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BRP Johnson 4HP Service Manual Download Page 46

3-4

IGNITION AND ELECTRICAL

INSPECTION

INSPECTION

Ignition Secondary Coil Resistance

Measure the secondary coil resistance in the CDI and coil
unit.

 Digital Voltmeter 

 Tester range: 

Ω

 (Resistance)

1. Remove the spark plug cap from the high-tension cord.

2. Measure the secondary coil resistance.

Ignition secondary coil resistance: 8.2 – 12.4 k

Ω

If the measurement is out of the specification, replace the
CDI and coil unit.

Spark Plug Cap

 Digital Voltmeter

 Tester range: 

Ω

 (Resistance)

Measure the spark plug cap resistance.

Spark plug cap resistance: 7.5 – 12.5 k

Ω

If the measurement is out of the specification, replace the
spark plug cap.

Tester probe connection

Probe

Other probe

High-tension cord

Core

Tester probe connection

Probe

Other probe

Cap end

Other cap end

Summary of Contents for Johnson 4HP

Page 1: ......

Page 2: ......

Page 3: ...nciples of operation and work pro cedures and may not represent the actual out board motor in exact detail This manual is intended for use by technicians who already possess the basic knowledge and sk...

Page 4: ...er the name of each system or unit an exploded view is provided with work instructions and other service information such as the tightening torque lubrication and locking agent points Example POWER UN...

Page 5: ...sure of any symbol s meanings SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque Apply NUT LOCK Apply oil Use engine oil unless otherwise specified A...

Page 6: ......

Page 7: ...DENTIFICATION NUMBER LOCATION 1 4 MODEL PRE FIX SERIAL NUMBER 1 4 ENGINE SERIAL NUMBER 1 4 FUEL AND OIL 1 4 GASOLINE RECOMMENDATION 1 4 ENGINE OIL 1 4 ENGINE BREAK IN 1 5 WARM UP RECOMMENDATION 1 5 TH...

Page 8: ...s work together pay attention to the safety of each other When it is necessary to run the outboard motor indoors make sure that exhaust gas is vented outdoors When testing an outboard motor in the wat...

Page 9: ...head and case bolts and nuts beginning with larger diameter and ending with smaller diameter Always tighten from inside to outside diagonally to the specified tightening torque Whenever you remove oil...

Page 10: ...ends of unleaded gasoline and alcohol with equivalent octane content may be used Allowable maximum blend of a single additive not combina tion 5 Methanol 10 Ethanol 15 MTBE If leaded gasoline is used...

Page 11: ...tant engine speed for an extended period at any time during the engine break in by varying the throttle position occasionally 1 FIRST 2 HOURS For first 15 minutes operate the engine in gear at idling...

Page 12: ...ove requirement use another pitch propeller to hold the engine speed within the range specified above Propeller selection chart Installing a propeller with pitch either too high or too low will cause...

Page 13: ...569 20 PERFORMANCE Maximum output kW PS 2 9 4 3 7 5 4 4 6 Recommended operating range r min 4000 5000 4500 5500 4750 5750 Idle speed r min 1300 50 in gear approx 1150 1300 50 in gear approx 1200 POWE...

Page 14: ...ty rating 10W 40 API classification SE SF SG SH SJ BREAK IN OIL FIRST 10 HOURS Evinrude Johnson Four Stroke Oil Engine oil amounts l US Imp qt 0 7 0 74 0 62 Gear oil HPF XR Gearcase Lubricant Gearcase...

Page 15: ...78 92 Engine oil Ultra Four Stroke Oil or Viscosity rating 10W 40 API classification SE SF SG SH SJ BREAK IN OIL FIRST 10 HOURS Evinrude Johnson Four Stroke Oil Engine oil amounts l US Imp qt 0 7 0 7...

Page 16: ...1 2810 1 2834 Limit mm in 32 238 1 2692 Camshaft journal oil clearance Upper STD mm in 0 016 0 062 0 0006 0 0024 Limit mm in 0 150 0 0059 Lower STD mm in 0 016 0 052 0 0006 0 0020 Limit mm in 0 150 0...

Page 17: ...00 5 512 0 2165 0 2170 Valve guide protrusion IN EX STD mm in 11 0 0 43 Valve stem outside diameter IN STD mm in 5 460 5 475 0 2150 0 2156 EX STD mm in 5 440 5 455 0 2142 0 2148 Valve stem deflection...

Page 18: ...028 2nd STD mm in 0 35 0 50 0 014 0 020 Limit mm in 1 00 0 039 Piston ring free end gap 1st 2nd STD mm in Approx 8 5 0 33 Limit mm in 6 8 0 27 Piston ring to groove clearance 1st 2nd STD mm in 0 03 0...

Page 19: ...20 1 1024 Crank pin outside diameter difference out of round and taper Limit mm in 0 010 0 0004 Conrod big end side clearance STD mm in 0 20 0 90 0 008 0 0035 Limit mm in 1 20 0 047 Conrod big end wid...

