Page 1 PNo. 003-21035-1 0509 NB 1000 Printrd in Japan...
Page 2 TABLE OF CONTENTS Service Safety General Service Information Fuel System Powerhead Midsection Gearcase Electrical System 1-/ 2-Cylinder...
Page 3 SECTION 1 SERVICE SAFETY TABLE OF CONTENTS Introduction ·························································································································· 1-2 Safety Statements················································································································ 1-2 Safety Precautions ··············································································································· 1-3 Workmanship Standards······································································································ 1-5 Test Tank Guidlines ·············································································································· 1-7 1-/ 2-Cylinder...
Page 4 SECTION 1 WARNING Inadequate knowledge of safe shop practices can result in severe injury or death. Review general safety procedures and speciﬁc safety information provided for each procedure prior to beginning any repairs. INTRODUCTION KC-5030 Marine manufacturers are required to comply with special regulations and standards to ensure their products are safe and reliable for the consumer.
Page 5: Service Safety
SERVICE SAFETY SAFETY PRECAUTIONS Handling Outboard Engines • Never disable the neutral switch start-in-gear prevention system to accommodate installation of a foot control or other option. Always test the neutral switch and emergency stop switch before returning an engine to the customer. •...
Page 6 SECTION 1 • Avoid running the engine at high RPM. Engine speed can easily increase to excessive RPM when under a no load condition. To avoid engine damage during testing, always use the correct test propeller and keep engine speed below 2000 RPM. •...
Page 7 SERVICE SAFETY Hazardous Materials • Gasoline vapors are highly ﬂammable and can cause an explosion. Never smoke or allow sparks or ﬂames nearby when handling fuel Always store gasoline in a shaded, well ventilated area in an approved safety container. •...
Page 8 SECTION 1 8. Keep all removed parts separated for ease of identiﬁcation during assembly. 9. Locate alignment marks on components being disassembled. If marks are not present and should be, scribe or match mark them yourself to ensure the pieces are assembled properly. 10.
Page 9 SERVICE SAFETY TEST TANK GUIDELINES When properly setup, test tanks provide a safe and controlled environment in which to perform outboard engine adjustment and testing procedures. Test tanks must be setup to the minimum dimensions shown. If multiple engines wiII be installed in the tank, secure partition plate (1) so that the minimum dimensions are maintained for each outboard engine installed.
Page 10: Table Of Contents
SECTION 2 GENERAL SERVICE INFORMATION TABLE OF CONTENTS General Precautions············································································································· 2-2 Abbreviations and Symbols ································································································· 2-3 Unit Conversions·················································································································· 2-4 Service Speciﬁcations·········································································································· 2-5 Engine Speciﬁcations········································································································· 2-17 Lubrication Chart ··············································································································· 2-20 Periodic Inspections··········································································································· 2-24 Break-ln Procedure ············································································································ 2-27 Tune-Up Procedure ············································································································ 2-28 Emergency Stop Switch and Lanyard················································································...
Page 11: General Precautions
SECTION 2 GENERAL PRECAUTIONS Before performing any service work on the outboard engine, read and understand Section 1 - Service Safety. Use only genuine factory replacement parts with equivalent characteristics such as type, material, and strength. Failure to do so may result in product malfunction and injury to the operator or passengers.
Page 12: General Service Information
GENERAL SERVICE INFORMATION ABBREVIATIONS AND SYMBOLS Abbreviations liter ampere L/hr liter per hour alternating current pound ampere-hour milliliter approx. approximately millimeter American Petroleum Institute millivolt ATDC after top dead center newton BTDC before top dead center N·m newton meter °C degree Celsius NMMA National Marine...
Page 13: Unit Conversions
SECTION 2 UNIT CONVERSIONS Units of Torque Unit Preﬁxes ft-lb 1.3558 = N-m Preﬁx Symbol Power ft-lb 0.1383 = kg-m mega x 1,000,000 in-Ib 0.1130 = N-m kilo x 1,000 in-lb 0.0115 = kg-m centi x 0.01 kg-m 7.2330 = ft-lb milli x 0.001 kg-m...
Page 14: Standard Torque Values
GENERAL SERVICE INFORMATION SERVICE SPECIFICATIONS Standard Torque Values Torque Size in-lb ft-lb kg-m 10 - 17 0.8 - 1.4 1 - 2 0.1 - 0.2 26 - 35 2.2 - 2.9 3 - 4 0.3 - 0.4 44 - 52 3.6 - 4.3 5 - 6 0.5 - 0.6...
Page 15 SECTION 2 Manufacturer Special Tools Required - 1-2 Cylinder 2.5/3.5 Tool Description Part No. Components Flywheel Puller 309-72214-0 Assembly Adapter Pressing Bolt 3V1-72211-0 Bolts T1900 Spring Pin Tool ✳ 345-72227-0 Pin Punch Spring Pin Tool ✳ 345-72228-0 HoIIow Punch Tool Box 353-72254-0 ✳...
Page 16 GENERAL SERVICE INFORMATION T1904 T1901 T1906 Tool Description Part No. Components Flywheel Puller 369-72211-0 Assembly Adapter Pressing Bolt Bolts 332-72215-0 Piston Pin Tool T1907 353-72249-0 Piston Ring Tool Driveshaft Needle 369-72900-0 Bearing Tool Assembly Backlash Measuring 369-72740-0 Tool Except 369-72730-0 Sub Assembly T1908 369-72727-0...
Page 17 SECTION 2 T1904 T1910 T1906 8/9.8 Tool Description Part No. Components Flywheel Puller 369-72211-0 Assembly Adapter pressing Bolt Bolts 332-72215-0 Piston Pin Tool 353-72249-0 Piston Ring Tool Driveshaft Needle 3B2-72900-0 Bearing Tool Assembly Backlash Measuring 369-72740-0 Tools Except 369-72730-0 Sub Assembly T1907 3B2-72727-0 3B7-72720-0...
Page 18 GENERAL SERVICE INFORMATION T1910 T1906 T1904 9.9/15/18 Tool Description Part No. Components Flywheel Puller 369-72211-0 Assembly Adapter pressing Bolt Bolts 332-72215-0 Piston Pin Tool T1918 353-72249-0 Piston Ring Tool Wrench, Bevel Gear B 346-72231-0 Socket, Bevel Gear B 350-72232-0 Needle Roller Bearing 3C8-72700-0 Puller 3C8-72701-0...
Page 19 SECTION 2 9.9/15/18 Continued Tool Description Part No. Components Backlash Measuring 3C8-72234-0 Tool Kit 345-72723-0 Shaft 3A3-72724-0 Plate 332-60002-0 O-ring 350-72245-0 Collar 930191-1000 Nut, M10 , 2 nuts 3B7-72720-0 Clamp Assembly for lower 910191-0625 Bolt, H625 pump case 3B7-72729-0 Plate, Dial Gauge Spring Pin Tool 345-72227-0 Pin Punch...
Page 20 GENERAL SERVICE INFORMATION T1904 T1910 T1906 25/30 Tool Description Part No. Components Flywheel Puller 369-72211-0 Assembly Adapter Pressing Bolt Bolts 345-72215-0 Piston Pin Tool T1918 353-72249-0 Piston Ring Tool Wrench, Bevel Gear 346-72231-0 Wrench B Nut Socket, Bevel Gear B 346-72232-0 Socket Needle Roller...
Page 21 SECTION 2 25/30 Continued Tool Description Part No. Components Bevel Gear 3A3-72755-0 Assembly Bearing Puller Bearing Outer Kit, 3B7-72739-0 Press Kit Bevel Gear Bering 346-72719-0 , Ø 32 mm Installing Tool Backlash Measuring 3C8-72234-0 TooI Kit 345-72723-0 Shaft 3A3-72724-0 Plate 332-60002-0 O-ring 346-72245-1...
Page 22 GENERAL SERVICE INFORMATION T1904 T1910 T1906 Tool Description Part No. Components Flywheel Puller Assembly Adapter 369-72211-0 Pressing Bolt Bolts 345-72215-0 Piston Pin Tool T1918 353-72249-0 Piston Ring Tool Wrench, Bevel Gear 346-72231-0 Wrench B Nut Socket, Bevel Gear 345-72232-0 Socket B Nut Needle Roller 3C8-72700-0...
Page 23 SECTION 2 40 Continued Tool Description Part No. Components Bearing Outer 3B7-72739-0 Kit, Press Kit Bevel Gear Bering 3C8-72719-0 , Ø 42 mm Installing Tool Backlash Measuring -72234-0 Tool 345-72723-0 Shaft 3A3-72724-0 Plate 332-60002-0 O-ring 353-72245-1 Collar Cone Disk 345-72763-0 , 3 pcs Spring, d=12 930191-1000...
Page 24: General Equipment Required
GENERAL SERVICE INFORMATION General Equipment Required Water Pressure Gauge, 0 - 15 psi [0 - 103 kPa / 0 - 1 kg / cm Fuel Pressure Gauge, 0 - 15 psi [0 - 103 kPa / 0 - 1 kg / cm Torque Wrench, 0 - 150 in-lb [0 - 17 N·m / 0- 1.7kg-m] Torque Wrench, 0 - 750 ft-lb [0 - 1000 N·m / 0 - 100 kg-m] Dial Gauge, minimum scale 0.0001 in [0.01 mm]...
Page 25: Consumables Required
SECTION 2 Consumables Required Threadlocker, Loctite ® Threadlocker, Loctite ® Gasket Dressing, Permatex Hylomar Aerosol High-Temp Gasket Dressing ® ® Gasket Sealant, Permatex High Tack Gasket Sealant ® Anaerobic Gasket Maker, Loctite ® Silicone Sealant, Permatex Hi-Temp RTV Silicone Gasket ®...
Page 26 GENERAL SERVICE INFORMATION ENGINE SPECIFICATI0NS Operation Test Propeller 2.5, 3.5A ..........309-64111-0 3.5B ........... 3F0-64111-0 Power 5 ............369-64111-0 2.5 ..........2.5 HP [1.8 kW] 8, 9.8 ..........3B2-64111-0 3.5 ..........3.5 HP [2.6 kW] 9.9, 15, 18 .......... 362-64111-0 5 ............
Page 27: Electrical System
SECTION 2 Crankshaft Dimensions Clutch System 2.5, 3.5A......None (Forward gear only) 3.5B..........Dog clutch type (Forward gear and Neutral only) 5, 8, 9.8, 9.9, 15, 18, 25, 30, 40 ... Dog clutch type (Forward-Neutral-Reverse) Electrical System Ignition Type..... Flywheel magneto capacitor discharge T1044 Ignition Timing...
