BRP Johnson 4HP Service Manual
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BRP Johnson 4HP Service Manual

BRP Johnson 4HP Service Manual

2007
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  • Page 3 Printed in the United States © 2006 BRP US Inc. All rights reserved. TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
  • Page 4 FOREWORD HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL POWER UNIT INSTALLATION To Locate What You Are Looking For: INSTALLATION Installation is reverse order of removal with special attention 1. The text of this manual is divided into sections. to the following steps.
  • Page 5 FOREWORD SYMBOLS SYMBOLS Listed in the table below are the symbols indicating instructions and other important information neces- sary for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings. SYMBOL DEFINITION SYMBOL...

  • Page 7: Table Of Contents

    GENERAL INFORMATION CONTENTS GENERAL INFORMATION CONTENTS WARNING / CAUTION / NOTE ........................ 1-2 GENERAL PRECAUTIONS ........................1-2 IDENTIFICATION NUMBER LOCATION ....................1-4 ....................... 1-4 MODEL, PRE-FIX, SERIAL NUMBER ........................1-4 ENGINE SERIAL NUMBER FUEL AND OIL ............................1-4 ......................1-4 GASOLINE RECOMMENDATION ............................

  • Page 8: Warning / Caution / Note

    GENERAL INFORMATION WARNING / CAUTION / NOTE WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the sym- bol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
  • Page 9 GENERAL INFORMATION GENERAL PRECAUTIONS • If parts replacement is necessary, replace the parts with Evinrude/Johnson Genuine Parts or their equivalent. • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. •...

  • Page 10: Identification Number Location

    GENERAL INFORMATION IDENTIFICATION NUMBER LOCATION IDENTIFICATION NUMBER LOCATION Model, Prefix, Serial Number The MODEL, PREFIX and SERIAL NUMBER of the motor are stamped on a plate attached to the clamp bracket. Example Typical placement example Engine Serial Number A second engine serial number plate is pressed into a boss on the cylinder block.

  • Page 11: Engine Break-In

    GENERAL INFORMATION ENGINE BREAK-IN ENGINE BREAK-IN The first 10 hours are critically important to ensure correct running of either a brand new motor or a motor that has been reconditioned or rebuilt. How the motor is operated during this time will have direct bearing on its life span and long- term durability.

  • Page 12: Propellers

    GENERAL INFORMATION PROPELLERS PROPELLERS An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered is shown below. 4 HP, 4000 – 5000 r/min Recommended full 5 HP, 4500 – 5500 r/min throttle speed range 6 HP, 4750 –...

  • Page 13: Specifications

    GENERAL INFORMATION *SPECIFICATIONS *SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit 4 HP 5 HP 6 HP DIMENSIONS AND WEIGHT Overall length (front to back) mm (in) 554 (21.8): with tiller handle raised Overall width (side to side) mm (in) 309 (12.2) Overall height...
  • Page 14 GENERAL INFORMATION *SPECIFICATIONS Data Item Unit 4 HP 5 HP 6 HP FUEL AND OIL Fuel Johnson highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R+M/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used.
  • Page 15 GENERAL INFORMATION *SPECIFICATIONS Data Item Unit 4 HP 5 HP 6 HP POWERHEAD Recommended operating range r/min 4000 – 5000 4500 – 5500 4750 – 5750 1300 ± 50 1300 ± 50 Idle speed r/min (in-gear: approx: 1150) (in-gear: approx: 1200) *Cylinder compression 550 –...
  • Page 16 GENERAL INFORMATION *SPECIFICATIONS Data Item Unit 4 HP 5 HP 6 HP CYLINDER HEAD/CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Cam height mm (in) 32.401 – 32.461 (1.2756 – 1.2780) Limit mm (in) 32.101 (1.2638) mm (in) 32.538 – 32.598 (1.2810 – 1.2834) Limit mm (in) 32.238 (1.2692)
  • Page 17 GENERAL INFORMATION *SPECIFICATIONS Item Unit Data VALVE/VALVE GUIDE Valve diameter mm (in) 24.0 (0.94) mm (in) 22.0 (0.87) Valve clearance (Cold engine mm (in) 0.03 – 0.07 (0.001 – 0.003) condition) mm (in) 0.03 – 0.07 (0.001 – 0.003) Valve seat angle —...
  • Page 18 GENERAL INFORMATION *SPECIFICATIONS Item Unit Data CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) Piston to cylinder clearance mm (in) 0.010 – 0.040 (0.0004 – 0.0016) Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 62.000 – 62.015 (2.4409 – 2.4415) Cylinder measuring position mm (in) 35 (1.4) from cylinder top surface...
  • Page 19 GENERAL INFORMATION *SPECIFICATIONS Item Unit Data CRANKSHAFT / CONROD Conrod small end inside diameter mm (in) 18.006 – 18.014 (0.7089 – 0.7092) Limit mm (in) 18.040 (0.7102) Conrod big end oil clearance mm (in) 0.015 – 0.035 (0.0006 – 0.0014) Limit mm (in) 0.080 (0.0031)
  • Page 20 GENERAL INFORMATION *SPECIFICATIONS Data Item Unit 4 HP 5 HP 6 HP ELECTRICAL Ignition timing Degrees BTDC 3° – 28° Over revolution limiter r/min 6000 Ignition coil resistance Secondary 8.4 – 12.4 [H.T.cord – pulser core] kΩ at 20°C Spark plug cap resistance 7.5 –...

  • Page 21: Tightening Torque

    GENERAL INFORMATION TIGHTENING TORQUE TIGHTENING TORQUE Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N·m kg-m Ib-ft Cylinder head cover bolt 6 mm Cylinder head bolt 8 mm 20.5 Crankcase bolt 6 mm Conrod cap bolt 8 mm 15.0 Rocker arm pivot bolt 6 mm...
  • Page 22 GENERAL INFORMATION TIGHTENING TORQUE Tightening torque – general bolt NOTE: These values are only applicable when torque for a general bolt is not listed in the “Important Fasteners” table. TIGHTENING TORQUE THREAD TYPE OF BOLT DIAMETER N·m kg-m Ib-ft 5 mm 2 –...

  • Page 23: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS SPECIAL TOOLS Snap ring pliers Vernier calipers Micrometer (25 – 50 mm) Micrometer (50 – 75 mm) Cylinder gauge set Micrometer (0 – 25 mm) Dial calipers (10 – 34 mm) Dial gauge (40 – 80 mm) (0,025 –...
  • Page 24 GENERAL INFORMATION SPECIAL TOOLS Handle adaptor Valve guide reamer Solid pilot (N-100-5,52) Valve guide reamer handle (N-503-1) (φ 5,5 mm) Valve guide reamer Valve guide remover / installer Handle (N-505) Piston ring compressor (φ 9,3 mm) Tweezers Deep socket wrench Shift lock pin remover 772269 Adapter Timing light...
  • Page 25 GENERAL INFORMATION SPECIAL TOOLS MATERIALS REQUIRED HPF XR™ TRIPLE-GUARD ® GREASE SILICONE SEALANT GEARCASE LUBRICANT MOLY LUBE™ × (400 ml 24 pcs.) NUT LOCK™ ULTRA™ 4-STROKE OIL THREE BOND “1104” THREE BOND “1207B” 1-19...