Page 20: ...e coil resistance Optional part at 20 C 0 6 1 0 R Y Battery charge coil output 12V Optional part AMP 6 7 Standard spark plug Type NGK BPR6ES Gap mm in 0 7 0 8 0 028 0 031 GEARCASE Design specification...

Page 21: ...6 mm 10 1 0 7 0 Carburetor mounting bolt 6 mm 10 1 0 7 0 Fuel pump mounting bolt 6 mm 8 0 8 6 0 Fuel tank mounting bolt 6 mm 10 1 0 7 0 Flywheel nut 12 mm 50 5 0 36 0 Engine oil drain plug 10 mm 10 1...

Page 22: ...til the bolt head is seated on the secured part first Completely loosen the bolt Retighten the bolt to the specified torque finally TYPE OF BOLT THREAD DIAMETER TIGHTENING TORQUE N m kg m Ib ft 5 mm 2...

Page 23: ...s 10 34 mm 8 Dial gauge 9 Magnetic stand 10 Thickness gauge 11 Steel V block set 12 0 025 0 076 mm Plastigauge 13 Engine tachometer 14 Valve lifter 15 Flywheel remover 16 Remover and installer 17 Remo...

Page 24: ...e reamer 5 5 mm 29 Valve guide remover installer 30 Valve guide reamer 9 3 mm 31 Handle N 505 32 Piston ring compressor 33 Tweezers 34 Deep socket wrench 35 Shift lock pin remover 36 772269 Adapter 37...

Page 25: ...9 GENERAL INFORMATION SPECIAL TOOLS MATERIALS REQUIRED HPF XR GEARCASE LUBRICANT 400 ml 24 pcs MOLY LUBE TRIPLE GUARD GREASE SILICONE SEALANT THREE BOND 1104 THREE BOND 1207B NUT LOCK ULTRA 4 STROKE O...

Page 26: ...1 20 GENERAL INFORMATION NOTES NOTES...

Page 27: ...ER INSPECTION 2 5 GEAR OIL 2 6 LUBRICATION 2 7 COOLING SYSTEM FLUSHING 2 8 SPARK PLUG 2 9 SPARK PLUG GAP 2 9 CONDITION OF ELECTRODE INSULATOR 2 9 VALVE CLEARANCE 2 10 CHECKING AND ADJUSTING VALVE CLEA...

Page 28: ...s Periodic Maintenance Chart I Inspect and clean adjust lubricate or replace if necessary T Tighten R Replace Interval Initial 10 hrs or 1 month Every 50 hrs or 3 months Every 100 hrs or 6 months with...

Page 29: ...our Stroke Oil or 4 stroke motor oil API classification SE SF SG SH SJ Viscosity rating SAE 10 W 40 BREAK IN First 10 Hours USE Evinrude Johnson Four Stroke Oil or SAE 10W 40 API SE SF SG SH SJ Perfor...

Page 30: ...plug to the specified torque Engine oil drain plug 10 N m 1 0 kg m 7 0 lb ft Do not re use the gasket once removed Always use a new gasket 6 Pour the recommended engine oil to the upper limit 7 Tighte...

Page 31: ...he engine oil filter 1 Remove the powerhead from the engine lower cover See page 6 2 to 6 4 2 Detach the engine oil filter with the holder from the crank case 3 Inspect the engine oil filter for dirt...

Page 32: ...ml 6 4 6 7 US Imp oz Recommended oil HPF XR Gearcase Lubricant 772269 Adapter 5 Install the oil level plug before removing the oil filler tube from the drain hole 6 Install the oil drain plug Do not...

Page 33: ...RICATION LUBRICATION Apply Triple Guard grease to the following points Triple Guard Grease Inspect every 50 hours 3 months Shift lever Steering bracket Throttle linkage Swivel bracket Steering bracket...

Page 34: ...Place the engine in vertical position in a well ventilated area with good drainage Remove the plug A from the flushing port Install flushing device 1 and garden hose Cover the water intake hole with t...

Page 35: ...g gap 0 7 0 8 mm 0 028 0 031 in Thickness gauge Condition of Electrode Insulator Check the electrode and insulator condition If the electrode is extremely worn or burnt replace the spark plug If the s...

Page 36: ...wise to bring the piston to Top Dead Center TDC on a compression stroke Rotate the crankshaft clockwise to prevent water pump impeller damage NOTE To confirm whether the piston is at the TDC position...

Page 37: ...g the valve clearance to within the specification Thickness gauge 7 Tighten the lock nut 1 to the specified torque while hold ing the pivot nut 2 Valve adjusting lock nut 11 N m 1 1 kg m 8 0 lb ft 8 R...

Page 38: ...ck and or adjust the idle speed after the engine speed has stabilized 4 Check the idle speed Idle speed in neutral gear 1250 1350 rpm Adjustment If the idle speed is out of the specification adjust th...

Page 39: ...nition timing make sure that the idle speed is adjusted within the specification 1 Start and warm up the engine 2 Attach the timing light cord to the spark plug high tension cord Timing light 3 Check...