Page 28: Fuel System
GENERAL SERVICE INFORMATION Alternator 2.5, 3.5 ............None 5 ........None (Optional - 12V 60W) 8, 9.8 ......None (Optional - 12V 80W) 9.9, 15, 18, 25, 30, 40 .......12V 80W Fuel and Lubricant System Charging Performance (at 1500 RPM) Required Fuel, Lubricant, and Mix Ratio See Fuel System Requirements in Section 3 Charging Performance (at 5500 RPM) 5 (Optional)............4 A...
Page 29: Lubrication Chart
SECTION 2 LUBRICATION CHART NOTE Recommended intervals are for freshwater recreational operation. Decrease interval by 50% for salt water and severe duty (commercial) operation. Lube Type: = Low Temperature Lithium Grease = Genuine Grease or equivalent Friction Surface Marine Grease T1942 = Non-ﬂammable solvent = Genuine Gear Oil or API Grade GL5 #80 - #90...
Page 30 GENERAL SERVICE INFORMATION T1949 T1951 T1950 T1801 T1954 T1953 T1955 T1956 T1957 Lubrication Points and Lubricant Engine Model Frequency Lube Fig. Location Hours Type Choke Mechanism • • • • • • Clamp Screw • • • • • • Grip •...
Page 31 SECTION 2 T1958 T1959 T1960 T1961 T1962 Lubrication Points and Lubricant Engine Model Frequency Lube Fig. Location Hours Type Reverse Lock • • • • • • Shift Lever Stopper • • • • • Starter Lock • • • •...
Page 32 GENERAL SERVICE INFORMATION T1802 T1803 T1804 Lubrication Points and Lubricant Engine Model Frequency Lube Fig. Location Hours Type First Gear Oil Change • • • • • • Top Off Gear Oil • • • • • • Oil Change (Note 2) •...
Page 33 SECTION 2 PERIODIC INSPECTI0NS NOTE It is recommended that a complete engine overhaul be performed after 300 operating hours. After Every Every Every Before 1st 10 30 Hrs 50 Hrs 100 Hrs ltem Inspection Each Remarks Hours 2 Days 7 Days 30 Days 60 Days Fastener...
Page 34 GENERAL SERVICE INFORMATION Every Every After Every Before 50 Hrs 100 Hrs 1st 10 30 Hrs ltem Inspection Each Remarks Hours 2 Days 7 Days Days Days Engine • Check with • Obtain normal Compres- compression operating sion gauge temperature and check at full throttle.
Page 35 SECTION 2 Every Every After Every Before 50 Hrs 1st 10 30 Hrs ltem Inspection Each Remarks Hours 2 Days 7 Days Days Days Sacriﬁcial • Inspect amount • Replace when anode Anodes of erosion. has been reduced • Test for proper to 2/3 its original size installation.
Page 36: Powerhead
GENERAL SERVICE INFORMATION BREAK-lN PROCEDURE CAUTION Failure to follow the Break-In Procedure in Owner’s Manual and special fuel mixture requirements for break-in may lead to serious engine damage and shortened engine life. To prevent serious engine damage and ensure long engine life, new engines, used engines with new powerhead, used engines with newly rebuilt powerhead, and engines coming out of storage must be run for a period of 10 hours in accordance with the break-in procedure.
Page 37: Tune-Up Procedure
SECTION 2 Next Eight Hours (2 to 10 Hours) • Run engine at 3/4 throttle. • For short periods of time, run engine at full throttle and then reduce speed back to 3/4 throttle. As this part of the break-in period progresses, open to full throttle for longer and longer periods of time, but never longer than 5 minutes.
Page 38: Emergency Stop Switch And Lanyard
GENERAL SERVICE INFORMATION 8. Adjust the engine ignition timing and carburetor. See Synchronization and Linkage Adjustments, this section. 9. Remove propeller and inspect propeller shaft oil seal for leakage. Inspect propeller, thrust washer, and other propeller shaft hardware for damage. Replace as needed. 10.
Page 39: Synchronization And Linkage Adjustments
SECTION 2 Stop Switch Test 1. Attach the lanyard lock clip to the stop switch. 2. Start the engine. 3. With engine running, puII the lanyard to disengage the lock clip. Engine should stop running. NOTE The stop switch also operates as a push-button switch with the lanyard left attached.
Page 40 GENERAL SERVICE INFORMATION Twin Cylinder Engines A. 8/9.8 Engines Because of a unique multi-cylinder ignition system, timing of the ignition is only necessary when the powerhead is disassembled and reassembled. This procedure is fairly simple as the only purpose is to ensure that the coil plate rotates in the proper direction.
Page 41 SECTION 2 5 Models Throttle Setting Full Open Full Closed (In Gear) Engine Match Mark Target RPM Match Mark Target RPM BTDC 30° 4500 - 5500 BTDC 5° The magneto of the 5 engine uses an “electrical lead angle” where ignition timing is advanced as engine RPM increases.
Page 42 GENERAL SERVICE INFORMATION 8/9.8 Models Throttle Setting Full Open Full Closed (In Gear) Engine Match Mark Target RPM Match Mark Target RPM BTDC 22° 4500 - 5500 ATDC 1.5° BTDC 26° 5000 - 6000 BTDC 2.5° T1971 The 8 and 9.8 engines are different electronically from other one and two cylinder engines.
Page 43 SECTION 2 Model 9.9/15/18, 25/30 and 40 Throttle Setting Full Open Full Closed (In Gear) Engine Match Mark Target RPM Match Mark Target RPM 9.9D BTDC 22° 4500 - 5300 ATDC 3° 9.9D BTDC 20° 4500 - 5300 ATDC 3° BTDC 22°...
Page 44 GENERAL SERVICE INFORMATION 4. Turn the throttle grip toward SLOW side. 5. Adjust the stopper bolt (for full close adjustment) so that it hits the stopper bolt at the position where the magneto coil plate timing mark (fully closed side) meets the ignition timing inspection line (crank case mating surface).
Page 45: Carburetor Adjustment
SECTION 2 7. (9.9/15/18 HP Engines Only) Rotate the adjusting screw so that the set distance is 0.45 - 0.47 in [11.5 -12 mm]. CAUTION Make this adjustment only after placing the gear shift lever in reverse. 8. Test gear shift lever operation in FORWARD, NEUTRAL and REVERSE.
Page 46 GENERAL SERVICE INFORMATION Jet Needle Adjustment CAUTI0N The 2.5/3.5 carburetor is properly adjusted when shipped from the factory. No adjustment should be made to the carburetor unless absolutely necessary. • The jet needle is held in position by a spring clip which ﬁts into one of four grooves on the needle.
Page 47: Anodes - Inspection And Testing
SECTION 2 ANODES - INSPECTION AND TESTING Engines are equipped with several sacriﬁcial anodes to help protect metal parts from the effects of galvanic corrosion (electrolysis). Disintegration of the anodes indicates they are performing their function. An anodes must be replaced when it has been reduced to 2/3 its original size (1/3 eroded).
Page 48 SECTION 3 FUEL SYSTEM TABLE OF CONTENTS General Precautions············································································································· 3-2 Service Speciﬁcations·········································································································· 3-3 Fuel System Requirements ·································································································· 3-4 Troubleshooting···················································································································· 3-6 Description of Operation ······································································································ 3-8 Separate Fuel Tank ············································································································ 3-12 Fuel Hose and Primer ········································································································ 3-13 Integral Fuel Tank ··············································································································· 3-14 Fuel Filter····························································································································...
Page 49 SECTION 3 GENERAL PRECAUTIONS WARNING Gasoline is extremely ﬂammable and can explode if mishandled. 1. Before performing any service work on the fuel system, read and understand Section 1 - Service Safety. 2. Before servicing the fuel system, disable the ignition system by removing all spark plug leads to prevent accidental starting of engine.
Page 50 FUEL SYSTEM SERVICE SPECIFICATI0NS Special Torque Values NOTE Refer to Section 2 for Standard Torque Values chart. Torque in-lb N·m kg-m Description Model 2.5 / 3.5 8 / 9.8 9.9 / 15 / 18 25 / 30 Carburetor 40 - 55 40 - 55 40 - 55 Mounting Bolt...
Page 51: Fuel System Requirements
SECTION 3 General Equipment Required Fuel Pressure Gauge, 0 - 15 psi [0 - 1 kg/cm Tee Fitting with 3/8 in O.D. barbs [9.5 mm O.D.] Torque Wrench, 0 - 150 in-lb [0- 17 N·m/0 - 1.7kg-m] Digital Pulse Tachometer Flexible Fuel Tubing, 3/8 in I.D.
Page 52 FUEL SYSTEM Mix Ratios CAUTI0N A 25:1 gasoline/oil mixture is required during engine break-in. Refer to Break-In Procedure in Section 2. Premixing A 50:1 gasoline/oil mixture (2% oil) is required. New engines or reconditioned powerheads require a 25:1 gasoline/oil mixture (4% oil) during break-in.
Page 53: Troubleshooting
SECTION 3 TROUBLESHOOTING The troubleshooting chart lists common engine symptoms related to problems with the fuel system. lt also indicates speciﬁc malfunctions in the fuel system which may be causing the problem so it can be isolated more effectively. Before beginning major troubleshooting operations on the fuel system, perform the following operations: •...
Page 54 FUEL SYSTEM Symptom Checks OIL MIXTURE Mixture too rich • • (too much oil) Mixture too lean • • • • • (not enough oil) CARBURETOR Carburetor out of adjustment • • • • • • • Carburetor obstruction or faulty •...
Page 55 SECTION 3 T1103 DESCRIPTION OF OPERATION There are two types of fuel systems, models 2.5 and 3.5 use a gravity fed fuel system. Models 5 through 40 have a fuel pump. 2.5 / 3.5 Fuel Flow Prior to starting, the air vent on fuel cap (1) and fuel cock (2) must be opened.
Page 56 FUEL SYSTEM T2047 5 - 40 Fuel Flow Upon engine startup, premixed fuel is drawn from fuel tank (1) by vacuum pressure on the suction side of the fuel pump through the fuel ﬁlter (2) and, into fuel pump (3). Fuel ﬂows from the fuel pump into the carburetor ﬂoat chamber (4).
Page 57: Fuel Pump
SECTION 3 T1003 Fuel Pump The fuel pump may be integral with the carburetor or mounted on the side of the crankcase and contains one or more internal diaphragms (1). The diaphragms move in response to changing crankcase pressures (2) which draws fuel in (3) and pumps fuel out (4).
Page 58 FUEL SYSTEM T2048jp Under idling conditions, the mixture of fuel and air is mainly output from the pilot outlet. As throttle is increased, the negative pressure applied to the pilot system increases and allows more of the mixture to ﬂow from the bypass. When the throttle is opened further, the increase of air causes a pressure drop which allows the main system to assume full control of fuel delivery.
Page 59 SECTION 3 Recirculating Recirculation hoses at the inlet manifold and crankcase recirculate unburned fuel for engine consumption. SEPARATE FUEL TANK Two types of separate fuel tanks are used. Smaller engines use the 3.1 gal [12 L] separate fuel tank. Larger engines use a 6.6 gal [25 L] separate fuel tank.