  • Page 26: Notes

    GENERAL INFORMATION NOTES NOTES 1-20...
  • Page 27 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ....................2-2 ......................2-2 PERIODIC MAINTENANCE CHART MAINTENANCE AND TUNE-UP PROCEDURES ..................2-3 ......................2-3 ENGINE OIL / ENGINE OIL FILTER ........................... 2-4 ENGINE OIL CHANGE ......................2-5 ENGINE OIL FILTER INSPECTION GEAR OIL ..............................

  • Page 28: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first. NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions.

  • Page 29: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each of the periodic maintenance requirements. Engine Oil / Engine Oil Filter ENGINE OIL LEVEL CHECK INSPECT THE OIL LEVEL BEFORE EVERY USE. 1.

  • Page 30: Engine Oil Change

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES Engine Oil Change CHANGE INITIALLY AFTER 10 HOURS (1 MONTH) AND EVERY 100 HOURS (6 MONTHS) THEREAFTER. NOTE: Change the engine oil while the engine is warm. 1. Place the outboard motor upright on a level surface. 2.

  • Page 31: Engine Oil Filter Inspection

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES Engine Oil Filter Inspection INSPECT EVERY 200 HOURS (12 MONTHS). To inspect the engine oil filter: 1. Remove the powerhead from the engine lower cover. (See page 6-2 to 6-4) 2. Detach the engine oil filter with the holder from the crank- case.

  • Page 32: Gear Oil

    PERIODIC MAINTENANCE GEAR OIL GEAR OIL CHANGE INITIALLY AFTER 10 HOURS (1 MONTH) AND EVERY 100 HOURS (6 MONTHS) THEREAFTER. 1. Place the outboard motor upright on a level surface. 2. Place a container under the gearcase. 3. Remove the gear oil drain plug before the gear oil level plug and drain the gear oil.

  • Page 33: Lubrication

    PERIODIC MAINTENANCE LUBRICATION LUBRICATION Inspect every 50 hours (3 months). ® Apply Triple-Guard grease to the following points.  Triple-Guard Grease Shift lever Steering bracket Throttle linkage Swivel bracket Steering bracket Clamp screw Propeller shaft...

  • Page 34: Cooling System Flushing

    PERIODIC MAINTENANCE COOLING SYSTEM FLUSHING COOLING SYSTEM FLUSHING DO NOT run the engine indoors or without adequate ven- tilation or permit exhaust fumes to accumulate incon- fined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

  • Page 35: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG SPARK PLUG • INSPECT EVERY 100 HOURS (6 MONTHS). • REPLACE EVERY 200 HOURS (12 MONTHS). Standard spark plug: NGK BPR6ES Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause igni- tion system malfunctions.

  • Page 36: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE VALVE CLEARANCE Inspect initially after 10 hours (1 month) and every 200 hours (12 months) thereafter. Checking and Adjusting Valve Clearance Checking 1. Remove the following parts: • Engine cover • Recoil starter • Spark plug •...
  • Page 37 PERIODIC MAINTENANCE VALVE CLEARANCE 4. Measure the valve clearance by inserting thickness 1. Lock nut gauge between the valve stem end and the rocker arm. 2. Pivot nut 3. Valve clearance  Thickness gauge Valve clearance (cold engine condition): 0.03 – 0.07 mm (0.001 – 0.003 in) 0.03 –...

  • Page 38: Idle Speed

    PERIODIC MAINTENANCE IDLE SPEED IDLE SPEED INSPECT INITIALLY AFTER 10 HOURS (1 MONTH) AND EVERY 200 HOURS (12 MONTHS) THEREAFTER. Checking 1. Check the link mechanism and the carburetor throttle valves for smooth operation. 2. Attach the tachometer cord to the spark plug high-tension cord.

  • Page 39: Carburetor

    PERIODIC MAINTENANCE CARBURETOR CARBURETOR INSPECT INITIALLY AFTER 10 HOURS (1 MONTH) AND EVERY 100 HOURS (6 MONTHS) THEREAFTER. Inspect the body, the float chamber, the lever, the linkage, the connector and the fuel inlet. If crack or other damage is found, replace. IGNITION TIMING INSPECT EVERY 200 HOURS (12 MONTHS).

  • Page 40: Breather Hose And Fuel Line

    PERIODIC MAINTENANCE BREATHER HOSE AND FUEL LINE BREATHER HOSE AND FUEL LINE • INSPECT INITIALLY AFTER 10 HOURS (1 MONTH) AND EVERY 50 HOURS (3 MONTHS) THEREAFTER. • REPLACE EVERY 2 YEARS. If leakage, cracks, swelling or other damage is found, replace the breather hose and/or the fuel line.

  • Page 41: Propeller / Nut / Cotter Pin

    PERIODIC MAINTENANCE PROPELLER / NUT / COTTER PIN PROPELLER / NUT / COTTER PIN 1. Cotter pin 2. Propeller nut INSPECT INITIALLY AFTER 10 HOURS (1 MONTH) 3. Propeller AND EVERY 100 HOURS (6 MONTHS) THEREAFTER. 4. Shear pin • Inspect the propeller for bent, chipped or broken blades.

  • Page 42: Cylinder Compression

    PERIODIC MAINTENANCE CYLINDER COMPRESSION CYLINDER COMPRESSION NOTE: Figures shown are guidelines only, not absolute service limits. Cylinder compression (with decompression system): 550 – 650 kPa (5.5 – 6.5 kg/cm , 78 – 92 psi) Low compression pressure can indicate one or more of the following: •...
  • Page 43 IGNITION AND ELECTRICAL CONTENTS IGNITION AND ELECTRICAL CONTENTS IGNITION SYSTEM ..........................3-2 ............................. 3-2 OUTLINE IGNITION TROUBLESHOOTING ......................3-3 INSPECTION ............................3-4 .................... 3-4 IGNITION SECONDARY COIL RESISTANCE ..........................3-4 SPARK PLUG CAP ......................... 3-5 ENGINE STOP SWITCH REMOVAL / INSTALLATION ........................3-6 ............................

  • Page 44: Ignition System

    IGNITION AND ELECTRICAL IGNITION SYSTEM IGNITION SYSTEM Outline A digital CDI (condenser discharge ignition) system is used on all models. The CDI and coil unit incorpo- rates an ignition coil and pulser core. If the magnetic reluctor bar on the flywheel passes through the pulser core, the exciter coil in the unit generates the electrical energy as shown in the chart below.

