Page 3 † ThreeBond is a registered trademark of Three Bond Co., Ltd. Bombardier logo is a registered trademark of Bombardier, Inc., used under license. The following trademarks are the property of BRP US Inc. or its affiliates: Carbon Guard™ Nut Lock™...
Page 4: Table Of Contents
SAFETY INFORMATION Before working on any part of the outboard, read the SAFETY section at the end of this manual. This manual is written for qualified, factory-trained Always follow common shop safety practices. If technicians who are already familiar with the use you have not had training related to common shop ®...
Page 5 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 6 ABLE ONTENTS SECTION ........PAGE INTRODUCTION .
Page 7: Table Of Contents
INTRODUCTION INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL ........... 6 .
Page 8: Models Covered In This Manual
INTRODUCTION MODELS COVERED IN THIS MANUAL MODELS COVERED IN Identifying Model and Serial Numbers THIS MANUAL Outboard model and serial numbers are located on the starboard stern bracket and on the power- This manual covers service information on head. Johnson 25 HP 4-Stroke models. Use this manual together with the proper Parts Catalog for part numbers and for exploded views of the outboard, which are a valuable aid to disassembly and reas-...
Page 9: Model Designation
INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION STYLE: LENGTH: J = Johnson L = 20” Long E = Evinrude MODEL RUN HORSEPOWER PREFIX 4-STROKE or SUFFIX J 25 R L 4 SU MODEL YR: DESIGN FEATURES: I = 1 AP = Advanced Propulsion N = 2 B = Blue Paint T = 3...
Page 10: Typical Page - A
INTRODUCTION TYPICAL PAGE – A TYPICAL PAGE – A Subsection title indicates beginning of the subsection. Italic subheading above Service Chart indicates pertaining models. Bold letter indicates liquid product to be applied to a surface Pay attention to torque specifications. Some units appear as in.
Page 11: Typical Page - B
INTRODUCTION TYPICAL PAGE – B TYPICAL PAGE – B Section Title Section Title INSTALLATION AND PREDELIVERY OUTBOARD RIGGING PROCEDURE Subsection Title Section Title Cable, Hose, and Wire Routing If a water pressure gauge is to be used, install the water pressure hose fitting in the cylinder block. Route all hoses, control cables, and wiring Use Pipe Sealant with Teflon (P/N 910048) on the through a protective sleeve or conduit into the...
Page 12: Typical Page - C
INTRODUCTION TYPICAL PAGE – C TYPICAL PAGE – C POWERHEAD INSTALLATION IMPORTANT: INSTALLATION The motor mount, washer, and screw are serviced as an assembly. Do not disas- Title in italics indicates semble. V4 M a procedure ODELS concerning a Install base gasket dry. Do not use Permatex Denotes necessary particular model step or information to...
Page 13: Typical Page - D
INTRODUCTION TYPICAL PAGE – D TYPICAL PAGE – D OILING SYSTEM COMPONENTS Oil Pressure Switch Two pulse hoses connect the pump to pulse fit- tings on the front of the cylinder/crankcase. The oil pressure switch is located in the oil injec- •...
Page 14: Abbreviations Used In This Manual
INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft. lbs. foot pounds barometric pressure sensor horsepower...
Page 15: Product Reference And Illustrations
SYMBOLS AND ILLUSTRATIONS Throughout this service manual, symbols are used to interpret electrical troubleshooting results BRP US Inc. reserves the right to make changes or to assign values in drawings. at any time, without notice, in specifications and Electrical models and also to discontinue models. The right is also reserved to change any specifications or When “∞”...
Page 16: Values
INTRODUCTION SYMBOLS When “Ω” follows a value on the meter face, the When “≥” precedes a value on the meter face, the procedure is measuring resistance. Ω is the sym- reading should be greater than, or equal to, the bol for ohm, the unit of measurement for resis- value shown.
Page 17 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SERVICE SPECIFICATIONS AND SPECIAL TOOLS TABLE OF CONTENTS TECHNICAL DATA ..............16 STANDARD TORQUE SPECIFICATIONS .
Page 18: Technical Data
SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA TECHNICAL DATA Full Throttle 4700-5300 Operating Range RPM Power 25 HP (18.4 kw) @ 5000 RPM 900 to 1000 in gear Idle RPM 950 to 1050 in neutral (R) Models: 152 lbs. (69 kg) (RL) Models: 159 lbs.
Page 19 SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA 6 Amp, Regulated (Rope Start) Alternator 15 Amp, Regulated (Electric Start) 12 Volt, 360 CCA (465 MCA) with Battery 90 Minutes Reserve Capacity or Minimum Recommendation 50 Ampere-Hour Tachometer Setting 6 Pulse/12 Pole (Requires Battery Charging) Fuse 20 A (Electric start models)
Page 20: Standard Torque Specifications
SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS STANDARD TORQUE SPECIFICATIONS Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N·m kg-m lb-ft Cylinder head cover bolt 6 mm Cylinder head bolt 10 mm 39.8 8 mm 16.6 Crankcase bolt 10 mm 36.2 Conrod cap bolt...
Page 21: Tightening Torque - General Bolt
SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS Tightening Torque – General Bolt IMPORTANT: These values apply only when a specific torque for a specific fastener is not listed in the appropriate section. When tightening two or more screws on the same part, DO NOT tighten screws completely, one at a time.
Page 22: Special Tools
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS Electrical / Ignition Digital multimeter DRC7265 CD Peak reading voltmeter 49799 Multimeter, analog 49793 Ohms resolution 0.01 P/N 507972 P/N 501873 Purchase through local supplier Flywheel removal screws 002570 Wire harness adapter leads 40269 Tachometer/timing light 49789...
Page 23: Fuel And Oil
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Fuel and Oil Fuel/Oil pressure gauge 002275 Fuel vacuum tester 23286 Oil pressure test adapter 002623 P/N 5000902 P/N 390954 P/N 350930 Gearcase Gearcase filler 49790 Dial indicator set Gearcase fill/drain adaptor 48642 P/N 501882 P/N 772269 Gearcase pressure tester...
Page 24: Powerhead
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Bearing Installer P/N 5034774 002645 Bearing remover P/N 5034764 002646 Prop shaft remover 005937 P/N 5034762 Installer handle 002575 Driveshaft holder P/N 5037512 005938 P/N 345822 Powerhead Cylinder bore gauge 45303 Gear alignment pin set 005516 Valve spring compressor DRC50025...
Page 25: Starter
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Starter Starter rope threading tool 23682 Starter spring winder/installer CO3583 P/N 387784 P/N 392093 Universal Puller Bridge P/N 432127 23146 Puller jaws (bearing) P/N 432130 23149 Temperature gun P/N 772018 45240 (replacement jaws P/N 437953) Puller jaws (small) P/N 432131 23150 Slide hammer P/N 391008...
Page 26: Shop Aids
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS SHOP AIDS Cleaning Solvent P/N 771087 Engine Tuner P/N 777185 Anti-Corrosion Spray P/N 777193 “6 in 1” Multi-Purpose Lubricant P/N 777192 D.P.L. Spray P/N 777183 Silicone spray P/N 775630 Ultra 4-Stroke Outboard Oil, P/N 775594 4-Stroke Outboard Oil, P/N 775597 HPF XR™...
Page 27 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS Moly Lube P/N 175356 Needle Bearing Grease, P/N 378642 Starter Bendix Lube P/N 337016 Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Adhesive 847 P/N 776964 P/N 777186 P/N 775612 Lubriplate† 777 P/N 317619 Black Neoprene Dip P/N 909570 Electrical Grease P/N 504824 2 + 4™...
Page 28 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS Gasket Sealing Compound P/N 317201 † † ThreeBond 1104, P/N 351052 Permatex No. 2, P/N 910032 ThreeBond 1207B, P/N 351053 † Pipe Sealant with Teflon P/N 910048 Thermal Joint Compound P/N 322170 RTV Silicone Sealant P/N 263753 †...
Page 29 INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS BOAT RIGGING ..............28 .
Page 30: Boat Rigging
INSTALLATION AND PREDELIVERY BOAT RIGGING BOAT RIGGING Additional remote control information: • Side-mount controls require a neutral lock fea- ture. Remote Controls • Single-outboard binnacle remote controls are Control Selection offered with or without an integrated key switch. WARNING WARNING The remote control used must have start- Always install and recommend use of an in-gear prevention.
Page 31: Battery Installation
INSTALLATION AND PREDELIVERY BOAT RIGGING Battery Installation Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from Each outboard requires its own starting battery. accessories. Finish this connection with a hex nut. Select a battery that meets or exceeds the mini- mum requirements.
Page 32: Fuel System Requirements
INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel System Requirements • The fuel primer bulb must be positioned in the fuel supply hose so the primer bulb can be held Overview with the arrow pointing “up” during priming. Fuel systems must meet the minimum specifica- tions.
Page 33: Outboard Installation
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION OUTBOARD WARNING INSTALLATION DO NOT install an outboard on a curved or irregular surface. Doing so can wear, bind, Hull Preparation and damage components, causing loss of control. Maximum Capacity WARNING Top Edge of Transom or Bracket Transom thickness or off-sets must also be con- Do not overpower the boat by installing an sidered.
Page 34: Transom Measuring And Drilling
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Transom Measuring and Drilling Determine transom height by measuring from the top edge of the transom, along the centerline. Hull Centerline Use a straightedge as a reference to extend the Locate the centerline of the boat transom as it bottom of the boat.
Page 35 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Drilling and Hardware Diagram Transom top surface 20 - M14 × P2.0 (Clamp screw) 176(6.9) 240(9.4) 4 - 10.5 164(6.5) Item Part name Part Number Quantity Bolt - (M 10 x 110 mm) 5037005 Washer No. 1 5037006 Washer No.
Page 36: Lifting The Outboard
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Lifting the Outboard Extend the output end of the steering cable and lubricate the inner core of cable prior to installa- Lift the outboard using the lift grips (NOT the tilt tion. grip or steering handle) and place it in the center of the boat’s transom.
Page 37: Outboard Mounting