Page 40: ...e the fuel filter WATER PUMP WATER PUMP IMPELLER Inspect the pump case and the under panel If wear crack distortion or corrosion is found replace If cuts tears or excessive wear is found replace the i...

Page 41: ...Seal BOLTS AND NUTS Check that all bolts and nuts listed below are tightened to the specified torque INSPECT INITIALLY AFTER 10 HOURS 1 MONTH AND EVERY 100 HOURS 6 MONTHS THEREAFTER INSPECT EVERY 50 H...

Page 42: ...dure 1 Start and warm up the engine then shut the engine off 2 Remove the spark plug 3 Install the compression gauge into the plug hole Compression gauge Compression gauge adaptor 12 mm 4 Disconnect t...

Page 43: ...AND ELECTRICAL CONTENTS IGNITION SYSTEM 3 2 OUTLINE 3 2 IGNITION TROUBLESHOOTING 3 3 INSPECTION 3 4 IGNITION SECONDARY COIL RESISTANCE 3 4 SPARK PLUG CAP 3 4 ENGINE STOP SWITCH 3 5 REMOVAL INSTALLATI...

Page 44: ...e electrical energy stored in the condenser is released to the ignition coil primary windings then a high surge voltage occurs in the ignition coil secondary windings and spark is generated The CDI an...

Page 45: ...gap 0 5 mm Check spark plug cap for any evidence of high tension leak Check the spark plug cap resistance See page 3 4 Cap resistance 7 5 12 5 k OK OK OK OK No or weak sparks No or weak sparks Sparks...

Page 46: ...il resistance Ignition secondary coil resistance 8 2 12 4 k If the measurement is out of the specification replace the CDI and coil unit Spark Plug Cap Digital Voltmeter Tester range Resistance Measur...

Page 47: ...inuity of the engine stop switch Stop switch continuity If the result is out of the specification replace the engine stop switch Tester probe connection Probe Other probe Blue Red Black Switch conditi...

Page 48: ...emove the flywheel nut using the Strap Wrench or 1 2 in breaker bar inserted in rectangular slot PRIOR TO REMOVING THE ELECTRICAL PARTS DIS CONNECT THE SPARK PLUG CAP FROM THE SPARK PLUG System constr...

Page 49: ...surfaces with cleaning solvent Tighten the flywheel nut to the specified torque Flywheel holder Flywheel nut 50 N m 5 0 kg m 36 0 lb ft CDI and coil unit Install the unit with an air gap of 0 5 mm be...

Page 50: ...3 8 IGNITION AND ELECTRICAL NOTES NOTES...

Page 51: ...L LEAKAGE CHECK PROCEDURE 4 3 FUEL HOSE CONNECTION 4 3 CARBURETORS 4 4 REMOVAL INSTALLATION 4 4 DISASSEMBLY 4 6 CLEANING AND INSPECTION 4 7 REASSEMBLY 4 8 FUEL PUMP 4 10 REMOVAL INSTALLATION 4 10 DISA...

Page 52: ...allow fuel to spill on hot engine parts or on operating electrical components Wipe up fuel spills immediately FUEL LINE Removal Installation Pay special attention to the following steps when removing...

Page 53: ...each type of pipe Be sure to connect and clamp each hose correctly by referring to the figure For the type A short barbed end pipe the hose must completely cover the pipe For the type B bent end pipe...

Page 54: ...ion REMOVAL 1 Loosen the screw 1 securing the throttle control inner cable 2 Remove the breather hose protector 2 from the flame arrester holder 3 3 Remove the fuel inlet hose 4 from the carburetor 4...

Page 55: ...uretor mounting bolts 2 to the specified torque Carburetor mounting bolt 10 N m 1 0 kg m 7 0 lb ft Throttle control cable installation and adjustment 1 Fully close the throttle control grip 2 Turn the...

Page 56: ...ify carburetor model identification Remove the following parts Carburetor 1 Screw 2 Spring 3 Idle adjusting screw 4 Pilot jet 5 Main nozzle 6 Main jet 7 Needle valve 8 Clip 9 Float pin 0 Float A Float...

Page 57: ...tion will result Do not use a wire or a small drill bit in order to clean the orifices and jets of the carburetor CARBURETOR BODY FLOAT CHAMBER Inspect the carburetor body and the float chamber If cra...

Page 58: ...found replace the valve FLOAT Inspect the float If crack or other damage is found replace the float REASSEMBLY Reassembly is reverse order of disassembly with special attention to the following steps...

Page 59: ...ct for smooth movement of float CHECKING AND ADJUSTING FLOAT HEIGHT Measure the float height NOTE Make sure that float weight is not applied to needle valve Vernier calipers Float height H 10 1 mm If...

Page 60: ...pump 2 Remove the two bolts 3 3 Remove the fuel pump 4 and the O ring 5 INSTALLATION Installation is reverse order of removal with special attention to the following steps Do not re use the O ring on...

Page 61: ...llowing parts Piston 6 Pin 7 Spring 8 Diaphragm 9 Spring 0 Pump body A O ring B REASSEMBLY Assembly is reverse order of disassembly with special atten tion to the following steps NOTE After connecting...