  • Page 45: Ignition Troubleshooting

    IGNITION AND ELECTRICAL IGNITION TROUBLESHOOTING IGNITION TROUBLESHOOTING Perform the following ignition system tests when the engine is hard to start in order to determine if the cause is in the ignition or another system. The cause will not be in the ignition system.

  • Page 46: Inspection

    IGNITION AND ELECTRICAL INSPECTION INSPECTION Ignition Secondary Coil Resistance Measure the secondary coil resistance in the CDI and coil unit.  Digital Voltmeter  Tester range: Ω (Resistance) 1. Remove the spark plug cap from the high-tension cord. 2. Measure the secondary coil resistance. Tester probe connection Probe Other probe...

  • Page 47: Engine Stop Switch

    IGNITION AND ELECTRICAL INSPECTION Engine Stop Switch 1. Lock plate  Digital Voltmeter 2. Button  Tester range:  (Continuity) Inspect the continuity of the engine stop switch. Tester probe connection Bl/R Probe Other probe Blue/Red Black Stop switch continuity: Switch condition Continuity Lock plate IN...

  • Page 48: Removal / Installation

    IGNITION AND ELECTRICAL REMOVAL / INSTALLATION REMOVAL / INSTALLATION System construction 1 Nut (1) 10 N·m (1.0 kg-m; 7.0 lb-ft) 2 Key (1) 3 Flywheel (1) 4 CDI and coil unit (1) 5 Spark plug cap (1) 6 Bolt (2) 50 N·m (5.0 kg-m;...

  • Page 49: Installation

    IGNITION AND ELECTRICAL REMOVAL / INSTALLATION 5. Remove the flywheel from the crankshaft using the spe- cial tool.  Flywheel remover 6. Remove the key from the crankshaft. Installation Installation is reverse order of removal with special attention to the following steps. Flywheel •...

  • Page 50: Notes

    IGNITION AND ELECTRICAL NOTES NOTES...
  • Page 51 FUEL SYSTEM CONTENTS FUEL SYSTEM CONTENTS PRECAUTION ON FUEL SYSTEM SERVICE ..................4-2 ........................4-2 GENERAL PRECAUTION FUEL LINE ..............................4-2 ........................4-2 REMOVAL / INSTALLATION ....................4-3 FUEL LEAKAGE CHECK PROCEDURE ........................4-3 FUEL HOSE CONNECTION CARBURETORS ............................4-4 ........................

  • Page 52: Precaution On Fuel System Service

    FUEL SYSTEM PRECAUTION ON FUEL SYSTEM SERVICE PRECAUTION ON FUEL SYSTEM SERVICE General Precaution Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system. • Keep the working area well ventilated and away from open flame (such as gas heater) or sparks.

  • Page 53: Fuel Leakage Check Procedure

    FUEL SYSTEM FUEL LINE FUEL LEAKAGE CHECK PROCEDURE After performing any fuel system service, always be sure that there is not fuel leakage by checking as follows. 1. Squeeze the fuel primer bulb until you feel resistance. 2. Once pressurized, check all connections and compo- nents for any signs of leakage.

  • Page 54: Carburetors

    FUEL SYSTEM CARBURETORS CARBURETORS Before servicing the fuel system, read and understand “PRECAUTION ON FUEL SYSTEM SERVICE” in the pre- vious section. Removal / Installation REMOVAL 1. Loosen the screw 1 securing the throttle control inner cable. 2. Remove the breather hose / protector 2 from the flame arrester holder 3.
  • Page 55 FUEL SYSTEM CARBURETORS INSTALLATION Installation is reverse order of removal with special attention to the following steps. Do not re-use the gasket once removed. Always use a new gasket. Install the flame arrester 1 with the smooth surface side • outward.

  • Page 56: Disassembly

    FUEL SYSTEM CARBURETORS DISASSEMBLY When disassembling the carburetor, refer to the assembly diagram. Refer to specification to identify carburetor model identification. Remove the following parts: Carburetor 1 • Screw 2 • Spring 3 • Idle adjusting screw 4 • Pilot jet 5 •...

  • Page 57: Cleaning And Inspection

    FUEL SYSTEM CARBURETORS CLEANING AND INSPECTION Clean thoroughly with cleaning solvent and compressed air before inspection. Wear safety glasses when using compressed air to expel solvent, carburetor cleaner etc. Do not place any rubber, plastic or non-metallic parts in cleaning solvent, as severe damage or deterioration will result.

  • Page 58: Reassembly

    FUEL SYSTEM CARBURETORS NEEDLE VALVE Inspect the needle valve. If broken tip or wear is found, replace the valve. FLOAT Inspect the float. If crack or other damage is found, replace the float. REASSEMBLY Reassembly is reverse order of disassembly with special attention to the following steps.
  • Page 59 FUEL SYSTEM CARBURETORS FLOAT Install the float and the float pin. Always install the float pin from the left side to the right side. (See the figure.) NOTE: After installing float, inspect for smooth movement of float. CHECKING AND ADJUSTING FLOAT HEIGHT approx.

  • Page 60: Fuel Pump

    FUEL SYSTEM FUEL PUMP FUEL PUMP Removal / Installation Before servicing the fuel system, read and understand “PRECAUTION ON FUEL SYSTEM SERVICE” in the pre- vious section. REMOVAL 1. Disconnect the inlet hose 1 and the outlet hose 2 from the fuel pump.

  • Page 61: Disassembly / Reassembly

    FUEL SYSTEM FUEL PUMP Disassembly / Reassembly DISASSEMBLY 1. Remove the following parts. Screws 1 • Nuts 2 • Outer plate 3 • Diaphragm 4 • Valve body 5 • 2. Turn the piston 6 until the pin 7 comes out through a cutaway of the pump body A.

  • Page 62: Inspection

    FUEL SYSTEM FUEL PUMP Inspection Diaphragm Inspect all diaphragms. If distortion, tears or other damage is found, replace the diaphragms. Check valves Inspect the check valves in the valve body. If tears, distortion or other damage is found, replace the fuel pump assembly. Pump body Inspect the pump body.

  • Page 63: Fuel Tank And Fuel Cock

    FUEL SYSTEM FUEL TANK AND FUEL COCK FUEL TANK AND FUEL COCK Removal / Installation REMOVAL 1. Remove the recoil starter. (See page 5-2) 2. Remove the two bolts securing the fuel tank. 3. Remove the fuel hoses from the fuel cock and immedi- ately plug the fuel tank hose in order to avoid fuel flow from the tank.

  • Page 64: Disassembly / Reassembly

    FUEL SYSTEM FUEL TANK AND FUEL COCK DISASSEMBLY / REASSEMBLY When disassembling or reassembling the fuel tank and the related parts, refer to the construction dia- gram below. Built-in fuel tank 10 N·m (1.0 kg-m; 7.0 lb-ft) Only for 5 HP Fuel tank (1) Clip (6) for 4 HP Cushion (1)

  • Page 65: Inspection

    FUEL SYSTEM FUEL TANK AND FUEL COCK Inspection Fuel connector Inspect the fuel connector and the connector plug. If leakage, deterioration or other damage is found, replace the connec- tor and/or the plug. 1. Connector 2. Connector plug Fuel primer bulb Inspect the fuel primer bulb.