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Drag Link Outboard Mounting Connect drag link to the steering cable with wash- Fastening the Outboard to the Transom ers and safety nut. Tighten the nut to 88 in. lbs. (10 N·m), then back the nut off 1/8 turn. WARNING The outboard must be correctly installed.
Page 38: Outboard Rigging
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING IMPORTANT: OUTBOARD RIGGING Use a marine sealant rated for above or below waterline use. RTV silicone is not approved for below waterline use. Polyurethane WARNING sealants are not easily removed and may damage outboard or boat mounting surfaces when To prevent accidental starting of engine, removed.
Page 39: Control Cable Installation
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Control Cable Installation Before installing wiring harness, check that seal is in place. Clean connectors and apply a light coat IMPORTANT: of Electrical Grease to the seal. Push connector Provide sufficient slack at out- together until latched. board end to permit unrestricted steering and tilt- ing of outboard.
Page 40 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Make sure that both forward and reverse gears der block rib. Refer to Installation/Adjustment on can be engaged with the same angle of remote p. 120. control handle travel from NEUTRAL position. 1. Match mark 005908 2.
Page 41: Fuel And Oil
INSTALLATION AND PREDELIVERY FUEL AND OIL FUEL AND OIL roller are aligned. Refer to Installation/Adjust- ment on p. 120. Fuel Requirements WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Improper handling of fuel could result in property damage, serious injury or death. Always turn off the outboard before fuel- ing.
Page 42: Oil Requirements
INSTALLATION AND PREDELIVERY FUEL AND OIL When using alcohol-extended fuels, be aware of Oil Requirements the following: • IMPORTANT: The boat’s fuel system may have different 4-Stroke outboards are shipped requirements regarding the use of alcohol fuels. without oil in the crankcase. Oil must be added Refer to the boat’s owner guide.
Page 43: Running Checks
INSTALLATION AND PREDELIVERY RUNNING CHECKS RUNNING CHECKS IMPORTANT: DO NOT perform break-in using a flushing device. DO NOT start-up or run the engine out of water. DO NOT leave a running WARNING engine unattended. DO NOT run outboard without a water sup- During the break-in, check water pump operation ply to the outboard’s cooling system.
Page 44: Fuel System
INSTALLATION AND PREDELIVERY RUNNING CHECKS Fuel System Tachometer Pulse Setting Perform running checks of the fuel system by fol- Confirm accuracy of tachometer reading. lowing these steps: • Adjust dial on back of tachometer to 6 pulse/12 • pole setting. Squeeze fuel primer bulb until hard or activate electric primer.
Page 45: Propeller Selection
INSTALLATION AND PREDELIVERY PROPELLER SELECTION PROPELLER SELECTION Procedure The propeller selection process is very important Refer to Propeller Hardware Installation on to the engine’s service life and to boat perfor- p. 44 before installing propeller. mance. Proceed carefully and thoroughly while considering the following points: The correct propeller, under normal load condi- •...
Page 46: Propeller Hardware Installation
INSTALLATION AND PREDELIVERY PROPELLER SELECTION Propeller Hardware Installation Wedge a block of wood between propeller blade and the anti-ventilation plate. WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally.
Page 47: Trim Tab Adjustment
INSTALLATION AND PREDELIVERY PROPELLER SELECTION Trim Tab Adjustment WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to compensate for this steering torque.
Page 48: Notes
INSTALLATION AND PREDELIVERY NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 49 MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . 48 ANTI-CORROSION PROTECTION .
Page 50: Inspection And Maintenance Schedule
MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outboard inspection and maintenance to be performed by an authorized Dealer. IMPORTANT: Outboards used for rental operations, commercial applications, or other high hour use applications require more frequent inspections and maintenance.
Page 51 MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE Engine Maintenance and Inspection Schedule Frequency Engine Care Description Product Operator’s Guide, review Timing belt Replace every four years Valve tappet clearance, inspect Driveshaft splines, inspect and lubricate Fuel system components, inspect and repair leaks Carburetor, inspect Breather line, replace Fastener inspection, tighten loosened components...
Page 52: Anti-Corrosion Protection
MAINTENANCE ANTI-CORROSION PROTECTION ANTI-CORROSION PROTECTION Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion. Outboards are equipped with sacrificial anodes.
Page 53: Testing Procedure - Continuity
MAINTENANCE ANTI-CORROSION PROTECTION For best anode performance: Bonding Wires • Replace all anodes that have eroded or disinte- Check bonding wires for breaks, corrosion or grated to two-thirds of their original size. other damage. Clean wire terminals with solvent. • Do not paint or apply protective coatings to Replace if necessary.
Page 54: Cooling System
MAINTENANCE COOLING SYSTEM COOLING SYSTEM IMPORTANT: To prevent damage, do not run outboard above fast idle. Water must flow from the Check the condition of cooling system compo- water pump indicator. If it does not, shut off the nents regularly. The outboard cooling system con- outboard and repair as needed.
Page 55: Fuel System
MAINTENANCE FUEL SYSTEM FUEL SYSTEM Fuel Filter If water accumulation, sediment, leakage, cracks, Breather and Fuel Line or other damage is found, replace the fuel filter. If leakage, cracks, swelling, or other damage is If water or sediment is found, clean as follows: found, replace the breather line and/or the fuel •...
Page 56: Battery
MAINTENANCE BATTERY BATTERY LUBRICATION Check battery connections frequently. Periodically Engine Oil remove battery to clean and service connections. Oil Level Check WARNING Place outboard upright on a level surface. Battery electrolyte is acidic—handle with Remove the oil level dipstick (filler cap) and wipe care.
Page 57: Engine Oil Filter
MAINTENANCE LUBRICATION Recommended oil: Pour recommended oil into oil filler opening, then • install filler cap. Evinrude/Johnson Ultra 4-Stroke oil, or • SAE 10W-40, API classification SE, SF, SG, SH, Oil amount: • Oil change only: 1.6 Qt. (1.5 L) •...
Page 58: Gearcase Lubricant
MAINTENANCE LUBRICATION IMPORTANT: Examine drained lubricant for excessive metal Before fitting new oil filter, be sure fragments and for any indication of water in oil to oil o-ring. (cloudy or milky appearance). Lubricant that is black in color with a burnt odor indicates worn, overheated oil.
Page 59: Linkages And Fittings
MAINTENANCE LUBRICATION Linkages and Fittings Apply Triple-Guard grease to the points shown. Throttle cable Throttle cable Swivel bracket NSI cable Clamp screw Propeller shaft Steering bracket WARNING When servicing the propeller, always shift the outboard to NEUTRAL position, and twist and remove all spark plug leads so the engine cannot be started accidentally.
Page 60: Spark Plugs
MAINTENANCE SPARK PLUGS SPARK PLUGS VALVE CLEARANCE Spark plugs should be removed and examined Measurement periodically. Replace worn, fouled or damaged Remove side covers. Refer to side cover spark plugs. Removal and Installation on p. 177. • Remove spark plugs and inspect condition. •...
Page 61: Adjustment
MAINTENANCE VALVE CLEARANCE Use a feeler gauge to measure clearance Tighten lock nut to 95 in. lbs. (11 N·m) while hold- between valve stem end and rocker arm. ing pivot nut. 005544 005546 Valve clearance: (cold engine) Recheck valve clearance. •...
Page 62: Idle Speed
MAINTENANCE IDLE SPEED IDLE SPEED IGNITION TIMING Check throttle link mechanism and carburetor IMPORTANT: Before checking ignition timing, throttle valve for smooth operation. make sure idle speed is adjusted within specifica- tion. Connect a shop tachometer to the engine. Start and warm the engine. Connect a shop tachometer and timing light to the no.
Page 63: Storage
MAINTENANCE STORAGE STORAGE Turn the flywheel in a clockwise direction to dis- tribute the fogging oil throughout the cylinders. Install and torque the spark plugs. WARNING If outboard is equipped with a portable fuel tank, To prevent injury from contact with rotat- disconnect fuel hose from outboard and tank.
Page 64: Pre-Season Service
MAINTENANCE PRE-SEASON SERVICE PRE-SEASON SERVICE SUBMERGED ENGINES If the outboard was removed from the boat for Once an outboard has been submerged in fresh storage, make certain it has been reinstalled with or salt water, it must be serviced within three (3) factory specified hardware.
Page 65: Engine Dropped Overboard (Running)
MAINTENANCE SUBMERGED ENGINES Disassemble all electrical connectors. Clean con- Engine Dropped Overboard nectors and terminals, and treat with water dis- (Running) placing electrical spray. Apply Electrical Grease to terminals prior to reassembly. Coat all exposed Follow the same procedures as Engine Dropped solenoid terminals and engine grounds with Black Overboard (Not Running).
Page 66: Notes
MAINTENANCE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 67 ELECTRICAL ELECTRICAL TABLE OF CONTENTS CAUTION SYSTEM ..............66 .
Page 68: Caution System
ELECTRICAL CAUTION SYSTEM CAUTION SYSTEM Over-Revolution Caution System The CDI unit engages the over-revolution limiter Two caution systems alert the operator when an above 5500 RPM. abnormality occurs: • If the engine is operated at a speed above 5500 • Over-revolution Caution RPM for more than 10 seconds, the engine •...
Page 69: Low Oil Pressure Caution System
ELECTRICAL CAUTION SYSTEM Low Oil Pressure Caution System Oil Pressure Caution System Tests The oil pressure switch activates the low oil pres- sure caution system when engine oil pressure IMPORTANT: Before checking the oil pressure drops below 7 psi (49 kPa). caution circuit, make sure the engine oil pressure •...
Page 70: Oil Pressure Switch Service
ELECTRICAL CAUTION SYSTEM Oil Pressure Caution Lamp Circuit Oil Pressure Switch Service Remove the blue lead wire from the oil pressure Removal switch. Loosen screw and disconnect blue lead wire from Start the engine. oil pressure switch. Touch the blue lead wire to engine ground. If the Remove the oil pressure switch.