Page 62: ...r other damage is found replace the diaphragms Check valves Inspect the check valves in the valve body If tears distortion or other damage is found replace the fuel pump assembly Pump body Inspect the...

Page 63: ...to avoid fuel flow from the tank Wipe up fuel spills immediately 4 Remove the two screws and the fuel cock from the lower cover INSTALLATION Installation is reverse order of removal with special atte...

Page 64: ...a gram below Built in fuel tank 1 Fuel tank 1 2 Cushion 1 3 Tank cap assembly 1 4 Gasket 1 5 Bolt 2 6 Washer 2 7 Cushion 2 8 Fuel cock assembly 1 9 Cock cap 1 0 O ring 1 A Gasket 1 B Screw 2 C Clip 6...

Page 65: ...replace the bulb Fuel hose Inspect the fuel hoses If cut crack leakage abrasion tear or deterioration is found replace the hoses Fuel cock Inspect the fuel cock If leakage deterioration or other dam a...

Page 66: ...4 16 FUEL SYSTEM NOTES NOTES...

Page 67: ...5 1 MANUAL STARTER CONTENTS MANUAL STARTER CONTENTS REMOVAL 5 2 DISASSEMBLY 5 3 REASSEMBLY 5 5 INSPECTION 5 6 INSTALLATION 5 6 NEUTRAL START INTERLOCK NSI 5 7 NOTES 5 8...

Page 68: ...cable 2 from the bracket 3 2 Remove the NSI cable from the clutch notch plate 4 3 Remove the fuel tank cap 4 Detach the cushion plate 5 of the fuel tank 5 Loosen the lock nuts 6 and remove the NSI ca...

Page 69: ...l spring wear safety glasses and hand protection when winding or unwinding the component 6 N m 0 6 kg m 4 5 lb ft System construction 1 Reel 1 2 Screw 1 3 Friction plate 1 4 Ratchet 2 5 Spring 2 6 Rop...

Page 70: ...ove the screw 2 3 Remove the friction plate 3 the ratchets 4 and the springs 5 4 Remove the rope 6 from the reel 1 5 Slowly remove the reel 1 with the recoil spring 7 from the recoil case 8 NOTE Do no...

Page 71: ...on Because of the coiled tension in the recoil spring wear safety glasses and hand protection when winding or unwinding the components Apply Triple Guard grease to the recoil spring Triple Guard greas...

Page 72: ...reel and the recoil case If crack or other dam age is found replace Inspect the recoil rope If wear or fraying is found replace Inspect the recoil spring If crack deformation or excessive curve is fo...

Page 73: ...he arrow mark a 5 Tighten the nuts 2 6 Pull the recoil starter and make sure that the starter does not work when the shift lever 4 is in FORWARD and REVERSE position 7 Apply Triple Guard grease to the...

Page 74: ...5 8 MANUAL STARTER NOTES NOTES...

Page 75: ...G 6 18 CAMSHAFT 6 19 CYLINDER PISTON PISTON RING 6 21 PISTON PIN CONROD CRANKSHAFT 6 26 OIL SEAL BEARING 6 30 THERMOSTAT 6 32 REASSEMBLY 6 33 PISTON TO CONROD 6 33 PISTON RING TO PISTON 6 34 CRANKSHAF...

Page 76: ...cock See page 4 13 10 Remove the CDI and coil unit See page 3 7 NOTE The powerhead is detached from the driveshaft housing with the lower cover as a set If the disassembly of the powerhead is not requ...

Page 77: ...the cable binder then take out the lead wires and the throttle control cable from the lower cover 12 Remove the two bolts and the fuel tank bracket 13 Remove the bolt and the port side plate 14 Remove...

Page 78: ...POWERHEAD REMOVAL 15 Detach the powerhead with the lower cover 16 Remove the two bolts then detach the powerhead and the gasket from the lower cover 17 Remove the cushion rubbers and the oil filler c...

Page 79: ...powerhead 3 Install the powerhead to the lower cover then tighten the two bolts to the specified torque Lower cover mounting bolt 10 N m 1 0 kg m 7 0 lb ft 4 Remove the two dowel pins from the lower c...

Page 80: ...rts removed have been returned to the original posi tions Gearcase gear engagement is properly adjusted See page 8 16 Fuel hose routing matches service manual illustration See page 9 3 and 9 4 Wire ro...

Page 81: ...manifold and the gas ket 2 Take out the thermostat Cylinder Head Valve Rocker Arm 1 Remove the four bolts the cylinder head cover and the gasket NOTE Make sure that the piston is at the TDC position o...

Page 82: ...uts 1 then remove the pivot nuts 2 and the rocker arms 3 6 Using the special tools remove the valve cotters 4 while compressing the valve spring Valve lifter Attachment Tweezers 7 Remove the valve spr...

Page 83: ...indicated and remove the bolts 2 Remove the crankcase from the cylinder block NOTE Pry the crankcase with a screwdriver as shown in the figure 3 Remove the crankshaft thrust washer 1 and the cam shaf...