  • Page 66: Notes

    FUEL SYSTEM NOTES NOTES 4-16...
  • Page 67 MANUAL STARTER CONTENTS MANUAL STARTER CONTENTS REMOVAL ..............................5-2 DISASSEMBLY ............................5-3 REASSEMBLY ............................5-5 INSPECTION ............................5-6 INSTALLATION ............................5-6 NEUTRAL START INTERLOCK (NSI) ..................... 5-7 NOTES ..............................5-8...

  • Page 68: Removal

    MANUAL STARTER REMOVAL REMOVAL 1. Loosen the lock nuts and remove the NSI cable from the bracket 2. Remove the NSI cable from the clutch notch plate 3. Remove the fuel tank cap. 4. Detach the cushion plate of the fuel tank. 5.

  • Page 69: Disassembly

    MANUAL STARTER DISASSEMBLY DISASSEMBLY Because of the coiled tension in the recoil spring, wear safety glasses and hand protection when winding or unwinding the component. System construction 1 Reel (1) 2 Screw (1) 3 Friction plate (1) 4 Ratchet (2) 5 Spring (2) 6 Rope (1) 7 Recoil spring (1)
  • Page 70 MANUAL STARTER DISASSEMBLY 1. Hitch the rope 6 into the notch on the reel 1 and turn the reel clockwise in order to release the coiled tension in the recoil spring. 2. Remove the screw 2. 3. Remove the friction plate 3, the ratchets 4 and the springs 5.

  • Page 71: Reassembly

    MANUAL STARTER REASSEMBLY REASSEMBLY Reassembly is the reverse order of disassembly with special attention to the following steps. Do not re-use the E-ring once removed. Always use a new E-ring. Secure the outer end of the recoil spring 7 on the boss in •...

  • Page 72: Inspection

    MANUAL STARTER INSPECTION INSPECTION NOTE: If excessive wear, crack, defect or other damage is found on any component, replace. • Inspect the ratchet and the all springs. If excessive wear or other damage is found, replace. • Inspect the reel and the recoil case. If crack or other dam- age is found, replace.

  • Page 73: Neutral Start Interlock (Nsi)

    MANUAL STARTER NEUTRAL START INTERLOCK (NSI) NEUTRAL START INTERLOCK (NSI) ADJUSTMENT 1. Shift into “NEUTRAL” position. 2. Adjust and tighten the lock nuts 1 as shown position. 3. Loosen the adjustment nuts 2. 4. Adjust the nuts 2 until the center of the reel stopper 3 aligns with the arrow mark a.

  • Page 74: Notes

    MANUAL STARTER NOTES NOTES...
  • Page 75 POWERHEAD CONTENTS POWERHEAD CONTENTS REMOVAL ..............................6-2 INSTALLATION ............................6-5 DISASSEMBLY ............................6-7 ......................... 6-7 OIL FILTER / OIL PUMP ...................... 6-7 INTAKE MANIFOLD / THERMOSTAT ..................... 6-7 CYLINDER HEAD / VALVE / ROCKER ARM CYLINDER / PISTON / CRANKSHAFT / CONROD / CAMSHAFT ............6-9 INSPECTION AND SERVICING ......................

  • Page 76: Removal

    POWERHEAD REMOVAL REMOVAL Before removing the powerhead: • Drain the engine oil. (See page 2-4) • Shift into “NEUTRAL” position. 1. Remove the recoil starter. (See page 5-2) 2. Remove the spark plug. (See page 2-9) 3. Rotate the flywheel clockwise to bring the position to TDC on a compression stroke.
  • Page 77 POWERHEAD REMOVAL 11. Remove the cable binder, then take out the lead wires and the throttle control cable from the lower cover. 12. Remove the two bolts and the fuel tank bracket. 13. Remove the bolt and the port side plate. 14.
  • Page 78 POWERHEAD REMOVAL 15. Detach the powerhead with the lower cover. 16. Remove the two bolts, then detach the powerhead and the gasket from the lower cover. 17. Remove the cushion rubbers and the oil filler cap.

  • Page 79: Installation

    POWERHEAD INSTALLATION INSTALLATION Installation is reverse order of removal with special attention to the following steps. Do not re-use the gasket and the O-ring. Always use new parts. 1. Check that the oil pump, the plate and the oil filter / holder are installed in the original position.
  • Page 80 POWERHEAD INSTALLATION FINAL ASSEMBLY CHECK Perform the following checks in order to ensure proper and safe operation of the repaired unit. • All parts removed have been returned to the original posi- tions. • Gearcase gear engagement is properly adjusted. (See page 8-16) •...

  • Page 81: Disassembly

    POWERHEAD DISASSEMBLY DISASSEMBLY Oil Filter / Oil Pump Remove the oil filter / holder, the plate and the inner / outer oil pump from the crankcase. Intake Manifold / Thermostat 1. Remove the four bolts, the intake manifold and the gas- ket.
  • Page 82 POWERHEAD DISASSEMBLY 4. Remove the gasket, the dowel pins and the push rods from the cylinder block. 5. Remove the valve adjusting lock nuts 1, then remove the pivot nuts 2 and the rocker arms 3. 6. Using the special tools, remove the valve cotters 4 while compressing the valve spring.

  • Page 83: Cylinder / Piston / Crankshaft / Conrod / Camshaft

    POWERHEAD CYLINDER / PISTON / CRANKSHAFT / CONROD / CAMSHAFT CYLINDER / PISTON / CRANKSHAFT / CONROD / CAMSHAFT 1. Loosen the six crankcase bolts in the order indicated and remove the bolts. 2. Remove the crankcase from the cylinder block. NOTE: Pry the crankcase with a screwdriver as shown in the figure.
  • Page 84 POWERHEAD CYLINDER / PISTON / CRANKSHAFT / CONROD / CAMSHAFT 7. Remove the piston with the conrod through the top of the cylinder bore. 8. Remove the crankshaft from the cylinder block. 9. Remove the circlips 7, the piston pin 8, the conrod 9 and the piston ring set 0 from the piston A.

  • Page 85: Inspection And Servicing

    POWERHEAD INSPECTION AND SERVICING INSPECTION AND SERVICING NOTE: If excessive wear, cracks, defect or other damage is found on any component, replace. Cylinder Head 1. Remove all carbon from the combustion chamber. NOTE: • Do not use any sharp edged tool in order to scrape carbon off the cylinder head or the head components.