Page 71: Temperature Sensor Tests
ELECTRICAL CAUTION SYSTEM Temperature Sensor Tests Place the sensor’s tip in water and gradually heat the water while monitoring changes in resistance. The temperature sensor is a thermistor type sen- sor which sends a voltage signal to the CDI unit. The input signal is used to detect both tempera- ture and temperature change over time.
Page 72: Battery Charging System
ELECTRICAL BATTERY CHARGING SYSTEM BATTERY CHARGING SYSTEM The battery charging system includes the battery charge coil, rectifier/regulator, and battery. AC current generated by the battery charge coil is converted by the rectifier into regulated DC current which is used to charge the battery. Manual start models Magneto Battery charge coil...
Page 73: Inspection
ELECTRICAL BATTERY CHARGING SYSTEM Inspection Battery Charge Coil Resistance Disconnect battery charge coil wires from rectifier. Battery Charge Coil Output Connect Ohmmeter test probes to battery charge Disconnect battery charge coil wires from rectifier. coil lead wires as shown. Connect Peak Reading Voltmeter to battery Tester probe connection charge coil lead wires as shown.
Page 74 ELECTRICAL BATTERY CHARGING SYSTEM Rectifier and Regulator Fuse Disconnect all lead wires of rectifier and regulator. Remove the fuse from fuse case. Measure the resistance between leads in the Inspect the fuse and replace with a new 20-amp combinations shown: fuse if needed.
Page 75: Removal And Installation
ELECTRICAL BATTERY CHARGING SYSTEM Fuse Case Removal and Installation Disconnect battery cables at the battery. Before removing electrical parts: • Disconnect battery cables at the battery. Disconnect white lead wire of rectifier from engine • Twist and remove all spark plug leads. wire harness.
Page 76: Electric Starter System
ELECTRICAL ELECTRIC STARTER SYSTEM ELECTRIC STARTER SYSTEM Operation The starting circuit includes the battery, starting motor, ignition switch (or starter button), neutral switch, and related wiring. The starter motor magnetic switch coils are magnetized when the starter button is closed. The resulting plunger and pinion shift lever movement causes the pinion to engage the engine flywheel gear, the magnetic switch main contacts to close, and engine cranking to take place.
Page 77 ELECTRICAL ELECTRIC STARTER SYSTEM Remote Models Hold-in coil Pull-in coil Magnetic switch Plunger Shift lever Ring gear Starter Pinion & Fuse 20A motor Battery over-running clutch Starter relay Ignition switch Movable contact Stationary contact Neutral switch...
Page 78: Troubleshooting
ELECTRICAL ELECTRIC STARTER SYSTEM Troubleshooting Before troubleshooting the electric starter system, make sure: • Battery is fully charged • All cables and wires are securely connected • Shift is in NEUTRAL position. Engine does not start. Does engine turn over Does starter motor rotate? with continued cranking? •...
Page 79: Inspection
ELECTRICAL ELECTRIC STARTER SYSTEM Inspection Neutral Switch Disconnect neutral switch lead wire. Ignition Switch (Remote Models) Disconnect the ignition switch from remote control wiring harness. Check continuity between switch terminals at the key positions shown: Switch Terminals Position START 1. Neutral switch 005566 PUSH Check continuity between lead wires while operat-...
Page 80 ELECTRICAL ELECTRIC STARTER SYSTEM motor relay. Disconnect starter motor relay from Connect 12V positive (+) to terminal (4), and (–) to wire connector. terminal (3). Then, check continuity between ter- minal (1) and (2) when 12 V is applied. 1. Starter relay 005568 004731 12 V Power...
Page 81: Starter Motor Service
ELECTRICAL ELECTRIC STARTER SYSTEM Starter Motor Service Remove four screws securing starter motor and bracket. Lift up and remove bracket. Removal Remove engine side covers. Refer to side cover Removal and Installation on p. 177. Remove flywheel cover and flywheel. Refer to component Removal on p.
Page 82 ELECTRICAL ELECTRIC STARTER SYSTEM Disassembly Remove the magnetic switch. When servicing starter motor, clean component parts thoroughly. DO NOT use a degreasing tank or grease dissolv- ing solvent on yoke assembly, armature coil, over- running clutch assembly, magnetic switch, or rub- ber or plastic parts.
Page 83 ELECTRICAL ELECTRIC STARTER SYSTEM Pull the brush spring up to separate the brush Remove the center bracket, with shift lever, pin- from the surface of the commutator, then remove ion, and pinion shaft, from front housing. the brush holder. 1. Center bracket 004749 2.
Page 84 ELECTRICAL ELECTRIC STARTER SYSTEM Remove the pinion stopper and pinion. Remove the pinion shaft, washers, and rubber ring from center bracket. WARNING Wear safety glasses when disassembling and assembling stopper ring. 1. Pinion shaft 004753 2. Washers 3. Rubber ring Inspection and Servicing 1.
Page 85 ELECTRICAL ELECTRIC STARTER SYSTEM Measure commutator outside diameter. Check for continuity between the commutator and • the armature core/shaft. Replace armature if con- Standard: 1.14 in. (29.0 mm) tinuity is indicated. • Service limit: 1.10 in. (28.0 mm) If measurement exceeds service limit, replace armature.
Page 86 ELECTRICAL ELECTRIC STARTER SYSTEM Brushes Brush Spring Check the length of each brush. Inspect brush spring for wear, damage, or other • abnormal conditions. Standard: 0.61 in. (15.5 mm) • Service limit: 0.37 in. (9.5 mm) Check the brush spring tension. •...
Page 87 ELECTRICAL ELECTRIC STARTER SYSTEM Pinion and Over-Running Clutch Gear Inspect pinion for wear, damage, or other abnor- Inspect planetary gears and internal gear for wear, mal conditions. damage, or other abnormal conditions. Replace if necessary. Check that clutch locks when turned in direction of drive and rotates smoothly in reverse direction.
Page 88 ELECTRICAL ELECTRIC STARTER SYSTEM Front Housing Plunger Inspect front housing for wear, damage, or other Inspect plunger for wear or other damage. abnormal conditions. Replace if necessary. Replace if necessary. Inspect bushing for wear or other damage. Replace if necessary. 004769 Magnetic Switch 004767...
Page 89 ELECTRICAL ELECTRIC STARTER SYSTEM Check for continuity across magnetic switch “S” Place plunger against a flat surface and push the terminal and “M” terminal. magnetic switch down. With switch held down, check for continuity between terminal “B” and ter- If no continuity, replace coil. minal “M.”...
Page 90 ELECTRICAL ELECTRIC STARTER SYSTEM Assembly Assembly is reverse order of disassembly with special attention to the following steps. When installing pinion shift lever, refer to diagram for installation direction. 7 N . m (0.7 kg-m, 5.1 lb-ft) 5.5 N . m (0.55 kg-m, 4.0 lb-ft) 1.
Page 91 ELECTRICAL ELECTRIC STARTER SYSTEM Performance Tests While connected as above with plunger out, dis- connect negative lead from terminal “M.” IMPORTANT: Each test must be performed Check that plunger and pinion remain out. If within 3 to 5 seconds to avoid coil damage from plunger and pinion return inward, replace mag- overheating.
Page 92 ELECTRICAL ELECTRIC STARTER SYSTEM No-Load Performance Test Installation Connect battery and ammeter to starter motor as Installation is reverse order of removal with spe- shown: cial attention to the following steps: Check that starter rotates smoothly and steadily Place starter motor in position, then install two with pinion moving out.
Page 93 IGNITION SYSTEM IGNITION SYSTEM TABLE OF CONTENTS SERVICE CHART ..............92 OPERATION .
Page 94: Service Chart
IGNITION SYSTEM SERVICE CHART SERVICE CHART 142 lb-ft (196 N . m) 1 Flywheel bolt 2 Washer 3 Key 4 Flywheel 5 Crankshaft position sensor 6 Screw 7 Charge coil (Stator) 8 Bolt Crankshaft NOTE: Clean flywheel and crankshaft mating surfaces with cleaning solvent.
Page 95: Operation
IGNITION SYSTEM OPERATION OPERATION The ignition system is a condenser discharge type. The condenser built in the CDI unit stores the electri- cal energy generated by the power source coil (stator). The electrical energy stored in the condenser is released to the ignition coil primary windings by the igni- tion timing signal calculated by the CDI unit from the crankshaft position sensor signals.
Page 96: Troubleshooting
IGNITION SYSTEM TROUBLESHOOTING TROUBLESHOOTING Perform the following ignition system tests when engine is hard to start to determine if the cause is in the ignition or other system. START Check ignition timing by Sparks using timing light. Check spark condition (2°...
Page 97: Ignition Tests
IGNITION SYSTEM IGNITION TESTS IGNITION TESTS Resistance Test Disconnect power source coil lead wire connector from CDI unit. WARNING Connect ohmmeter to coil lead wires as shown: Always disconnect the battery cables at Tester probe connection the battery before beginning resistance tests.
Page 98: Crankshaft Position Sensor
IGNITION SYSTEM IGNITION TESTS Crankshaft position Sensor Resistance Test Disconnect sensor lead wire connector from CDI Output Test unit. Disconnect crankshaft position sensor lead wire Connect ohmmeter test probes to coil lead wires connector from CDI unit. as shown: Connect Peak Reading Voltmeter to sensor lead Sensor Tester probe connection wires as shown.
Page 99: Ignition Coil
IGNITION SYSTEM IGNITION TESTS Ignition Coil Secondary Resistance Test Remove the spark plug caps from the high-ten- Primary Resistance Test sion leads. Disconnect ignition coil lead wire connector from Connect ohmmeter test probes black primary lead engine harness. and to the high-tension lead as shown: Connect ohmmeter test probes to coil lead wires Tester probe connection as shown:...
Page 100: Cdi Unit
IGNITION SYSTEM IGNITION TESTS CDI Unit Spark Plug Cap Output Test Resistance Test Disconnect 6 pin wire harness connector from CDI Measure spark plug cap resistance. unit. Spark plug cap resistance: Ω Connect 6 pin Test Cord, P/N 5034231, between •...
Page 101: Component Servicing
IGNITION SYSTEM COMPONENT SERVICING COMPONENT Remove three bolts and flywheel cover. SERVICING Removal WARNING Before removing ignition parts: Disconnect battery cables at the battery. Twist and remove all spark leads. 005582 Disconnect the battery cables at the battery. Twist and remove spark plug leads. Remove manual starter if applicable.
