ﬂoat (16) of the oil level sensor (2) control the half-...
Page 229 SECTION 7 At the same time, an abnormal condition from either sensor also activates the warning horn (6). The CD Unit activates the horn by sending an output signal to lead (20). Note that the lower oil level ﬂoat (16) also causes the lower oil level indicator (18) in the LCD multi-purpose meter (4) to ﬂash when it detects a low oil condition.
Page 230 ELECTRICAL SYSTEM The following table summarizes the availability of the sensors and approximate RPM when this feature is activated: Sensor Type RPM Limitation Overheat Sensor Water Pressure Sensor 2800 ± 400 RPM 2800 ± 400 RPM Oil Level Sensor (lower ﬂoat only) Half-Maximum RPM Limitation Feature - Test Perform this test when engine speed is limited to about half maximum RPM or has a miss at about half maximum RPM.
Page 231 5. Disconnect one sensor input at a time: Disconnect Engine Models Sensor Terminals Water Pressure (noton 40 and 50) 40 / 50 / 60 / (60, 70 optional) 70 / 80 / 90 Overheat (40 optional) T1487 7-52 3-/ 4-Cylinder...
Page 232 ELECTRICAL SYSTEM Disconnect Engine Models Sensor Terminals Water Pressure 115 / 120 / 140 Lower Oil Level Float • Disconnect terminals indicated. • Run engine. • If engine performance is acceptable, replace sensor and/or replace or repair wiring. • If engine performance is still not acceptable, disconnect terminals for next sensor.
Page 233 Callout in Name in Engine Models Illustration Parts Book 40 / 50 / 60 / Cable Harness A 70 / 80 / 90 115 / 120 / 140 Cable Harness C 8. Run engine with all terminals connected. If engine performance is acceptable, test is complete (reconnect all wires disconnected during test).
Page 234 ELECTRICAL SYSTEM 9. Replace CD Unit. See Ignition System Repair Procedures - CD Unit. Run engine. Is engine performance acceptable? If it is, test is complete (reconnect all wires disconnected during test). If engine performance is still not acceptable, proceed with next step.
Page 235 SECTION 7 Overspeed Limitation Test Perform this test if engine has a high speed miss. NOTE An engine may over-speed if the propeller is not sized correctly. Refer to the engine owner’s manual to determine the correct propeller. The test assumes that: •...
Page 236 ELECTRICAL SYSTEM NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure. Check for continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coils before conducting the following procedure.
Page 237 SECTION 7 3. Run engine. Is engine performance acceptable? If it is, test is complete (reconnect all wires disconnected during test). If engine performance is still not acceptable, proceed with next step. 4. Replace exciter coil(s). See Ignition System Repair Procedures Exciter Coil.
Page 238: Ignition System Repair Procedures
ELECTRICAL SYSTEM IGNITION SYSTEM REPAIR PROCEDURES WARNING Disable ignition system, by disconnecting exciter coil terminals (4), (5), (6), (7), [(8) and (9) for models 60B and 70B only] to prevent accidental engine startup during removal and replacement of the ﬂywheel. CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation.
Page 239 SECTION 7 T1480 CAUTION The force needed to loosen and tighten the ﬂywheel nut requires ﬂywheel be removed and installed with engine mounted and secured on an engine stand. CAUTION Use proper precautions when performing tests with the engine cover removed. Do not wear loose clothing or jewelry.
Page 240 ELECTRICAL SYSTEM Flywheel Replacing the exciter coil or coil plate assembly requires the removal of the ﬂywheel, see Section 4, Flywheel, for the proper procedure. NOTE Flywheel magnets must be of a particular strength in order to run the ignition system. Weak magnets can cause low ignition voltage which may affect engine performance.
Page 241 SECTION 7 Removal 1. Remove the ﬂywheel. 2. Disconnect following terminals for exciter coil (1) connectors. Note that these terminals interconnect cable from coil plate assembly (2) to cable from CD Unit (3): Engine Models Disconnect Terminals 60B and 70B T1479 T1480 7-62...
Page 242 5. For models 40 / 50 / 60 / 70 / 80 / 90 ONLY: Cut tie wrap. 6. For models 40 / 50 / 80 / 90 ONLY: Remove exciter coil screws (1) and exciter coil from the mounting bracket.