Page 84: ...AFT CONROD CAMSHAFT 7 Remove the piston with the conrod through the top of the cylinder bore 8 Remove the crankshaft from the cylinder block 9 Remove the circlips 7 the piston pin 8 the conrod 9 and t...

Page 85: ...ack in the intake and the exhaust ports the combustion chamber and the head surface Valve seat Inspect the valve seats for crack or other damage Cylinder head distortion Using a straightedge and the t...

Page 86: ...de diameter Measure the valve stem outside diameter using the microme ter Valve stem outside diameter Standard IN 5 460 5 475 mm 0 2150 0 2156 in EX 5 440 5 455 mm 0 2142 0 2148 in Valve guide inside...

Page 87: ...ection X Y and measure the deflection Valve stem deflection Service limit IN and EX 0 35 mm 0 014 in If the measurement exceeds the service limit replace the valve and or the valve guide NOTE For the...

Page 88: ...t Measure the valve head radial runout Dial gauge Magnetic stand V block set Valve head radial runout Service limit 0 08 mm 0 003 in If the measurement exceeds the service limit replace the valve Valv...

Page 89: ...ve lapper on the valve head Valve lapper 5 Rotate the valve while gently tapping the valve contact area against the seat 6 Continuously pattern on the valve seating face with Prus sian Blue 7 Measure...

Page 90: ...at contact width section on page 6 15 4 If the width A is too high or wide reface the valve seat using the 15 angle cutter If the width A is too low or narrow reface the valve seat using the 45 angle...

Page 91: ...ide out from the combustion chamber side toward the valve spring side Valve guide remover and installer NOTE Do not reuse the valve guide once removed Always use a new oversize valve guide when assemb...

Page 92: ...spring free length Standard IN and EX 29 5 mm 1 16 in Service limit IN and EX 28 3 mm 1 11 in If the measurement exceeds the service limit replace the valve spring Valve spring preload Measure the va...

Page 93: ...upper and lower outside diameter Camshaft holders cylinder block and crankcase inside diameter Micrometer Dial caliper Camshaft journal oil clearance Standard Upper 0 016 0 062 mm 0 0006 0 0024 in Lo...

Page 94: ...6 20 POWERHEAD CAMSHAFT Decompression parts Inspect the decompression parts in the camshaft If abnormal movement is found replace the camshaft...

Page 95: ...ceeds the service limit resurface or replace the cylinder NOTE The cylinder can be resurfaced using a surface plate and a 400 grit wet sandpaper Move the cylinder in a figure eight pattern when sandin...

Page 96: ...mit rebore or replace the cylinder Piston to cylinder clearance To check the clearance measure the following items Cylinder bore at 35 mm elevation from the gasket surface at a right angle to the cran...

Page 97: ...are marked as shown in the fig ures Piston 1st ring and 2nd ring Oil ring NOTE For the oil ring side rail measure the outer diameter of the rail in order to distinguish because there is no I D mark Ov...

Page 98: ...hickness gauge Thickness gauge Piston ring to groove clearance Standard 1st and 2nd 0 03 0 07 mm 0 001 0 003 in Service limit 1st and 2nd 0 12 mm 0 005 in If the measurement exceeds the service limits...

Page 99: ...014 in 2nd 0 35 0 50 mm 0 014 0 020 in Service limit 1st 0 70 mm 0 028 in 2nd 1 00 mm 0 039 in If the measurement exceeds the service limit replace the piston ring Piston ring free end gap Measure th...

Page 100: ...in Service limit 0 040 mm 0 0016 in Pin clearance in conrod small end Standard 0 006 0 019 mm 0 0002 0 0007 in Service limit 0 050 mm 0 0020 in If the clearance exceeds the service limit replace the p...

Page 101: ...o the specified torque in two steps NOTE Do not rotate the conrod with the Plastigage in place Conrod bolt 1st step 10 N m 1 0 kg m 7 0 lb ft 2nd step 20 N m 2 0 kg m 14 5 lb ft 5 Remove the conrod an...

Page 102: ...crankshaft Conrod big end width Standard 23 30 23 80 mm 0 917 0 937 in Crank pin width Standard 24 00 24 20 mm 0 945 0 953 in Crank pin Inspect the crank pin for uneven wear or damage Measure the cra...

Page 103: ...he clearance measure the following items Crankshaft lower holder crankcase inside diameter Crankshaft lower journal outside diameter Micrometer Dial caliper Crankshaft lower journal oil clearance Stan...

Page 104: ...on the oil seals and the bearing do not remove the oil seals and the bearing Do not re use the oil seal once removed Always use a new oil seal Replacing crankshaft upper oil seal bearing Triple Guard...

Page 105: ...crankshaft lower oil seal 432127 Puller Bridge 432131 Smaller Puller Jaws 3 Apply Triple Guard grease to the outer circumference of the oil seals 4 Drive the crankshaft lower oil seal down into posit...

Page 106: ...erating temperature as follows 1 Insert a length of thread between the thermostat valve body and suspend the thermostat in a container filled with water 2 Place the thermometer in the container and he...

