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BRP Johnson J30TEL4SUA 2007 Service Manual

30 hp, 4 stroke
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  • 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: Table Of Contents

    ABLE ONTENTS SECTION ........PAGE INTRODUCTION .

  • Page 7: Introduction

    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 swivel bracket and on the powerhead. This manual covers service information on Johnson 30 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 30 P L 4 SU DESIGN FEATURES: MODEL YR: AP = Advanced Propulsion I = 1 B = Blue Paint N = 2 C = Counter Rotation...

  • 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 ..............18 STANDARD TORQUE SPECIFICATIONS .

  • Page 18: Service Specifications And Special Tools

    Any of the above gasolines with 10% Ethanol or 5% Methanol with 5% co-solvents Minimum Octane 87 AKI (R+M)/2 or 90 (RON) 2+4 Fuel Conditioner, Fuel System Cleaner, Carbon Guard Additives Use only BRP recommended fuel additives. The use of other additives may result in engine damage.
  • Page 19 SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA 12-Volt, 360 CCA (465 MCA) with Battery, Minimum 90 Minutes Reserve Capacity or Recommendation 50 Ampere-Hour Engine Fuse (25 Amp) P/N 5031911 Charge Coil Output 15 Amperes Type Auto Pressure-Temperature Controlled Thermostat opens 143°F (62°C) Type Magneto Powered Capacitor Discharge...

  • Page 20: Standard Torque Specifications

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS STANDARD TORQUE SPECIFICATIONS Standard Torque Chart Size In. Lbs. Ft. Lbs. N·m No. 6 7–10 0.58–0.83 0.8–1.1 No. 8 15–22 1.25–1.83 1.7–2.5 No. 10 24–36 2–3 2.7–4.0 No. 12 36–48 3–4 4.0–5.4 1/4 in.

  • Page 21: Electrical / Ignition

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS Electrical / Ignition Digital multimeter DRC7265 Spark tester 4-pin connector test cord Ohms resolution 0.01 P/N 508118 P/N 5034228 Purchase through local supplier CD Peak reading voltmeter Tachometer/timing light 6-pin connector test cord P/N 507972 P/N 507980 P/N 5034618...

  • Page 22: Fuel

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Fuel Fuel vacuum tester Carburetor synchronizer set P/N 390954 P/N 5034619 Gearcase Spacer (Pinion bearing depth) Gearcase adapter Propeller shaft bearing remover P/N 350932 P/N 772269 P/N 5034764 Driveshaft holder Gear adjusting gauge set Propeller shaft bearing installer P/N 345834 P/N 5034774...

  • Page 23: Special Tools

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Bearing installer/remover Oil Seal Remover Slide hammer P/N 391008 P/N 342685 Adapter P/N 340624 Propeller shaft remover Small puller jaws P/N 432131 Test wheel P/N 5032468 P/N 5034762 (replacement jaws P/N 437952) Bushing P/N 5034620 Stopper P/N 5034621 Magnetic Stand Large puller jaws P/N 432129...

  • Page 24: Powerhead

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Powerhead Compression gauge Handle adapter (NEWAY P/N 503-1) Piston ring compressor Adapter (12 mm) Cylinder bore gauge Oil filter wrench Plastigage † P/N 771310 Flywheel holder Oil pressure gauge Solid pilot (NEWAY P/N-100-5.52) P/N 5034227 P/N 5000900 Handle (NEWAY P/N-505)
  • Page 25 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Valve guide installer Valve guide reamer Valve spring compressor (10.5 mm bore diameter) P/N 346186 Valve guide installer Valve guide reamer handle Valve lifter attachment P/N 5000899 Valve guide installer attachment Valve guide stem seal installer Valve seat cutter (N-121) attachment Valve guide reamer...

  • Page 26: Universal

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Universal Micrometer set (0 - 75 mm) Tie strap installation tool Universal Puller Set P/N 323716 P/N 378103 Syringe Tilt tube nut wrench Vernier calipers P/N 346936 P/N 912084 Thickness gauge Torque wrench extension Temperature gun P/N 912031 P/N 772018...
  • Page 27 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 28 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 29: Shop Aids

    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 30: Notes

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 31: Installation And Predelivery

    INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS BOAT RIGGING ..............30 .

  • Page 32: Boat Rigging

    INSTALLATION AND PREDELIVERY BOAT RIGGING BOAT RIGGING • All wiring must be compatible with Modular Wir- ing System (MWS) components Remote Controls Control Selection WARNING The remote control used must have start- in-gear prevention. This feature can pre- vent injuries resulting from unexpected boat movement when the outboard starts.
  • Page 33 INSTALLATION AND PREDELIVERY BOAT RIGGING Installation Guidelines SystemCheck™ Monitor Install the appropriate remote control following all The SystemCheck engine monitor alerts the oper- instructions provided with the remote control. ator of certain engine problems. Refer to the Operator’s Guide for detailed information related Make sure the following items are checked: to the various warning signals.

  • Page 34: 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 35: 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 36: 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 37: 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 38 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Drilling and Hardware Diagram Transom top surface 12.9 in. (327 mm) 12.9 in. (327 mm) sealant 0.53 in (13 mm) 12.9 in. (327 mm) 9.9 in. (251 mm) TYPICAL - Stern bracket for your engine may appear different, but dimensions apply to all 30 to 140 Models. Item Part name Part Number...

  • Page 39: 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 40: 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 84 in. lbs. (10 N·m), then back the nut off 1/8 turn. WARNING The outboard must be correctly installed.

  • Page 41: Outboard Rigging

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING OUTBOARD RIGGING IMPORTANT: 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 42: Control Cable Identification

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Remove grommet from front panel. Control Cable Identification IMPORTANT: Control cable function must be identified before rigging outboard. Identify each control cable: • Put the control handle into NEUTRAL position. The throttle cable casing guide will retract com- pletely and the shift cable casing guide will go to the midpoint of its travel.

  • Page 43: Control Cable Installation

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Control Cable Installation Pull end of cable to remove slack and adjust shift cable trunnion nut to fit in anchor pocket. Shift Cable Move the remote control handle to NEUTRAL. Make sure gearcase is in NEUTRAL gear detent. Remove cable retainer screw and plate.
  • Page 44 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Attach throttle cable to throttle lever pin using flat Install cable retainer and screw and torque screw washer and retainer clip supplied with outboard. to 60 to 84 in.lbs. (7 to 9 N·m). 002860 002862 Pull on throttle cable to remove backlash.

  • Page 45: Water Pressure Gauge Connection

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Water Pressure Gauge Connection Locate water hose on starboard side of powerhead. Cut hose approximately 2.75 in. (70 mm) from block fitting. 1. Cut hose here 003002 Install T-fitting supplied in kit, with restricted part of fitting toward water pressure gauge. Route hose through rigging grommet in lower engine cover.

  • Page 46: Fuel And Oil

    INSTALLATION AND PREDELIVERY FUEL AND OIL FUEL AND OIL When using alcohol-extended fuels, be aware of the following: • Fuel Requirements The boat’s fuel system may have different requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide. WARNING •...

  • Page 47: Oil Requirements

    INSTALLATION AND PREDELIVERY RUNNING CHECKS RUNNING CHECKS Oil Requirements IMPORTANT: 4-Stroke outboards are shipped WARNING without oil in the crankcase. Oil must be added before starting the engine for the first time. DO NOT run outboard without a water sup- ply to the outboard’s cooling system.

  • Page 48: Fuel System

    INSTALLATION AND PREDELIVERY RUNNING CHECKS IMPORTANT: Fuel System DO NOT perform break-in using a flushing device. DO NOT start-up or run the Perform running checks of the fuel system by fol- engine out of water. DO NOT leave a running lowing these steps: engine unattended.

  • Page 49: Tachometer Pulse Setting

    INSTALLATION AND PREDELIVERY RUNNING CHECKS Tachometer Pulse Setting Operating Temperature Confirm accuracy of tachometer reading. An outboard running at idle speed should achieve • a temperature based on the engine’s thermostatic Adjust dial on back of tachometer to 6 pulse/12 pole setting.

  • Page 50: 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. 49 before installing propeller. mance. Proceed carefully and thoroughly while considering the following points: The correct propeller, under normal load condi- •...

  • Page 51: 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 52: Notes

    INSTALLATION AND PREDELIVERY NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 53 MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . 52 ENGINE SIDE COVERS .

  • Page 54: 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 55 MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE Engine Maintenance and Inspection Schedule Frequency Description Electrical and ignition wires and connections, inspect Carburetor synchronization and linkage, inspect and lubricate Idle speed, check Valve clearance, check Gearcase lubricant, replace Engine oil, change Engine oil filter, replace Fuel filter, replace Gearcase lubricant, inspect fill level and condition Starter pinion shaft, inspect and lubricate...

  • Page 56: Engine Side Covers

    MAINTENANCE ENGINE SIDE COVERS ENGINE SIDE COVERS ANTI-CORROSION PROTECTION Remove four (4) screws and the port side cover. 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.

  • Page 57: Metallic Component Protection

    MAINTENANCE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY IMPORTANT: Anodes that are not eroding may indicate that the anodes are not properly CONNECTIONS grounded. The anodes and mounting screws must be clean and tight for effective corrosion protec- tion. WARNING For best anode performance: Battery electrolyte is acidic.