Page 243 SECTION 7 For models 60B / 70B / 60C / 70C ONLY: Remove 10 11 alternator coil screws and move alternator coil (1) out of way. Pull exciter coil leads (2) out of way of way of alternator coil. Remove exciter coil screws (3) and exciter coil from the mounting bracket.
Page 244 On models 115 / 120 / 140 you must replace the pulser coil assembly. Individual pulser coils are not available. On models 40 / 50 / 60B / 70B / 60C / 70C / 80 / 90 you must replace the entire coil plate assembly (see procedure later in this section).
Page 245 SECTION 7 T1501 T1502 3. Remove the screws (1) and clamps (2) and remove pulser coil assembly (3) from the mounting bracket (4). Cleaning and Inspection Clean upper main bearing seal and o-ring (1) guide plate and bushing, ignition timing link, alternator assembly, electrical leads and connectors with isopropyl alcohol as required.
Page 246 Disconnect negative battery cable from battery before removing coil plate assembly. On models 40 / 50 / 60B / 70B / 60C / 70C / 80 / 90 the pulser coils cannot be replaced individually. You must replace the entire coil plate assembly.
Page 247 SECTION 7 T1479 T1480 2. Disconnect the following terminals: Exciter coil (1) terminals. Note that these terminals 18 19 interconnect cable from coil plate assembly (2) to cable from CD Unit (3): 7-68 3-/ 4-Cylinder...
Page 248 Pulser coil (1) terminals. Note that these terminals interconnect cable from coil plate assembly (2) to cable from CD Unit (3): Engine Models Disconnect Terminals 40 / 50 / 60B / 70B / 9 10 60C / 70C / 80 / 90 7-69...
Page 249 (2) to rectiﬁer / regulator (3): Engine Models Disconnect Terminals 40 / 50 / 60B / 70B / 60C / 70C / 80 / 90 3. Remove the screws (1) and remove coil plate assembly T1505 (2) from the mounting bracket.
Page 250 ELECTRICAL SYSTEM Installation Install in reverse order of removal. NOTE Disconnect negative battery cable from battery before installing coil plate assembly. Use threadlocker on screw threads before installing screws. T1506 Apply light coat of low temperature lithium grease to the upper main bearing outer and guide plate. Ignition Coil NOTE Disconnect negative battery cable from battery...
Page 251 CD Unit is serviced. Removal 1. For models 40 / 50 / 60B / 70B / 60C / 70C / 80 / 90: Carefully stretch elastic CD Unit hold down (1) and remove it T1511 from CD Unit retaining groove (2).
Page 252 CD Unit to avoid pinching them. For models 40 / 50 / 60B / 70B / 60C / 70C / 80 / 90 make sure that BLACK/YELLOW connector is tucked behind CD Unit before you install it (1).
Page 253: Starting System
SECTION 7 STARTING SYSTEM WARNING Disable ignition system, by disconnecting exciter coil terminals (4), (5), (6), (7), [(8) and (9) for models 60B and 70B only] to prevent accidental engine startup during testing of starter circuit. T1479 T1480 7-74 3-/ 4-Cylinder...
Page 254 ELECTRICAL SYSTEM CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation. Failure to use the speciﬁed tools can result in injury or damage to the ﬂywheel or coil plate electrical components. CAUTION The force needed to loosen and tighten the ﬂywheel nut requires ﬂywheel be removed and installed with engine mounted and secured on an...
Page 255 SECTION 7 Before you begin testing of starting system : • Check battery ﬂuid level and speciﬁc gravity. Charge or replace as required. See Battery Care and Maintenance, this section. • Checkthe following electrical connections and make sure they are secure and free of corrosion: - Battery cables and clamps.
Page 256 ELECTRICAL SYSTEM NOTE The electrical drawings have been simpliﬁed to show only those elements necessary to test the starter circuit. Two types of starter circuits are used and illustrated in: • Figure 1 - models with remote control box. • Figure 2 - models without remote control box. T1515 7-77 3-/ 4-Cylinder...
Page 257 SECTION 7 1. Disconnect negative battery cable (3) from negative battery terminal (1). 2. Set analog multimeter to check continuity. Connect one tester lead to negative battery terminal (1) and the other tester lead to the ground connection (2) for negative battery cable (3).