Page 107: ...e O ring and the circlip once removed Always use new parts Piston to Conrod 1 Apply engine oil to the piston pin 1 the piston pin bore and the conrod 3 2 Fit the conrod to the piston 1 as shown in the...

Page 108: ...ring to the piston with the N mark toward the piston head side NOTE The 1st ring differs from the 2nd ring in shape Distinguish the 1st ring from the 2nd ring by referring to the figure Ring gap dire...

Page 109: ...nder wall 5 Insert the piston conrod assembly into the cylinder bore from the cylinder head side using the special tool Piston ring compressor NOTE Position the circle mark on the piston head to the f...

Page 110: ...crankshaft gear install the camshaft to the cylin der block Crankcase to Cylinder 1 Clean the mating surfaces of the cylinder block and the crankcase 2 Install the two dowel pins in the cylinder bloc...

Page 111: ...guide plate to the specified torque Deep socket wrench Rocker arm pivot bolt 10 N m 1 0 kg m 7 0 lb ft 3 Apply engine oil to the valve stems 4 Install the valves 1 2 the valve springs 3 and the valve...

Page 112: ...specified torque according to the numerical order in the figure Cylinder head bolt approx 50 torque 1st step 14 N m 1 4 kg m 10 0 lb ft 6 Loosen the all bolts to 0 N m 0 kg m 0 lb ft according to the...

Page 113: ...e direction as shown in the figure Intake Manifold Thermostat 1 Install the thermostat to the cylinder block 2 Install the intake manifold and the gasket then tighten the four intake manifold bolts di...

Page 114: ...w If overheating occurs the components of the cooling system must be inspected for blockage corrosion build up or component damage Component inspection Refer to page Water pump Impeller 8 8 Water tube...

Page 115: ...sage in the top of the cylinder to the crankshaft upper bearing From the periphery of crankshaft upper bearing and the camshaft upper journal the oil runs down and lubricates the each component by spl...

Page 116: ...6 42 POWERHEAD NOTES NOTES...

Page 117: ...VER ROD 7 5 REMOVAL 7 5 INSTALLATION 7 6 STEERING BRACKET DRIVESHAFT HOUSING SWIVEL BRACKET CLAMP BRACKET 7 7 DISASSEMBLY 7 7 INSPECTION 7 10 DRIVESHAFT HOUSING STEERING BRACKET 7 10 CLAMP BRACKET SWI...

Page 118: ...e intake manifold 2 Remove the lead wires cable binder then take out the throttle control cable from the lower cover See page 6 3 3 Remove the engine stop switch from the tiller handle 4 Remove the pi...

Page 119: ...pivot nut 17 N m 1 7 kg m 12 5 lb ft Install the throttle control inner cable to the carburetor See page 4 5 Check that the throttle control is smoothly operated from the fully closed position to the...

Page 120: ...e stopper bolt Nut Lock Make sure that the throttle control inner cable fits in the groove on the drum of the handle rod Triple Guard grease 17 N m 1 7 kg m 12 5 lb ft 12 N m 1 2 kgf m 8 5 lb ft 1 Til...

Page 121: ...h rod connecting plate bolt 2 NOTE Do not over loosen the rod connecting plate bolt Loosen the bolt approximately one turn 4 Remove the bolt 3 the clutch rod arm 4 and the spacer 5 from the shaft of t...

Page 122: ...otch pin or clutch lever notch plate replace Apply Triple Guard grease to the notch pin the notch holes and the O rings on the clutch notch plate Triple Guard grease Apply Nut Lock to the clutch rod a...

Page 123: ...page 6 2 2 Remove the gearcase See page 8 2 3 Remove the tiller handle See page 7 2 4 Remove the clutch lever rod See page 7 5 5 Remove the three bolts and the rear handle grip 6 Remove the water tube...

Page 124: ...wivel clamp bracket assembly 11 Remove the two bolts the steering bracket and the bracket cover 12 Remove the upper mount and the lower mount 13 Remove the tilt pin 14 Remove the nut the washer the lo...

Page 125: ...MIDSECTION STEERING BRACKET DRIVESHAFT HOUSING SWIVEL BRACKET CLAMP BRACKET 17 Remove the two bushings 18 Remove the cotter pin and the shaft 19 Remove the shallow drive lever the washer and the spri...

Page 126: ...ousing steering bracket and the bracket cover If cracks or other damage is found replace Clamp Bracket Swivel Bracket Inspect the clamp brackets swivel bracket and the bracket cover If cracks or other...

Page 127: ...Washer 2 18 Steering bracket 1 19 Steering bracket cover 1 20 Bolt 2 21 Upper mount 1 22 Lower mount 1 23 Driveshaft housing 1 24 Gasket 1 25 Dowel pin 2 26 Plug 1 27 Gasket 1 28 Water inspection plug...

Page 128: ...ase Tighten the clamp bracket shaft nut to the specified torque Clamp bracket shaft nut 25 N m 2 5 kg m 18 0 lb ft Apply Nut Lock to the clamp bracket lower rod nut Nut Lock Driveshaft Housing Steerin...