  • Page 58: Carburetors

    MAINTENANCE CARBURETORS Clean the terminals, the battery posts, and the CARBURETORS connectors with a solution of baking soda and water. A wire brush or battery terminal tool can be General used to remove corrosion buildup. Rinse and Inspect the carburetor bodies, linkages, fuel inlet, clean all surfaces.
  • Page 59 MAINTENANCE CARBURETORS Remove the impulse plug of the No. 3 intake man- Check the idle speed, then rotate the idle adjust- ifold. ing screw of the No. 3 carburetor to set the idle speed in neutral gear at 850 to 950 RPM. 1.
  • Page 60 MAINTENANCE CARBURETORS Connect each synchronizer tube hose to its corre- Adjust the throttle valve screw(s) until the carbure- sponding adapter. tors are synchronized (steel balls at the same height in each of the tubes) and the engine idles smoothly. 1. No. 1 intake manifold position 001342 2.

  • Page 61: Dashpot Adjustment

    MAINTENANCE CARBURETORS Dashpot Adjustment IMPORTANT: Dashpot adjustments must be made in neutral gear. The dashpot provides a controlled return to idle speed when the throttle is closed. A properly func- Stop the engine. Remove the flywheel cover or tioning and adjusted dashpot holds the engine recoil starter.

  • Page 62: Engine Oil And Filter

    MAINTENANCE ENGINE OIL AND FILTER ENGINE OIL AND FILTER Changing the Engine Oil and Filter Checking the Engine Oil Level IMPORTANT: Whenever the engine oil filter is IMPORTANT: Check the engine oil level before being replaced, change the engine oil at the same every use.
  • Page 63 MAINTENANCE ENGINE OIL AND FILTER Oil Filter Replacement Filling Remove the engine port side cover. Refer to Install a new gasket and the engine oil drain plug. ENGINE SIDE COVERS on p. 54. Tighten the drain plug to a torque of 115 in. lbs. (13 N·m).

  • Page 64: Fuel System

    MAINTENANCE FUEL SYSTEM FUEL SYSTEM Fuel Filter If water accumulation, sediment, leakage, cracks, Hoses and Connections or other damage is found, replace the fuel filter. WARNING To remove the fuel filter, disconnect the hoses from the filter and remove the filter from the Failure to check for fuel leakage could bracket.

  • Page 65: Gearcase

    MAINTENANCE GEARCASE GEARCASE Overheated lubricant will give the lubricant a black color and burned odor. Draining Internal gearcase inspection is recommended when lubricant is contaminated or shows signs of WARNING failure. Gearcase lubricant may be under pressure Filling and/or hot if plug is removed from recently operated outboard.

  • Page 66: Idle Speed

    MAINTENANCE IDLE SPEED IDLE SPEED IMPORTANT: Before adjusting idle speed, make sure that the carburetor throttle valves are properly synchronized. Refer to “Synchronizing IMPORTANT: Before synchronizing the throttle the Carburetor Throttle Valves” on page 56. valves, check the link mechanism and the carbu- retor valves for smooth operation.

  • Page 67: Ignition Timing

    MAINTENANCE IGNITION TIMING IGNITION TIMING OVERBOARD WATER PRESSURE INDICATOR Start the engine and allow the engine to warm up to normal operating temperature. Check the function of overboard water pressure Make sure that the idle speed is adjusted properly. indicator. Clean or replace the hose or nozzle as Refer to “IDLE SPEED”...

  • Page 68: Lubrication Points

    MAINTENANCE LUBRICATION POINTS LUBRICATION POINTS Apply Triple-Guard grease to the following lubrication points. 1. Propeller shaft 001380 2. Swivel bracket 3. Tilt tube 4. Throttle/shift linkage 5. Throttle/shift linkage (additional points for tiller handle models)

  • Page 69: Spark Plugs

    MAINTENANCE SPARK PLUGS SPARK PLUGS Use a thickness gauge to measure the spark plug gap. The correct gap is 0.031 to 0.035 in. (0.8 to 0.9 mm). CAUTION If the gap is out of specification, adjust it within the Only use resistor (R) type spark plugs with specified range.

  • Page 70: Valve Clearance

    MAINTENANCE VALVE CLEARANCE VALVE CLEARANCE Adjusting Loosen the locknut. Use a screwdriver to turn the Checking valve adjusting screw to bring valve clearance to within the specification. IMPORTANT: The engine must be cold when checking the valve clearance. Hold the adjusting screw in place and tighten the locknut to a torque of 97 in.
  • Page 71 ENGINE CONTROL ENGINE CONTROL TABLE OF CONTENTS COMPONENTS ..............70 .

  • Page 72: Components

    ENGINE CONTROL COMPONENTS COMPONENTS Crankshaft Position Sensor (CPS) There are two crankshaft position sensors Flywheel installed below the flywheel rotor. When the reluc- tor bar on the flywheel passes the sensors, a sig- The flywheel contains permanent magnets which nal (voltage pulse) is generated and sent to power energize the charge coil, the crankshaft position pack.

  • Page 73: Emergency Stop Switch

    ENGINE CONTROL COMPONENTS Emergency Stop Switch Ignition Coil The emergency stop switch is connected to the The ignition coil consists of two windings of wire power pack through the engine wiring harness. wrapped around a compacted ferrite core. The When activated, this switch directs the power coil has primary and secondary terminal connec- pack output to ground, stopping the ignition sys- tions and a ground plate.

  • Page 74: Operation

    ENGINE CONTROL OPERATION OPERATION The CPSs monitor engine speed and send signals to the power pack. Based on these signals, the power pack determines the optimum ignition tim- The ignition system is a condenser discharge type ing and supplies voltage stored in the condenser system.

  • Page 75: Troubleshooting

    ENGINE CONTROL TROUBLESHOOTING TROUBLESHOOTING The cause is not in the ignition system. START Sparks Not good Check the spark condition. Check the ignition timing. No or weak sparks Not good Check the condition of the Replace the spark plug. spark plug. Sparks Disconnect the emergency Check and/or replace the emergency stop switch...

  • Page 76: Ignition Tests

    ENGINE CONTROL IGNITION TESTS IGNITION TESTS Secondary Side Remove the spark plug cap from the high tension cord. Connect an ohmmeter between the black WARNING ignition coil lead wire and the high tension cord. Before working on or removing any elec- If the measurement is out of specification, replace trical parts, disconnect the battery cables the ignition coil.

  • Page 77: Charge Coil Tests

    ENGINE CONTROL IGNITION TESTS Charge Coil Tests Cranking Output Disconnect the charge coil lead wire from the Resistance power pack. Connect a 6 pin test cord, P/N Disconnect the charge coil lead wire from the 5034618, as shown. Connect a peak voltage power pack.

  • Page 78: Crankshaft Position Sensor (Cps) Coil Tests

    ENGINE CONTROL IGNITION TESTS Crankshaft Position Sensor (CPS) Cranking Output Disconnect the CPS lead wire from the power Coil Tests pack. Connect a 4 pin test cord, P/N 5034228, as Resistance shown. Connect a peak voltage tester between the sensor coil leads as shown. Disconnect the CPS lead wire from the power pack.

  • Page 79: Power Pack Cranking Output Test

    ENGINE CONTROL IGNITION TESTS Power Pack Cranking Output Emergency Stop Switch Test Continuity Test Connect the ignition coil lead wires to the power Disconnect the emergency stop switch lead wire. pack. Connect a peak voltage tester to the ignition Check for continuity between the switch leads. coil primary lead wires.

  • Page 80: Caution Systems

    ENGINE CONTROL CAUTION SYSTEMS CAUTION SYSTEMS If the operator decreases the engine speed to less than the maximum engine speed setting within 10 seconds, the over-revolution caution control will There are three caution systems that alert the be cancelled. operator when an abnormality occurs on the engine: To cancel the over-revolution caution control when •...

  • Page 81: Test Procedures

    ENGINE CONTROL CAUTION SYSTEMS If the engine speed is over 3000 RPM, the over- Checking the Caution Lamp revolution caution control will be activated. The Remove the blue/yellow lead wire from the oil engine speed will be automatically controlled by pressure switch.

  • Page 82: Removal And Installation

    ENGINE CONTROL REMOVAL AND INSTALLATION Checking the Cylinder Temperature REMOVAL AND Sensor Resistance INSTALLATION Remove the cylinder temperature sensor. Flywheel Removal Disconnect the battery cables at the battery. Remove three (3) bolts and the flywheel cover. 1. Cylinder temperature sensor 001672 Connect an ohmmeter between the sensor lead wires.

  • Page 83: Charge Coil And Crankshaft Position Sensors

    ENGINE CONTROL REMOVAL AND INSTALLATION Use Universal Puller Set, P/N 378103, to loosen Apply engine oil to the threads of the flywheel bolt. the flywheel from the crankshaft. Install the washer and the bolt. Tighten the bolt to a torque of 140 ft. lbs. (190 N·m). 1.

  • Page 84: Oil Pressure Switch

    ENGINE CONTROL REMOVAL AND INSTALLATION Remove three (3) bolts and the charge coil, then Installation disconnect the charge coil lead wires. Wrap sealing tape around the threads of the oil pressure switch. Cut off any excess sealing tape from the threads before installing. 1.

  • Page 85: Electrical

    ELECTRICAL ELECTRICAL TABLE OF CONTENTS BATTERY CHARGING SYSTEM ............84 .

  • Page 86: Battery Charging System

    ELECTRICAL BATTERY CHARGING SYSTEM BATTERY CHARGING SYSTEM Operation The battery charging system is composed of the battery charge coil, rectifier and regulator, and battery. The AC current generated by the battery charge coil is converted by the rectifier and regulator into regu- lated DC current, which is used to charge the battery.