Page 258 ELECTRICAL SYSTEM 5. Connect RED tester lead to positive battery terminal (4). If meter does not indicate 11.8 to 13.2 VDC (battery voltage), see Battery Care and Maintenance, this section. If meter indicates battery voltage go to next step. T1515 7-79 3-/ 4-Cylinder...
Page 259 SECTION 7 6. Reconnect negative battery cable (3) to negative battery terminal (1). 7. Connect RED tester lead to starter solenoid terminal (5). If meter does not indicate battery voltage, replace battery cable (6). If meter indicates battery voltage go to next step. 8.
Page 260 ELECTRICAL SYSTEM 10. Connect RED tester lead to connector closest to fuse holder (11). If meter does not indicate battery voltage, repair or replace cable between (5) and (11). If meter indicates battery voltage, go to next step. T1515 7-81 3-/ 4-Cylinder...
Page 261 SECTION 7 11. Connect RED tester lead to connector closest to 9 10 fuse holder (12). If meter does not indicate battery voltage, ﬁnd source 9 10 of overload or short and replace 20A engine fuse (13). Possible sources of short or overload: •...
Page 262 ELECTRICAL SYSTEM 12. Connect RED tester lead to connector closest to 9 10 main key switch (14). T1515 7-83 3-/ 4-Cylinder...
Page 263 SECTION 7 NOTE For models with remote control box - Make sure you test the correct terminal in this step. Terminal (14) is connected directly to the main key switch (10) and the RED lead that comes out of the large cable (15) that connects the engine compartment (16) to the remote control box (17).
Page 264 ELECTRICAL SYSTEM If meter does not indicate battery voltage, repair or 11 12 replace cable between (12) and (14). If meter indicates battery voltage, go to next step. 13. Connect RED tester lead to main key switch lead 11 12 (19) and turn main key switch (10) to START position.
Page 265 SECTION 7 NOTE For models without remote control box - You might have to pull connector (15) apart and measure voltage at terminal indicated in drawing. If meter does not indicate battery voltage, test main 13 14 key switch. Refer to Main Key Switch Test in this section.
Page 266 ELECTRICAL SYSTEM 14. Connect RED tester lead to neutral start switch 13 14 lead (20) and turn main key switch (10) to START position. If meter does not indicate battery voltage, test neutral 13 14 start switch (21). Refer to Neutral Start Switch Test in this section.
Page 267 SECTION 7 15. For models with remote control box ONLY - Connect RED tester lead to starter solenoid lead (22) and turn main key switch (10) to START position. If meter does not indicate battery voltage, repair or replace cable between (20) and (22). If meter indicates battery voltage, go to next step.
Page 268 ELECTRICAL SYSTEM 16. Connect RED tester lead to starter solenoid lead 15 16 (7) and turn main key switch (10) to START position. If meter does not indicate battery voltage, test starter solenoid (8). Refer to Starter Solenoid Test in this section. T1515 7-89 3-/ 4-Cylinder...
Page 269 Disconnect negative battery cable from battery before removing starter motor. For models 40 / 50 / 80 / 90 / 115 / 120 / 140 move oil tank out of the way for access. 1. Disconnect starter solenoid cable (1) and ground cable (2).
Page 270 ELECTRICAL SYSTEM 2. Release pinion collar (1) by tapping it with a socket (2) [with same outside diameter as pinion collar and clearance for motor shaft] and mallet (3). 3. Push down on pinion collar (2) and remove locking ring (1).
Page 271 SECTION 7 5. Clean removed components with cleaning solvent and examine pinion gear for wear and chipped teeth and spring for tension or distortion and replace assembly as required. NOTE Do not allow cleaning solvent to come in contact with starter motor. 6.
Page 272 ELECTRICAL SYSTEM 8. Push down on pinion collar (2) and install locking ring (1). 9. Tap pinion collar (1) in place. Disassemble Starter Motor NOTE Bolts for models 80 / 90 / 115 /120 / 140 may not be available as separate parts. Check current Parts Catalog for availability.
Page 273 120 / 140 [14 - 15mm] 3. Check spring tension. If springs are weak, replace brush assembly. 4. For models 40 / 50 / 60 / 70 - check continuity with analog multimeter between : T1520 Brush (2) and (3). Replace brush assembly if meter indicates continuity.