  • Page 86: Valve / Valve Guide

    POWERHEAD VALVE / VALVE GUIDE Water jacket Inspect the water jackets for clog or obstruction. Clean the water jackets if necessary. VALVE / VALVE GUIDE Using the micrometer and a bore gauge, take the diameter readings on the valve stems and the guides in order to check the guide to stem clearance.
  • Page 87 POWERHEAD VALVE / VALVE GUIDE Valve stem deflection If unable to measure the valve guide inside diameter, mea- sure the valve stem deflection.  Dial gauge Magnetic stand 1. Install the valves into the valve guide. 2. Lift the valves 8 – 10 mm off seat. 3.
  • Page 88 POWERHEAD VALVE / VALVE GUIDE Valve stem runout Measure the valve stem runout.  Dial gauge Magnetic stand “V” block set Valve stem runout: Service limit: 0.05 mm (0.002 in) If the measurement exceeds the service limit, replace the valve. Valve head radial runout Measure the valve head radial runout.
  • Page 89 POWERHEAD VALVE / VALVE GUIDE Valve seat contact width Measure the valve seat contact width as follows. 1. Remove all carbon from the valve and seat. 2. Coat the valve seat evenly with Prussian Blue (or equiva- lent). 3. Install the valve into the valve guide. 4.

  • Page 90: Valve Seat Servicing

    POWERHEAD VALVE / VALVE GUIDE Valve Seat Servicing IN. EX If the valve seat contact width is out of the specification, reface the valve seat as follows: Valve seat Valve seat angle: IN 15°, 45° EX 15°, 45°  Valve seat cutter 45° (NEWAY122) Valve seat cutter 15°...

  • Page 91: Valve Guide Replacement

    POWERHEAD VALVE / VALVE GUIDE NOTE: Clean and assemble the cylinder head and the valve compo- nents. Fill the intake and the exhaust ports with solvent in order to check for leaks between the valve seat and the valve. If any leaks occur, inspect the valve seat and the face for burrs or other things that could prevent the valve from seal- ing.

  • Page 92: Valve Spring

    POWERHEAD VALVE SPRING 5. Ream the valve guide bore with the 5.5 mm reamer.  Valve guide reamer (φ5,5 mm) Reamer handle NOTE: Clean and oil the valve guide bore after reaming. VALVE SPRING Valve spring free length Measure the valve spring free length. ...

  • Page 93: Camshaft

    POWERHEAD CAMSHAFT CAMSHAFT Cam face Inspect the cam face for scratches and wear. Cam wear Measure the cam height H.  Micrometer Cam height: Standard: 32.401 – 32.461 mm (1.2756 – 1.2780 in) 32.538 – 32.598 mm (1.2810 – 1.2834 in) Service limit: 32.101 mm (1.2638 in) 32.238 mm (1.2692 in)
  • Page 94 POWERHEAD CAMSHAFT Decompression parts Inspect the decompression parts in the camshaft. If abnormal movement is found, replace the camshaft. 6-20...

  • Page 95: Cylinder / Piston / Piston Ring

    POWERHEAD CYLINDER / PISTON / PISTON RING CYLINDER / PISTON / PISTON RING Cylinder distortion Using a straightedge and the thickness gauge, measure the gasket surface of the cylinder at a total of six locations as shown in the figure. ...
  • Page 96 POWERHEAD CYLINDER / PISTON / PISTON RING Cylinder bore wear (difference) Using the cylinder bore gauge, measure the cylinder bore in the thrust and axial directions at the two positions A and B.  Cylinder gauge set Check for the following: •...
  • Page 97 POWERHEAD CYLINDER / PISTON / PISTON RING Identification of oversize piston / piston ring Two oversize piston / piston ring components, 0.25 mm and 0.50 mm, are available. Oversize piston / piston ring are marked as shown in the fig- ures.
  • Page 98 POWERHEAD CYLINDER / PISTON / PISTON RING Piston ring to groove clearance Before checking, the piston grooves must be clean, dry and Piston ring free of carbon. Fit the piston ring into the piston groove, and measure the clearance between the ring and the ring groove using the thickness gauge.
  • Page 99 POWERHEAD CYLINDER / PISTON / PISTON RING Piston ring end gap Measure the piston ring end gap with the piston ring in the lowest position of the cylinder bore.  Thickness gauge Piston ring end gap Standard: 0.20 – 0.35 mm (0.008 – 0.014 in) 0.35 –...

  • Page 100: Piston Pin / Conrod / Crankshaft

    POWERHEAD PISTON PIN / CONROD / CRANKSHAFT PISTON PIN / CONROD / CRANKSHAFT Piston pin clearance To check the clearance, measure the following items. • Piston pin outside diameter in the thrust and axial direc- tions. • Piston pin hole diameter in the thrust and axial directions. ...
  • Page 101 POWERHEAD PISTON PIN / CONROD / CRANKSHAFT Conrod big end oil clearance Check the clearance as follows. 1. Clean the surface of the conrod, the conrod cap and the crank pin. 2. Place a piece of the Plastigage on the crank pin parallel to the crankshaft, avoiding the oil hole.
  • Page 102 POWERHEAD PISTON PIN / CONROD / CRANKSHAFT Conrod big end side clearance Measure the clearance with the conrod installed on the crank pin as shown in the figure.  Thickness gauge Conrod big end side clearance: Standard: 0.20 – 0.90 mm (0.008 – 0.035 in) Service limit: 1.20 mm (0.047 in) If the measurement exceeds the service limit, replace the conrod assembly and/or crankshaft.
  • Page 103 POWERHEAD PISTON PIN / CONROD / CRANKSHAFT Crankshaft runout Measure the crankshaft runout as shown in the figure.  Dial gauge Magnetic stand Steel “V” block set Crankshaft runout: Service limit: 0.05 mm (0.002 in) If the measurement exceeds the service limit, replace the crankshaft.

  • Page 104: Oil Seal / Bearing

    POWERHEAD OIL SEAL / BEARING OIL SEAL / BEARING Visually check the oil seals installed in the cylinder block and crankcase for cuts, nicks, excessive wear or other damage. Visually check the crankshaft upper bearing for pitting, roughness or other damage. NOTE: If neither defective nor any damage is found on the oil seals and the bearing, do not remove the oil seals and the bearing.
  • Page 105 POWERHEAD OIL SEAL / BEARING 5. Apply Triple-Guard grease to the outer circumference of the oil seal. 6. Drive the oil seal down into position as shown in the fig- ure. Do not contact the oil seal to the bearing. 1 –...

  • Page 106: Thermostat

    POWERHEAD THERMOSTAT THERMOSTAT If salt deposits, corrosion, wear or other damage is found, clean or replace the thermostat. Thermostat operation Check the thermostat operating temperature as follows. Thermometer 1. Insert a length of thread between the thermostat valve / body and suspend the thermostat in a container filled with water.