  • Page 87: Test Procedures

    ELECTRICAL BATTERY CHARGING SYSTEM Test Procedures Checking the Charge Coil Resistance Disconnect the charge coil leads from the rectifier Checking the Charge Coil Cranking Output and regulator. Disconnect the charge coil leads from the rectifier Measure the resistance between the coil leads. If and regulator.
  • Page 88 ELECTRICAL BATTERY CHARGING SYSTEM Disconnect all wires from the fuse case. Check for WARNING continuity between the white/red lead wire with the plate terminal and the other two lead wires. If Excessive battery discharge rates might there is no continuity, replace the fuse case. overheat the battery, causing electrolyte gassing and creating an explosive atmo- sphere.

  • Page 89: Removal And Installation

    ELECTRICAL ELECTRIC STARTER SYSTEM ELECTRIC STARTER Removal and Installation Battery Charge Coil SYSTEM Refer to the ENGINE CONTROL section for these Schematics procedures. Rectifier and Regulator Tiller Handle Models Remove two (2) bolts and the rectifier and regula- tor. Disconnect the lead wire connectors. 1.

  • Page 90: Troubleshooting

    ELECTRICAL ELECTRIC STARTER SYSTEM Troubleshooting IMPORTANT: Before testing the electric starter system, make sure that the battery is fully charged, all cables and wires are securely connected, and the shift lever is in Neutral. Tiller Handle Models to rectifier & regulator 1.
  • Page 91 ELECTRICAL ELECTRIC STARTER SYSTEM Remote Control Models See “MWS” Control Harness Wiring 1. Starter motor 001699 2. Starter motor sub cable 3. Starter motor relay 4. Fuse (25 A) 5. Battery (12 V) Measure the voltage at Starter motor will not run. the starter motor relay Battery cable failure...

  • Page 92: Test Procedures

    ELECTRICAL ELECTRIC STARTER SYSTEM Test Procedures Neutral Switch Continuity Test Checking the Starter Switch for Continuity Shift Position Result (TEL Models only) Neutral Continuity Disconnect the starter switch lead wire. Check for Forward Infinity continuity between the wiring leads under the fol- Reverse Infinity lowing conditions.

  • Page 93: Starter Motor

    ELECTRICAL STARTER MOTOR STARTER MOTOR Method 2 Disconnect all cables and lead wires from the Removal starter motor relay. Measure the continuity between the relay terminals. Disconnect the battery cables at the battery. Connect the yellow/green wire to the positive (+) Remove three (3) bolts and the flywheel cover.

  • Page 94: Disassembly

    ELECTRICAL STARTER MOTOR Remove the starter motor sub cable. Remove two Disassembly (2) bolts and the starter motor band. WARNING When removing or installing any type of retaining rings, wear eye protection to avoid personal injury. Push down on the pinion stop. Use a screwdriver to pry off the stop ring.

  • Page 95: Inspection And Testing

    ELECTRICAL STARTER MOTOR Remove two (2) through bolts and the front cover. Remove the nut, the washers, the plastic washer and the O-ring from the rear cover. Remove two Remove two (2) washers, the shim, the armature, (2) screws and the brush holder assembly. the bottom washer, and the stator from the rear cover.
  • Page 96 ELECTRICAL STARTER MOTOR Use vernier calipers to measure the commutator WARNING outside diameter. To avoid personal injury, wear eye protec- If the measurement is less than the service limit, tion and set compressed air pressure to replace the armature. less than 25 psi (172 kPa). Commutator Outside Diameter Standard 1.18 in.

  • Page 97: Assembly

    ELECTRICAL STARTER MOTOR Use vernier calipers to check the length of each Assembly brush. Install the brush holder assembly in the rear cover. Install and tighten the screws securely. If any brushes are worn below the service limit, they must be replaced. Install a new O-ring, the plastic washer, two (2) Brush Length washers, and the nut that secures the brush...
  • Page 98 ELECTRICAL STARTER MOTOR Apply Moly Lube to the armature shaft and the IMPORTANT: Align the notches in the covers shaft bore in the front cover. with the tab on the stator when assembling the starter motor. IMPORTANT: When installing the armature, be careful not to break any brushes in the brush holder.

  • Page 99: Installation

    ELECTRICAL STARTER MOTOR Installation Install the starter motor sub cable. Install the dowel pins, the spacers, and the starter motor. 1. Starter motor sub cable 001706 2. Bolts (2) 3. Starter motor band 1. Starter motor 001708 Install the negative (–) battery cable and the bolt. 2.

  • Page 100: Notes

    ELECTRICAL NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 101 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS FUEL LINES ............... 100 .

  • Page 102: Fuel Lines

    FUEL SYSTEM FUEL LINES FUEL LINES Fuel Hose Connections Note that fuel hose connections vary according to Removal and Installation each type of pipe. Connect each hose correctly by referring to the following figure. Pay special attention to the following when remov- ing or installing fuel hoses: Install the hose clamp 0.1 to 0.3 in.

  • Page 103: Carburetors

    FUEL SYSTEM CARBURETORS CARBURETORS Remove two (2) bolts that secure the silencer case. Removal Remove two (2) bolts that secure the air silencer Remove three (3) bolts and the flywheel cover. pipe to the crankcase. 1. Bolts (3) 001394 1. Air silencer case bolts (2) 001610 2.
  • Page 104 FUEL SYSTEM CARBURETORS Remove the bolt, the fuel filter bracket, and the Remove the carburetor/inlet case assembly, then fuel filter. remove the fuel inlet hose from the bottom 3-way joint. Remove four (4) screws and the air silencer case. 1. Throttle control rod 001612 2.

  • Page 105: Disassembly

    FUEL SYSTEM CARBURETORS Remove the plates, the air silencer pipe, the car- Disassembly buretors, the insulators, and the gaskets from the When disassembling the carburetor, refer to the inlet case. Discard the carburetor gaskets. following figure. Remove the indicated parts. 1.

  • Page 106: Cleaning And Inspection

    FUEL SYSTEM CARBURETORS IMPORTANT: IMPORTANT: For carburetors with pilot screw DO NOT use wire or small drill covers, DO NOT remove the cover and the pilot bits to clean the carburetor orifices and jet. screw. Carburetor Body Check all drillings and passages with a syringe filled with isopropyl alcohol.

  • Page 107: Assembly

    FUEL SYSTEM CARBURETORS Jet and Nozzle Assembly Inspect the jet and nozzle for obstructions, cracks, When installing new parts from a carburetor and other damage. rebuild kit, inspect gaskets and compare to origi- nal gaskets to ensure all holes are correctly punched.
  • Page 108 FUEL SYSTEM CARBURETORS IMPORTANT: Adjusting the Accelerator Pump Lever Gap Make sure that the weight of the float is not applied to the needle valve. IMPORTANT: In normal use, adjustment of the accelerator pump lever is unnecessary. It has been adjusted at factory. Adjust the gap between the accelerator pump lever and the pump plunger rod by turning the adjusting screw.

  • Page 109: Installation

    FUEL SYSTEM CARBURETORS Installation Install the choke solenoid (TEL models only) or the carburetor protector (tiller handle model only). Install and tighten the bolts securely. CAUTION Install the choke rods and the throttle link rods Do not reuse gaskets. The sealing ability on each carburetor.
  • Page 110 FUEL SYSTEM CARBURETORS Install the fuel pump. Refer to “FUEL PUMP” on Install the choke rod and the E-ring on the bottom page 111. carburetor (tiller handle model only). 1. Fuel pump 001635 1. Choke rod 001611 Install the fuel filter bracket and the bolt. Install and tighten two (2) bolts that secure the air silencer pipe to the crankcase.

  • Page 111: Throttle Control

    FUEL SYSTEM THROTTLE CONTROL THROTTLE CONTROL Remote Control Models Throttle Linkage Adjustments When replacing a throttle linkage rod or a connec- tor, refer to the following figures to adjust the length of the rod to the correct specification. Make sure that an equal length of rod is threaded into each connector.

  • Page 112: Throttle Cable Installation And Adjustment

    FUEL SYSTEM THROTTLE CONTROL Throttle Cable Installation and With the throttle fully closed, make sure that the match mark on the throttle cam is aligned with the Adjustment center of the throttle lever roller. Rotate throttle control handle to fully close the throttle.

  • Page 113: Fuel Pump

    FUEL SYSTEM FUEL PUMP FUEL PUMP Remove the fuel pump and the O-ring. Note the position of the pump rod before removal. IMPORTANT: Before replacing a suspect fuel pump, remove and clean the fuel filter and install a new filter element. Also, remove the fuel hose from the fuel tank and blow low-pressure com- pressed air through all passages and hoses to be sure they are open.

  • Page 114: Inspection

    FUEL SYSTEM FUEL PUMP Turn the piston until the pin comes out through the Inspect the check valves in the valve body for cutaway of the pump body. Remove the pin, the damage. piston, the diaphragm rod, and the two springs. 1.

  • Page 115: Installation

    FUEL SYSTEM FUEL PUMP Installation Rotate the crankshaft until the top cylinder piston is at TDC on the compression stroke. Install the pump rod, a new O-ring, and the fuel pump. Install and tighten two (2) bolts to a torque of 7 ft.

  • Page 116: Operation

    FUEL SYSTEM OPERATION OPERATION Carburetor 001650...

  • Page 117: Accelerator Pump System

    FUEL SYSTEM OPERATION Accelerator Pump System through the brass tube and outlet nozzle, spraying into carburetor bore. The 30 HP models are equipped with an accelera- tor pump system. This system consists of an accelerator pump on each carburetor with brass tubes connecting the pump to the fuel output noz- zles on each carburetor.