Page 60: Cleaning And Inspection
FUEL SYSTEM FUEL HOSE AND PRIMER T1110 Separate fuel tanks are connected to the engines by a hose with a primer bulb. The primer bulb forces fuel into the carburetor ﬂoat chamber for engine starting. Check valves on each side of the primer bulb maintain fuel ﬂow, in one direction only, from the tank to the engine.
Page 61 SECTION 3 3. Inspect primer bulb and hoses for cracks and deterioration. 4. Inspect tank and engine quick connectors for damage and wear. Make sure check valves in quick disconnects open freely when pressed. 5. Inspect primer bulb check valves for damage. CAUTION New hose clamps must be used in assembly.
Page 62: Fuel Filter
FUEL SYSTEM 3. Inspect overall condition of tank exterior and interior. Cracked or damaged tanks must be removed from service. 4. Inspect the cap (1) and gasket (2) for cracks, vent hole blockage or deterioration. 5. Inspect tank, fuel ﬁlter and fuel pump (if equipped) connections for cracks and damage.
Page 63 SECTION 3 ln-Line Fuel Filter Replacement NOTE In-line fuel ﬁlters cannot be serviced. Replace in-line fuel ﬁlters once a year or with each tune-up. When replacing an in-line fuel ﬁlter, note direction of fuel ﬂow as indicated by the arrow on the ﬁlter housing for proper installation.
Page 64 FUEL SYSTEM FUEL PUMP CAUTION Before servicing the fuel pump, disconnect the fuel hose from the engine to prevent excessive fuel spillage. NOTE Fuel for the 2.5 and 3.5 engines is gravity fed to the carburetor. There is no fuel pump to be serviced on T1118 these engines.
Page 65 SECTION 3 T1119 T1120 NOTE Past production models 25, 30, and 40 contained an internal guide plate (7) and spring (8) assemblies under tension. The rubber diaphragm (9) that required the guide plate and spring has been replaced by a resin ﬁlm (white opaque) diaphragm (10) which no longer requires the guide plate and spring.
Page 66 FUEL SYSTEM T1121 Inspection 1. Inspect pump body (1) for cracks. 2. Inspect check valves (2) for deformation. 3. Inspect pump covers (3) for cracks and surface deformation. 4. lnspect guide plate (4) and spring (5), if equipped, for deformation and tension. 5.
Page 67 SECTION 3 CARBURETORS Two basic types of carburetors are used; the round slide valve type used on the 2.5 and 3.5 horsepower engines, and the butterﬂy valve type used on 5 horsepower and up. Slide Carburetor Specifications Model Item Speciﬁcations Main Jet T1124 2.5A / 3.5A / 3.5B...
Page 68 FUEL SYSTEM T1128 T1126 T2050 1. Remove drain screw (4) from ﬂoat chamber and allow to drain. 2. Lift throttle lever (5) up. Unscrew cap (6) and remove throttle assembly (7). If necessary, disassemble throttle assembly. 3. Remove ﬂoat chamber (8) and ﬂoat (9). 4.
Page 69 SECTION 3 Cleaning CAUTION DO NOT clean carburetor by submerging or soaking in a carburetor dip cleaner or hot tank. Do not expose plastic parts to any carburetor cleaner. 1. Clean all metal components using a mild aerosol solvent or isopropyl alcohol.
Page 70 FUEL SYSTEM 4. Inspect the following slide valve components: • Check throttle wire (1) for wear and fraying. • Check return spring (2) for damage. • Check spring receiver (3) for distortion. • Check jet needle clip (4) for damage. Normal clip setting is second groove from bottom.
Page 71 SECTION 3 T1133 T1134 4. Install ﬂoat chamber. Use Loctite 242 on screw threads and tighten securely. 5. Install drain screw (4) and new gasket. 6. Install throttle stop screw and spring (13). T1126 7. lf removed, install choke assembly. Use a drift to peen end of shaft screw to prevent nut from coming loose.
Page 72 FUEL SYSTEM T1155 T1156 T1124 T1135 lnstallation 1. Check that the round boss on the carburetor mates with the hole in the clamp. 2. Position the carburetor on the crankcase inlet and push until fully seated. Make sure that the carburetor is vertical. Tighten clamp securely.
Page 73 SECTION 3 2. HIGH SPEED (1/4 to 3/4 Throttle) – The jet needle clip is factory set to the second needle groove from the bottom and does not normally need adjustment. Move the jet needle clip (1) up to a higher groove to make the fuel-air mixture leaner or down to a lower groove to make the fuel-air mixture richer.
Page 74 FUEL SYSTEM T1140 T1141 Disassembly NOTE 5 to 18 models are equipped with integral fuel pump. To ensure proper cleaning of the carburetor, remove and service the fuel pump at this time. Refer to Fuel Pump, this section. 1. Remove drain screw (1) from ﬂoat chamber (2) and allow T1142 to drain.
Page 75 SECTION 3 7. Remove any serviceable plugs (11) and jets (12). Typical carburetor shown. Cleaning CAUTION DO NOT clean carburetor by submerging or soaking in a hot tank or carburetor dip cleaner. DO NOT expose plastic parts to carburetor cleaner. 1.
Page 76 FUEL SYSTEM Inspection CAUTION DO NOT inspect passages or holes with wire or similar materials. Doing so may scratch or enlarge jet holes and alter the fuel/air ratio. NOTE Before inspection, all carburetor components must be cleaned. All worn or damaged parts must be replaced.
Page 77 SECTION 3 6. Inspect gasket surfaces for damage. 7. Check throttle shaft and choke shaft assemblies for excessive play. inspect the butterﬂy valves for damage and smooth operation. lf assemblies are defective, the carburetor must be replaced. 8. Visually inspect the fuel ﬁtting, carburetor cover, ﬂoat chamber, drain screw, and all other screws and washers for damage.
Page 78 FUEL SYSTEM 6. Check the ﬂoat height with the carburetor inverted on a ﬂat surface. Measure the distance between the top of the ﬂoat and the ﬂoat chamber surface. NOTE lf ﬂoat height is not correct, remove the ﬂoat valve assembly and make minor adjustments by slightly bending the tabs on the metal ﬂoat hinge clip.
Page 79 SECTION 3 REED VALVE NOTE To inspect the reed valve of a one cylinder engine, the powerhead must be disassembled, Refer to the Powerhead section for removal and inspection procedures in this section. Disassembly 1. Follow steps listed in Carburetor Removal procedure, this section. T2052 2.
Page 80 FUEL SYSTEM • Lift height of each reed valve and stopper must be within specification. 2.5 / 3.5 8 / 9.8 9.9 / 15 / 18 25 / 30 No. Valves Strips 1 Strip 1 Strip 2 Strips 2 Strips 4 Strips 4 Strips Valves / Strip...
Page 81 SECTION 3 Assembly Components must be clean and aII serviceable gaskets must be replaced. NOTE The reed valve of the 8 and 9.8 is unique and requires special handling. This reed valve is made of a thin 0.00787 in (0.2 mm) stainless steel and can be damaged if mishandled.
Page 82 SECTION 4 POWERHEAD TABLE OF CONTENTS General Precautions ············································································································· 4-2 Service Speciﬁcations ·········································································································· 4-3 Troubleshooting···················································································································· 4-6 Description of Operation ······································································································ 4-7 Cylinder Compression Test ·································································································· 4-8 Thermostat ·························································································································· 4-9 RPM Performance Test ······································································································ 4-10 Recoil Starter······················································································································ 4-11 Flywheel ····························································································································· 4-20 Powerhead ·························································································································...
Page 83 SECTION 4 GENERAL PRECAUTIONS Before performing any service work on the powerhead, read and understand the Service Safety section at the beginning of this manual. Use the manufacturer special tools as indicated during servicing of the powerhead. Use caution when performing tests with the engine cover removed. Do not wear loose clothing or jewelry.
Page 84 POWERHEAD 1-/ 2-Cylinder...
Page 85 SECTION 4 1-/ 2-Cylinder...
Page 86 POWERHEAD Manufacturer Special Tools Required Flywheel Puller Assembly, 309-72214-0 (2.5 / 3.5 only) Flywheel Puller Assembly, 336-72214-0 (5 - 40) Flywheel Stripper, 3B6-72214-1 Piston Pin Tool, 332-72215-0 Piston Ring Tool, 353-72249-0 Thickness Gauge Set, 353-72251-0 General Equipment Required Compression Gauge, 0 - 199 psi [0 - 1,350 kPa / 0 - 13.7 kg/cm Water Pressure Gauge, 0 - 15 psi [0 - 98 kPa / 0 - 1 kg/cm Torque Wrench, 0 - 150 in-lb [0 - 17 N-m / 0 - 1.7kg-m] Torque Wrench, 0 - 750 ft-lb [0 - 1000 N-m / 0 - 100 kg-m]...
Page 87 SECTION 4 TROUBLESHOOTING The troubleshooting chart lists common engine symptoms related to problems with the powerhead. It also indicates speciﬁc component failures which may be causing the problem so it can be isolated more effectively. Symptom Checks • Poor crankcase seal Ignition timing or throttle linkage •...
Page 88 POWERHEAD DESCRIPTION OF OPERATION The power head of this outboard motor is a two- stroke engine (or two-stroke cycle engine). The engine completes its one cycle operation including gas mixture suction, compression, explosion and exhaust while the crankshaft rotates once i. e. the piston moves upward and then downward (two strokes).
Page 89 SECTION 4 CYLINDER COMPRESSI0N TEST 1. Operate engine to normal operating temperature. 2. Stop engine. 3. Disconnect the magneto leads to disable the ignition system. WARNING T1162 Ignition system must be disabled to prevent accidental engine startup during compression test. 4.
Page 90 POWERHEAD THERMOSTAT Removal 1. Remove thermostat cap screws. Gently tap thermostat cap (3) with rubber mallet to loosen and remove cap and gasket. Discard gasket. 2. Remove thermostat and inspect for obvious damage and corrosion. 3. Check pressure relief valve for proper operation. T2011 4.
Page 91 SECTION 4 RPM PERFORMANCE TEST CAUTION Do not perform RPM test if engine shows signs of overheating. Perform this test with correct test propeller installed and with the engine in a test tank. 1. Operate engine up to normal operating temperature. T1170 2.
Page 92: Recoil Starter
POWERHEAD RECOIL STARTER WARNING The 5 - 40 engines have neutral start mechanism (start-in-gear protection) attached to the recoil starter. This feature disables the engine from starting while in gear (forward or reverse). During reassembly of the engine following repair, ensure that you DO NOT DISABLE THE START-IN-GEAR PROTECTION.