Page 102 IGNITION SYSTEM COMPONENT SERVICING Use Universal Puller Set, P/N 378103, and Disconnect the 6-pin wiring harness connector Screws, P/N 5034235, to loosen flywheel from from CDI unit. crankshaft. Install the puller on flywheel with body flat side up. Seat the shoulder screws completely. Hold puller by its handle, and tighten pressing screw until fly- wheel releases.
Page 103: Installation
IGNITION SYSTEM COMPONENT SERVICING Disconnect Red and Yellow lead wire from rectifier Installation & regulator. Installation is reverse order of removal with spe- cial attention to the following steps: Apply Nut Lock to threads of stator screws and tighten screws securely. Apply Nut Lock to threads of crankshaft position sensor screws and tighten screws securely.
Page 104: Notes
IGNITION SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 105 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS CARBURETOR OPERATION ............104 .
Page 106: Carburetor Operation
FUEL SYSTEM CARBURETOR OPERATION CARBURETOR OPERATION Float System Float pin Float valve Fuel inlet joint Float valve seat Float FUEL Idling/Trolling 1 Pilot jet 2 Pilot air jet 3 Pilot outlet 4 Bypass port #1 5 Pilot screw FUEL+AIR (MIXTURE) FUEL After passing through the pilot jet, fuel mixes with air supplied from the pilot air jet.
Page 107: Low-Mid Speed
FUEL SYSTEM CARBURETOR OPERATION Low-Mid Speed 1 Pilot jet 2 Pilot air jet 3 Pilot outlet 4 Bypass port 5 Pilot screw 6 Throttle valve FUEL+AIR (MIXTURE) FUEL As the throttle valve is opened gradually, air flowing through the throttle bore increases in proportion to the valve opening angle.
Page 108: Accelerator Pump
FUEL SYSTEM CARBURETOR OPERATION Accelerator Pump When quickly accelerated, the engine draws a large volume of air with fuel lagging behind causing the mixture to be transitionally lean. The accelerator pump compensates for such a fuel deficiency. This is a plunger type pump that pressure feeds fuel, at the time of quick acceleration, to the acceleration pump nozzle, which sprays fuel into the main bore.
Page 109: Auto-Enrichener System
FUEL SYSTEM CARBURETOR OPERATION Auto-Enrichener System Remote models are equipped with an auto-enrichener system. The automatic enrichener device consists of the PTC heater, the thermo-wax, and the plunger/needle. When the thermo-wax is cold, the plunger/needle moves upward, and fuel is drawn into the enrichener circuit from the float chamber.
Page 110: Manual Starter System
FUEL SYSTEM CARBURETOR OPERATION Manual Starter System When starter knob is pulled, fuel is drawn into the starter circuit from the float chamber. The starter jet meters this fuel, which then flows into fuel pipe and mixes with the air coming from the upper part of float chamber.
Page 111: Carburetor Service
FUEL SYSTEM CARBURETOR SERVICE CARBURETOR SERVICE Remove two screws securing plate. Removal Remove the STBD side cover. Refer to side cover Removal and Installation on p. 177. Remove recoil starter (rope start models). Refer to starter REMOVAL on p. 219. Remove flywheel cover (electric start models).
Page 112: Disassembly
FUEL SYSTEM CARBURETOR SERVICE Disassembly IMPORTANT: On carburetors with covered pilot screw, DO NOT remove the cover and adjust pilot Remote models: screw. • Remove screws, auto-enrichener, and heater guard. 1. Top cover 004659 1. Screws 005606 2. Auto-enrichener 3. Heater guard 1.
Page 113 FUEL SYSTEM CARBURETOR SERVICE Remove the four screws securing the float cham- Remove the float pin screw. Remove float, float ber, then remove the chamber and gasket. pin, and needle valve. 1. Float chamber 004661 1. Float pin screw 004663 1.
Page 114: Cleaning And Inspection
FUEL SYSTEM CARBURETOR SERVICE Remove the main jet and main nozzle. Remove the accelerator pump plunger and spring. 1. Main jet 004665 1. Accelerator pump plunger 004668 2. Spring Cleaning and Inspection Carburetor must be completely disassembled. Use a clean bristle brush to remove gum or var- nish deposits.
Page 115 FUEL SYSTEM CARBURETOR SERVICE Inspect needle valve seat. Replace carburetor Inspect the float. body if worn or damaged. 004672 004669 Inspect the auto-enrichener needle valve. If bro- Inspect jet and nozzle. ken tip or wear is found, replace the auto- enrichener.
Page 116: Assembly
FUEL SYSTEM CARBURETOR SERVICE Assembly 1. Carburetor body 2. Main nozzle 3. Main jet 4. Pilot jet 5. Cap 21 26 6. Float 7. Needle valve 8. Needle valve pin 9. Clip 10. Pin 12 13 11. Screw 12. Stop screw 13.
Page 117 FUEL SYSTEM CARBURETOR SERVICE Assembly is reverse order of disassembly with Measure and adjust float height. special attention to the following steps: • Float height: 13.5 ± 2 mm Install the float, with float pin and needle valve. Secure float pin with screw. 1.
Page 118: Installation
FUEL SYSTEM CARBURETOR SERVICE Installation Tighten carburetor and plate mounting screws to 88 in. lbs. (10 N·m). Installation is reverse order of removal with spe- cial attention to the following steps: IMPORTANT: Do not re-use gaskets. Air leak- age will cause a lean air/fuel mixture which can result in severe engine damage.
Page 119: Fuel Pump
FUEL SYSTEM FUEL PUMP FUEL PUMP IMPORTANT: Do not re-use o-ring. Removal Remove the STBD side cover. Refer to side cover Removal and Installation on p. 177. Remove the fuel filter from filter bracket. 1. O-ring 005611 2. Pump rod Inspection The fuel pump assembly is not serviceable.
Page 120: Intake Manifold Service
FUEL SYSTEM INTAKE MANIFOLD SERVICE INTAKE MANIFOLD Remove screw, throttle drum (with throttle cables), and throttle cam. Remove two screws and cable SERVICE bracket. Removal Remove recoil starter (rope start models). Refer to starter REMOVAL on p. 219. Remove flywheel cover (electric start models). Refer to ignition COMPONENT SERVICING on p.
Page 121: Installation
FUEL SYSTEM INTAKE MANIFOLD SERVICE Installation Tighten manifold screws 220 in. lbs. (25 N·m). Installation is reverse order of removal with spe- cial attention to the following steps: Install gaskets and intake manifold. IMPORTANT: Port and starboard intake mani- fold gaskets are shaped differently. 1.
Page 122: Throttle Control
FUEL SYSTEM THROTTLE CONTROL THROTTLE CONTROL Installation/Adjustment Tiller Models Rotate throttle control grip to bring the throttle to Rotate the throttle control grip from fully closed full close. position to fully open position several times. With the throttle control grip at full close, make Align the match mark a on throttle cam 1 with sure the match mark a on throttle cam 1 aligns the center of throttle lever roller 2 and hold this...
Page 123 FUEL SYSTEM THROTTLE CONTROL Remote Models Install two throttle cable 1 · 2 to throttle drum 3, this condition unmoved and turn the cable lock interlink throttle lever 4 and each cable brackets nuts 8 so as to removed play on inner cables. Tighten the lock nuts securely.
Page 124: Notes
FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 125 POWERHEAD POWERHEAD TABLE OF CONTENTS SPECIFICATIONS ..............124 TEST PROCEDURES .
Page 126: Specifications
POWERHEAD SPECIFICATIONS SPECIFICATIONS Data Item Unit 25 HP CYLINDER HEAD/CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Cam height mm (in) 32.921 – 33.081 (1.2961 – 1.3024) Limit mm (in) 32.821 (1.2922) mm (in) 32.921 – 33.081 (1.2961 – 1.3024) Limit mm (in) 32.821 (1.2922)
Page 127 POWERHEAD SPECIFICATIONS Data Item Unit 25 HP VALVE/VALVE GUIDE Valve diameter mm (in) 31.0 (1.22) mm (in) 26.0 (1.02) Valve clearance mm (in) 0.03 – 0.07 (0.001 – 0.003) (when cold) mm (in) 0.03 – 0.07 (0.001 – 0.003) Valve seat angle 30°, 45°, 60°...
Page 128 POWERHEAD SPECIFICATIONS Data Item Unit 25 HP CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in) 0.03 (0.001) Piston to cylinder mm (in) 0.020 – 0.040 (0.0008 – 0.0016) clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 71.000 – 71.020 (2.7953 – 2.7961) Cylinder measuring position mm (in) 50 (2.0) from cylinder top surface...
Page 129 POWERHEAD SPECIFICATIONS Data Item Unit 25 HP CRANKSHAFT / CONNECTING ROD Connecting rod mm (in) 18.006 – 18.014 (0.7089 – 0.7092) small end inside diameter Connecting rod mm (in) 0.020 – 0.030 (0.0008 – 0.0012) big end oil Limit mm (in) 0.065 (0.0026) clearance Connecting rod...
Page 130: Test Procedures
POWERHEAD TEST PROCEDURES TEST PROCEDURES WARNING Compression Testing Disconnect the safety lanyard from the emergency stop switch prior to cranking Start and run outboard until it achieves operating the engine. This will prevent any residual temperature, then shut OFF. fuel from the cylinders from being ignited Remove spark plugs.
Page 131: Oil Pressure Test
POWERHEAD TEST PROCEDURES Oil Pressure Test Connect an engine tachometer. Check the engine oil level. Start and run outboard until it achieves operating temperature. Remove side covers. Refer to side cover Removal and Installation on p. 177. After warm up, shift into forward gear and increase speed to 3000 RPM.
Page 132: Removal And Installation
POWERHEAD REMOVAL AND INSTALLATION REMOVAL AND Remove screws and two ignition coils, then dis- connect primary lead wire connectors. INSTALLATION Removal WARNING To prevent accidental starting of engine while servicing, twist and remove spark plug leads. Disconnect the battery cables at the battery. 1.
Page 133 POWERHEAD REMOVAL AND INSTALLATION Remove flywheel, stator, and crankshaft position Remove electric starter. Refer to Starter Motor sensors. Refer to ignition COMPONENT SERVIC- Service on p. 79. ING on p. 99. 005572 005584 Remove screws and wire clamps. Disconnect all engine wiring harness connectors from CDI unit and remove CDI unit from electric parts holder.
Page 134 POWERHEAD REMOVAL AND INSTALLATION Remove twelve powerhead mounting screws and Remove two screws securing front panel to crank- two nuts. case. Lift powerhead from oil pan. 005645 005648 005646 005649 Loosen clamp and remove oil strainer. 005647 1. Oil strainer 005650...
Page 135: Installation
POWERHEAD REMOVAL AND INSTALLATION Installation Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft. Installation is reverse order of removal with spe- cial attention to the following: Lower the powerhead on to oil pan. If necessary, rotate crankshaft to align crankshaft and drive- Install oil strainer and secure with clamp.