Page 274 Check current Parts Catalog for availability. 1. For models 40 / 50 / 60 / 70: Remove nut (8), washer (9), washer (10), bushing (11) and o-ring (12). For models 80 / 90 / 115 / 120 / 140: Remove nut (8), washer (9) and washer (10).
Page 275 2. Remove screws (1). 34 35 3. For models 40 / 50 / 60 / 70: Remove brush assembly (1). For models 80 / 90 / 115 / 120 / 140: Remove brush assembly (1) carefully guiding the starter motor terminal (2) through the bushing (3).
Page 276 1. Apply genuine grease to bearing cup (1). 39 40 2. For models 40 / 50 / 60 / 70 ONLY: Install bushing (1). 3. For models 40 / 50 / 60 / 70: Install brush assembly (1). For models 80 / 90 / 115 / 120 / 140: Install brush assembly (1).
Page 277 SECTION 7 5. For models 40 / 50 / 60 / 70: Install O-ring (12), bushing (11), washer (10), washer (9) and secure with nut (8). For models 80 / 90 / 115 / 120 / 140: Install washer (10), washer (9) and secure with nut (8).
Page 278 T1533 T1536 T1537 4. For models 40 /50 / 60 / 70: Retract brushes 49 50 51 as you slide motor base (1) over commutator (2). Align notch (3) in motor base with tab (4) in motor body (5) and seat motor base to motor body.
Page 279 Disconnect negative battery cable from battery before installing starter motor. For models 40 / 50 / 80 / 90 / 115 / 120 / 140 move oil tank out of the way for access. For models 115 / 120 / 140 make sure you install the mount rubber B (1).
Page 280 ELECTRICAL SYSTEM 1. Slide starter motor into bracket (4), apply threadlocker to bolt threads, and install mounting bolts. 2. Install starter motor band (3) apply threadlocker to bolt threads, and starter motor band bolts. 3. Connect starter solenoid cable (1) and ground cable (2). 4.
Page 281 SECTION 7 Main Key Switch Test 1. Disconnect terminals (2), (3), (4), (5), (6), (7), (8), (9), (10), (11), (12) and (13). 2. Set analog multimeter for continuity. With main key switch (1) set to OFF, ON, START, and PUSH IN positions, check for continuity between a clean chassis ground and one of these terminals (test one terminal at a time): Terminal...
Page 282 ELECTRICAL SYSTEM 4. With main key switch set to the ON position, check for continuity between terminals (2) and (8). If meter does not show continuity, replace main key switch. Check for continuity between the following terminals, if meter shows continuity, replace main key switch. Terminal Terminal Terminal...
Page 283 SECTION 7 6. With main key switch set to the OFF position, PUSH IN the key, check for continuity between terminals (4) and (6). If meter does not show continuity, replace main key switch. Check for continuity between all remaining terminals, if meter shows continuity, replace main key switch.
Page 284 ELECTRICAL SYSTEM Neutral Start Switch Test 1. For models without remote control box: Disconnect terminals (2) and (3). For models with remote control box: Disconnect terminals (2), (3) and (4). 2. For models without remote control box: Set analog multimeter for continuity.
Page 285: Charging System
SECTION 7 Choke Solenoid Test 1. Disconnect terminals (2) and (3). 2. Set analog multimeter for continuity. Check for continuity between a clean chassis ground and one of these terminals (test one terminal at a time): Terminal Terminal T1551 If meter shows continuity in any of these tests, replace choke solenoid (1).
Page 286 ELECTRICAL SYSTEM CAUTION When repairs are complete, make sure all ignition and electrical leads are properly routed and clamped in their original positions and the start- ingear prevention system must be tested before returning engine to customer. CAUTION The following tests must be performed with correct test propeller and with the engine in a test tank.
Page 287 The alternator coil test is used to determine whether the alternator coils (1), located on the coil plate assembly (2) [models 40 / 50 / 60 / 70 / 80 / 90] or the alternator assembly (2) [models 115 / 120 / 140] are open or shorted. The output from the alternator coil goes to the rectiﬁer/regulator (9).
Page 288 1. Disconnect the following terminals: Engine Models Disconnect Terminals 40 / 50 / 60 / 70 / 80 / 90 115 / 120 / 140 2. Set the digital multimeter to ohms and connect the leads between the following terminals to read the...