Page 129: ...cover bolt 10 N m 1 0 kg m 7 0 lb ft Tighten the four swivel bracket cover bolts to the specified torque Swivel bracket cover bolt 10 N m 1 0 kg m 7 0 lb ft Apply Nut Lock to the water tube guide plat...

Page 130: ...7 14 MIDSECTION NOTES NOTES...

Page 131: ...UPPORT HOUSING 8 8 DRIVESHAFT 8 8 REASSEMBLY AND INSTALLATION 8 9 FORWARD GEAR 8 11 PINION GEAR 8 11 DRIVESHAFT DRIVESHAFT SUPPORT HOUSING 8 11 SHIFT ROD ASSEMBLY 8 12 WATER PUMP AND RELATED ITEMS 8 1...

Page 132: ...E Do not over loosen the rod connecting plate bolt Loosen the bolt approximately one turn 3 For the long 20 in model remove the two nuts and washers For the short 15 in model remove the two bolts 4 Se...

Page 133: ...propeller shaft bearing housing NOTE Pry the housing with a screwdriver into the groove as shown in the figure 2 positions 9 Remove the four nuts and washers 10 Remove the water pump case 11 Remove th...

Page 134: ...housing with a screwdriver as shown in the figure 15 Pull out the driveshaft with the driveshaft support housing and remove the washer 16 Take out the following parts Pinion gear Pinion gear backup sh...

Page 135: ...nts 1 Separate the following parts Bearing housing Reverse gear backup shim Reverse gear Reverse gear thrust washer Push rod Push rod pin 2 Remove the dog spring 3 Drive the dog pin out of the clutch...

Page 136: ...eler shaft splines If damage is found replace the shaft GEARCASE Inspect the gearcase If cracks or other damage is found replace the gearcase Visually check the forward gear bearing If pitting noisy r...

Page 137: ...nt exceeds the service limit replace PROPELLER SHAFT BEARING HOUSING Inspect the housing If crack or other damage is found replace the housing Visually check the oil seals If cuts nicks excessive wear...

Page 138: ...Inspect the housing If cracking corrosion or other damage is found replace the housing Visually check the oil seals If cuts nicks excessive wear or other damage is found replace the oil seal Visually...

Page 139: ...kg m 8 0 lb ft 17 N m 1 7 kg m 12 5 lb ft 17 N m 1 7 kg m 12 5 lb ft 1 Gearcase 1 2 Dowel pin 1 3 Anode 1 4 Bolt 1 5 Plug 1 6 Gasket 1 7 Bolt 2 for S model 8 Nut 2 for L model 9 Washer 2 for L model...

Page 140: ...ear 1 11 Forward gear thrust washer 1 12 Push rod 1 13 Push rod pin 1 14 Spring 1 15 Clutch dog shifter 1 16 Dog pin 1 17 Spring 1 18 Propeller shaft 1 19 Reverse gear thrust washer 1 20 Reverse gear...

Page 141: ...the gasket the O ring and the cotter pin once removed Always use new parts FORWARD GEAR Apply gear oil to the following parts Forward gear backup shim Forward gear Forward gear thrust washer HPF XR Ge...

Page 142: ...Apply Nut Lock to the shift rod guide stopper bolt and tighten the bolt to the specified torque Nut Lock Shift rod guide stopper bolt 8 N m 0 8 kg m 6 0 lb ft WATER PUMP AND RELATED ITEMS Install the...

Page 143: ...ller shaft Reverse gear thrust washer Reverse gear Reverse gear backup shim Propeller shaft bearings HPF XR Gearcase Lubricant Apply Triple Guard grease to the O ring and the oil seals of the bearing...

Page 144: ...e test NOTE Apply low initial pressure of 20 40 kPa 0 2 0 4 kg cm2 2 8 5 7 psi first then apply the specified pressure Leakage test pressure 100 kPa 1 0 kg cm2 14 2 psi Do not exceed pressure of 110 k...

Page 145: ...ansom S model Silicone Seal Gearcase nut bolt 17 N m 1 7 kg m 12 5 lb ft NOTE When installing the gearcase to the driveshaft housing check for the following points The water tube is through the hole i...

Page 146: ...clutch lever to the Neutral position 3 Move the shift rod so the push rod is exactly on the Neu tral position A of the shift cam while rotating the propeller clockwise by hand 4 Tighten the plate bolt...

Page 147: ...r and Mounting position Numerical index item Available thickness mm Design specification thickness mm 1 Pinion gear backup shim 1 7 1 8 1 9 2 0 2 1 2 0 2 Forward gear backup shim 0 8 0 9 1 0 1 1 1 2 1...

Page 148: ...eshaft support housing gasket Driveshaft support housing 2 Install the driveshaft support housing with the two nuts diagonally NOTE Use a spacer such as a M8 nut in order to secure the hous ing onto t...

Page 149: ...r shaft the forward gear thrust washer and the housing assembly Do not install the following parts Reverse gear and related shim washer Push rod Push rod pin NOTE Securing the propeller shaft housing...

