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Johnson J10RLSUR, Service Manual

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6

INTRODUCTION

MODELS COVERED IN THIS MANUAL

MODELS COVERED IN 
THIS MANUAL

This manual covers service information on

Johnson

 9.9 and 15 HP 2-Stroke models.

Identifying Model and Serial 
Numbers

Outboard model and serial numbers are located
on the swivel bracket and on the powerhead.

Model Number

Start

Shaft

Steer

J10RSUR

Rope

15”

Tiller

J10RLSUR

Rope

20”

Tiller

J15RSUA

Rope

15”

Tiller

J15RLSUA

Rope

20”

Tiller

J15RTSUR

Rope

15”

Tiller

9.9/15 HP Swivel Bracket

1.

Model and serial number

000820

9.9/15 HP Powerhead

1.

Serial number

000821

1

1

Summary of Contents for J10RLSUR

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Page 3: ...ubriplate is a registered trademark of Fiske Brothers Refining Company NGK is a registered trademark of NGK Spark Plugs U S A Inc NMEA is a registered trademark of the National Marine Electronics Asso...

Page 4: ...l and never rush or guess a service pro cedure Human error is caused by many factors carelessness fatigue overload preoccupation unfamiliarity with the product and drugs and alco hol use to name a few...

Page 5: ...dly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent accidental starting while servicing disconnect the battery ca...

Page 6: ...1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS 17 2 INSTALLATION AND PREDELIVERY 31 3 MAINTENANCE 49 4 ELECTRICAL 67 5 IGNITION 85 6 FUEL SYSTEM 103 7 POWERHEAD 119 8 MIDSECTION 147 9 GEARCASE 163 10 MANU...

Page 7: ...E B 9 TYPICAL PAGE C 10 TYPICAL PAGE D 11 ABBREVIATIONS USED IN THIS MANUAL 12 UNITS OF MEASUREMENT 12 LIST OF ABBREVIATIONS 12 ENGINE EMISSIONS INFORMATION 13 MANUFACTURER S RESPONSIBILITY 13 DEALER...

Page 8: ...Model and Serial Numbers Outboard model and serial numbers are located on the swivel bracket and on the powerhead Model Number Start Shaft Steer J10RSUR Rope 15 Tiller J10RLSUR Rope 20 Tiller J15RSUA...

Page 9: ...S 0 Ex SU 2007 MODEL RUN or SUFFIX DESIGN FEATURES AP Advanced Propulsion B Blue Paint C Counter Rotation D Evinrude E TEC E Electric Start w Remote Steering F Direct Injection G Graphite Paint H High...

Page 10: ...e units appear as in lbs Use appropriate torque Tightening torque for a fastener Subsection title indicates beginning of the subsection Italic subheading above Service Chart indicates pertaining model...

Page 11: ...essure hose through cover grommet with oil tank sending unit harness Route hose along battery cables toward the back of the powerhead Use tie straps to fasten in place If temperature gauge is to be us...

Page 12: ...matex No 2 gasket sealant to inner exhaust housing flange Coat both sides of a new base gasket with Gasket Sealing Compound ALL MODELS Install a new base gasket on adapter To ensure proper sealing mat...

Page 13: ...38 A faulty electrical circuit or an inoperative pres sure switch activates service code 38 no oil sen sor feedback or lack of oil pressure and the EMM Service Code 39 If no oil pressure is detected...

Page 14: ...dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CPS crankshaft position sensor DI Direct Injection ECU electronic control unit...

Page 15: ...board maintenance performed to maintain emission lev els within prescribed certification standards The owner operator is not to and should not allow anyone to modify the outboard in any manner that wo...

Page 16: ...raphs and illustrations used in this man ual may not depict actual models or equipment but are intended as representative views for refer ence only Certain features or systems discussed in this manual...

Page 17: ...ym bol for ohm the unit of measurement for resis tance Values When precedes a value on the meter face it indicates your reading must be less than or equal to the value shown When precedes a value on t...

Page 18: ...16 INTRODUCTION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 19: ...LS 17 1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS TABLE OF CONTENTS TECHNICAL DATA 18 STANDARD TORQUE SPECIFICATIONS 20 SPECIAL TOOLS 21 ELECTRICAL IGNITION 21 FUEL 22 GEARCASE 23 POWERHEAD 24 STARTER...

Page 20: ...Rod Crankpin 0 8120 to 0 8125 in 20 63 to 20 64 mm Piston Ring End Gap Both 0 005 to 0 015 in 0 13 to 0 38 mm Lower Piston Ring Groove Side Clearance 0 004 in 0 10 mm maximum Test Propeller 340177 Min...

Page 21: ...regulated accessory Tachometer Setting 5 Pulse 10 pole with alternator A C lighting Accessory Engine Fuse 20 Amp P N 514021 COOLING Type Auto Pressure Temperature Controlled Thermostat 143 F 62 C IGN...