Page 289 (one terminal at a time) to check for any resistance to ground: Connect Multimeter Engine Models Between These Terminals • Terminal 40 / 50 / 60 / 70 / 80 / 90 • Terminal • Terminal 115 / 120 / 140 • Terminal • Terminal...
Page 290 If the meter does not indicate any resistance to ground, proceed to the next step. 7. Set the analog multimeter to “40” on the “ACV” scale. 8. Insert the banana plug of the RED tester lead into the meter connection labeled “+VΩ” and the banana plug of the BLACK tester lead into the meter connection labeled “-COM”.
Page 291 Reference the following electrical drawings for the rectiﬁer/regula tor test. - Figure 1 - models 40 / 50 / 60 / 70 / 80 / 90. - Figure 2 - models 115 / 120 / 140. The rectiﬁer/regulator tests check whether the rectiﬁer/regulator (1) is shorted or open.
Page 292 “+VΩ” and the banana plug of the BLACK tester lead into the meter connection labeled “-COM”. 4. For models 40 / 50 / 60 / 70 / 80 / 90: Connect the RED and BLACK tester leads to the terminals as shown and note the results: •...
Page 293 SECTION 7 NOTE Continuity on chart means that the meter showed continuity (some resistance indicated by meter - exact value depends on test conditions). No Continuity on chart means that meter had no deﬂection. RED Tester Lead Terminal Terminal Terminal Terminal Terminal Continuity...
Page 294 ELECTRICAL SYSTEM Charging System Repair Procedures WARNING Disable ignition system, by disconnecting exciter coil terminals (4), (5), (6), (7), [(8) and (9) for 60B/ 70B only] to prevent accidental engine startup during removal and replacement of the ﬂywheel. T1479 T1480 7-115 3-/ 4-Cylinder...
Page 295 SECTION 7 CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation. Failure to use the speciﬁed tools can result in injury or damage to the ﬂywheel or coil plate electrical components. CAUTION The force needed to loosen and tighten the ﬂywheel nut requires ﬂywheel be removed and T1490...
Page 296 2. Disconnect following terminals for alternator coils 11 12 (1). Alternator coils are located on the coil plate assembly (2) [models 40 / 50 / 60 / 70 / 80 / 90] or the alternator assembly (2) [models 115 / 120 / 140]. T1552...
Page 297 40 / 50 / 60 / 70 / 80 / 90 115 / 120 / 140 3. For models 40 / 50 / 60 / 70 / 80 / 90 ONLY: Remove coil plate assembly cable clamp screws (1) and cable clamp (2).
Page 298 5. For models 40 / 50 / 60 / 70 / 80 / 90 ONLY: Cut tie wrap. 6. For models 40 / 50 / 60 / 70 / 80 / 90 ONLY: Remove alternator coil screws (1) and alternator coils (2) from the mounting bracket.
Page 299 SECTION 7 Cleaning and Inspection Clean coil plate assembly, upper main bearing seal (1), set ring, ignition timing link, exciter coil(s), pulser coils, coil leads, and coil connectors with isopropyl alcohol as required. Check for the following and repair or replace as required: •...
Page 300 SECTION 8 POWER TRIM/TILT TABLE OF CONTENTS General Precautions ......................8-2 Service Speciﬁcations ......................8-3 Air Bleeding Procedure ....................... 8-6 Trim Sender/Trim Meter Test ....................8-7 Power Trim/Tilt ........................8-11 Troubleshooting ......................... 8-19 3-/ 4-Cylinder...
Page 301: General Precautions
SECTION 8 GENERAL PRECAUTIONS Before performing any service work on the power trim/tilt system, read and understand the Service Safety section at the beginning of this manual. Pressurized hydraulic oil in the PT/T unit can cause serious injury. Always wear safety glasses and skin protection when servicing the system.
Page 302 POWER TRIM/TILT SERVICE SPECIFICATIONS Special Torque Values Torque in-lb (ft-lb) N·m Description Threadlocker kg-m 40 / 50 Old Style PT/T New Style PT/T (17 - 22) PT/T Assembly — 23 - 31 — — Mounting Bolt 2 - 3 43 - 60...
Page 303 SECTION 8 Torque in-lb (ft-lb) N·m Description Threadlocker kg-m 40 / 50 Old Style PT/T New Style PT/T (36 - 54) (58 - 87) (58 - 87) Tilt Rod Nut 49 - 74 78 - 118 78 - 118 Loctite 242 4.9 - 7.4...