Page 136 POWERHEAD REMOVAL AND INSTALLATION Install cylinder head cover gasket and cylinder head cover. Tighten cover screws 88 in. lbs. (10 N·m). 005648 1. Cylinder head cover 005543 2. Cover screw Install electric starter. Tighten starter and bracket screws to 16.5 ft. lbs. (23 N·m). Refer to Starter Motor Service on p.
Page 137: Oil Pump
POWERHEAD OIL PUMP OIL PUMP Check rotors and rotor plate for excessive wear or damage. Replace as necessary. Disassembly Assembly Remove seven screws and oil pump rotor plate. Apply a thin coat of engine oil to inner and outer rotors, inside surfaces of oil pump case, and plate. Install outer and inner rotors in pump case.
Page 138: Cylinder Head
POWERHEAD CYLINDER HEAD CYLINDER HEAD Loosen and remove valve adjusting lock nuts, then remove pivot nuts and rocker arms. Removal Remove powerhead. Refer powerhead REMOVAL AND INSTALLATION on p. 130. Remove screws and starter motor band. 1. Lock nuts 005662 2.
Page 139 POWERHEAD CYLINDER HEAD Remove 13 screws, thermostat cover, and oil gal- Remove four screws securing bottom crankcase. lery plate. IMPORTANT: To prevent valve damage, be sure rocker arms have been removed before removing bottom half of crankcase. 1. Thermostat cover 005664 2.
Page 140: Disassembly
POWERHEAD CYLINDER HEAD Use a 10 mm deep socket to remove four cylinder Disassembly head bolts in the order shown. Use Valve Spring Compressor, P/N 346186, and attachment from Valve Lifter Adaptor Kit, P/N 5000899, and tweezers to remove valve cot- ters while compressing valve spring.
Page 141: Cleaning/Inspection
POWERHEAD CYLINDER HEAD Remove valve spring retainer, valve spring, and Cleaning/Inspection valve. Cylinder Head Remove all carbon from combustion chambers. IMPORTANT: Do not use sharp edged tools to scrape carbon off cylinder head or components. Be careful not to scuff or nick metal surfaces. 1.
Page 142 POWERHEAD CYLINDER HEAD mm). If measurement exceeds this limit, resurface Rocker Arm/Push Rod or replace cylinder head. Inspect rocker arms. Replace if cracked, distorted, or damaged. Inspect push rods. Replace if bent or worn. 005674 005677 Valve/Valve Guide To check valve guide to valve stem clearance, measure the following: Valve stem outside diameter: •...
Page 143 POWERHEAD CYLINDER HEAD If clearance exceeds service limit, replace valve stem end chamfer. When chamfer has been worn and/or valve guide. away, replace valve. If unable to measure valve guide inside diameter, measure valve stem deflection as follows: Install valve into valve guide. Position the valve head at approximately 5 mm away from valve seat.
Page 144 POWERHEAD CYLINDER HEAD Measure valve head thickness. If measurement If measurement exceeds service limit, repair valve exceeds service limit, replace valve. seat. Refer to Valve Seat Servicing on p. 144. • Standard: 0.0394 in. (1.0 mm) • Service limit: 0.0197 in. (0.5 mm) 1.
Page 145: Assembly
POWERHEAD CYLINDER HEAD Valve Spring Assembly Measure valve spring free length. If measurement Valve Guide Replacement is lower than service limit, replace valve spring. • Standard: 1.608 in. (40.84 mm) IMPORTANT: Be careful not to damage cylinder • Service limit: 1.5487 in. (39.21 mm) head when replacing valve guide.
Page 146 POWERHEAD CYLINDER HEAD Valve Seat Servicing Drive valve guide in from valve spring side to the specified height. If the contact between valve and seat is not uni- form, the valve seat must be refaced. Measure valve guide protrusion: • Protrusion: 0.39 ±...
Page 147 POWERHEAD CYLINDER HEAD Clean up any burrs using 45° cutter very lightly. Valves Apply Nut Lock to threads of rocker arm pivot Lap valve on seat in two steps, first with coarse bolts. Install pivot bolts and tighten 16.5 ft. lbs. (23 grit lapping compound applied to face, and sec- N·m).
Page 148: Installation
POWERHEAD CYLINDER HEAD IMPORTANT: Install each valve and spring in its original position. Set valve spring in place with narrow spiral area facing valve spring seat. 1. Valve cotter 004547 2. Groove Installation 1. Wide spiral area 004545 2. Narrow spiral area 3.
Page 149 POWERHEAD CYLINDER HEAD Lightly seat all cylinder head screws. Then Install 8 mm and 10 mm screws from Crankshaft tighten, in stages, following the pattern shown. Remover/Installer Kit, P/N 5037487, in positions • shown. Tighten to 20 ft. lbs. (28 N·m) •...
Page 150 POWERHEAD CYLINDER HEAD Install washer and idle gear shaft nut. Tighten nut Install rocker arms, pivot nuts, and valve adjusting securely. lock nuts on to pivot bolts. Install two studs in crankcase. 1. Lock nuts 005662 2. Pivot nuts 3. Rocker arms 1.
Page 151: Crankshaft, Pistons And Camshaft
POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT CRANKSHAFT, PISTONS Remove connecting rod screws and caps. AND CAMSHAFT Disassembly Remove the powerhead. Refer to REMOVAL AND INSTALLATION on p. 130. Remove the cylinder head assemblies. Refer to cylinder head Removal on p. 136. Remove the idle gear and camshaft.
Page 152 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Remove piston pin circlips. Remove oil filter and oil pressure switch. Remove piston pin from connecting rod. Remove piston rings from piston. 1. Oil pressure switch 005702 Remove shaft and washer from idle gear. 1. Circlips 004566 2.
Page 153: Cleaning/Inspection
POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Cleaning/Inspection IMPORTANT: If cracks, excessive wear, or other damage is found on any component, replace com- ponent. Camshaft Inspect cam face and journals for pitting, scratches, wear, or damage. If any of these condi- tions are found, replace camshaft. Use a micrometer to measure the cam height.
Page 154 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Cylinder Check water jackets for clogs or obstructions. Use a straightedge and a thickness gauge to measure the cylinder distortion on the gasket sur- face at six locations as shown. The service limit for distortion is 0.001 in. (0.03 mm).
Page 155 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT surement exceeds service limit, rebore or replace Subtract the piston skirt measurement from the cylinder. cylinder bore measurement to determine clear- ance. Cylinder bore: • Standard: 2.7953 to 2.7961 in. (71.000 to 71.020 mm) Piston skirt diameter: •...
Page 156 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Pistons and Rings Measure piston ring end gap with piston ring in the lowest position of cylinder bore. If measurement Measure piston ring to groove clearance after exceeds service limit, replace piston ring. decarbonizing. Piston ring end gap, standard: Standard piston ring groove width: •...
Page 157 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Check that the piston pin and the piston pin hole are free from excessive wear and damage. Apply engine oil on piston pin so that piston pin can move smoothly in the piston pin hole. To check piston pin to piston pin hole clearance, measure the following: •...
Page 158 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Measure connecting rod big end side clearance Measure the crank pin outside diameter in the with connecting rod installed on crank pin. If mea- thrust and axial directions at two positions as surement exceeds service limit, replace the con- shown: necting rod and/or crankshaft.
Page 159 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Measure the connecting rod big end inside diame- Measure connecting rod big end oil clearance as ter as follows: follows: • • Clean the surface of the rod and cap. Clean the surfaces of rod, cap, and crankpin. •...
Page 160 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT • Crankshaft Apply engine oil to screws and tighten in two steps to 102 in. lbs. (12 N·m). Measure crankshaft runout using “V” blocks and a dial indicator. If measurement exceeds service limit, replace crankshaft and/or crankcase. Crankshaft runout: •...
Page 161: Assembly
POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Assembly Apply engine oil to outer surface of bearing. Drive bearing into upper cavity until it bottoms on shoul- IMPORTANT: der. If original components are not replaced, each piston, piston pin, and connecting rod is to be assembled and installed in its original location.
Page 162 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Remove lower crankshaft oil seal. Drive bearing into cavity until it bottoms on shoul- der. 005732 005735 Apply engine oil to outer surface of oil seal. Drive Piston and Connecting Rod seal into position with lip (spring side) facing inward.
Page 163 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT IMPORTANT: IMPORTANT: Install connecting rods in direc- When installing spacer, do not tion shown. End gap of circlip should not align with allow ends to overlap in the groove. cutaway in piston pin bore. 1. Incorrect 004599 2.
Page 164 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Position rings so that gaps are staggered at Piston to Cylinder approximately 90° angles. Apply engine oil to piston and cylinder walls. Place piston and connecting rod assembly into cylinder bore from cylinder head side. IMPORTANT: Position the up mark (O) on pis- ton toward the flywheel.
Page 165 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Apply engine oil to crank pin, connecting rod, and Camshaft Timing Gear cap. Fit the spring plate on the no. 2 gear so that the pin contacts the end of the spring plate. Install dowel pins and cap to connecting rod. IMPORTANT: Install each connecting rod cap in its original location.
Page 166 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Camshaft to Cylinder Block Idle Gear Apply engine oil to tappets and install in block. Fit the scissors gear spring plate on the no. 2 gear as shown. 1. Tappets 005698 1. Spring plate 005749 Apply engine oil to each camshaft lobe and jour- nal.
Page 167 POWERHEAD CRANKSHAFT, PISTONS AND CAMSHAFT Install the idle gear shaft and washer. Install the idle gear. Check that aligning marks on all three gears match as shown. 1. Shaft 005703 2. Washer 1. Alignment marks 005761 Turn crankshaft and camshaft into positions Install cylinder heads and bottom crankcase.
Page 168: Thermostat Service
POWERHEAD THERMOSTAT SERVICE Turn the crankshaft in the normal rotating direction THERMOSTAT SERVICE and check that the timing mark on the camshaft is pointing straight up when the crankshaft timing Removal mark is pointing straight down. Remove the flywheel. Refer to COMPONENT SERVICING on p.
Page 169: Inspection