Page 93 SECTION 4 4. Remove ratchet e-ring (7), ratchet (5), ratchet guides A and B (8) and (9), starter shaft bolt (14), starter shaft (11) and ﬁnally the reel (3). NOTE Take note of the direction in which the ratchet guides A and B are mounted.
Page 94 POWERHEAD T1563 T1702 Removal — 2.5/3.5 WARNING The 2.5/3.5A (2) engine operates in forward gear only. When started, the propeller will turn. The 3.5B (2) engine is equipped with a gear shift, allowing the engine to be set to NEUTRAL or FORWARD only.
Page 95 SECTION 4 2. Pull out the rope a little and put it in the notch of the case. 3. While holding the starter case (1) and the rope (4), turn the reel slowly to loosen the starter spring (2). 4. Detach E-ring (10). 5.
Page 96 POWERHEAD Cleaning and Inspection All worn, damaged, or missing parts must be replaced. 1. Clean metal parts with solvent and dry with low pressure compressed air. Clean plastic parts with dry cloth. 2. Inspect following components as follows: Starter rewind spring for cracked or broken end loops. T1187 •...
Page 97 SECTION 4 T1600 T1570 T1568 1. Install the starter locking rod, the starter locking cam shaft and the starter handle. 2. Verify that the ratchet operates when the proper load is applied to the ratchet. Set ratchet face up, apply grease and measure force.
Page 98 POWERHEAD Ratchet Load Requirements 5 / 8 / 9.8: 600 to 800 grams 9.9 / 15 / 18: 300 to 500 grams 25 / 30: 300 to 500 grams 300 to 500 grams Assembly — 2.5 / 3.5 For assembling, use the procedure reverse to the 15 16 disassembly while observing the following notes.
Page 99 SECTION 4 T2201 4-18 1-/ 2-Cylinder...
Page 100 SECTION 4 Installation 1. Position recoil starter on powerhead and install mounting bolts. 2. Make sure engine is in NEUTRAL. Install the start-in-gear protection mechanism (1) , (2) , (3) and (4). 3. Test the operation of the start-in-gear protection mechanism. WARNING start-in-gear protection mechanism must be installed.
Page 101 POWERHEAD CAUTION The force needed to loosen and tighten the ﬂywheel nut requires ﬂywheel be removed and installed with engine mounted and secured on an engine stand. NOTE Reference the following speciﬁcation table for ﬂywheel Removal and Installation special tool requirements.
Page 102 SECTION 4 Inspection 1. Inspect ﬂywheel for cracks, chips, and damaged taper. 2. Inspect crankshaft for thread damage and damaged taper. 3. lnspect ﬂywheel key and keyway for damage. Installation WARNING T2018 Ignition system must be disabled to prevent accidental engine startup during installation of the ﬂywheel.
Page 103 POWERHEAD POWERHEAD Typical 1-Cylinder T1676 4-23 1-/ 2-Cylinder...
Page 104 SECTION 4 Typical 2-Cylinder T1677 4-24 1-/ 2-Cylinder...
Page 105 POWERHEAD RemovaI WARNING Ignition system must be disabled to prevent accidental engine startup during removal of the powerhead. NOTE If service work requires ﬂywheel to be removed, remove ﬂywheel before lifting powerhead from the T2020 rest of the engine. See Flywheel, this section. NOTE Mark the mounting location of all clamps so they can be returned to their original positions during assembly...
Page 106 SECTION 4 Disassembly Preliminary 1. Remove all carburetor, ignition, and electrical components from the powerhead. 2. Remove the intake manifold and reed valves. See Intake Manifold in Section 3. NOTE The reed valve of the single cylinder models is attached directly to the crankcase. Therefore, it is removed after dividing the crankcase.
Page 107 POWERHEAD T2203 T1680 T1592 T1682 T1683 Exhaust Cover 6. Remove the exhaust cover bolts. Insert screwdrivers into pinch grooves to separate and remove outer and inner exhaust covers. Crankcase and Crankshaft 7. Remove and discard oil seal (1) and o-ring (2) from lower crankcase head (or engine base or lower cowl).
Page 108 SECTION 4 Pistons NOTE Pistons, rings, and connecting rod bearings are wear parts which seat with operation of the engine. Make sure these parts are marked and kept together so they can be returned to their original positions during assembly. 11.
Page 109 POWERHEAD Cleaning 1. Remove all carbon accumulation from exhaust port areas and cylinder head combustion chambers. 2. Use gasket remover and Scotch-Brite Abrasive Pads to remove all traces of gasket and sealer from the cylinder block, crankcase, cylinder head, intake manifold, exhaust covers, and air silencer.
Page 110 SECTION 4 3. Check the cylinder head for warpage using a machinist straight edge and the thickness gauge set (Part No. 353- 72251-0). lf warpage exceeds 0.004 in [0.10 mm], replace the cylinder head. 4. Using an accurate dial indicator, measure the crankshaft deﬂection with the upper and lower main bearings installed.
Page 111 POWERHEAD If any dimension is not within speciﬁcation, replace the crankshaft assembly. Dimension 1 Dimension 2 Dimension 3 Model in [mm] in [mm] in [mm] 1.417 ± 0.002 2.5 / 3.5 [36 ± 0.05] 1.975 ± 0.002 [40 ± 0.05] 1.654 ±...
Page 112 SECTION 4 T2028 T2027 T1235 7. Measure and record the diameter of each cylinder 28 29 bore and the outside diameter of its respective piston. Subtract the values to calculate the piston clearances. lf any bore diameter or piston clearance exceeds the speciﬁed limit, the cylinder must be professionally bored oversize for use with an oversize piston.
Page 113 POWERHEAD The ring end gap must be within speciﬁcation: Standard Ring End Gap Repair Limit Ring End Gap Model in [mm] in [mm] 2.5 / 3.5 0.007 - 0.013 [0.18 - 0.33] 0.031 [0.8] or over 0.008 - 0.016 [0.20 - 0.40] 0.031 [0.8] or over 8 / 9.8 0.007 - 0.013 [0.18- 0.33]...
Page 114 SECTION 4 Preliminary 1. Before instaIIation, lightly coat the outside surfaces of new bearing seals and o-rings with genuine engine oil or TC- W3 oil. Apply bearing cup grease to the seal lips. Press ﬁt the seals into place using an appropriate size seal installer to avoid damaging the seal or component.
Page 115 POWERHEAD T2031 T2032 Insert bearing (14) into small end of connecting rod (15). Correctly position piston (16) onto the connecting rod. Align components so piston pin hole is not obstructed and install piston pin (18) using piston pin tool. Install new piston pin clips (19). Do not reuse old clips. Cylinder Block and Crankcase 7.
Page 116 SECTION 4 8. Degrease the crankcase ﬂange and mating surface of the cylinder block. Apply anaerobic gasket maker(Loctite 518) to the cylinder block frange. The application must cover the ﬂange evenly and not be excessive. 9. Install crankcase on cylinder block. 10.
Page 117: Midsection
POWERHEAD Exhaust Cover 14. Lightly coat both sides of new (inner and outer) exhaust cover gaskets with gasket sealant. Install gaskets and mount exhaust covers to cylinder block. Torque exhaust cover bolts to speciﬁcation from lowest embossed number to highest. Final Assembly 15.
Page 118 SECTION 4 19. Apply high temperature gasket dressing to engine base gasket and install gasket on powerhead. lnstaIIation 1. Degrease the engine base surface and coat driveshaft splines (1) with genuine engine oil or TC-W3 oil. 2. Apply high temperature gasket dressing to bottom surface of engine base gasket.
Page 119 SECTION 5 MIDSECTION TABLE OF CONTENTS General Precautions············································································································· 5-2 Service Speciﬁcations·········································································································· 5-3 Tiller Steering Handle ··········································································································· 5-4 Lower Engine Cover··········································································································· 5-18 Driveshaft Housing············································································································· 5-19 Stern and Swivel Brackets ································································································· 5-25 Swivel Bracket and Reverse Lock ····················································································· 5-33 1-/ 2-Cylinder...
Page 120 SECTION 5 GENERAL PRECAUTIONS Before performing any service work on the midsection, read and understand the Service Safety section at the beginning of this manual. Replace locking fasteners when their locking feature becomes weak. Use only factory replacement parts. When using compressed air to clean or dry parts, make sure air supply is regulated not to exceed 25 psi [172 kPa / 1.76 kg/cm Always inspect and test the start-in-gear prevention system before returning engine to customer.
Page 121: Gearcase
MIDSECTION SERVICE SPECIFICATIONS Special Torque Values Torque in-Ib (ft-Ib) kg-m Description Threadlocker Model 2.5/3.5 8/9.8 9.9/15/18 25/30 Engine Mounting Bolt — Bracket Bolt Nut 99-133 (8.6-10.8) Type I: (17.4-18.1) (17.4-18.1) — (Tilt Tube Nut) 11.1-15.1 11.7-14.7 (10.8-14.4) 23.5-25.5 23.5-25.5 1.14-1.54 1.2-1.5 14.7-19.6 2.4-2.6...
Page 122 SECTION 5 Consumable Supplies Required Threadlocker, Loctite ® Threadlocker, Loctite ® Gasket Dressing, Permatex Hylomar Aerosol High-Temp Gasket Dressing ® ® Silicone Sealant, Permatex Hi-Temp RTV Silicone Gasket ® Super Bond Adhesive, Permatex Super Glue Gel ® Cleaning Pads, Scotch-Brite Abrasive Pads ®...
Page 123 MIDSECTION Model 5 T2206 Removal The tiller steering handle for the 2.5/3.5 engine is for steering only. For the 5 engine, the tiller arm steers and uses a single cable to control the throttle. The 8/9.8 engine tiller arm steers and uses dual cables to control the throttle.
Page 124 SECTION 5 Models 8/9.8 T2207 Disassembly 1. Remove grip (2). 2. Disconnect throttle cables (3) from throttle shaft (4). Remove the throttle shaft. 3. Fully disassemble all remaining components as illustrated. Cleaning and Inspection All worn, damaged, or missing parts must be replaced. 1.
Page 125 MIDSECTION Models 9.9/15/18/25/30/40 T2208 3. Inspect all plastic and rubber bushings and spacers, grip (2), and friction piece (5) for cracks or deformation caused by wear. 4. Check all fasteners for thread damage, aIl washers for deformation. 5. Replace throttle labeI (6) if damaged or missing.
Page 126 SECTION 5 6. Verify the following components and their friction surfaces are not cracked, bent, or wom: • Steering handle (7) • Steering bracket (8) 7. Inspect throttle cables (3) for kinks, wear, cracks in the protective covering, and excessive stretch. Assembly T1650 NOTE...
Page 127 MIDSECTION Installation 1. lnstall the tiller steering assembly. 2. Connct throttle cable(s) (or throttle shaft). 3. Adjust screw (12) by tightening or loosening it to obtain proper grip turning resistance. 9.9/15/18 Linkage Adjustment T2002 Adjustment of Throttle Mechanism Item Description Timing Mark Ignition Timing Inspection Line Link Rod 5-65L...