  • Page 118: Notes

    FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 119: Powerhead

    POWERHEAD POWERHEAD TABLE OF CONTENTS TEST PROCEDURES ............. . . 118 .

  • Page 120: Test Procedures

    POWERHEAD TEST PROCEDURES TEST PROCEDURES WARNING Cylinder Compression Test Disconnect the safety lanyard from the emergency stop switch prior to cranking Start the engine. Allow the engine to warm up, the engine. This will prevent any residual then shut off the engine. fuel from the cylinders from being ignited Remove the engine side covers.

  • Page 121: Engine Oil Pressure Test

    POWERHEAD TEST PROCEDURES Engine Oil Pressure Test Start the engine and warm up engine as follows: • Summer: 5 minutes at 2000 RPM Check the engine oil level. • Winter: 10 minutes at 2000 RPM Remove the oil pressure switch. Install an oil pres- After warm-up, shift the engine into forward gear sure gauge and adapter into the oil pressure and increase the engine speed to 3000 RPM.

  • Page 122: Removal And Installation

    POWERHEAD REMOVAL AND INSTALLATION REMOVAL AND ILLER ANDLE ODELS Remove the throttle cables from the throttle drum. INSTALLATION Remove the bolt, the throttle drum, the throttle Removal lever rod, and the throttle limiter rod. WARNING To prevent accidental starting while ser- vicing, twist and remove the spark plug leads and disconnect the battery cables at the battery.
  • Page 123 POWERHEAD REMOVAL AND INSTALLATION EMOTE ONTROL ODELS ODELS Remove the bolt, the throttle drum, the throttle Remove the fuel pump. Refer to the FUEL SYS- lever rod, and the throttle control rod. TEM section. 1. Bolt 001398 1. Fuel pump 001400 2.
  • Page 124 POWERHEAD REMOVAL AND INSTALLATION Remove the two (2) bolts that secure the front EMOTE ONTROL ODELS panel. Disconnect the choke solenoid lead wire. ODELS Remove the starter motor. Refer to the ELECTRI- CAL section. 1. Bolts (2) 001405 2. Front panel Remove the flywheel, the charge coil, and the crankshaft position sensors (CPS).
  • Page 125 POWERHEAD REMOVAL AND INSTALLATION Remove three (3) ignition coils. Disconnect the For models with a power trim and tilt (PTT) unit, primary lead wire. remove the bolts, then the PTT motor relay and bracket. Remove two (2) bolts and the rectifier and regula- tor.
  • Page 126 POWERHEAD REMOVAL AND INSTALLATION Disconnect the clutch rod from the shift rod by Remove two (2) pins and the side cover seal. loosening the locknut and the turnbuckle. 1. Pins (2) 001414 2. Side cover seal 1. Locknut 001412 Remove 13 bolts. Lift the powerhead from the Remove the screw, the shift lever and shaft, and engine holder.

  • Page 127: Installation

    POWERHEAD REMOVAL AND INSTALLATION Installation Apply Gasket Sealing Compound to the threads of the powerhead mounting bolts. Install and tighten Before installing the powerhead, remove the oil the bolts to the following specified torques. pump stop from the oil pan: Powerhead Mounting Bolt Torques •...
  • Page 128 POWERHEAD REMOVAL AND INSTALLATION To engage the oil pump shaft, install the oil pump • Install a new gasket on the bolt. Install and stop in the oil pan: tighten the bolt to a torque of 17 ft. lbs. (23 •...
  • Page 129 POWERHEAD REMOVAL AND INSTALLATION Connect the clutch rod to the shift rod. Tighten the For models with a power trim and tilt (PTT) unit, locknut and the turnbuckle. install the PTT motor relay and bracket. Secure the bracket with the bolts. 1.
  • Page 130 POWERHEAD REMOVAL AND INSTALLATION Install the battery charge coil, the crankshaft posi- Install the inlet case and carburetor assembly. tion sensors, and the flywheel. Refer to the Refer to the FUEL SYSTEM section. ENGINE CONTROL section. 1. Inlet case 001402 2.
  • Page 131 POWERHEAD REMOVAL AND INSTALLATION Install the starter motor. Refer to the ELECTRI- Install the fuel pump. Refer to the FUEL SYSTEM CAL section. section. 1. Starter motor 001403 1. Fuel pump 001400 IMPORTANT: Before installing the cylinder head EMOTE ONTROL ODELS cover, check the valve clearance.
  • Page 132 POWERHEAD REMOVAL AND INSTALLATION Install the cover on the cylinder head. Install and Install the throttle control rod, the throttle lever rod, tighten the bolts to a torque of 89 in. lbs. (10 N·m). the throttle drum, and the bolt. Connect the breather hose to the cylinder head cover.

  • Page 133: Timing Chain And Tensioner

    POWERHEAD TIMING CHAIN AND TENSIONER TIMING CHAIN AND Install the throttle cables to the throttle drum. Refer to the FUEL SYSTEM section. TENSIONER Removal Remove the powerhead. Remove two (2) bolts, the dowels, and the upper oil seal housing. 1. Throttle cables 001396 2.
  • Page 134 POWERHEAD TIMING CHAIN AND TENSIONER Turn the crankshaft in its normal running direction Remove the bolt, the washer, the spacer, and the until the No.1 cylinder reaches top dead center. timing chain tensioner. The No. 1 cylinder will be at top dead center when Remove two (2) bolts and the timing chain guide.

  • Page 135: Inspection

    POWERHEAD TIMING CHAIN AND TENSIONER Inspection Installation Inspect the timing chain, the tensioner, the guide, Align the crankshaft timing mark with the crank- and the sprockets for wear and damage. case timing mark by turning crankshaft. Inspect the plunger and the latch of the tensioner Install the dowel pin into the camshaft.
  • Page 136 POWERHEAD TIMING CHAIN AND TENSIONER Apply Nut Lock to the threads of three (3) timing After installation, apply oil to the timing chain and sprocket bolts. Install and tighten the bolts to a the tensioner. torque of 97 in. lbs. (11 N·m). 1.
  • Page 137 POWERHEAD TIMING CHAIN AND TENSIONER Pull the stopper out of the tension adjuster. Adjust the valve clearance. Apply oil to the lip of the upper oil seal. Install two (2) dowel pins and the upper oil seal housing. Install and tighten the bolts securely. 1.

  • Page 138: Cylinder Head

    POWERHEAD CYLINDER HEAD CYLINDER HEAD Installation Insert two (2) dowel pins. Install a new cylinder Removal head gasket on the cylinder head. Remove the powerhead. Remove the timing chain. Use a 10 mm deep socket wrench to loosen twelve (12) cylinder head bolts in the order indi- cated below.

  • Page 139: Disassembly

    POWERHEAD CYLINDER HEAD Apply engine oil to the cylinder head bolts and Disassembly place them in the bolt holes. Then tighten the bolts Remove the cylinder head. in the following manner: • STEP 1 – Tighten the bolts to the initial torque Remove four (4) bolts and the upper cylinder head according to the tightening sequence.
  • Page 140 POWERHEAD CYLINDER HEAD Remove two (2) screws and the camshaft thrust Remove the valve spring retainer, the valve plate. spring, and the valve. 1. Screws (2) 001465 1. Cotters 001468 2. Camshaft thrust plate 2. Valve spring retainer 3. Valve spring Remove the camshaft by pulling it out toward the Use a screwdriver to remove valve stem seal and timing sprocket side.

  • Page 141: Inspection And Servicing

    POWERHEAD CYLINDER HEAD Inspection and Servicing The cylinder head can be resurfaced using a sur- face plate and #400 grit wet sandpaper. Move the Cylinder Head cylinder head in a figure eight pattern when sand- Remove all carbon deposits from the combustion ing.
  • Page 142 POWERHEAD CYLINDER HEAD Camshaft The service limit for camshaft runout is 0.004 in. (0.10 mm). If the measurement exceeds this spec- Inspect the cam face, the camshaft journals, and ification, replace the camshaft. the journal bores for pitting, scratches, wear, or damage.
  • Page 143 POWERHEAD CYLINDER HEAD IMPORTANT: the cam riding face is excessively worn, replace The journal are numbered are in the rocker arm. order from the flywheel magnet to the bottom of the cylinder. Camshaft Journal Outside Diameter Journal Standard Service Limit 1.7096 –...
  • Page 144 POWERHEAD CYLINDER HEAD Valve Stem and Valve Guide If the measurement exceeds the service limit, replace the rocker arm and/or the shaft. Use a micrometer to measure the outside diame- ter of the valve stems. Be sure to take readings at Rocker Arm-to-Shaft Clearance more than one place along the length of each 0.0005 –...
  • Page 145 POWERHEAD CYLINDER HEAD Subtract the valve stem outside diameter from the Inspect the valve stem end face for pitting and valve guide inside diameter to determine the valve wear. The valve stem end may be refaced. Be guide-to-stem clearance. careful not to wear down the chamfer too far. If the measurement exceeds the service limit, Use vernier calipers to measure the valve stem replace the valve guide and/or the valve.
  • Page 146 POWERHEAD CYLINDER HEAD Ream the valve guide hole with a 10.5 mm reamer Ream the valve guide bore with a 5.5 mm reamer. to true the hole and remove any burrs. Clean and oil the valve guide bore after reaming. IMPORTANT: Turn the reamer in a clockwise direction, NEVER counterclockwise.
  • Page 147 POWERHEAD CYLINDER HEAD The service limit for valve head radial runout is Measure the valve seat contact width as follows: 0.003 in. (0.08 mm). If the measurement exceeds • Remove all carbon deposits from the valve and this specification, replace the valve. the valve seat.
  • Page 148 POWERHEAD CYLINDER HEAD Valve Seat Refacing Lap the valve on the valve seat in two steps: first with coarse grit lapping compound applied to the WARNING face, and then with fine grit lapping compound. To avoid personal injury, wear eye protec- tion when using a cutter.