POWERHEAD THERMOSTAT SERVICE Inspection Installation If salt deposits, corrosion, wear, or other damage Install thermostat, thermostat cover, and oil gallery are found, clean or replace. plate. Tighten screws 88 in. lbs. (10 N·m). Check thermostat opening temperature as fol- lows: •...
Page 170: Cooling System Diagram
POWERHEAD COOLING SYSTEM DIAGRAM COOLING SYSTEM DIAGRAM The water cooling system includes the lower unit water pump, lower unit to powerhead water supply tube, oil pan water pressure valve, powerhead water passages, and thermostat. The cooling system cools both the powerhead and exhaust. If overheating occurs, inspect the cooling system for blockage, corrosion, or damage.
Page 171: Engine Lubrication Diagram
POWERHEAD ENGINE LUBRICATION DIAGRAM ENGINE LUBRICATION DIAGRAM A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrica- tion. Oil from the pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery.
Page 172: Notes
POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 173 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............172 SIDE COVER .
Page 174: Service Chart
MIDSECTION SERVICE CHART SERVICE CHART OVER 1. Side cover STBD 2. Side cover PORT 3. Side cover protector 4. Washer 5. Screw 16 17 6. Front panel protector 7. Screw 8. Screw 9. Pin 10. Front panel 11. Bolt 12. Pin 13.
Page 175 MIDSECTION SERVICE CHART IL PAN 28 30 50 N . m (5.0 kg-m, 36.2 lb-ft) 1. Gasket 21. Gasket 50 N . m 2. Oil pan 22. Water flash plug (5.0 kg-m, 36.2 lb-ft) 3. Plug 23. Upper mount cover STBD 4.
Page 176 MIDSECTION SERVICE CHART RIVESHAFT OUSING 64 N . m (6.4 kg-m, 46.3 lb-ft) 32. Driveshaft housing 44. Bolt 33. Bolt 45. Nut 34. Dowel pin 46. Lower reverse thrust mount 35. Bush 47. Lower side mount 36. Screw 48. Lower mount 37.
Page 177 MIDSECTION SERVICE CHART TERN RACKET 43 N . m 4.3 kg-m 31.0 lb-ft 1. STBD clamp bracket 2. PORT clamp bracket 3. Clamp bracket shaft 4. Washer 5. Nut 25. Shim 6. Cap 26. Key 7. Clamp screw 27. Lower mount bracket 8.
Page 178 MIDSECTION SERVICE CHART ILLER ANDLE 1 Tiller handle 2 Tiller handle cover 3 Bolt 4 Spacer 5 Shim 6 Wave washer 7 Handle grip 8 Handle rod 9 Pin 0 Adjuster A Bush B Spring C Stopper D Washer E Screw F Throttle cable G Washer H Bush...
Page 179: Side Cover
MIDSECTION SIDE COVER SIDE COVER DRIVESHAFT HOUSING AND OIL PAN Removal and Installation Pull out rear hook lever. Removal Remove five screws from starboard side cover. Remove the powerhead. Refer to Powerhead Removal on p. 130. Remove the gearcase. Refer to Gearcase REMOVAL AND INSTALLATION on p.
Page 180 MIDSECTION DRIVESHAFT HOUSING AND OIL PAN Remove the two lower mount cover screws and Remove two upper mount nuts and driveshaft remove both lower mount covers. housing (with oil pan). WARNING When removing the upper mount nuts, driveshaft housing must be firmly sup- ported.
Page 181: Disassembly
MIDSECTION DRIVESHAFT HOUSING AND OIL PAN Disassembly Remove six screws and oil pan. Remove three pins and side cover seal. 1. Screws 005785 2. Oil pan 1. Pins 005782 2. Cover seal Remove three screws, water pressure valve cover, and valve. Remove upper mount cover screws and port and starboard mount covers.
Page 182: Cleaning And Inspection
MIDSECTION DRIVESHAFT HOUSING AND OIL PAN Remove screw and water tube. Check the driveshaft and oil pan housings for dis- tortion. Place the housing on a surface plate. Use a dial indicator to check the flatness by measuring the run-out on the top edge of the housing. The maximum allowable run-out is 0.009 in.
Page 183: Assembly
MIDSECTION DRIVESHAFT HOUSING AND OIL PAN Assembly Install the oil pan on the driveshaft housing and tighten six screws 36 ft. lbs. (50 N·m). Assembly is reverse order of disassembly with special attention to the following steps: Install water tube grommets and water tube in driveshaft housing.
Page 184 MIDSECTION DRIVESHAFT HOUSING AND OIL PAN Port Side Mount Starboard Side Mount Install the upper mount assembly into oil pan. Install the upper mount assembly into oil pan. Install mount cover with arrow facing forward. Be Install mount cover with arrow facing forward. Be sure retaining pin on cover fits into retaining pin sure retaining pin on oil pan fits into retaining pin hole on the mount.
Page 185 MIDSECTION DRIVESHAFT HOUSING AND OIL PAN Driveshaft Housing/Oil Pan Lower Mount Install side cover seal with three pins. Assemble the lower side mounts, lower side cush- ion, and lower thrust mount to lower mount. Arrow on mount must face forward when installed. 1.
Page 186: Stern Bracket
MIDSECTION STERN BRACKET Install lower mount cover. Apply Nut Lock to STERN BRACKET threads of cover screws and tighten to 198 in. lbs. (23 N·m). Disassembly Remove driveshaft housing/oil pan assembly. Refer to Removal on p. 177. Remove the two screws securing tiller handle bracket and tiller handle (tiller models).
Page 187 MIDSECTION STERN BRACKET Remove key, shim, and washer. Remove washer, upper bushing, and steering adjuster plate. 1. Circlip 005813 2. Lower mount bracket 1. Steering bracket 005815 3. Key 2. Washer 4. Shim 3. Bushing 5. Washer 4. Steering adjuster plate Remove steering friction screw, cover, washer, Remove swivel bracket seal and lower bushing.
Page 188 MIDSECTION STERN BRACKET Remove nut, washer, washer, steering friction Use an appropriate tool to bend lock tab away lever, plate, friction plate washer, friction adjuster from tilt tube nut. plate, and friction plate washer (tiller models). 1. Lock tab 005820 1.
Page 189 MIDSECTION STERN BRACKET Slide port clamp bracket off clamp bracket shaft. Remove screws and tilt support arms from clamp brackets. 1. Port clamp bracket 005823 1. Screw 005825 2. Tilt support arm Pull starboard clamp bracket outward to remove clamp bracket and bracket shaft from swivel Remove release lever and bushings.
Page 190: Inspection
MIDSECTION STERN BRACKET Remove two large springs from reverse lock arm Inspection and swivel bracket. Inspect all parts for excessive wear, cracks, defects, or damage. Replace as necessary. Assembly Assembly is reverse order of disassembly with special attention to the following steps: Apply Nut Lock to threads of shallow drive arm screws.
Page 191 MIDSECTION STERN BRACKET Apply Nut Lock to tilt support arm screws. Install Assemble the clamp bracket shaft, starboard tilt support arms. Tighten screws 160 in. lbs. (18 clamp bracket, release lever, bushings, and N·m). swivel bracket. 1. Screw 005825 1. Clamp bracket shaft 005835 2.
Page 192 MIDSECTION STERN BRACKET Install spacer, clamp bracket bolt, and washer. Install tilt support arms. Apply Nut Lock to screw threads and tighten 160 in. lbs. (18 N·m). Apply Nut Lock to threads of bolt. Install nut and tighten 88 in. lbs. (10 N·m). 1.
Page 193 MIDSECTION STERN BRACKET Tighten steering friction adjuster nut 27 in. lbs. (3 IMPORTANT: Make sure that steering adjuster N·m). is placed between upper bushing and swivel bracket housing. 1. Nut 005841 1. Upper bushing 005843 Apply Triple-Guard grease to bushings, oil seal lip, 2.
Page 194 MIDSECTION STERN BRACKET Apply Triple-Guard grease to steering bracket Align key with channel in lower mount bracket and shaft and install in swivel bracket. install bracket. Install circlip to retain bracket. 1. Steering bracket shaft assembly 005845 1. Lower mount bracket 005848 2.
Page 195: Steering Handle
MIDSECTION STEERING HANDLE STEERING HANDLE Disconnect emergency stop switch wire. Removal WARNING To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Remove the STBD side cover. Refer to Side Cover Removal and Installation on p. 177. 005791 Loosen throttle cable lock nuts.
Page 196: Installation
MIDSECTION STEERING HANDLE Installation Apply Nut Lock to threads of handle cover screws. Install handle cover and tighten screws 198 in. lbs. Installation is reverse order of removal with spe- (23 N·m). cial attention to the following: Apply Nut Lock to threads of handle bracket screws.
Page 197 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............196 PROPELLER .
Page 198: Service Chart
GEARCASE SERVICE CHART SERVICE CHART 11 N . m (1.1 kg-m, 8.0 lb-ft) 1. Bolt 2. Stopper 3. O-ring 4. O-ring 5. Pin 6. Shift rod 7. Magnet 8. Spacer 9. Pin 10. Shift cam 11. Gearcase 12. Pinion bearing 13.
Page 199 GEARCASE SERVICE CHART 35. Driveshaft 67. Stopper 36. Collar 68. Propeller 37. Washer bush 38. Pinion gear 69. Propeller 39. Pinion nut 70. Spacer 40. Bolt 71. Washer 41. Rubber seal 72. Nut 42. Driveshaft oil 73. Pin seal housing 43.
Page 200: Propeller
GEARCASE PROPELLER PROPELLER LUBRICANT Inspection Draining Carefully check the propeller and outboard for the WARNING following conditions: • Damaged blades and signs of propeller cavita- Gearcase lubricant may be under pressure tion and/or hot. If plug is removed from a •...
Page 201: Filling
GEARCASE LEAK TEST LEAK TEST To check for water contamination, drain lubricant into a suitable glass container. Allow the drained oil to settle for a minimum of one hour to deter- Drain lubricant before testing. mine if there is an abnormal amount of water in STEP 1 the oil.
Page 202: Removal And Installation
GEARCASE REMOVAL AND INSTALLATION REMOVAL AND Loosen the clutch rod lock nut. Unscrew the clutch rod connector to separate the clutch rod from the INSTALLATION shift rod. Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads.
Page 203: Installation
GEARCASE REMOVAL AND INSTALLATION Installation Clutch Adjustment Install two dowel pins. Connect the clutch rod and shift rod in the follow- ing sequence: Apply a light coat of Gasket Sealing Compound to • Screw the clutch rod connector on the clutch mating surfaces of gearcase and driveshaft hous- rod to the end of its thread.
Page 204: Water Pump
GEARCASE WATER PUMP WATER PUMP Inspection Inspect the impeller vanes for cuts, cracks, tears, Disassembly or excessive wear. Replace if necessary. Remove gearcase from exhaust housing as Inspect the pump case and inner sleeve for described in REMOVAL AND INSTALLATION on cracks, distortion, or corrosion.
Page 205: Assembly
GEARCASE WATER PUMP Assembly Apply a light coat of Triple-Guard grease to the inside of inner sleeve. Place the gasket and plate into position. Install the pump case while rotating driveshaft Insert the key in the driveshaft and slide the impel- clockwise to flex the impeller vanes in the correct ler onto the driveshaft.
Page 206: Disassembly