Page 128 SECTION 5 Adjusting Link Rods 1. Prior to adjusting ignition timing, adjust Link Rods 5-60L and 5-65L to the following speciﬁcations depending on model being serviced: r r r r of Link Rod 5-60L 5-65L 9.9C 9.9D 2.83-2.87 in 2.95 in 9.9D T2003 (72 - 73 mm)
Page 129 MIDSECTION CAUTION Look vertically down the crankcase when adjusting the ignition timing. NOTE The marks engraved on the magneto coil plate are 5° apart. When engine been properly assembled. the longest engraved line should be 0°. T1637 Adjusting when Throttle is Fully-Closed Item Description Timing Marks...
Page 130 SECTION 5 T1652 25/30/40 Twist Handle and Linkage Adjustment Twist Handle and Linkage Disassembly 1. Loosen the M6 nylon nut (11) and remove the two handle bolts (4). 2. Remove the handle assembly from the steering bracket. 3. Remove the Spring pin (12) from the universal pinion (1). 4.
Page 131 MIDSECTION Twist Handle and Linkage Inspection 1. Check all components for wear or cracks. 2. Lubricate aII moving surfaces. Twist Handle and Linkage Assembly 1. lnstall throttle shaft A (10) after applying grease. 2. lnstall grip on handle A and insert the handle grip (9) and mounting screw (8).
Page 132 SECTION 5 T1656 14 15 Throttle Linkage Adjustment Item Description Advancer Arm Stud Bolt Advancer Arm Bushing Ø 5 Rod Joint BaIl Joint Cap BalI Joint B Advancer Link Rod, 5-50L Handle Link Rod, 5-75L Throttle Cam Throttle Cam Bushing Wave Washer Throttle Link Rod Throttle Link Rod Snap, 3.5-2...
Page 133 MIDSECTION T1657 Item Description Item Description Starter Lock Spring Starter Lock Arm Starter Lock Rod Throttle Stop Arm Starter Lock Rod Snap Wave Washer Bushing Starter Lock Lever Cap Throttle Stop Arm Rod Starter Lock Arm Rod Ball Joint Cap Starter Lock Arm Rod Snap Ball Joint B Starter Lock Lever Shaft...
Page 134 SECTION 5 1. Turn the handle grip so that the collar center of the carburetor throttle lever in on the “S” marking line. 2. Adjust the length of the handle link rod so that the START (1) match mark on the handle grip is aligned to the START position on the tiller handle.
Page 135 MIDSECTION T1663 T1662 20 21 4. Check that the throttle valve is fully open, and the ignition timing mark at starting comes to the crankcase mating surface. Under this state, adjust the advancer arm stopper bolts (1) so that the advancer arm stops at the throttle valve full-open and full-close positions, and lock the bolts with a nuts.
Page 136 SECTION 5 T1634 T1666 T1667 LOWER ENGINE COVER Removal 1. Remove powerhead as described in Section 4. 2. Remove control cables, electrical leads and grommets as required from lower engine cover. 3. Remove lower engine cover bolts (4). T1664 4. Lift cover off engine base. 8/9.8 Shift Rod and Throttle Removal 1.
Page 137 MIDSECTION DRIVESHAFT HOUSING Removal 1. Remove powerhead as described in Section 4. 2. Remove tiIler steering handle if equipped, this section. 3. Remove lower engine cover, this section. 4. Remove gearcase as described in Section 6. 5. Remove upper rubber mount nut (1). 6.
Page 138 SECTION 5 Disassembly CAUTION Engine base and driveshaft housing are aligned with dowel pins and may be difﬁcult to separate. Avoid damage to the mating surfaces and gently pry sections apart if necessary ... Model 40 only. 3. Remove exhaust pipe (1), water pipe (2), and guard pipe (3) ... Models 9.9/15/18 only.
Page 139 MIDSECTION T1619 NOTE The 5 engine does not have an exhaust pipe. Water is drawn through an inlet located in front of the propeller and pumped out through a tube beneath the engine. 5-21 1-/ 2-Cylinder...
Page 140 SECTION 5 T1620 5-22 1-/ 2-Cylinder...
Page 141 MIDSECTION Cleaning and Inspection All worn, damaged, or missing parts must be replaced. 1. Before cleaning, examine the following rubber parts as applicable and remove if damaged, dry, or brittle: • Lower cover grommets and seal ring • Lower engine cover seal (1) •...
Page 142 SECTION 5 T2005 6. Install water pipe (4) in engine base (5) and align for installation in the driveshaft housing. 7. Verify knocks (where used) are installed in driveshaft housing. Apply high temperature gasket dressing to both sides of new driveshaft housing gasket and install gasket on housing.
Page 143 MIDSECTION STERN AND SWIVEL BRACKETS NOTE The following procedures cover full disassembly of the stern and swivel bracket components with the engine mounted on an engine stand. To service only the stern brackets, suspend engine with adequate hoist and remove and install stern brackets as illustrated. Models 2.5/3.5 Model 5 Models 8/9.8...
Page 144 SECTION 5 2.5/3.5 Stern and Swivel Bracket Disassembly 1. Remove the thrust rod (4). 2. Remove stern bracket bolt, nut and washers (1), (9), (2). 3. Remove distance shaft, nuts and washers (5), (6), (7). 4. Remove thrust support (3). 5.
Page 145 MIDSECTION T2008 5 Stern Bracket Disassembly 1. Remove the reverse lock arm bolts (11). 2. Remove reverse arm lock and springs (12). 3. Remove swivel bracket bolts (13). 4. Remove drive shaft housing. 5. Remove thrust plates (9). 6. Remove both upper and lower bushings (7), (8). 7.
Page 146 SECTION 5 T1644 8/9.8 Stern Bracket Disassembly 1. Remove tilt stop assembly (1). 2. Remove stern bracket bolt (2), nut (3) and washers (4 and 5). 3. Remove thrust rod (6). 4. Remove distance plate (7). 5-28 1-/ 2-Cylinder...
Page 147 MIDSECTION 9.9/15/18 Stern Bracket Disassembly Two types of stern brackets are used on the 9.9/15/18 engines and are identiﬁed as Type I and Type II: • Type I has a metal rod type stern bracket bolt similar to the smaller engines •...
Page 148 SECTION 5 T1645 Type ll Stern Bracket 1. Remove thrust rod (1). 2. Remove nuts (2). 3. Remove pipe caps on bracket bolt (3). 4. Holding bracket bolt nut (4) with wrench, remove bracket bolt nut (5). 5. Remove bracket bolt (6). 6.
Page 149 MIDSECTION 25/30 and 40 Stern Bracket Disassembly NOTE Only minor variations exist between 25/30 and 40 model brackets. 1. Remove the reverse lock spring (1). 2. Remove the split pin from the reverse lock rod (2) and remove the reverse lock rod (2) and reverse lock (3). 5-31 1-/ 2-Cylinder...
Page 150 SECTION 5 3. Remove the reverse lock lever spring (4). 4. Remove the reverse lock arm shafts (5) and remove the reverse lock arm (6). 5. Remove the reverse lock link (7). 6. Remove the reverse lock lever shafts (8) and remove the reverse lock lever (9).
Page 151 MIDSECTION SWIVEL BRACKET AND REVERSE LOCK The swivel bracket and reverse locks of one and two cylinder engines differ in function. The following describes features of swivel brackets and reverse locks. Engine Swivel Bracket Reverse Lock 2.5/3.5 Turning Radius: 360° Ring Inhibit Turning Radius: 360°...
Page 152 SECTION 5 1. Install swivel bracket and springs (if applicable) while installing bracket nuts. 2. Install bracket distance piece (or plate) with bolts (or nuts). 3. Install the thrust rod. 4. Install the reverse lock lever and shaft. 5. Install the reverse lock link (if applicable, and cotter pin). 6.
Page 153 SECTION 6 GEARCASE TABLE OF CONTENTS General Precautions············································································································· 6-2 Service Speciﬁcations·········································································································· 6-3 Water Pump ························································································································· 6-5 Gearcase ···························································································································· 6-10 Backlash - Shim AdjustmentTable ····················································································· 6-34 Gearcase Repair Procedures ····························································································· 6-36 1-/ 2-Cylinder...
Page 154 SECTION 6 GENERAL PRECAUTIONS Before performing any service work on the gearcase, read and understand the Service Safety section at the beginning of this manual. Full servicing of the gearcase requires manufacturer special tools. Follow aIl special tool requirements as speciﬁed. Substituting special tools with those not provided by the manufacturer may result in severe personal injury, equipment or engine damage, or faulty service work.
Page 155 GEARCASE SERVICE SPECIFICATI0NS Special Torque Values Torque in-Ib (ft-Ib) kg-m Description Threadlocker Model 2 / 3 / 5 8 / 9.8 / 9.9 / 15 / 18 25 / 30 (21.7 - 28.9) (21.7 - 28.9) PropelIer Nut 29.4 - 39.2 29.4 - 39.2 —...
Page 156 SECTION 6 Manufacturer Special Tools Required Part Part Name Number Bevel Gear A Bearing PuIIer Ass’y 3A3-72755-0 • • Bearing Outer Press Rod 3B7-72731-0 • • Bearing Outer Press Plate 353-72732-0 • Bearing Outer Press Plate 346-72732-0 • Bearing Outer Press Guide 346-72733-0 •...
Page 157: Water Pump
GEARCASE General Equipment Required TorqueWrench, 0- 150 in-lb[0 - 17 N-m / 0- 1.7 kg-m] TorqueWrench, 0 - 150 ft-lb [0 - 200 N-m / 0 - 20 kg-m] Dial Gauge, minimum scale0.0001 in [0.01 mm] Gearcase Pressure Tester, Stevens S-34 or equivalent ®...
Page 158: Disassembly And Assembly
SECTION 6 T1754 T1703 T1704 T1705 T1706 Disassembly and Assembly 2.5/3.5 w/o Shift Lever 1. Disassemble the water pump com- 3.5 w/ Shift Lever ponent as illustrated and verify the kit parts match the originals before discarding old parts. 5, 8/9.8 NOTE 25/30 Lower pump case dowel pins are difﬁcult to remove and...
Page 159 GEARCASE T2042 T1344 T1707 2. Remove all gasket residue from lower pump case with abrasive cleaning pads and gasket remover. Do not scrape the gasket surface with metal scraper. Thoroughly clean all components with isopropyl alcohol and dry with Iou pressure compressed air.
Page 160 SECTION 6 T1351 T1352 T1353 8. InstalI Iower pump case dowel pins (7) if removed and o- ring (8). 9. Apply gasket sealant to both sides of guide plate gasket (9). Mount gasket and guide plate (10) on lower pump case. 10.