  • Page 107: Reassembly

    POWERHEAD REASSEMBLY REASSEMBLY Reassembly is reverse order of disassembly with special attention to the following steps. • If the original components are not replaced, each pis- ton, piston pin and conrod is to be assembled and installed in the original order and position. •...

  • Page 108: Piston Ring To Piston

    POWERHEAD REASSEMBLY Piston Ring to Piston Oil ring 1. Apply engine oil to the piston rings. 2. Install the spacer 1 first, then the side rails 2 to the pis- ton. Incorrect When installing the spacer, do not allow the ends to overlap in the groove.

  • Page 109: Crankshaft And Piston To Cylinder

    POWERHEAD REASSEMBLY Crankshaft and Piston to Cylinder 1. Apply engine oil to the crankshaft journals and pin. 2. Apply Triple-Guard grease to the lip of the upper oil seal.  Triple-Guard grease 3. Install the crankshaft to the cylinder block. 4.

  • Page 110: Camshaft To Cylinder

    POWERHEAD REASSEMBLY Camshaft to Cylinder 1. Apply engine oil to the tappets. 2. Install the tappets in the cylinder block. 3. Apply engine oil to the cam faces and the cam journals. 4. While aligning each punch mark on the camshaft gear and the crankshaft gear, install the camshaft to the cylin- der block.

  • Page 111: Cylinder Head / Valve

    POWERHEAD REASSEMBLY Cylinder Head / Valve 1. Apply Nut Lock to the mounting side threads of the rocker arm pivot bolts.  Nut Lock 2. Tighten the bolts with the rod guide plate to the specified torque.  Deep socket wrench ...

  • Page 112: Cylinder Head To Cylinder

    POWERHEAD REASSEMBLY Cylinder Head to Cylinder 1. Install the two dowel pins and the gasket to the cylinder block. 2. Install the two push rods onto the end of the tappets in the cylinder block. NOTE: Before installing the cylinder head, make sure that the piston is at the TDC position on a compression stroke.

  • Page 113: Cylinder Head Cover

    POWERHEAD REASSEMBLY Cylinder Head Cover Install the cylinder head cover and the gasket, then tighten the four cylinder head cover bolts diagonally to the specified torque.  Cylinder head cover bolt: 8 N·m (0.8 kg-m; 6.0 lb-ft) NOTE: Make sure that the cylinder head cover gasket is installed in the direction as shown in the figure.

  • Page 114: Operation

    POWERHEAD OPERATION OPERATION Water Cooling System The water cooling system includes the gearcase water pump, the water supply tube, the powerhead water passages and the thermostat. This system cools both the powerhead and exhaust and is shown in schematic from below. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build-up or component damage.

  • Page 115: Engine Lubrication System

    POWERHEAD OPERATION Engine Lubrication System A camshaft driven trochoid type pump provides engine oil to all powerhead components requiring lubri- cation. Oil from the bottom of the crankcase is drawn through the oil filter and is pumped. The oil is passed through the passage in the camshaft lubricating the journals, then through the internal passage in the top of the cylinder to the crankshaft upper bearing.

  • Page 116: Notes

    POWERHEAD NOTES NOTES 6-42...
  • Page 117 MIDSECTION CONTENTS MIDSECTION CONTENTS TILLER HANDLE ............................7-2 ........................7-2 REMOVAL / INSTALLATION ............................ 7-3 INSTALLATION DISASSEMBLY / REASSEMBLY ......................7-3 ............................. 7-3 DISASSEMBLY ............................7-4 REASSEMBLY CLUTCH LEVER / ROD ........................... 7-5 ............................7-5 REMOVAL ............................ 7-6 INSTALLATION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET .... 7-7 .............................

  • Page 118: Tiller Handle

    MIDSECTION TILLER HANDLE TILLER HANDLE Removal / Installation REMOVAL 1. Remove the throttle cable from the carburetor and the intake manifold. 2. Remove the lead wires / cable binder, then take out the throttle control cable from the lower cover. (See page 6-3) 3.

  • Page 119: Installation

    MIDSECTION DISASSEMBLY / REASSEMBLY Installation Installation is reverse order of removal with special attention to the following steps. • Apply Triple-Guard grease to the bushings.  Triple-Guard grease • Tighten the pivot bolt and the pivot nut to the specified torque.

  • Page 120: Reassembly

    MIDSECTION DISASSEMBLY / REASSEMBLY Reassembly Reassembly is reverse order of disassembly with special attention to the following steps. • Install the cable stopper to avoid being on the boss A of the handle body. • Apply Nut Lock to the cable stopper bolt. ...

  • Page 121: Clutch Lever / Rod

    MIDSECTION CLUTCH LEVER / ROD CLUTCH LEVER / ROD Removal 1. Remove the powerhead. (See page 6-2) 2. Shift the clutch lever in the Neutral position. 3. Remove the clutch adjust hole cover 1, then loosen the clutch rod connecting plate bolt 2. NOTE: Do not over-loosen the rod connecting plate bolt.

  • Page 122: Installation

    MIDSECTION CLUTCH LEVER / ROD Installation Installation is reverse order of removal with special attention to the following steps. Do not re-use the O-ring, the E-ring and the cotter pin once removed. Always use new parts. • If excessive wear or other damage is found on the notch pin or clutch lever notch plate, replace.

  • Page 123: Steering Bracket / Driveshaft Housing / Swivel Bracket / Clamp Bracket

    MIDSECTION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET Disassembly 1. Remove the powerhead. (See page 6-2) 2. Remove the gearcase. (See page 8-2) 3. Remove the tiller handle. (See page 7-2) 4.
  • Page 124 MIDSECTION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET 10. Remove the driveshaft housing / steering bracket assem- bly and the bushings from the swivel / clamp bracket assembly. 11. Remove the two bolts, the steering bracket and the bracket cover.
  • Page 125 MIDSECTION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET 17. Remove the two bushings. 18. Remove the cotter pin and the shaft. 19. Remove the shallow drive lever, the washer and the spring.

  • Page 126: Inspection

    MIDSECTION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET INSPECTION NOTE: If excessive wear, cracks or other damage is found on any component, replace. Driveshaft Housing / Steering Bracket Inspect the driveshaft housing, steering bracket and the bracket cover.

  • Page 127: Reassembly

    MIDSECTION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET REASSEMBLY Reassembly is reverse order of disassembly with special attention to the following steps. 10 N·m (1.0 kg-m; 7.0 lb-ft) 10 N·m (1.0 kg-m; 7.0 lb-ft) 1. Swivel bracket (1) 28.

  • Page 128: Swivel Bracket / Clamp Bracket

    MIDSECTION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET Swivel Bracket / Clamp Bracket Do not re-use the cotter pin once removed. Always use a new cotter pin. • Apply Triple-Guard grease to the clamp bracket bushings. ...