GEARCASE DISASSEMBLY DISASSEMBLY Use Slide Hammer, P/N 391008, and Prop Shaft Remover, P/N 5034762, to pull out the propeller shaft bearing housing assembly. WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa). IMPORTANT: Clean and inspect all components during disassembly.
Page 207 GEARCASE DISASSEMBLY Remove two screws securing the driveshaft oil Remove the forward gear, along with thrust seal housing to the gearcase. washer, back up shim, and bearing. Remove the pinion gear and shim. 1. Driveshaft seal housing screws 005871 1. Forward gear 005873 2.
Page 208: Propeller Shaft Bearing Housing Components
GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Remove clutch dog shifter, push pin, and return spring. Components Remove propeller shaft components and reverse gear from bearing housing assembly. 1. Push pin 005878 2. Return spring Use Puller Bridge, P/N 432127, and Small Puller 1.
Page 209: Shift Rod Components
GEARCASE DISASSEMBLY Shift Rod Components Pinion Bearing Push out pin and remove the shift cam. Remove Inspect the pinion bearings in place. If necessary, spacer and magnet. remove the bearings using Universal Pinion Bear- ing Remover and Installer kits, P/N 5005927 and P/N 5005928.
Page 210: Cleaning And Inspection
GEARCASE CLEANING AND INSPECTION CLEANING AND • Driveshaft — check splines for chips, wear, and cracks. Bearing and gear surfaces must not INSPECTION show signs of metal transfer, corrosion, or dis- coloration. Severe spline wear might indicate an exhaust housing or gearcase has been dis- WARNING torted by impact damage.
Page 211: Assembly
GEARCASE ASSEMBLY ASSEMBLY Drive the bearing down into position by gently striking the installer shaft until the washer contacts the spacer. Before beginning assembly, refer to CLEANING AND INSPECTION. Pinion Bearing Assemble tools from Universal Pinion Bearing Remover and Installer kits, P/N 5005927 and P/N 5005928, as shown: 1.
Page 212: Pinion Gear And Driveshaft
GEARCASE ASSEMBLY Pinion Gear and Driveshaft Apply gear oil to the pinion gear and install in gearcase. 004403 Apply Nut Lock to threads of pinion nut. Install nut on driveshaft and tighten to 13 ft. lbs. (18 N·m). 005921 Install driveshaft collar with tongue of collar located in groove on the gearcase.
Page 213: Shift Rod/Shift Cam Assembly
GEARCASE ASSEMBLY The lipped portion of the seals should face toward Shift Rod/Shift Cam Assembly the water pump. Apply Triple-Guard grease to the Apply Triple-Guard grease to the shift rod guide o- seal lips. rings. Slide complete shift rod guide and o-rings on the shift rod and install pin.
Page 214: Propeller Shaft
GEARCASE ASSEMBLY Propeller Shaft Propeller Shaft Bearing Housing IMPORTANT: IMPORTANT: Before installing propeller shaft Check adjust shimming parts, check driveshaft thrust play. Refer to SHIM- before installing seals and o-rings in bearing MING ADJUSTMENTS on p. 214. housing. Refer to SHIMMING ADJUSTMENTS on p.
Page 215 GEARCASE ASSEMBLY Using suitable bearing installation tool obtained locally, press the bearing against outer race until fully seated in the housing. 8_16_2 When the housing is fully seated, tighten both retaining screws to 89 in. lbs. (10 N·m). Reverse Gear Bearing 005936 Check and adjust backlash.
Page 216: Shimming Adjustments
GEARCASE SHIMMING ADJUSTMENTS SHIMMING Forward Gear/Pinion Gear Correctly assemble forward gear, pinion gear, ADJUSTMENTS driveshaft, and related components. Refer to ASSEMBLY on p. 209. If gearcase has been rebuilt or has had compo- nents replaced, shimming for correct gear contact Check that a slight amount of backlash exists and backlash will have to be adjusted to ensure between pinion gear and forward gear by slightly...
Page 217: Gear Tooth Contact Pattern
GEARCASE SHIMMING ADJUSTMENTS If thrust play is too large, thickness of forward gear Pull out propeller shaft and housing to check tooth back up shim must be increased. contact pattern. If thrust play is too small, back up shim thickness Approx.
Page 218: Propeller Shaft Thrust Play
GEARCASE SHIMMING ADJUSTMENTS Propeller Shaft Thrust Play After adjusting all gear positions, measure the propeller shaft play. If not within the following val- ues, make a shim adjustment: • Propeller shaft thrust play: 0.008 to 0.016 in. (0.2 to 0.4 mm) IMPORTANT: Maintain the forward gear thrust washer at standard thickness (1.5 mm) and adjust...
Page 219 MANUAL STARTER MANUAL STARTER TABLE OF CONTENTS SERVICE CHART ..............218 REMOVAL .
Page 220: Service Chart
MANUAL STARTER SERVICE CHART SERVICE CHART 1 Reel 2 Bolt 3 Friction plate 4 Friction spring 5 E-ring 6 Ratchet (Pawl) 7 Ratchet guide 8 Return spring 9 Recoil spring 0 NSI cable A Spring B Recoil case C Spring D Reel stopper E Rope F Grip...
Page 221: Removal
MANUAL STARTER REMOVAL REMOVAL Loosen the clamp securing breather hose, then remove breather hose from starter case. WARNING Avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Wear safety glasses while disassembling and assembling manual starters to avoid personal injury caused by rewind spring tension.
Page 222: Disassembly
MANUAL STARTER DISASSEMBLY DISASSEMBLY Remove the e-ring, ratchet (pawl), ratchet guide, and return spring. Turn reel clockwise to release the tension in the recoil spring. 1. E-ring 005623 1. Reel 005621 Remove screw and friction plate, with friction spring. Remove the reel. 1.
Page 223: Inspection
MANUAL STARTER INSPECTION INSPECTION Remove NSI cable from the recoil case. Remove the reel stopper spring and reel stopper. IMPORTANT: If any part is worn excessively, cracked, defective, or damaged, it must be replaced. Inspect the ratchet (pawl), stopper arm, and all springs.
Page 224: Assembly
MANUAL STARTER ASSEMBLY ASSEMBLY Assembly is reverse order of disassembly with special attention to the following steps: Install reel stopper, stopper spring, and NSI cable. 1. Recoil spring boss 005625 WARNING Because of the coiled tension in the recoil spring, wear safety glasses and hand pro- 1.
Page 225: Installation
MANUAL STARTER INSTALLATION Secure the ratchet with e-ring. Apply Nut Lock to screw and tighten securely. 1. E-ring 005623 1. Friction spring 005631 2. Square lug 3. Screw Install the recoil rope. After assembly, guide rope into notch in reel and rotate reel approximately five turns counterclock- wise until the spring is tensioned.
Page 226: Neutral Start Interlock (Nsi)
MANUAL STARTER NEUTRAL START INTERLOCK (NSI) NEUTRAL START INTERLOCK (NSI) Installation/Adjustment WARNING If the NSI cable is removed or not adjusted properly, there is a high risk of being thrown overboard if motor starts in gear. Shift into NEUTRAL position. Install the NSI cable in the recoil starter, the clutch shaft plate, and the cable bracket.
Page 227 WIRE/HOSE ROUTING WIRE/HOSE ROUTING TABLE OF CONTENTS WIRING DIAGRAMS ..............226 .
Page 228: Wiring Diagrams
WIRE/HOSE ROUTING WIRING DIAGRAMS WIRING DIAGRAMS Rope Start Models...
Page 229: Tiller Electric Models
WIRE/HOSE ROUTING WIRING DIAGRAMS Tiller Electric Models...
Page 230: Remote Electric Models
WIRE/HOSE ROUTING WIRING DIAGRAMS Remote Electric Models...
Page 231: Wire Routing
WIRE/HOSE ROUTING WIRE ROUTING WIRE ROUTING...
Page 232 WIRE/HOSE ROUTING WIRE ROUTING...
Page 233 WIRE/HOSE ROUTING WIRE ROUTING...
Page 234 WIRE/HOSE ROUTING WIRE ROUTING Nagative - battery cable Starter motor Clamp Fix the wiring harness, starter motor lead wire, starter switch lead wire and caution lamp. lead wire. Positive + Starter motor band battery cable Caution lamp Starter switch...
Page 235: Fuel/Water Hose Routing
WIRE/HOSE ROUTING FUEL/WATER HOSE ROUTING FUEL/WATER HOSE ROUTING Do not over-bend (kink) or twist hoses when installing. When installing hose clips, position tabs to avoid contact with other parts. Check that hoses do not contact rods and levers during either engine operation or standstill. Extreme care should be taken not to cut, abrade or cause any other damage on hoses.
Page 236 WIRE/HOSE ROUTING FUEL/WATER HOSE ROUTING Fuel hose (Fuel pump to carburetor) Fuel hose/protector (Fuel filter to fuel pump) Fuel filter Fuel pump Clamp Fuel hose/protector (Connector to fuel filter)
Page 237 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 238 S–2...
Page 239: 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 240: 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 241: 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 242: 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 243 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 244: 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 245 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 246 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 247: 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 248 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 249: 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 250: 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 251 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 252: 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 253: 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 254 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 255 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 256 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 257: 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 258: 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 259: 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 260: 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...
Page 261 INDEX INDEX Charging System n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Description 70 Abbreviations 12 Service 73...
Page 262 INDEX Engine n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Specifications 16 Idle Exhaust Housing...
Page 263 INDEX Operating Temperature 42 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Safety S–1 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Serial Number Location 6...
Page 264 INDEX Flywheel Holder, P/N 5034227 99, 101 Torque Specifications, Standard 18 Gear Alignment Pin Set, P/N 5037488 164, Trim Tab Adjustment 45 Troubleshooting Installer Handle, P/N 345822 213 Electric Start 76 Lifting Eye, P/N 321537 S–17 Ignition 94 Oil Pressure Gauge, P/N 5000902 129 Oil Pressure Test Adapter, P/N 350930 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Valve...

