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5 HP Outboard • Troubleshooting & Repair Manual
Section 2 • Troubleshooting
Troubleshooting
Most complaints concerning engine operation can be
classified as one or a combination of the following:
No Start
Hard Start
Lack of Power
Vibration
Overheating
High Oil Consumption
When the cause of a malfunction is not readily apparent,
perform a check of the compression, ignition,
carburetion and cooling systems. This check-up,
performed in a systematic manner, can usually be done in a
matter of minutes. It is the quickest and surest method of
determining the cause of failure. This check-up will point
out potential future failures, which can be corrected in
advance. The basic check-up procedure is the same for all
engine models.
Check Lower Unit
What appears to be a problem with engine operation, such
as hard starting, vibration, etc., may be the fault of the
lower unit rather than the engine itself. Listed are the most
common effects of problems and probable causes.
WARNING
To prevent accidental starting, the
spark plug wire must be removed
from the spark plug and grounded
after removing boot. Failure to do so
can cause personal injury. If the
propeller or propeller shaft is turned
with the outboard in gear it is
possible that the engine will crank
over and start. Remove the spark plug
lead and select NEUTRAL when
servicing the outboard. To prevent
serious injury from contact with a
rotating propeller, do not run the
outboard unless the propeller is
either removed from the outboard or
the unit is in water. Remove the
propeller whenever it is necessary to
test run the outboard..
TROUBLESHOOTING
No Start - Hard Start
1. Check remote control assembly for proper
adjustment.
2. Check neutral safety system for shorted wires, loose
or corroded connections, or defective modules or
switches.
Vibration
1. Mounting bolts loose - tighten.
2. Check for lower unit damage.
Power Loss
1. Bind or drag in unit - place engine in
Operate lower unit manually to check for binding.
2. No lubrication in lower unit.
Noise
1. No lubricant in lower unit.
2. Worn bearings or gears.
Cooling
Chaff or dirt can clog the cooling system, especially after
prolonged service in very dusty conditions. Continued
operation with a clogged cooling system can cause severe
overheating and possible engine damage. Periodically inspect
the cylinder fins (
required. Clean and inspect more often when dust or when
airborne debris is present.
Figure 10 — Cooling Fins
13
and fan
Figure 10)
1
1
2
.
NEUTRAL
. Clean as
2
2
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