Page 304 Output Direction of Rotation — Forward / reverse Forward / reverse Forward / reverse Circuit Breaker Type — Internal, bi-metallic, current-sensitive 40- 120 sec. at 20 sec. (minimum) Circuit Breaker Activation — — at 80A Circuit Breaker Reset — —...
Page 305: Air Bleeding Procedure
SECTION 8 Manufacturer Special Tools Required Tilt Rod Guide Wrench, 3B7-72791-0, 3C8-72791-0 Trim Rod Guide Wrench, 3B7-72792-0 Power Trim/Tilt Test Stand, 3B7-72794-0 General Equipment Required Ammeter, 0 - 100A Analog Multimeter, Electronic Specialties Model M-530 or equivalent ® Digital Multimeter, Electronic Specialties Model KD 3200 or equivalent ®...
Page 306: Trim Sender/Trim Meter Test
POWER TRIM/TILT T1317 T1318 PT/T Storage Positions The engine or PT/T assembly itself should be stored so the PT/T unit is in one of the positions shown. Storing the unit in other positions will allow air to enter the system. PT/T Oil Fill Positions NOTE Refer to Power Trim/Tilt Speciﬁcations for oil...
Page 307 SECTION 8 T1320 NOTE Reference the applicable electrical diagram for all R = RED P = PINK testing : B = BLACK O = ORANGE Figure 1 - Models equipped with trim analog meter. L = BLUE Lg = LIGHT GREEN W = WHITE Figure 2 - Models equipped with LCD multi-purpose meter.
Page 308: Power Trim/Tilt
POWER TRIM/TILT T1321 R = RED Lg = LIGHT GREEN B = BLACK Y = YELLOW L = BLUE Sb = SKY BLUE W = WHITE R/G = RED/GREEN P = PINK P/L = PINK/BLUE O = ORANGE 3-/ 4-Cylinder...
Page 309 SECTION 8 Trim Indicator Input Voltage 1. Disconnect the following: Analog trim meter - terminals (1) and (2). LCD trim meter - terminals (1), (2), (3), (4) and connector (5). 2. Using a multimeter, test for 12 VDC input to the trim meter. Connect the RED tester lead to: Analog trim meter - terminal (3).
Page 310 POWER TRIM/TILT If no voltage or low voltage is obtained, the trim meter or trim meter output wiring is defective. Repair or replace as needed before proceeding. 6. Reconnect all wiring and repeat voltage output test for 9 VDC. If no voltage or low voltage is obtained, perform the following: Analog trim meter- Check all wiring between trim sender (9) and terminals (5), (6), (7), and (8) for shorts-to-ground.
Page 311 SECTION 8 T1322 Models 40 and 50 1. Motor Assembly 11.Inner Collar 7.Upper Chamber Side Check 2. Drive Joint 12.Lower Chamber Side Check Valve (Valve Seat Assembly A) 3. Filter B Valve (Valve Seat Assembly B) 8.Spool 4. Pump 13.Free Piston 9.Relief Valve UP...
Page 312 POWER TRIM/TILT T1323 Models 60 / 70 / 80 / 90 / 115 / 120 / 140 - Old PT/T 1. Motor Assembly 14. Pilot Relief Valve DOWN 8.Spool 2. Filter B 15. Cap 9.Shaft 3. Pump Coupling 16. Reservoir Tank 10.Lower Chamber Side Check 4.
Page 313 SECTION 8 T1324 Models 60 / 70 / 80 / 90 / 115 / 120 / 140 - New PT/T 1. Motor Assembly 7.Oriﬁce 13. Filter 2. Bracket Assembly 8.Valve Seat 14. Reservoir Tank 3. Pump Coupling 9.Oriﬁce 15. Cap 4.
Page 314 POWER TRIM/TILT T1325 T1326 T1327 Removal 1. Operatethe PT/T motor and raise engine to fully UP position. Engage the tilt stopper to lock engine in position. NOTE If power trim/tilt motor is not functional, open manual valve several turns and raise engine by hand. 2.
Page 315 Reference the following speciﬁcation table for Disassembly and Assembly special tool requirements. Tool Part Number Applicability 3C8-72791-0 40 / 50 Tilt Rod Guide Wrench Old Style and New 3B7-72791-0 Tilt Rod Guide Wrench Style PT/T Old Style and New...