  • Page 149: Assembly

    POWERHEAD CYLINDER HEAD If the spring’s preload is less than the service limit, Assembly replace the valve spring. IMPORTANT: Before assembling the cylinder Valve Spring Preload head, inspect and service the components. Refer 43 to 50 lbs. (193 to 223 N) for Standard to “Inspection and Servicing”...
  • Page 150 POWERHEAD CYLINDER HEAD Use a Valve Lifter, P/N 346186, and Attachment, Apply engine oil to the surface of each camshaft P/N 5000899, to compress the valve springs. lobe and journal. Install the camshaft from timing sprocket side of the cylinder head. 001467 1.
  • Page 151 POWERHEAD CYLINDER HEAD Install four (4) dowel pins in the rocker arm shaft Install the rocker arm shaft brackets and the bolts. brackets. Tighten the bolts to a torque of 14 ft. lbs. (19 N·m). 1. Dowel pins (4) 001522 1.

  • Page 152: Piston, Cylinder, And Crankshaft

    POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT PISTON, CYLINDER, AND Remove eight (8) bolts and the exhaust cover. CRANKSHAFT Removal First, remove the powerhead, the timing chain, and the cylinder head. Remove the oil filter. 1. Bolts (8) 001531 2. Exhaust cover Remove eight (8) outer bolts, then eight (8) inner bolts.
  • Page 153 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Remove connecting rod cap nuts and the con- IMPORTANT: To prevent damage to the piston necting rod caps. rings, remove any carbon deposits from the top of the cylinder bore wall before removing the piston. Use quick drying paint to mark the corresponding cylinder number on each piston.

  • Page 154: Inspection And Servicing

    POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Inspection and Servicing WARNING Cylinder When removing or installing any type of Use a straightedge and a thickness gauge to retaining rings, wear eye protection to measure the cylinder distortion on the gasket sur- avoid personal injury. face at six (6) locations as shown.
  • Page 155 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Check the water jackets for clogs or obstructions. The difference between the two depth measure- ments is the cylinder bore taper. The difference between the axial and transverse measurements is the cylinder bore out-of-round. The service limit for cylinder bore wear is 0.004 in. (0.10 mm).
  • Page 156 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Pistons and Rings Oil Ring Two oversize piston and piston ring components Oversize ID Mark are available. Oversize pistons and piston rings 0.25 mm Two blue marks are marked as shown below. 0.50 mm Red mark Piston Oversize ID Mark...
  • Page 157 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT If the measurement exceeds the service limit, If the measurement exceeds the service limit, replace the piston and/or the piston rings. replace the piston rings. Piston Ring-to-Groove Clearance Piston Ring End Gap 0.0012 to 0.0027 in. 0.005 to 0.011 in.
  • Page 158 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Wrist Pin and Bores Use dial calipers to measure the connecting rod small bore inside diameter. Inspect the wrist pin and the bores in the piston and the connecting rod for wear and damage. If the measurement exceeds the service limit, replace the connecting rod.
  • Page 159 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Connecting Rod and Crankpin If any crankpin is worn or damaged, or the out-of- round or taper exceeds the service limit, replace Install a connecting rod (with bearing) on the the crankshaft. crankshaft as shown. Use a thickness gauge to measure the connecting rod large bore side clear- Crankpin Specifications ance.
  • Page 160 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Connecting Rod Bearings Place a piece of Plastigage on the crankpin, paral- lel to the crankshaft. DO NOT place the Plasti- Inspect the bearing shells in the connecting rod gage over the oil hole. large bores and connecting rod caps for the proper contact pattern and signs of fusion, pitting, burning, or flanking.
  • Page 161 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Use the scale on the Plastigage envelop to mea- Assemble the crankshaft thrust bearing, the sure the Plastigage on the crankpin at its widest crankshaft journal bearing, the crankshaft, and the point. crankcase to the cylinder block. If the measurement exceeds the service limit, Apply engine oil to 16 crankcase bolts, then place replace the connecting rod bearing.
  • Page 162 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Crankshaft Main Bearings Crankshaft Thrust Bearing Flange Thickness Inspect the crankshaft bearing shells for pitting, 0.0972 to 0.0992 in. Standard scratches, and wear. Replace any damaged bear- (2.470 to 2.520 mm) ings. IMPORTANT: NEVER replace only one bearing shell.
  • Page 163 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT IMPORTANT: • Make sure that the alignment tabs STEP 3 – Finally, tighten the bolts to the final on the bearing shells properly engage the align- torque according to the tightening sequence. ment notches in the connecting rod and cap. DO Crankcase Bolt Torques NOT apply oil to the bearing at this time.
  • Page 164 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Remove eight (8) outer bolts, then eight (8) inner Selecting a Main Bearing bolts. Remove the crankcase from the cylinder Whenever a main bearing requires replacement, block. select a new bearing according to following proce- dure.
  • Page 165 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT The starboard side of the cylinder block has four the following thickness (measured at the center (4) stamped code letters. The letters A, B, and C of the bearing). represent the following bearing holder inside diameter shown below.

  • Page 166: Installation

    POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT Installation Apply engine oil to the oil ring. Install the spacer to the piston, then the side rails. IMPORTANT: Before installing the pistons and the crankshaft, inspect and service the compo- nents. Refer to “Inspection and Servicing” on page 152.
  • Page 167 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT IMPORTANT: shown. Failure to stagger the piston ring gaps The top compression ring differs may result in crankcase oil dilution. from the second compression ring in shape and color of the surface contacting the cylinder wall. 1.
  • Page 168 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT If removed, install the crankshaft main bearings. IMPORTANT: The oil groove sides of the thrust Apply engine oil to the bearing wear surfaces. DO bearing must face toward the crank webs. NOT apply oil between the bearing holder and the back of the bearing.
  • Page 169 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT IMPORTANT: Apply engine oil to the connecting rod bolts. Install Make sure that the tab of the oil and tighten the connecting rod cap nuts in the fol- seal fits into the groove in the cylinder. lowing manner: •...
  • Page 170 POWERHEAD PISTON, CYLINDER, AND CRANKSHAFT • IMPORTANT: STEP 3 – Finally, tighten the bolts to the final After tightening the crankcase torque according to the tightening sequence. bolts, make sure that the crankshaft rotates smoothly when turned by hand. Crankcase Bolt Torques Bolt size Initial Second...

  • Page 171: Thermostat

    POWERHEAD THERMOSTAT THERMOSTAT Place the thermometer in the container and heat the water. Observe the water temperature when the valve opens and releases the thread. Removal Thermostat Operating Temperature Disconnect the water hose from the thermostat Standard 136 to 144°F (58 to 62°C) cover.

  • Page 172: Operation

    POWERHEAD OPERATION OPERATION Water Cooling System The water cooling system includes the water pump, the water supply tube, the water pressure valve, the powerhead water passages, and the thermostat. This system cools both the powerhead and the midsection. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion buildup, or damage.

  • Page 173: Engine Lubrication System

    POWERHEAD OPERATION Engine Lubrication System A camshaft driven, trochoid type pump provides engine oil to all powerhead components requiring lubri- cation. Oil from the oil pan is drawn though the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery.

  • Page 174: Notes

    POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 175 MIDSECTION MIDSECTION TABLE OF CONTENTS CLEANING AND INSPECTION ............174 .

  • Page 176: Cleaning And Inspection

    MIDSECTION CLEANING AND INSPECTION CLEANING AND Exhaust Housing Before checking the exhaust housing for distor- INSPECTION tion, thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion. General Check the exhaust housing for distortion. Place WARNING the housing on a surface plate.

  • Page 177: Steering Handle

    MIDSECTION STEERING HANDLE STEERING HANDLE Disconnect the emergency stop switch lead wire and the engine start button lead wire. Removal Remove the starboard side lower cover. Refer to the MAINTENANCE section. Loosen the lock nut and remove the throttle cables from the throttle drum. Remove the bolt and the plate.

  • Page 178: Installation

    MIDSECTION STEERING HANDLE Installation Install the tiller handle and the throttle cable assembly. Install the tiller handle bracket. Install and tighten two (2) bolts securely. Install the tiller handle cover. Apply Nut Lock the the threads of two (2) bolts. Install and tighten the bolts to a torque of 17 ft.

  • Page 179: Tilt Assist Cylinder

    MIDSECTION TILT ASSIST CYLINDER TILT ASSIST CYLINDER Removal Raise the engine to the full tilt position and lower the manual tilt lock levers. WARNING The tilt assist cylinder contains high pres- sure gas. To avoid personal injury, it must not be disassembled, punctured, inciner- ated, or exposed to heat.
  • Page 180 MIDSECTION TILT ASSIST CYLINDER Remove the tilt cylinder lower shaft bolts. WARNING When removing or installing any type of retaining rings, wear eye protection to avoid personal injury. Remove the two (2) retaining rings, then push out the tilt cylinder upper shaft and the bushings. 1.