  • Page 129: Lubrication

    MIDSECTION STEERING BRACKET / DRIVESHAFT HOUSING / SWIVEL BRACKET / CLAMP BRACKET • Tighten the two steering bracket cover bolts to the speci- fied torque.  Steering bracket cover bolt: 10 N·m (1.0 kg-m; 7.0 lb-ft) • Tighten the four swivel bracket cover bolts to the specified torque.

  • Page 130: Notes

    MIDSECTION NOTES NOTES 7-14...
  • Page 131 GEARCASE CONTENTS GEARCASE CONTENTS REMOVAL AND DISASSEMBLY ......................8-2 ................8- DISASSEMBLY OF PROPELLER SHAFT COMPONENTS INSPECTION ............................8-6 PROPELLER ............................8-6 GEARCASE .............................. 8-6 GEAR ................................ 8-6 PROPELLER SHAFT COMPONENTS ....................8-7 PROPELLER SHAFT BEARING HOUSING .................... 8-7 SHIFT ROD AND SHIFT CAM ......................... 8-8 WATER PUMP AND RELATED ITEMS ....................

  • Page 132: Removal And Disassembly

    GEARCASE REMOVAL AND DISASSEMBLY REMOVAL AND DISASSEMBLY Disconnect the spark plug cap from the spark plug before removing the gearcase. 1. Drain the gear oil. (See page 2-6.) 2. Remove the clutch adjust hole cover, then loosen the rod connecting plate bolt. NOTE: Do not over-loosen the rod connecting plate bolt.
  • Page 133 GEARCASE REMOVAL AND DISASSEMBLY 7. Remove the two bolts securing the propeller shaft bear- ing housing. 8. Remove the propeller shaft bearing housing. NOTE: Pry the housing with a screwdriver into the groove as shown in the figure. (2-positions) 9. Remove the four nuts and washers. 10.
  • Page 134 GEARCASE REMOVAL AND DISASSEMBLY 13. Pull out the shift rod assembly. 14. Remove the driveshaft support housing. NOTE: Pry the housing with a screwdriver as shown in the figure. 15. Pull out the driveshaft with the driveshaft support housing and remove the washer. 16.

  • Page 135: Disassembly Of Propeller Shaft Components

    GEARCASE REMOVAL AND DISASSEMBLY Disassembly of Propeller Shaft Components 1. Separate the following parts. • Bearing housing • Reverse gear backup shim • Reverse gear • Reverse gear thrust washer • Push rod • Push rod pin 2. Remove the dog spring. 3.

  • Page 136: Inspection

    GEARCASE INSPECTION INSPECTION NOTE: If excessive wear, cracks, or other damage is found on any component, replace. PROPELLER • Inspect the propeller. If bent, chipped or other damage is found on the blades, replace or repair the propeller. • Inspect the propeller bushing. If excessive wear or other damage is found on the splines, replace the bushing.

  • Page 137: Propeller Shaft Components

    GEARCASE PROPELLER SHAFT COMPONENTS PROPELLER SHAFT COMPONENTS • Inspect the push rod and the push rod pin. If excessive wear or other damage is found, replace. • Inspect the clutch dog shifter. If excessive wear, cracks, chipping or other damage is found, replace. •...

  • Page 138: Shift Rod And Shift Cam

    GEARCASE SHIFT ROD AND SHIFT CAM SHIFT ROD AND SHIFT CAM • Inspect the “stepped” surfaces of the shift cam. If exces- sive wear, chipping or other damage is found, replace the cam. • Inspect the shift rod guide. If excessive wear, pitting, corro- sion or other damage is found, replace the guide.

  • Page 139: Reassembly And Installation

    GEARCASE REASSEMBLY AND INSTALLATION REASSEMBLY AND INSTALLATION Reassembly and installation is reverse of removal and disassembly with special attention to the following steps. 11 N . m (1.1 kg-m, 8.0 lb-ft) 11 N·m (1.1 kg-m; 8.0 lb-ft) 11 N . m (1.1 kg-m, 8.0 lb-ft) 11 N·m (1.1 kg-m;...
  • Page 140 GEARCASE REASSEMBLY AND INSTALLATION 11 N . m 11 N·m (1.1 kg-m, 8.0 lb-ft) (1.1 kg-m; 8.0 lb-ft) 1. Driveshaft (1) 13. Push rod pin (1) 25. O-ring (1) 2. Circlip (2) 14. Spring (1) 26. Propeller shaft bearing housing (1) 3.

  • Page 141: Forward Gear

    GEARCASE FORWARD GEAR • Make sure that all parts used in assembly are clean and lubricated. • After assembly, check the parts for tightness and smoothness of operation. • Before final assembly, be absolutely certain that all gear contact, shim adjustments and tolerances are correct.

  • Page 142: Shift Rod Assembly

    GEARCASE SHIFT ROD ASSEMBLY SHIFT ROD ASSEMBLY • Apply Triple-Guard grease to the shift rod guide, O-rings and the top of the dust boot.  Triple-Guard Grease • Install the shift rod assembly with the stepped section of the shift cam toward the propeller shaft. •...

  • Page 143: Propeller Shaft Components

    GEARCASE PROPELLER SHAFT COMPONENTS PROPELLER SHAFT COMPONENTS • Install the clutch dog shifter with the mark “F” toward the forward gear side. • Apply gear oil to the following parts. • Push rod pin • Push rod • Clutch dog shifter sliding area of the propeller shaft •...

  • Page 144: Leakage Check

    GEARCASE LEAKAGE CHECK LEAKAGE CHECK Check for leakage of the oil seals and O-ring when applying the specified pressure inside of the gearcase.  S34 Stevens Pressure Tester 772269: Adapter Procedure 1. Install the special tool into the oil level hole. 2.

  • Page 145: Gear Oil

    GEARCASE GEARCASE INSTALLATION GEARCASE INSTALLATION • Apply Moly Lube to the driveshaft splines.  Moly Lube • Apply Silicone Seal to the gearcase retaining nuts and tighten the nuts to the specified torque. (retaining bolts for the transom “S” model) ...