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BRP Johnson J25R4SUR Service Manual

Safety Information

Service Specifications and Special Tools

Technical Data

Standard Torque Specifications

Special Tools

Shop Aids

Installation and Predelivery

Boat Rigging

Outboard Installation

Outboard Rigging

Fuel and Oil

Running Checks

Propeller Selection

Notes

Maintenance

Inspection and Maintenance Schedule

Anti-Corrosion Protection

Cooling System

Fuel System

Battery

Lubrication

Spark Plugs

Valve Clearance

Idle Speed

Ignition Timing

Storage

Pre-Season Service

Submerged Engines

Notes

Electrical

Caution System

Battery Charging System

Electric Starter System

Ignition System

Service Chart

Operation

Troubleshooting

Ignition Tests

Component Servicing

Notes

Fuel System

Carburetor Operation

Carburetor Service

Fuel Pump

Intake Manifold Service

Throttle Control

Notes

Powerhead

Specifications

Test Procedures

Removal and Installation

Oil Pump

Cylinder Head

Crankshaft, Pistons and Camshaft

Thermostat Service

Cooling System Diagram

Engine Lubrication Diagram

Notes

Midsection

Service Chart

Driveshaft Housing and Oil Pan

Side Cover

Stern Bracket

Steering Handle

Gearcase

Service Chart

Propeller

Lubricant

Leak Test

Removal and Installation

Water Pump

Disassembly

Cleaning and Inspection

Assembly

Shimming Adjustments

Manual Starter

Wire/Hose Routing

Wiring Diagrams

Wire Routing