  • Page 181: Installation

    MIDSECTION TILT ASSIST CYLINDER Installation Place the tilt assist cylinder and lower shaft in position between the stern brackets. If removed, install the release lever, the bolt, and the locknut as shown. Tighten the bolt and the locknut securely. 1. Starboard stern bracket 001753 2.
  • Page 182 MIDSECTION TILT ASSIST CYLINDER Apply Triple-Guard grease to the tilt shaft upper Install the two (2) bolts and the starboard stern bushings, then install the bushing in the tilt assist bracket nuts. Tighten the starboard clamp screw. cylinder as shown. 1.

  • Page 183: Exhaust Housing And Oil Pan

    MIDSECTION EXHAUST HOUSING AND OIL PAN EXHAUST HOUSING AND Remove two (2) lower mount nuts and washers. OIL PAN Removal Remove the powerhead. Refer to the POWER- HEAD section. Remove the gearcase. Refer to the GEARCASE section. Remove the screw and the bonding wire from the exhaust housing.

  • Page 184: Disassembly

    MIDSECTION EXHAUST HOUSING AND OIL PAN Disassembly Remove four (4) bolts and the engine holder from the top of the oil pan. Remove three (3) bolts and the upper mount assembly (starboard and port sides). 1. Bolts (4) 001769 2. Engine holder 1.
  • Page 185 MIDSECTION EXHAUST HOUSING AND OIL PAN Remove the oil relief valve. Remove the water tube from the exhaust housing. 1. Oil relief valve 001772 1. Water tube 001774 Use an oil seal remover to remove the driveshaft Remove two (2) bolts, the valve cover, and the oil seal from the engine holder.

  • Page 186: Assembly

    MIDSECTION EXHAUST HOUSING AND OIL PAN Assembly Install the water pressure valve and the valve cover. Install and tighten the bolts securely. Use an oil seal installer to install a new driveshaft oil seal in the engine holder. Make sure that the lip of the oil seal is facing downward.
  • Page 187 MIDSECTION EXHAUST HOUSING AND OIL PAN Install the oil pan to the exhaust housing. Install Install the oil strainer to the engine holder. Install and tighten six (6) bolts securely. and tighten the bolts securely. 1. Dowel pins (2) 001787 1.
  • Page 188 MIDSECTION EXHAUST HOUSING AND OIL PAN Install the engine holder to the oil pan. Apply Nut Lock to three (3) bolts. Install and tighten the bolts to a torque of 88 in. lbs. (10 N·m). 1. Dowel pins (2) 001789 2.

  • Page 189: Installation

    MIDSECTION EXHAUST HOUSING AND OIL PAN Install the lower mounts and the covers on the Apply Nut Lock to the threads of the upper mount exhaust housing. Make sure that the arrow on the nuts. Install and tighten the upper mount nuts to a lower mount is pointing upward.

  • Page 190: Stern Brackets, Steering Arm, And Swivel Bracket

    MIDSECTION STERN BRACKETS, STEERING ARM, AND SWIVEL BRACKET IMPORTANT: STERN BRACKETS, An insulation washer must be installed between the bonding wire terminal and STEERING ARM, AND the exhaust housing. SWIVEL BRACKET Attach the bonding wire to the exhaust housing. Tighten the screw securely. Removal Remove the exhaust housing and the oil pan.
  • Page 191 MIDSECTION STERN BRACKETS, STEERING ARM, AND SWIVEL BRACKET Remove the retaining ring, then slide the lower Remove the washer, the plate, the upper bushing, mount bracket from the steering shaft. Remove and the steering adjuster from the steering arm. the key, the shim, and the washer. 1.
  • Page 192 MIDSECTION STERN BRACKETS, STEERING ARM, AND SWIVEL BRACKET Remove the retaining ring and push out the tilt cyl- Remove the PTT unit (or tilt assist cylinder). inder upper rod. 1. PTT unit (or tilt assist cylinder) 001801 1. Tilt cylinder upper rod 001798 Remove the bonding wire from the port side stern Remove the tilt tube nut from the stern bracket.

  • Page 193: Installation

    MIDSECTION STERN BRACKETS, STEERING ARM, AND SWIVEL BRACKET Installation Install the tilt tube nut. Leave the nut loose for eas- ier installation of the PTT unit (or the tilt assist cyl- IMPORTANT: inder). An insulation washer must be installed between the bonding wire terminal and Install the PTT unit (or the tilt assist cylinder) the stern bracket.
  • Page 194 MIDSECTION STERN BRACKETS, STEERING ARM, AND SWIVEL BRACKET Apply Triple-Guard grease to the upper bushing. Install the washer and the shim, then insert the Install the upper bushing (tapered end first), the key into the groove on the steering arm shaft. steering adjuster, the plate, and the washer in the Align the key with the channel in the lower mount swivel bracket.
  • Page 195 MIDSECTION STERN BRACKETS, STEERING ARM, AND SWIVEL BRACKET Attach the bonding wires to the swivel bracket and the lower mount bracket. Tighten the screws securely. 1. Screws 001793 2. Bonding wires Apply Triple-Guard grease through each grease nipple. 1. Grease nipple 001816 1.

  • Page 196: Notes

    MIDSECTION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 197: Gearcase

    GEARCASE GEARCASE TABLE OF CONTENTS COMPONENTS ..............196 PROPELLER .

  • Page 198: Components

    GEARCASE COMPONENTS COMPONENTS 1. Driveshaft 11. Stopper 001868 2. Preload spring 12. Gearcase 3. Preload spring collar 13. Pinion bearing 4. Pinion gear 14. Trim tab 5. Propeller shaft 15. Sub water filter 6. Clutch dog shifter 16. Water filter 7.
  • Page 199 GEARCASE COMPONENTS 21. Shift rod 28. Water pump case 001869 22. Stopper 29. Impeller 23. Boot 30. Under plate 24. Shift rod guide 31. Driveshaft bearing housing 25. Magnet 32. Bearing 26. Holder 33. Grommet 27. Shift cam 34. Notch plate...

  • Page 200: Propeller

    GEARCASE PROPELLER PROPELLER Inspection Check for the following: Removal • Damaged blades and signs of propeller cavita- tion (burned paint, etc.) WARNING • Spun or overheated inner hub • Worn or twisted propeller bushing splines and To prevent accidental starting while ser- inadequate lubricant vicing, remove the emergency stop lan- •...

  • Page 201: Trim Tab Adjustment

    GEARCASE TRIM TAB ADJUSTMENT TRIM TAB ADJUSTMENT Wedge a block of wood between propeller blade and the anti-ventilation plate. CAUTION Install the propeller nut and torque to: • 156 in. lbs. (18 N·m) Improper trim tab adjustment can cause difficult steering and loss of control. If cotter pin holes in the propeller nut and propeller shaft are not aligned, tighten the nut until they are in line.

  • Page 202: Lubricant

    GEARCASE LUBRICANT LUBRICANT Internal gearcase inspection is recommended when lubricant is contaminated or shows signs of failure. Draining Filling WARNING Secure the gearcase in a vertical position. Gearcase lubricant may be under pressure and/or hot if plug is removed from recently Remove the lubricant level plug and the lubricant operated outboard.

  • Page 203: Leak Test

    GEARCASE LEAK TEST LEAK TEST REMOVAL AND INSTALLATION Drain lubricant before testing. STEP 1 Removal Install lubricant drain/fill plug and seal, thread pressure test gauge fitting and seal in lubricant WARNING level hole. During service, the outboard may drop Pressurize 3 to 6 psi (21 to 42 kPa). unexpectedly.

  • Page 204: Installation

    GEARCASE REMOVAL AND INSTALLATION Remove six (6) bolts and separate the gearcase Installation from the exhaust housing. If removed, insert two (2) dowel pins. Coat the driveshaft splines with Triple-Guard grease. Apply a light coat of Gasket Sealing Compound to the mating surfaces of the gearcase and the exhaust housing.
  • Page 205 GEARCASE REMOVAL AND INSTALLATION Fill the gearcase with the specified lubricant. REVERSE to check whether both gears engage Refer to “LUBRICANT” on page 200. at an equal angle from NEUTRAL. Connect the clutch rod to the shift rod. Make sure that the chamfered edge of the turnbuckle faces downward to seat against the locknut when tight- ened.

  • Page 206: Water Pump

    GEARCASE WATER PUMP WATER PUMP Inspection Check the impeller for overheating, hub separa- Disassembly tion, and visible signs of wear or damage. Remove the gearcase from the exhaust housing. Check the plate and inside the housing for scor- Refer to “REMOVAL AND INSTALLATION” on ing, distortion, and impeller material transfer.

  • Page 207: Assembly

    GEARCASE DISASSEMBLY DISASSEMBLY Assembly Install a new gasket and the plate on top of the gearcase. IMPORTANT: Clean and inspect all components during disassembly. Replace all damaged compo- Insert the impeller key in the driveshaft, then slide nents, seals, O-rings, and gaskets upon assem- the impeller onto the driveshaft.

  • Page 208: Propeller Shaft Bearing Housing Removal

    GEARCASE DISASSEMBLY Propeller Shaft Bearing Propeller Shaft Disassembly Housing Removal IMPORTANT: Clean and inspect all components Remove the water pump from the gearcase. Refer during disassembly. Replace all damaged compo- to “WATER PUMP” on page 204. nents, seals, O-rings, and gaskets upon assem- bly.

  • Page 209: Pinion Gear And Driveshaft Removal

    GEARCASE DISASSEMBLY Use appropriate tool to push pin out of the clutch Pinion Gear and dog shifter. Remove the clutch dog shifter from the Driveshaft Removal shaft. Remove the propeller shaft bearing housing from the gearcase. Refer to “Propeller Shaft Bearing Housing Removal”...
  • Page 210 GEARCASE DISASSEMBLY To remove the driveshaft bearing housing from the Remove the pinion gear, thrust washer, forward gearcase, use two 6mm bolts as screw jacks. gear, shim, and bearing. Turn each bolt alternately and equally to keep the housing level as it separates from the gearcase. 1.