Page 161 GEARCASE 3. Slide the impeller down the driveshaft onto lower pump case. 4. Insert impeller key (4) in driveshaft and align impelIer slot with key. Hold the impeller key in place and push impeller down until seated in position. 5. Lubricate the impeller blades with soapy water and slide upper pump case down driveshaft.
Page 162 SECTION 6 GEARCASE Typical Gearcase – 2.5/3.5 T1709 6-10 1-/ 2-Cylinder...
Page 163 GEARCASE T1711 T1710 Removal and Disassembly WARNING Ignition system must be disabled to prevent accidental engine start-up during removal of the gearcase. 1. Remove split pin (1), propeller (2), and shear pin (3). 2. Remove gearcase bolts (4) and gearcase assembly (6) from the drive shaft housing (5).
Page 164 SECTION 6 T1712 T1713 5. Remove the water pump impeller (8) and impeller key. Remove the water pump case (9). Install a water pump repair kit if gearcase has been in service for any length of time. See Water Pump, this section. 6.
Page 165 GEARCASE Typical Gearcase – 3.5B T1714 6-13 1-/ 2-Cylinder...
Page 166 SECTION 6 T1715 T2210 Removal and Disassembly WARNING Ignition system must be disabled to prevent accidental engine start-up during removal of the gearcase. Place engine in neutral gear. 1. Remove drive shaft housing grommet. 2. Loosen shift rod joint bolt (9). NOTIE Shift rod joint bolt can only be loosened.
Page 167 GEARCASE T1717 T2210 7. Remove the shift rod (5) from the shift rod lever (6). 8. Pull up the water pipe (7) from the drive shaft housing. 9. Remove the propeller shaft housing bolts (10). 10. Remove the propeller shaft housing (11). Note the push rod dropping and check the o-ring (12) for damage.
Page 168 SECTION 6 T2043 T1721 T1720 12. Remove the pump case bolts (16). Remove the pump case (17) and pump impeller (15). 13. Install a water pump repair kit if gearcase has been in service for any length of time. See Water Pump, this section. 14.
Page 169 GEARCASE Typical Gearcase — 8/9.8/9.9/15/18/25/30/40 T1723 6-17 1-/ 2-Cylinder...
Page 170 SECTION 6 T1361 T1362 Removal WARNING Ignition system must be disabled to prevent accidental engine start-up during removal of the gearcase. T1724 1. Place engine in FORWARD gear so shift rod joint (1) is accessible. 2. Use spring pin tooI A (3) (Part No. 345-72227-0) to remove upperspring pin from shift rod joint.
Page 171 GEARCASE T1367 T1369 Disassembly CAUTION Gearcase must be secured in a suitable holding ﬁxture during disassembly. 1. Drain all gearcase oil into a container and inspect the oil for metal chips. T1370 NOTE Small metal fragments may indicate normal wear of gears, bearings, and shafts.
Page 172 SECTION 6 T1372 T1726 T1727 8. Lift the driveshaft from the gearcase and set it aside. 9. Reach inside gearcase and remove roller bearing (8) and bevel gear A (9). NOTE Taper bearing for bevel gear A is only used on Model 10.
Page 173 GEARCASE T1378 T1730 T1380 T1379 13. Remove bevel gear C (16) from the propeller shaft housing. 14. Insert screwdriver under one end of clutch pin snap spring (17). Remove spring from groove by unwrapping it from clutch. Discard the spring. 15.
Page 174 SECTION 6 Cleaning and Inspection NOTE All worn, damaged, and missing paIls must be replaced. 1. Discard the clutch pin snap spring and all seals and o-rings that have been removed. 2. Clean all gearcase components with solvent and dry with low pressure compressed air.
Page 175 GEARCASE Assembly CAUTION Gearcase must be secured in a suitable holding ﬁxture during assembly. Assembly — 2.5 / 3.5 1. Install propeller shaft assembly. 2. lnstall water pump case. 3. lnstall pump impeller key. 4. Install pump impeller. Assembly — 3.5B 1.
Page 176 SECTION 6 2.5 / 3.5 and 3.5B 12. Install the gear case assembly to the driveshaft housing. Tighten the gear case bolt. 3.5B Only 13. When connecting the cam rod and shift rod to each other with the shift rod joint, set the cam rod and shift rod at the neutral position. 14.
Page 177 GEARCASE T1733 T1734 T1390 7. Install bevel gear A (8) so tapered roller bearing (9) is seated in outer race. 8. Replace cam rod bushing internal o-rings (10) and external o-ring (11). Coat the internal o-rings and inner surface of bushing with speciﬁed gear oil.
Page 178 SECTION 6 T2045 T1739 T1740 13. lnstall clutch push rod (19) so tapered end faces bevel gearA. 14. Compress the clutch spring by applying pressure to push rod (19). Align the holes of the clutch and spring holder and insert clutch pin (20). CAUTION Wear safety glasses and DO NOT hold spring end of propeller shaft towards face or body when...
Page 179 GEARCASE T1400 T1402 T1743 19. Align the clutch push rod with the clutch cam and slide the propeller shaft and housing into the gearcase opening. Push forward and rotate the propeller shaft as needed until bevel gears have engaged. Ensure the propeller shaft housing bolts are completely clean and apply Loctite 242 to the bolt threads.
Page 180 SECTION 6 • pump vacuum tester until gauge indicates 3 - 5 in [76 - 127mm] of mercury. If loss of vacuum occurs at either range, apply oil around suspected seal. lf leak stops or oil is drawn in, the seal is defective and must be replaced.
Page 181 GEARCASE Bevel Gear B Adjustment - (25/30 and 40 Only) 2. Insert shimming gauge (3) into gearcase (25/30 gauge: 346-72250-0, 40 gauge: 3C8-72250-0). NOTE Correct positioning of the shimming gauge in the gearcase is critical, Make sure tapered side (4) is fully seated I'n bevel gearA bearing outer race with ilat side (5) and notch (6) facing upward.
Page 182 SECTION 6 3. Eliminate all looseness between driveshaft and gearcase using one of the following methods: • Lift driveshaft upward and tap down on gearcase with rubber mallet. • Slide acompression spring (obtain locally) over driveshaft and seat onto lower pump case. Install backlash measuring tool clamp assembly (Part No.
Page 183 GEARCASE T1405 T1744 5. With the tapered roller bearing installed, position bevel gear A in gearcase so bearing is fully seated in outer bearing race. Rotate the driveshaft to ensure gears are property meshed. 6. Assemble the following backlash tool components. Note the correct quantity and orientation of conedisk spring washers: Assemble three conedisk spring washers (10), o-ring (11), and collar (12).
Page 184 SECTION 6 T1411 T1746 T1747 10. Mount a magnetic base and dial gauge (obtain locally) as shown. Lift driveshaft upward and tap down on gearcase with rubber mallet to eliminate all looseness and proceed to adjust the setup so dial gauge (19) is aligned with V-notch (20). 11.
Page 185 GEARCASE T1417 T1748 lnstallation WARNING Ignition system must be disabled to prevent accidental engine start-up during installation of the gearcase. T1750 1. Lightly coat the driveshaft splines with genuine engine oil or TC-W3 oil and apply silicone spray lubricant to water pipe lower seal (1).
Page 186 SECTION 6 6-34 1-/ 2-Cylinder...
Page 187 GEARCASE 6-35 1-/ 2-Cylinder...
Page 188 SECTION 6 GEARCASE REPAIR PROCEDURES CAUTION DO NOT attempt gearcase repairs without proper manufacturer special tools. Use this section when service work requires disassembly or replacement of the following gearcase components: • Driveshaft roller bearings. • Gearcase needle bearing. • Propeller shaft housing needle bearing. •...
Page 189 GEARCASE Gearcase Needle Bearing - Models 9.9 / 15 / 18 / 25 / 30 / 40 NOTE Obtain needle roller bearing puller kit (Part No, 3C8- 72700-0). T1753 Removal 1. Insert shaft (1) through needle bearing from water pump side of gearcase.
Page 190 SECTION 6 lnstaIIation 1. lnsert shaft (1) through needle bearing housing in gearcase. 2. Coat the new needle bearing with genuine gear oil. Slide bearing onto shaft from propeIIer shaft side of gearcase so bearing stamped surface (2) faces propeller shaft side. CAUTION Stamped surface of needle bearing must face propeller shaft side of gearcase or bearing could...
Page 191 GEARCASE Installation 1. Attach retainer A (2) to shaft groove (3) with raised surface of retainer facing bearhg. 2. Coat new needle bearing with gear oIl. Slide bearing onto shaft so bearing stamped surface faces retainer A (2). CAUTION Stamped surface of needle bearing must face retainer or bearing could be damaged during installation.
Page 192 SECTION 6 T1448 T1449 T1450 5. Insert rod (2) into gearcase so plate (1) is seated within the bearing race. 6. Slide guide (5) onto rod and seat into position on gearcase. Raised surface of guide must ﬁt tightly within the circumference of the gearcase opening.
Page 193: Electrical System
SECTION 7 ELECTRICAL SYSTEM TABLE OF CONTENTS General Precautions············································································································· 7-2 Service Speciﬁcations·········································································································· 7-3 Electrical Servicing Standards ····························································································· 7-7 Troubleshooting·················································································································· 7-10 Description of Operation ···································································································· 7-12 Battery Care and Maintenance ·························································································· 7-17 (See 3/4 Cylinder Manual - Section 7) Ignition System ·················································································································· 7-20 Ignition System Repair Procedures····················································································...
Page 194 SECTION 7 GENERAL PRECAUTIONS Before performing any service work on the electrical system, read and understand the Service Safety section at the beginning of this manual. Use the manufacturer and special tools as indicated during servicing of the electrical system. Avoid electrical shock: •...
Page 195 ELECTRICAL SYSTEM SERVICE SPECIFICATIONS Special Torque Values Torque in-Ib (ft-Ib) kg-m Description Threadlocker Model 2.5 / 3.5 5 / 8 / 9.8 9.9 / 15 / 18 25 / 30 / 40 Spark Plug (19 - 21) (19 - 21) (19 - 21) (19 - 21) 25 - 29...
Page 196 SECTION 7 GeneraI Equipment Required Analog Multimeter, Electronic Specialties Model M-530 or equivalent ® Digital Multimeter, Electronic Specialties Model KD 3200 or equivalent ® Spark Gap Tester, Stevens S- 13C, S-48, or equivalent ® Digital Pulse Tachometer, 10 - 6000 RPM, Electronic Specialties Model 321 or equivalent ®...
Page 197 ELECTRICAL SYSTEM Spark Plug With Resistor 2.5 / 3.5: NGK BPR6HS-10 or Champion RL87YC10 With Resistor 5 / 8 / 9.8: NGK BPR7HS-10 or Champion RL82YC10 With Resistor 9.9 / 15 / 18 / 25 / 30 / 40: NGK BR7HS-10 or Champion RL82C10 Spark Plug Gap in[mm] 2.5 / 3.5 / 5, 8, 9.8, 9.9, 15, 18, 25, 30, 40C:...