  • Page 146: Clutch Adjustment

    GEARCASE CLUTCH ADJUSTMENT CLUTCH ADJUSTMENT Adjustment procedure • Disconnect the spark plug cap from the spark plug in order to eliminate the chance of accidental engine starting. • To prevent injury from the propeller blades, wear gloves. 1. Loosen the rod connecting plate bolt approximately one turn.
  • Page 147 GEARCASE GEARS - SHIMMING AND ADJUSTMENT GEARS - SHIMMING AND ADJUSTMENT If the gearcase has been rebuilt or has had components replaced, shimming for correct gear contact and backlash will have to be adjusted in order to ensure smooth, reliable operation of gears. Shim / Washer and Mounting position Numerical index / item Available thickness (mm)

  • Page 148: Forward Gear / Pinion Gear Shim Adjustment

    GEARCASE GEARS - SHIMMING AND ADJUSTMENT Forward Gear / Pinion Gear Shim Adjustment Adjust the forward gear / pinion gear shimming as shown below. Step to prior to adjustment 1. Install the following parts to the gearcase. • Forward gear bearing (if removed) •...
  • Page 149 GEARCASE GEARS - SHIMMING AND ADJUSTMENT Checking and adjusting tooth contact pattern (Pinion and Forward gear) Check tooth contact pattern by using the following proce- dure. 1. To assess tooth contact, apply a light coat of Prussian Blue on the convex surface of the forward gear. 2.
  • Page 150 GEARCASE GEARS - SHIMMING AND ADJUSTMENT Optimum tooth contact Optimum tooth contact approx. 1/3 of The optimum tooth contact is shown in the figure. tooth width approx. A shim adjustment may be necessary in order to obtain the 1 mm HEEL optimum tooth contact pattern.
  • Page 151 GEARCASE GEARS - SHIMMING AND ADJUSTMENT Checking Reverse Gear Check the reverse gear / pinion gear shimming as shown below. 1. Feeling with your hand, recheck the condition by rotating the driveshaft of the optimum forward gear tooth contact. (See the page 8-18 and 8-19) 2.
  • Page 152 GEARCASE NOTES NOTES 8-22...
  • Page 153 WIRE / HOSE ROUTING CONTENTS WIRE / HOSE ROUTING CONTENTS WIRE AND HOSE ROUTING ........................9-2 ............................9-3 4 HP MODELS .............................9-4 5/6 HP MODELS WIRING DIAGRAM ............................9-5 OPTIONAL ELECTRICAL PARTS INSTALLATION ................9-6 CABLE / WIRE ROUTING .........................9-7 NOTES ...............................9-8...

  • Page 154: Wire And Hose Routing

    WIRE / HOSE ROUTING WIRE AND HOSE ROUTING WIRE AND HOSE ROUTING • Do not over-bend (kink) or twist hoses when installing. • When installing hose clips, position tube to avoid contact with other parts. • Check that hoses do not contact rods and levers during either engine operation or standstill. •...

  • Page 155: Hp Models

    WIRE / HOSE ROUTING WIRE AND HOSE ROUTING 4 HP Models Fuel hose Air vent hose (Fuel cock to Carburetor) Fuel cock Carburetor Clamp: Air vent hose does not touch motor cover and recoil case. Fuel hose (Fuel pump to Fuel cock) Lower cover plate VIEW A Grommet...

  • Page 156: 5/6 Hp Models

    WIRE / HOSE ROUTING WIRE AND HOSE ROUTING 5/6 HP Models Air vent hose Fuse hose (Fuel tank to Fuel cock) Throttle cable holder Fuse hose (Fuel cock to 3 way joint) Clamp DETAIL A Fuel cock VIEW C Lower cover plate Grommet Fuel hose (Fuel tank to Fuel cock)

  • Page 157: Wiring Diagram

    WIRE / HOSE ROUTING WIRING DIAGRAM WIRING DIAGRAM CDI AND COIL UNIT SPARK PLUG FLYWHEEL MAGNETO Wire color B: Black B/R: Blue/Red EMERGENCY STOP AND ENGINE STOP SWITCH Emergency stop switch: Lock plate IN = RUN Lock plate OUT = STOP Emergency stop switch: Button pushed = STOP...

  • Page 158: Optional Electrical Parts Installation

    WIRE / HOSE ROUTING OPTIONAL ELECTRICAL PARTS INSTALLATION OPTIONAL ELECTRICAL PARTS INSTALLATION NOTE: Before tightening the battery charge coil bolts, check that the coil is installed in the correct position. Visually check the clearances between the inside magnets of the flywheel and the coil circumference by using the three holes on the flywheel.

  • Page 159: Cable / Wire Routing

    WIRE / HOSE ROUTING CABLE / WIRE ROUTING CABLE / WIRE ROUTING 30 mm Protector tube NOTE: • Wind the protector tube on the cable and position the wire as shown. • Route the cable and the wire through the upper side of the tiller handle.

  • Page 160: Notes

    WIRE / HOSE ROUTING NOTES NOTES...
  • Page 161 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... S–3 ..........S–4 OUTBOARD SHIFT SYSTEMS AND SAFETY .
  • Page 162 S–2...

  • Page 163: Marine Products And The Safety Of People Who Use Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices.

  • Page 164: Outboard Shift Systems And Safety

    SAFETY Outboard Shift Systems and Safety The outboard Shift The outboard Shift System starts here System starts here at the remote at the remote control lever... control lever..and ends here at the propeller. When control lever is in What is most important? FORWARD, NEUTRAL or REVERSE...

  • Page 165: Outboard Speed Control System And Safety

    SAFETY Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead. What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL...

  • Page 166: Outboard Steering Control System And Safety

    SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: • Must not come apart; • Must not jam;...
  • Page 167 SAFETY How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets Marine Industry Safety Standards (ABYC). • Read, understand, and follow manufacturer’s instructions When • Follow warnings marked “ ” closely. rigging •...

  • Page 168: Outboard Fuel, Electrical System, And Safety

    SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? •...
  • Page 169 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing • As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads Sleeves, boots, shields •...
  • Page 170 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard GASOLINE Check for leaks under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.

  • Page 171: Outboard Mounting System And Safety

    SAFETY Outboard Mounting System and Safety The mounting system includes: • outboard parts • bolts, nuts, and washers • boat’s transom What is most important? • Outboard must stay in position on boat’s transom. What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...
  • Page 172 SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.

  • Page 173: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety

    SAFETY Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? • Shock absorption system must always be ready to absorb some blows to the lower parts of the outboard. • Outboard must not trim in too far suddenly. What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat.

  • Page 174: Outboard Emergency Stop System And Safety

    SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..and ends here in the ignition system on the powerhead. What is most important? • The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop / key switch.
  • Page 175 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.

  • Page 176: Summing Up

    SAFETY Summing up Now you know some things that can take the joy out of boating. No doubt about it—proper safety takes time! • Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments •...

  • Page 177: Marine Products And The Safety Of People Who Fix Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: •...
  • Page 178 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock...
  • Page 179 SAFETY Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
  • Page 180 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 181: Handling Lead/Acid Batteries

    SAFETY Handling Lead/Acid Batteries If spilled or Strong acid solution splashed on any (sulfuric acid) part of body... If solution gets into eyes, wash and contact a doctor immediately. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket.

  • Page 182: Gasoline - Handle With Care

    SAFETY Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown... Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink...

  • Page 183: Hazardous Products

    SAFETY Hazardous Products Know how items in the shop can hurt people... READ • “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an emergency arise • “How to dispose of can” It’s all on the back of the can or bottle label.

  • Page 184: Safety Awareness Test

    SAFETY Safety Awareness Test The Technician’s Safety Awareness Test..1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and proce- dures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual? 4) Will you follow all safety warnings, precautions, instructions and recommendations...

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