  • Page 211: Driveshaft Disassembly

    GEARCASE DISASSEMBLY Driveshaft Disassembly Remove the washer, the preload spring, the other washer, and the tab lock washer. Note the position IMPORTANT: of the tab lock washer before removal. Clean and inspect all components during disassembly. Replace all seals, O-rings, gaskets, and damaged components.

  • Page 212: Shift Rod Disassembly

    GEARCASE BEARING AND SEAL REMOVAL Shift Rod Disassembly BEARING AND SEAL Remove the stop from the shift rod guide. REMOVAL IMPORTANT: Inspect bearings for damage while in place. If a bearing is removed for any reason, it must be replaced. Propeller Shaft Bearing Housing Seals Use an oil seal remover or 2-jaw puller and plate...
  • Page 213 GEARCASE BEARING AND SEAL REMOVAL Propeller Shaft Bearings Drive out the bearing by striking the top of the shaft with heavy rawhide mallet. Be careful not to Use bearing removal tool, P/N 5034764, to press damage the gearcase. bearing from housing. 1.

  • Page 214: Bearing And Seal Installation

    GEARCASE BEARING AND SEAL INSTALLATION Driveshaft Bearing Housing Seals BEARING AND SEAL Use an oil seal remover or 2-jaw puller and plate INSTALLATION assembly, P/N 432131, to draw two (2) oil seals out of the driveshaft bearing housing. Be careful Propeller Shaft Bearing not to damage driveshaft bearing race.
  • Page 215 GEARCASE BEARING AND SEAL INSTALLATION Propeller Shaft Bearing Using suitable bearing installation tool obtained locally, press the bearing against outer race until Housing Seals fully seated in the housing. Apply Triple-Guard grease to the inner circumfer- ence of the housing. Place the new seals in position (one at a time) with the lips facing toward the propeller.
  • Page 216 GEARCASE BEARING AND SEAL INSTALLATION Driveshaft Bearing Housing Insert tool and bearing into gearcase. Using raw- hide mallet, drive bearing into place until washer Bearing Race and Seals contacts spacer, P/N 350932. To install driveshaft bearing race, use bearing tool installation, P/N 342685, to press race until seated in housing Apply Triple-Guard grease to the inner circumfer-...

  • Page 217: Assembly

    GEARCASE ASSEMBLY ASSEMBLY Install the shift rod cam on the shift rod, then insert the cam pin. Pre-Assembly Inspection WARNING To avoid personal injury, wear eye protec- tion and set compressed air pressure to less than 25 psi (172 kPa). Clean all gearcase components in solvent and dry them with compressed air.

  • Page 218: Driveshaft Assembly

    GEARCASE ASSEMBLY rod cam (with detent notch) is positioned over the Place the tab lock washer and the other thrust detent ball in the gearcase. washer in the preload spring collar. Make sure that the tab of the lock washer fits into the slot at the pinion gear end of the spring collar.

  • Page 219: Pinion Gear And Driveshaft Installation

    GEARCASE ASSEMBLY Pinion Gear and IMPORTANT: Before completing this installation procedure, check the forward gear to pinion gear Driveshaft Installation backlash, the tooth contact pattern, and the initial Install the pinion shim from the gearcase. driveshaft thrust play. Refer to “SHIMMING AND GEAR BACKLASH CHECKS”...

  • Page 220: Propeller Shaft Assembly

    GEARCASE ASSEMBLY then install the pinion nut on the other end. clutch dog shifter pin through the clutch dog shifter Tighten the nut to a torque of 13 ft. lbs. (18 N·m). and the push pin. 1. Driveshaft holder, P/N 345834 001833 1.

  • Page 221: Propeller Shaft Bearing Housing Installation

    GEARCASE ASSEMBLY Install the forward gear thrust washer, the reverse Install propeller shaft bearing housing. gear thrust washer, the reverse gear, the shim, and the propeller shaft bearing housing. 1. Propeller shaft bearing housing 001829 When the bearing housing is fully seated, install 1.

  • Page 222: Shimming And Gear Backlash Checks

    GEARCASE SHIMMING AND GEAR BACKLASH CHECKS SHIMMING AND GEAR Temporarily fasten the driveshaft bearing housing to the gearcase using two (2) bolts and nuts BACKLASH CHECKS placed through the two diagonally opposite gear- case mounting holes. If the gearcase has been rebuilt or any internal components have been replaced, the gears must be properly shimmed and adjusted to ensure smooth, reliable operation of the gears.

  • Page 223: Checking The Tooth Contact Pattern

    GEARCASE SHIMMING AND GEAR BACKLASH CHECKS Checking the Tooth Contact Carefully pull out the propeller shaft and bearing housing to check the tooth contact pattern. Pattern Apply a light coat of Gear Mark Compound, P/N 772666, on the convex surface of the forward gear.

  • Page 224: Checking The Driveshaft Thrust Play

    GEARCASE SHIMMING AND GEAR BACKLASH CHECKS Incorrect Top Side Toe Contact Checking the Driveshaft Thrust Play CAUTION Initial Check Do not set the tooth contact to this pat- tern. Damage to the gears may result. After obtaining the optimum tooth contact, mea- sure the driveshaft thrust play.

  • Page 225: Checking The Propeller Shaft Thrust Play

    GEARCASE SHIMMING AND GEAR BACKLASH CHECKS Thread the sliding hammer onto the propeller Checking the Propeller Shaft shaft and strike a few gentle outward taps. Thrust Play After adjusting all gear positions, measure the propeller shaft thrust play. IMPORTANT: Maintain the forward gear thrust washer at the standard thickness.

  • Page 226: Notes

    GEARCASE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 227 POWER TRIM AND TILT POWER TRIM AND TILT TABLE OF CONTENTS SYSTEM WIRING ..............226 .

  • Page 228: System Wiring

    SYSTEM WIRING Wiring Diagram Fuse Starter motor Battery PTT motor PTT motor relay PTT switch To B+ Remote control box 004353...

  • Page 229: Testing The Ptt Motor Relay

    POWER TRIM AND TILT SYSTEM WIRING Testing the PTT Motor Relay Connect “R” wire of the relay to the positive (+) terminal of a 12V battery, and “B” wire to negative Disconnect the battery cables at the battery. (–) terminal. Disconnect all cables/lead wires from PTT relay.

  • Page 230: Service Procedures

    POWER TRIM AND TILT SERVICE PROCEDURES SERVICE PROCEDURES Bleeding the Air Check that the manual release valve is tightened Checking the Oil Level to a torque of 16 in. lbs. (1.8 N·m). Turn the valve clockwise to close the valve. DO NOT overtighten Raise the engine to the full tilt position.

  • Page 231: Power Trim And Tilt (Ptt) Unit

    POWER TRIM AND TILT POWER TRIM AND TILT (PTT) UNIT POWER TRIM AND TILT WARNING (PTT) UNIT When removing or installing any type of retaining rings, wear eye protection to Removal avoid personal injury. Raise the engine to the full tilt position and lower the manual tilt lock levers.

  • Page 232: Installation

    POWER TRIM AND TILT POWER TRIM AND TILT (PTT) UNIT Disconnect the PTT motor cable wire leads (green Slide the starboard stern bracket fully outward to and blue) from the PTT relay. the right side. Remove the PTT unit from between the stern brackets.
  • Page 233 POWER TRIM AND TILT POWER TRIM AND TILT (PTT) UNIT Position the PTT unit between the stern brackets. Operate the PTT motor to extend the tilt cylinder Install and tighten the tilt tube nut to a torque of 31 rod. Align the tilt cylinder rod with the hole in the ft.

  • Page 234: Ptt Motor

    POWER TRIM AND TILT PTT MOTOR PTT MOTOR Place the lower mounting eye of the PTT unit in a vise. Tighten the vise only enough to secure the PTT unit. DO NOT overtighten the vise. Removal WARNING To avoid personal injury, wear eye protec- tion and set compressed air pressure to less than 25 psi (172 kPa).

  • Page 235: Disassembly

    POWER TRIM AND TILT PTT MOTOR these components, which may cause system Note the position of the O-ring on the brush operating problems. holder. Remove the O-ring. 1. PTT motor 001921 1. Armature 001929 2. Drive joint 2. Brush holder 3.
  • Page 236 POWER TRIM AND TILT PTT MOTOR Inspect the surface of the commutator. If the sur- If the undercut is less than the service limit, cut face is gummy or dirty, clean the surface with 400 the mica to the specified depth. Use compressed grit emery paper.

  • Page 237: Assembly

    POWER TRIM AND TILT PTT MOTOR Assembly Installation Install the O-ring on the brush holder. Make sure Make sure that the drive joint is aligned and firmly that the O-ring is positioned correctly inserted into the gear pump assembly. Carefully slide the armature onto the brush holder Check the level of PTT oil in the pump.
  • Page 238 POWER TRIM AND TILT PTT MOTOR Install the reservoir. Install and tighten two (2) Pour the recommended PTT oil into the reservoir screws to a torque of 40 in. lbs. (4.5 N·m). to the specified level. Install the reservoir plug. 1.

  • Page 239: Operation

    POWER TRIM AND TILT OPERATION OPERATION The power trim and tilt (PTT) system is operated by a “rocker” type switch (protected by a rubber thumb pad) on top of the remote control box handle. When the switch is depressed, power is delivered to the electric motor via the relay. The relay with the blue wire connected to the pump is for trim/tilt “up”.