Page 198 SECTION 7 Ignition Coil Resistance Primary Coil 0.18- 0.24 Ω 2.5/ 3.5: 0.2 - 0.38 Ω 0.2 - 0.3 Ω 9.9 / 15 / 18 / 25 / 30 / 40: Secondary Coil 2.5 / 3.5: 2.7 - 3.7 KΩ 3.0 - 4.4 KΩ...
Page 199: Electrical Servicing Standards
ELECTRICAL SYSTEM ELECTRICAL SERVICING STANDARDS Electrical Connectors When you replace electrical components or perform diagnostic tests, you must disconnect electrical connectors in many instances. The following discussion will help you recognize connectors in electrical drawings and show you how to disconnect and connect them.
Page 200 SECTION 7 T1477 T1479 T1465 Special cases are the connectors used to test components located on the coil plate assembly. For testing purposes, the ﬁrst connector is located at the far end of the cable (away from the coil plate assembly). Bullet Connectors NOTE Bullet connectors (1) are shown like this in electrical...
Page 201 ELECTRICAL SYSTEM Electrical Cable Color Codes Electrical cables have color coded conductors so you can locate the correct conductor during troubleshooting and repair procedures. AII conductor colors are in capital letters in this manual. Some conductors have a background color and a different color stripe that runs the length of the conductor.
Page 202 SECTION 7 TROUBLESHOOTING The troubleshooting chart lists common engine symptoms related to problems with the electrical system. lt also indicates speciﬁc malfunctions in the electrical system which may be causing a problem so it can be isolated more effectively. Before beginning major troubleshooting on the electrical system, perform the following operations: •...
Page 203: Ignition System
ELECTRICAL SYSTEM Ignition System SYMPTOM Wilt not start Starts but Poor accel- Engine will Low or high Cranks but and pops or stops eration, low not shut speed miss will not start CHECKS backfi res immediately top end RPM Faulty stop circuit - see Test 2 - •...
Page 204: Charging System
SECTION 7 Charging System SYMPTOM Battery does not maintain charge or overcharges CHECKS • Blown fuse Shorted or faulty • alternator coil • T1770 Faulty recitier/regulator • Faulty charge circuit wiring DESCRIPTI0N OF OPERATION Ignition System The ignition system consists ofthe magneto (1), Capacitive Discharge (CD) unit (2), ignition coil (3), main key switch (4) and emergency stop switch (5).
Page 205 ELECTRICAL SYSTEM T1981 T1982 Magneto The electrical system consists of a ﬂywheel (1), coil plate assembly (2), a CD unit (3) and an ignition coil (4). The 1/2 cylinder engines are comprised of seven basic electrical systems. The following chart demonstrates not only the differences but the similarities: 2.5A(2) 2.5A...
Page 206 SECTION 7 T1982 T1983 Coil Plate The coil plate is a part to which exciter coil, pulser coil and alternator coil are attached. (2.5, 3.5 and 5 Hp models do not use the coil plate.) The coil plate is rotated for ignition advance. Exciter Coil The exciter coil (5) consists of many windings of wire wrapped around a metal lamination.
Page 207 ELECTRICAL SYSTEM CD Unit The CD Units incorporate a printed circuit board (PCB) encased in a black resin housing to protect the circuitry from water and vibration. Major components include a diode used to rectify current generated by the exciter coil, a capacitor which charges the voltage supplied, a thyristor which serves as a breaker and a zener diode used to control the thyristor.
Page 208 SECTION 7 T2213 T1986 Starting System - Optional Electric Start (8 / 9.8 / 9.9 / 15 / 18 / 25 / 30 / 40) The starting system consists of the battery, main key switch, neutral start switch, starter solenoid (3), starter motor (4) and 15 A engine fuse (5).
Page 209: Battery Care And Maintenance
ELECTRICAL SYSTEM BATTERY CARE AND MAINTENANCE WARNING Batteries produce and explosive mixture of oxygen and hydrogen. Keep sparks or open ﬂame away from battery. CAUTION Battery electrolyte is a poisonous, acidic solution. Always: • Wear protective gloves and safety glasses when working with battery acid.
Page 210 SECTION 7 Testing 1. Check electrolyte level. 2. Check speciﬁc gravity using a hydrometer. 3. Note temperature of ﬂuid or ambient air (in celcius). 4. Calculate corrected speciﬁc gravity using the following formula: Corrected speciﬁc gravity = MSP + (temperature - 20) x 0.0007 Where: MSP = measured speciﬁc gravity Temperature = Temperature in degrees celcius...
Page 211 ELECTRICAL SYSTEM Terminal Voltage Test 1. Check electrolyte level and specﬁc gravity. 2. Connect a Variable Load High Rate Discharge Tester to battery terminals. 3. Discharge at a rate of 3 x ampere hour rating of battery for 15 seconds. •...
Page 212 SECTION 7 lGNITI0N SYSTEM CAUTION All cranking output tests must be performed with spark plugs installed and torqued in the cylinder head. lt necessary to remove the spark plugs, be sure to keep the spark gap tester away from open spark plug holes. CAUTION Avoid electrical shock: •...
Page 213 ELECTRICAL SYSTEM Ignition System Performance Testing Ignition Performance Testing is divided into two sections. The ﬁrst section consists of a ﬂow chart. This chart presents the correct sequence of performing ignition system performance tests to effectively and efﬁciently check for problems in starting and running the engine.
Page 214 SECTION 7 Ignition System Performance Testing Flow Chart T1557 7-22 1-/ 2-Cylinder...
Page 215 ELECTRICAL SYSTEM Test 1 - Spark Test NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure. Check for continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coils before conducting the folIowing procedure.
Page 216 SECTION 7 Test 2 - Stop Circuit Test Stop circuit malfunction can cause the engine not to start or prevent it from stopping. Several component failures can cause the stop circuit to malfunction. Use this ﬂow chart to isolate and repair all component failures. NOTE After you complete each stop circuit test, refer back to the ﬂow chart for the next step.
Page 217 ELECTRICAL SYSTEM Test 2a - Stop Circuit Main Key Switch Test (if so equipped) This test is used to determine whether the main key switch and connecting wiring are functioning normally. NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure.
Page 218 SECTION 7 6. Disconnect CD Unit (8) terminals (5) and (6). 7. Connect one meter lead to terminal (6) and the other to terminal (2) and check continuity. If the meter does not show continuity, replace the cable. 8. Connect one meter lead to terminal (6) and the other to a clean engine ground.
Page 219 ELECTRICAL SYSTEM 1. Remove negative lead from battery. 2. Disconnect emergency stop switch terminals (1), (2), (3) and (4). 3. Set analog multimeter to check continuity. Connect one meter lead to terminal (1) and the other to terminal (3). 4. Attach lanyard (5) to emergency stop switch (6), meter must not show continuity.
Page 220 SECTION 7 T1989 Test 3 - Exciter Coil Test NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure. Check for continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coils before conducting the following procedure.
Page 221 ELECTRICAL SYSTEM T1780 The exciter coil test is used to determine the output voltage, in DVA, from the exciter coil (1), located on the coil plate assembly (2) to the CD Unit while you are cranking the engine. 1. Disconnect the following terminals: Engine Models Disconnect Terminals 2.5 / 3.5...
Page 222 SECTION 7 T1781 3. The meter should indicate the following resistance: Engine Models Results 280 - 420 Ω ± 25% 2.5 / 3.5 93 - 140 Ω ± 25% 224 - 336 Ω ± 25% 8 / 9.8 168 - 252 Ω ± 25% 9.9D / 15D / 18E 130 - 195 Ω...
Page 223 ELECTRICAL SYSTEM Connect Multimeter Engine Models Between These Terminals 2.5 / 3.5 / 3.5B • Terminal 4 5 / 8 / 9.8 • Terminal 4 • Terminal 6 9.9D / 15D / 18E / 25C / 30A / 40 • Terminal 4 •...
Page 224 SECTION 7 8. At cranking RPM, the tester should show the following results: Engine Models Test Results 2.5 / 3.5 / 3.5B, 5, 8 / 9.8, 9.9 / 100 DVA Minimum 15 / 18, 25 / 30 and 40 9. If the exciter coil test results are not within the acceptable range, replace the exciter coil set.
Page 225 ELECTRICAL SYSTEM T1991 - Models 9.9 / 15 / 18 / 25 / 30 and 40 The pulser coil test is used to determine the output 10 11 voltage, in DVA, from the pulser coil (1), located on the coil plate assembly (2), to the CD Unit (3) while you are cranking the engine.
Page 226 SECTION 7 3. The meter should indicate the following resistance for pulser coils: Engine Models Results 2.5 / 3.5 80 - 117 Ω ± 25% 8 / 9.8 30 - 46 Ω ± 25% 9.9D / 15D / 18E 9.9D / 15D / 18E 30 - 46 Ω...
Page 227 ELECTRICAL SYSTEM 7. Set the analog multimeter to “20” on the “DVA” scale. Connect the RED and BLACK tester leads as follows to check the output voltage (DVA) of the pulser coil at cranking speed: Engine Models Black Lead Red Lead •...
Page 228 SECTION 7 T1784 T1988A Test 5 - CD Unit Output Test - Cranking RPM NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure. Check for continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coil before conducting the following procedure.
Page 229 ELECTRICAL SYSTEM WARNING To avoid possible shock hazard, do not handle ignition coils or spark gap tester during cranking tests. NOTE To prevent possible arcing of high voltage, route tester leads at least 2 in [51 mm] from any metal surface. Ground unused test leads to a clean engine ground.
Page 230 SECTION 7 Test 6 - Ignition Coil Tests NOTE Make sure all electrical terminals are connected during this test except those that are noted in the test procedure. Check for continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coils before conducting the following procedure.
Page 231 ELECTRICAL SYSTEM Repeat readings for each ignition coil: Engine Models Results 2.5 / 3.5 2.7 - 3.7 KΩ ± 25% 3.0 - 4.4 KΩ ± 25% 8 / 9.8 1.95 - 3.25 KΩ ± 25% 9.9 / 15 / 18 4.1 - 6.1 KΩ...
Page 232 SECTION 7 NOTE Some steps refer to other ignition tests. After you complete those tests, return to the ﬂow chart for further instructions. Output Tests - Engine Running - Flow Chart T1992 7-40 1-/ 2-Cylinder...
Page 233: Ignition System Repair Procedures
ELECTRICAL SYSTEM IGNITION SYSTEM REPAIR PROCEDURES WARNING Disable ignition system, by disconnecting exciter coil terminals (4), (5), (6), (7), to prevent accidental engine startup during removal and replacement of the ﬂywheel. CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation.