Page 150: ...rd gear shim Slightly increase the pinion gear shim thickness Do not set tooth contact in the top side toe contact posi tion Damage and chipping of the forward and pinion gear may result Example 2 Inc...

Page 151: ...If you feel that the load is larger reduce the reverse gear backup shim thickness Checking Propeller Shaft Thrust Play After adjusting all gear positions measure the propeller shaft thrust play Propel...

Page 152: ...8 22 GEARCASE NOTES NOTES...

Page 153: ...RE HOSE ROUTING CONTENTS WIRE HOSE ROUTING CONTENTS WIRE AND HOSE ROUTING 9 2 4 HP MODELS 9 3 5 6 HP MODELS 9 4 WIRING DIAGRAM 9 5 OPTIONAL ELECTRICAL PARTS INSTALLATION 9 6 CABLE WIRE ROUTING 9 7 NOT...

Page 154: ...ng hose clips position tube to avoid contact with other parts Check that hoses do not contact rods and levers during either engine operation or standstill Extreme care should be taken not to cut abrad...

Page 155: ...he hose protector and the lead wires Clamp Clamp Air vent hose does not touch motor cover and recoil case C B Fuel pump Fuel hose Fuel pump to Fuel clock Fuel hose Fuel pump to Fuel clock Breather hos...

Page 156: ...6 Throttle cable holder Clamp Fuel cock Grommet Air vent hose Fuse hose Fuel tank to Fuel cock Fuse hose Fuel cock to 3 way joint Lower cover plate Fuel hose Fuel tank to Fuel cock Fuel hose Fuel cock...

Page 157: ...with the optional flywheel CDI AND COIL UNIT SPARK PLUG FLYWHEEL MAGNETO Wire color B Black B R Blue Red EMERGENCY STOP AND ENGINE STOP SWITCH Emergency stop switch Lock plate IN RUN Lock plate OUT S...

Page 158: ...ion Visually check the clearances between the inside magnets of the flywheel and the coil circumference by using the three holes on the flywheel Intake manifold mounting bolt Fuel tank bracket Flywhee...

Page 159: ...ROUTING CABLE WIRE ROUTING CABLE WIRE ROUTING NOTE Wind the protector tube on the cable and position the wire as shown Route the cable and the wire through the upper side of the tiller handle 30 mm P...

Page 160: ...9 8 WIRE HOSE ROUTING NOTES NOTES...

Page 161: ...6 OUTBOARD FUEL ELECTRICAL SYSTEM AND SAFETY S 8 OUTBOARD MOUNTING SYSTEM AND SAFETY S 11 OUTBOARD HYDRAULIC TILT TRIM SHOCK ABSORPTION SYSTEM AND SAFETY S 13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFET...

Page 162: ...S 2...

Page 163: ...elf but also to protect the people around you It is impossible for this manual to cover every potentially hazardous situation you may encounter However your understanding and adherence to the recommen...

Page 164: ...REVERSE FORWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted by operator How ca...

Page 165: ...o STOP propeller What could happen If Operator cannot slow down the outboard or shift into NEUTRAL gear stop propeller Operator could panic and lose control of boat How can loss of speed control be mi...

Page 166: ...eel and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could be hit If steering jams opera...

Page 167: ...weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom can change a set up which was OK earlier If moved up or down even...

Page 168: ...kage must be eliminated Stray electric sparks must be avoided What could happen When not boating fuel leaking in car trunk or van or place where portable tank is stored base ment or cottage could be i...

Page 169: ...tion as shown in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark Plug Boots Not torn or cracked...

Page 170: ...er engine cover If tank cap has an air vent valve make sure it is closed Whenever possible remove hose from outboard and from tank Store hose around ears of tank This way gasoline is trapped in tank a...

Page 171: ...s transom Outboard may S L I D E on transom Boat may turn and be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits something solid and does not stay on...

Page 172: ...d may come loose Mount on flat surface only Use shims to make surface flat Use bolts nuts and washers supplied with outboard They are usually special and will not rust or weaken Check for a high speed...

Page 173: ...suddenly Boat may SINK At high speeds sudden trimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow warnings marked closely Test...

Page 174: ...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 s...

Page 175: ...un into something How can failure of the emergency stop system be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemb...

Page 176: ...Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damaged parts are replaced Repla...

Page 177: ...t hit you as it swings If engine does not have fixed lifting bracket and you use Universal Puller P N 378103 and Lifting Eye P N 321537 or Lifting Eye and Adapter Assembly P N 396748 use only the spec...

Page 178: ...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 ca...

Page 179: ...ust fumes from the engine or other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create CO accu mulation In high con...

Page 180: ...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 Always shut off the engine when near people in...

Page 181: ...er leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged pressure inside may build Ba...

Page 182: ...tches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors furnace dryer water heaters...

Page 183: ...re 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 And remember Little childre...

Page 184: ...and this Safety section in par ticular contain essential information to help prevent personal injury to yourself and your customers as well as prevent damage to equipment 6 Have you received training...

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