  • Page 240: Trim Tilt "Up" Circuit

    POWER TRIM AND TILT OPERATION Trim Tilt “UP” Circuit The electric motor is operating in a clockwise direction. Check valve “A” will open, allowing oil to flow from the reservoir to the pump. Oil flow from the pump enters the spool valve and moves it to the left, opening the “down”...

  • Page 241: Trim/Tilt "Down" Circuit

    POWER TRIM AND TILT OPERATION Trim/Tilt “DOWN” Circuit The electric motor is operating in a counterclockwise direction. Check valve “A” will open, allowing oil to flow from the reservoir to the pump. Oil flow from the pump enters the spool valve and moves it to the right, opening the “up”...

  • Page 242: Shock Absorber Circuit

    POWER TRIM AND TILT OPERATION Shock Absorber Circuit Shock valve Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high impact pressure in the upper cylinder chamber. The shock valve will then open, allowing oil to flow into the area between the tilt ram piston and the free piston, thereby dampening (absorbing) the impact.

  • Page 243: Manual Release Circuit (Manual Valve)

    POWER TRIM AND TILT OPERATION Manual Release Circuit (Manual Valve) Turn the manual valve a maximum of three full counterclockwise turns. When the manual valve is loosened, oil will flow unimpeded (without resistance) through the internal pump tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the manual valve must be closed again.

  • Page 244: Thermal Valve

    POWER TRIM AND TILT OPERATION Thermal Valve The PTT system incorporates a thermal valve for protection of the internal components if excessive downward force is exerted on the lower unit with the motor in a tilted position or, in the case of an impact in reverse gear, the stern clamp/swivel brackets and the transom.
  • Page 245 WIRE AND HOSE ROUTING WIRE AND HOSE ROUTING TABLE OF CONTENTS WIRE ROUTING ..............244 .

  • Page 246: Wire Routing

    WIRE AND HOSE ROUTING WIRE ROUTING WIRE ROUTING 1. Battery charge and power source coil 001951 2. Crankshaft position sensor No. 1 3. Choke solenoid 4. Clamp 5. Crankshaft position sensor No. 2 6. Starter motor...

  • Page 247: 30 Tel

    WIRE AND HOSE ROUTING WIRE ROUTING 30 TEL 1. Fuse 8. Ignition coil No. 3 001953 2. Electric parts holder 9. Rectifier ground lead wire 3. Cylinder temperature sensor 10. Rectifier and regulator 4. Clamp 11. Starter motor relay ground lead wire 5.

  • Page 248: 30 (Pl) Remote

    WIRE AND HOSE ROUTING WIRE ROUTING 30 (PL) Remote Fuse/Fuse case Fuse/Fuse case Clamp PTT motor relay holder PTT motor relay PTT relay ground cable PTT relay cable (+) Clamp Starter motor sub cable Battery cable (+) PTT motor cable connector (BL, G) Starter motor relay ground lead wire Starter motor relay...

  • Page 249: 30 Tel

    WIRE AND HOSE ROUTING WIRE ROUTING 30 TEL 30 (PL) Remote 1. Neutral switch 001956 1. Neutral switch 001957 2. Oil pressure switch 2. Oil pressure switch 3. Flywheel bolt 3. Battery cable (–) 4. Starter motor 4. Flywheel bolt 5.

  • Page 250: 30 Tel

    WIRE AND HOSE ROUTING WIRE ROUTING 30 TEL 1. Power source coil connector 6. Caution lamp connector 001959 2. Crankshaft position sensor connector 7. Band 3. Battery charge coil connector 8. Power pack 4. Stop switch connector 9. Electric parts holder 5.

  • Page 251: 30 Tel

    WIRE AND HOSE ROUTING WIRE ROUTING 30 TEL 30 (PL) Remote 1. Starter switch 001961 2. Emergency stop switch 1. Remote control harness 001962 2. Battery cable 3. Clip 4. PTT motor cable wire...

  • Page 252: Fuel / Water Hose Routing

    WIRE AND HOSE ROUTING FUEL / WATER HOSE ROUTING FUEL / WATER HOSE ROUTING 30 TEL 1. Hose clamp 001964 2. Fuel hose (fuel pump to carburetor) 3. Fuel filter 4. Clip 5. Fuel pump 6. Fuel connector plug 7. Fuel hose (connector to fuel filter)

  • Page 253: 30 (Pl) Remote

    WIRE AND HOSE ROUTING FUEL / WATER HOSE ROUTING 30 (PL) Remote 1. Hose clamp 001963 2. Fuel hose (fuel pump to carburetor) 3. Fuel filter 4. Clip 5. Fuel pump 6. Fuel connector plug 7. Fuel hose (connector to fuel filter)
  • Page 254 WIRE AND HOSE ROUTING FUEL / WATER HOSE ROUTING 1. Breather hose / protector 001966 2. Clamp 1. Clip 001965 2. 3-way joint (with clips) 3. Fuel hose (fuel pump to carburetor)
  • Page 255 WIRE AND HOSE ROUTING FUEL / WATER HOSE ROUTING...

  • Page 256: Notes

    WIRE AND HOSE ROUTING NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 257 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 258 S–2...

  • Page 259: 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 260: 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 261: 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 262: 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 263 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 264: 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 265 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 266 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 267: 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 268 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 269: 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 270: 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 271 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 272: 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 273: 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 274 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 275 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 276 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 277: 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 278: 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 279: 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 280: 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 281 INDEX INDEX Carburetor 101 Accelerator Pump Lever 106 Abbreviations 12 Assembly 105 Accelerator Pump Cleaning and Inspection 104 Description 115 Dashpot 59 Lever Gap Adjustment 106 Disassembly 103 Accessories Float Check 105 Fuel Filter Assembly, P/N 174176 33 Float Drop Setting 16 Adjustments Impulse Plug 57 Accelerator Pump Lever 106...
  • Page 282 INDEX Water Intake Screens 63 Drilling and Hardware Diagram 36 Cooling System Driveshaft Hose Routing 250 Assembly 216 Operating Temperature 47 Bearing Housing Seals 212 Servicing 169 Disassembly 209 Thermostat 169 Installation 217 Turbulence 34 Removal 207 Corrosion Anodes 54 Battery 56 Electric Starter System Driveshaft 205...
  • Page 283 INDEX Fuel System Additives 16, 44 Hoses Carburetor Servicing 101 Fuel System 33 Fuel Filter 33, 62 Fuel Hose Connections 100 Fuel Leakage Check 100 Idle Speed Adjustment 64 Fuel Pump 111 Ignition Fuel Requirements 44 Charge Coil 70 Hose Routing 250 Charge Coil Test 75 Hoses 33 Components 70...
  • Page 284 INDEX Models Covered 6 Priming Mounting the Engine 38 Fuel System 33 Hull Preparation 34 Propeller Inspection 198 Installation 49, 198 Neutral Start Protection 46 Removal 198 Neutral Switch Selection 48 Continuity 90 Test Propeller 16 Propeller Shaft Assembly 218 Oil Filter Bearing Housing Installation 219 Maintenance 60...
  • Page 285 INDEX Shift Linkage Lubrication 66 Technical Data 16 Shift Rod Thermostat Assembly 215 Inspection 169 Disassembly 210 Installation 169 Removal 209 Operating Temperature 47, 169 Shimming 220 Removal 169 Shock Absorber 240 Throttle Shop Aids 25 Adjustment 110 Spark Plug Information 17 Cable Installation 110 Spark Plugs Linkage Adjustments...
  • Page 286 INDEX Ignition Analyzer, P/N 501890 19 Operation 237 Large Puller Jaws, P/N 432129 21 Removal 229 Lifting Eye, P/N 321537 17 Shock Absorber 240 Oil Pressure Gauge Adapter, System Wiring 226 P/N 350930 22 Thermal Valve 242 Oil Pressure Gauge, P/N 5000900 22 Up Circuit 238 Pinion Bearing Removal/Installation, Wiring Diagram 226...
  • Page 287 MWS Instrument Wiring Harness DRC6165R...
  • Page 288 MWS Key Switch and Neutral Safety Switch START CHOKE/PRIMER 000954...
  • Page 289 MWS DASHBOARD SYSTEM CHECK TACHOMETER SPEEDOMETER PUL / +12V LIGHT SWITCH FUEL VOLTMETER TRIM/TILT WATER PRES. FUEL TANK SENDER WARNING HORN TO OUTBOARD DRC6278R...
  • Page 290 30 HP 4-STROKE REMOTE MODELS CKP SENSOR CKP SENSOR PTT MOTOR NO. 1 NO. 2 POWER PACK MAGNETO STARTER MOTOR FUSE 25A CYL TEMP SENSOR IGNITION COIL RECTIFIER & NO. 1 REGULATOR PTT RELAY OIL PRESSURE SWITCH STARTER 0.5kgf/cm or less MOTOR RELAY Bl/Y...
  • Page 291 30 HP 4-STROKE TEL MODELS CKP SENSOR CKP SENSOR NO. 1 NO. 2 POWER PACK MAGNETO STARTER MOTOR ENGINE START SWITCH Button pushed START FUSE 25A CYL TEMP SENSOR IGNITION COIL RECTIFIER & NO. 1 REGULATOR NEUTRAL SWITCH STARTER MOTOR RELAY Bl/Y IGNITION COIL EMERGENCY STOP &...

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Johnson j30pl4sua 2007

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