Page 234 SECTION 7 CAUTION Use proper precautions when performing tests with the engine cover removed. Do not wear loose clothing or jewelry. Keep hair, hands, and clothing away from the ﬂywheel and other moving parts. CAUTION When repairs are complete, make sure all ignition T1490 and electrical leads are properly routed and clamped in their original positions and the start-...
Page 235 ELECTRICAL SYSTEM T1993 T1785 T1994 Removal 1. Remove the ﬂywheel. 2. Disconnect terminals (4), (5), (6) and (7) for exciter coil (1) connectors. Note that these terminals interconnect cable from coil plate assembly (2) to cable from CD Unit (3): 3.
Page 236 SECTION 7 Cleaning and Inspection Clean coil plate assembly, upper main bearing seal (1), set ring, ignition timing link, alternator coils, pulser coils, coil leads, and coil connectors with isopropyl alcohol as required. Check for the following and repair or replace as required: •...
Page 237 ELECTRICAL SYSTEM Coil Plate Assembly Removal l. Remove the ﬂywheel. 2. Disconnect the following terminals: Exciter coil (1) terminals. Note that these terminals interconnect cable from coil plate assembly (2) to cable from CD Unit (3). Disconnect terminals (4), (5), (6) and (7). T1785 7-45 1-/ 2-Cylinder...
Page 238 SECTION 7 pulser coil (1) terminals. Note that these terminals interconnect cable from coil plate assembly (2) to cable from CD Unit (3). Disconnect terminals (4), (5), (6), (7), (8), (9), (10) and (11). Alternator coil (1) terminals. Note that these terminals interconnect cable from coil plate assembly (2) to rectiﬁer/ regulator (3).
Page 239 ELECTRICAL SYSTEM 3. Remove the screws (1) and remove coil plate assembly (2) from the set ring. Cleaning and Inspection Clean upper main bearing seal (1), guide plate (2) and 14 15 set ring (3) with dry cloth. Check for the following and repair or replace as required: •...
Page 240: Bolts
SECTION 7 T1506 T1507 T1788 Removal 1. Disconnect CD Unit output lead (1) from ignition coil primary cable (2). 2. Disconnect spark plug cap (1) from spark plug (2). 3. Remove bolts (1) and remove ignition coil. Cleaning and Inspection T1509 Clean mounting area with isopropyl alcohol.
Page 241 ELECTRICAL SYSTEM CD Unit NOTE Disconnect negative battery cable from battery before removing CD Unit. Removal 1. Remove bolts (1). 2. Remove CD Unit. T1789 Cleaning and Inspection Examine electrical conductors and connectors. Installation lnstall in reverse order of removal. NOTE Make sure that all electrical conductors are properly routed before you insert CD Unit to avoid pinching...
Page 242 SECTION 7 STARTING SYSTEM WARNING Disable ignition system, by disconnecting exciter coil terminals (4) and (5) to prevent accidental engine startup during testing of starter circuit. T1790 7-50 1-/ 2-Cylinder...
Page 243 ELECTRICAL SYSTEM CAUTION Use proper precautions when performing tests with the engine cover removed. Do not wear loose clothing or jewelry. Keep hair, hands, and clothing away from the ﬂywheel and other moving parts. CAUTION When repairs are complete, make sure all ignition and electrical leads are properly routed and clamped in their original positions and the start- in-gear prevention system must be tested before...
Page 244 SECTION 7 T1514A Starter Circuit Tests These tests are designed to quickly isolate the faulty starter circuit component if the engine does not crank. NOTE The electrical drawings have been simpliﬁed to show only those elements necessary to test the starter circuit.
Page 245 ELECTRICAL SYSTEM T1515 1. Disconnect negative battery cable (3) from negative battery terminal (1). 2. Set analog multimeter to check continuity. Connect one tester lead to negative battery terminal (1) and the other tester lead to the ground connection (2) for negative battery cable (3). 7-53 1-/ 2-Cylinder...
Page 246 SECTION 7 If the meter does not indicate continuity, clean connections and/or replace negative battery cable. If the meter indicates continuity, go to the next step. 3. Set analog multimeter to “iDCV” and set range to “20”. Connect BLACK tester lead to “- COM” and the RED tester lead to “+ VΩ”. 4.
Page 247 ELECTRICAL SYSTEM 11. Connect RED tester lead to connector closest to fuse holder (12). If meter does not indicate battery voltage, ﬁnd source of overload or short and replace 15 A engine fuse (13). Possible sources of short or overload: •...
Page 248 SECTION 7 NOTE For models without remote control box - You might have to pulI connector (15) apart and measure voltage at terminal indicated in drawing. If meter does not indicate battery voltage, test main key switch. Refer to Main Key Switch Test in this section. If meter indicates battery voltage, go to next step.
Page 249 ELECTRICAL SYSTEM T2214 T2215 Remove Starter Motor NOTE Disconnect negative battery cable from battery before removing starter motor. 1. Disconnect starter solenoid cable and ground cable. 2. Remove starter motor bolts (3). T1522 3. Slide starter motor out of bracket. 4.
Page 250 SECTION 7 T1523 T1793 T1794 T1525 4. Remove pinion gear (3), spring (4) and pinion collar (5). 5. Clean removed components with cleaning solvent and examine pinion gear for wear and chipped teeth and spring for tension or distortion and replace assembly as required. NOTE Do not allow cleaning solvent to come in contact with starter motor.
Page 251 ELECTRICAL SYSTEM Inspect Brush Assembly 1. Clean starter motor terminal and hardware (1) with isopropyl alcohol and ﬁne emery cloth and replace brush assembly if terminal or hardware cannot be restored to original condition. 2. Check brushes (2) and (3) for chips, 13 14 15 fractures, and wear.
Page 252 SECTION 7 T1530 T1526 T1529 Remove Brush Assembly 17 18 1. Remove screws (1). Remove brush assembly (1) carefully guiding the starter motor terminal (2) through the bushing (3). Install Brush Assembly 1. Apply genuine grease to bearing cup (1). T1531 2.
Page 253 ELECTRICAL SYSTEM T1537 T1533 T1536 2. Retract brushes as you slide motor base (1) 23 24 25 over commutator (2). Align notch (3) in motor base with tab (4) in motor body (5) and seat motor baseto motor body. 3. Grasp pinion collar (1) and rotate several times to make sure brushes are seated.
Page 254 SECTION 7 Install Starter Motor 1. Slide starter motor into bracket, apply threadlocker to bolt threads, and instaII mounting bolts. 2. Connect starter solenoid cable and ground cable. 3. Coat terminals with battery spray protector. Starter Solenoid Test 1. Disconnect terminals (4) and (5) and disconnect terminal (3) from chassis ground.
Page 255 ELECTRICAL SYSTEM T1546 Main Key Switch Test 1. Disconnect terminals (2), (3), (4), (5), (6), (7), (8), (9), (10), (11), (12) and (13). 2. Set analog multimeter for continuity. With main key switch (1) set to OFF, ON, START, and PUSH IN positions, check for continuity between a clean chassis ground and one of these terminals (test one terminal at a time): Terminal...
Page 256 SECTION 7 4. With main key switch set to the ON position, check for continuity between terminals (2) and (8). lf meter does not show continuity, replace main key switch. Check for continuity between the following terminals, if meter shows continuity, replace main key switch.
Page 257 ELECTRICAL SYSTEM Check for continuity between the following terminals, if meter shows continuity, replace main key switch. Terminal Terminal Terminal 8. With main key switch set to the START position, PUSH IN the key, check for continuity between terminals (2), (8), (10) and (12). lf meter does not show continuity, between all four terminals replace main key switch.
Page 258 SECTION 7 Choke Solenoid Test 1. Disconnect terminals (2) and (3). 2. Set analog multimeter for continuity. Check for continuity between a clean chassis ground and one of these terminals (test one terminal at a time): Terminal Terminal If meter shows continuity in any of these tests, replace choke solenoid (1).
Page 259 ELECTRICAL SYSTEM CAUTION When repairs are complete, make sure all ignition and electrical leads are properly routed and clamped in their original positions and the start- in-gear prevention system must be tested before returning engine to customer. CAUTION The following tests must be performed with correct test propeller and with the engine in a test tank.
Page 260 SECTION 7 T1552 Alternator Coil Tests NOTE Make sure aIl electrical terminals are connected during this test except those that are noted in the test procedure. Check for continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coils before conducting the following procedure.
Page 261 ELECTRICAL SYSTEM T1552 3. The meter should indicate the following resistance: Engine Models Results Y-W : 0.65 - 0.98 40new Y-B : 0.31-0.47 W-B : 0.37-0.55 0.24 - 0.38 Ω Y-W : 0.65 - 0.98 25C3 / 30A4 Y-B : 0.31-0.47 W-B : 0.37-0.55 0.24 - 0.36 Ω...
Page 262 SECTION 7 T1553 7. Set the analog multimeter to “40” on the “ACV” scale. 8. Insert the banana plug of the RED tester lead into the meter connection labeled “+VΩ” and the banana plug of the BLACK tester lead into the meter connection labeled “-COM”. 9.
Page 263 ELECTRICAL SYSTEM Rectiﬁer/Regulator Tests NOTE Make sure aIl electrical terminals are connected during this test except those that are noted in the test procedure. Check ior continuity between chassis ground and the ground connection for the magneto plate, CD Unit, and ignition coils before conducting the following procedure.
Page 264 SECTION 7 T1797 NOTE Continuity on chart means that the meter showed continuity (some resistance indicated by meter - exact value depends on test conditions). No Continuity on chart means that meter had no deﬂection. RED Tester Lead Terminal Terminal Terminal Terminal Continuity...
Page 265 ELECTRICAL SYSTEM CAUTION Flywheel is under high torque and requires the use of special tools for removal and installation. Failure to use the speciﬁed tools can result in injury or damage to the ﬂywheel or coil plate electrical components. CAUTION T1490 The force needed to loosen and tighten the ﬂywheel nut requires ﬂywheel be removed and...
Page 266 SECTION 7 T1552 Alternator Coils NOTE Disconnect negative battery cable from battery before removing alternator coils. This procedure assumes alternator coils are available as a separate replaceable component. Some engine conﬁgurations might require replacement of entire coil plate assembly. Check current Parts Catalog for availability.
Page 267 ELECTRICAL SYSTEM T1994 T2218 T1993 3. Remove coil plate assembly cable clamp screws (1) and cable clamp (2). NOTE Make sure you don't cut electrical conductors inside of coil plate assembly cable when you slit cable shield. 4. For models 9.9 / 15 / 18 / 25 / 30 / 40 ONLY: Carefully slit coil plate assembly cable shield (1).
Page 268 SECTION 7 Installation Install in reverse order of removal. NOTE Use threadlocker on screw threads before installing screws. 7-76 1-/ 2-Cylinder...

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