Page 316 POWER TRIM/TILT CAUTION Use the following precautions during disassembly and assembly of the PT/T unit: • PT/T exterior must be thoroughly cleaned be- fore disassembly to prevent contaminants from entering the hydraulic system. • Use the required special tools to prevent dam- age to components.
Page 317 Manual Valve Guidelines: On models 40 and 50 and old style PT/T, use caution to assemble the seal washers, spring, and inner collar in the correct order. Inner collar (1) must be positioned properly as shown to avoid breakage.
Page 318: Troubleshooting
POWER TRIM/TILT 2. Avoid damage to the brushes during disassembly and assembly of the motor. 3. On old style PT/T, ensure motor match marks (4) are aligned when assembling armature yoke compressor. 4. Ensure armature shaft is seated properly in pump coupling. Installation Installation is done in the reverse order of Removal.
Page 319 SECTION 8 CAUTION Never connect PT/T motor leads directly to battery when testing. Use battery jumper cables to prevent sparking and damage to the motor lead terminals. NOTE Refer to Outboard Motors Service Data publication for wiring diagrams when performing electrical testing.
Page 320 • Connect either the UP or DOWN lead to positive (+). • Connect ground lead to negative (-). Models 40 and 50 and new style PT/T: • Connect either lead to positive (+) and the other to negative (-). 8-21...
Page 321 SECTION 8 3. Proceed as follows: • If symptoms disappear, go to PT/T Electrical Troubleshooting in this section. • If symptoms remain or test results vary, ﬁrst perform the No Load Motor Test in this section to rule out possible motor problems. While motor is removed, verify the pump coupling is not damaged or disconnected.
Page 322 Reference the applicable PT/T circuit diagram for the Sb = SKY BLUE following switch tests: P = PINK - Figure 1 - Models 40 and 50 and new style PT/T L = BLUE - Figure 2 - Old style PT/T G = GREEN...
Page 323 SECTION 8 T1335 Main Switch R = RED Operate components which run off the main switch circuit, such as starter motor, choke solenoid, and warning horn. If these B = BLACK components do not operate or operate improperly, the main switch L = BLUE may be defective.
Page 324 2. Disconnect the RED leads from solenoid terminals (5) and (6). 3. Disconnect the PT/T motor leads from the solenoid terminals. 4. Proceed as follows: Models 40 and 50 and new style PT/T: NOTE Reference Figure • Connect ohmmeter across UP solenoid terminals (7) and (8) and verify continuity is present when solenoid is OFF.
Page 325 SECTION 8 • Connect ohmmeter across DOWN solenoid terminals (9) and (10) and verify continuity is present when solenoid is OFF. Then place DOWN solenoid lead (4) in contact with the RED lead that was disconnected from terminal (6) and verify no continuity when solenoid is ON.
Page 326 Identify the symptom below which best describes the problem at hand and follow the speciﬁed Service Checks in the order indicated: Service Checks Symptoms 40 / 50 PT/T Old Style PT/T New Style PT/T Upward Trim/Tilt Problems 1, 2, 3, 4, 8, 9, 11,...
Page 327 SECTION 8 Service Check 2 - Pump Coupling 1. Remove motor. 2. Inspect pump coupling for wear, damage, or separation from the geared pump. Service Check 3 - Filters 1. Remove motor. 2. Remove and clean ﬁlter B. 3. Remove and clean manifold ﬁlter (new style PT/T). 4.
Page 328 POWER TRIM/TILT Service Check 6 - Lower Chamber Side Check Valve 1. Remove and clean lower chamber side check valve. 2. Inspect for thread and surface damage. 3. Inspect for damage or deterioration of o-rings. Service Check 7 - Upper Chamber Side Check Valve 1.
Page 329 SECTION 8 Service Check 11 - Tilt Cylinder Piston 1. Remove and clean tilt piston rod assembly. 2. Inspect for the following: • Damage to piston sliding surface in cylinder. • Damage or deformation of piston rod and rod guide. •...

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TOHATSU 40 Service Manual

Section 1 Service Safety

Section 2 General Service Information

Section 3 Fuel System

Section 4 Powerhead

Section 5 Midsection

Section 6 Gearcase

Section 7 Electrical System

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