Page 22: ...hese values apply only when a specific torque for a specific fastener is not listed in the appropri ate section When tightening two or more screws on the same part DO NOT tighten screws completely one...

Page 23: ...l connectors jumper wire 1 No 16 wire 8 in 200 mm 2 Pin P N 511469 3 Socket P N 581656 4 Shrink tube 510628 73158 CD Peak reading voltmeter P N 507972 49799 Amphenol crimping pliers P N 322696 30387 1...

Page 24: ...l extender P N 502054 CO3010 Spark checker P N 508118 49798 Tachometer timing light P N 507980 49789 Ball hex screwdriver P N 327622 23664 Orifice plug screwdriver P N 317002 23611 Float gauge P N 324...

Page 25: ...riveshaft seal installer P N 326554 9 9 15 HP 32883 Pinion bearing spacer P N 339753 9 9 15 HP 32638 Prop shaft bearing housing puller kit P N 386631 9 9 15 HP 32627 Prop shaft bearing housing seal in...

Page 26: ...ng pliers P N 331045 2 Replacement tip set P N 395967 2036 2 1 Crankshaft lower seal installer P N 433391 9 9 15 HP 23660 Crankshaft upper seal remover installer kit P N 391060 9 9 15 HP 23102 Cylinde...

Page 27: ...1641 1 2 Starter rope threading tool P N 378774 23682 Starter spring winder installer P N 342682 50068 Drive handle P N 311880 31932 Hose clamp wrench P N 325043 23674 Puller Bridge P N 432127 23146 S...

Page 28: ...mmer P N 432128 15345 Syringe P N 346936 50243 Tie strap installation tool P N 323716 18105 Temperature gun P N 772018 45240 Tilt tube service kit P N 434523 33249 Torque wrench extension P N 912031 2...

Page 29: ...in 1 Multi Purpose Lubricant P N 777192 Oil XD100 P N 777118 HI VIS Gearcase Lube P N 775605 Engine Tuner P N 777185 D P L Spray P N 777183 Oil XD50 P N 777225 HPF XR Gear Lube P N 778747 Anti Corrosi...

Page 30: ...e P N 504824 Black Neoprene Dip P N 909570 Triple Guard Grease P N 508298 Needle Bearing Grease P N 378642 Power Trim Tilt and Power Steering Fluid P N 775612 Thermal Joint Compound P N 322170 Extreme...

Page 31: ...r P N 777184 Gel Seal II P N 327361 ThreeBond 1104 P N 351052 ThreeBond 1207B P N 351053 Locquic Primer P N 772032 Carbon Guard P N 775629 Gasket Sealing Compound P N 317201 Pipe Sealant with Teflon P...

Page 32: ...30 SERVICE SPECIFICATIONS AND SPECIAL TOOLS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 33: ...OUNTING 39 OUTBOARD RIGGING 40 CONTROL CABLE INSTALLATION 40 CABLE HOSE AND WIRE ROUTING 42 FUEL AND OIL PRIMING 43 FUEL REQUIREMENTS 43 FUEL SYSTEM PRIMING 44 OIL REQUIREMENTS 44 BREAK IN OILING 44 B...

Page 34: ...provided with the remote control Make sure the following items are checked Correct length control cables and wiring har nesses Proper type and quality of cables and wiring harnesses Correct routing of...

Page 35: ...sh this connection with a hex nut IMPORTANT Do not use wing nuts to fasten ANY battery cables Wing nuts can loosen and cause electrical system damage not covered under warranty Tighten all connections...

Page 36: ...ould be as short and horizontal as possible Use corrosion resistant metal clamps on per manently installed fuel hoses Multi outboard applications require separate fuel tank pickups and hoses A fuel se...

Page 37: ...Supply Configuration 1 Primer bulb 2 Water separating fuel filter 3 Anti siphon valve in fuel pick up of tank DRC6797 1 2 3 Component 25 HP 130 HP Models 135 HP 250 HP Models Fuel tank pickup tube 5...

Page 38: ...transom and splash well area pro vide adequate clearances The top edge of the transom should be wide enough to allow full steering travel The ABYC standard for most single outboard installations is 33...

Page 39: ...being installed should come close to matching the transom height of the boat Determine transom height by measuring from the top edge of the transom along the centerline Use a straightedge as a refere...

Page 40: ...som or bracket Steering Systems Mechanical Cables All Evinrude Johnson outboards equipped with tilt tubes are designed to be compatible with mechanical steering systems that meet ABYC Standard P 17 Si...

Page 41: ...for above and below waterline use under hex heads of bolts on the mounting plates and to the bolt shanks IMPORTANT After 30 minutes of operation retighten clamp screws by hand DO NOT use tools to tig...

Page 42: ...ubber grommet from front of lower engine cover Remove cable retainer Apply a lib eral amount of Triple Guard grease to both anchor pockets Attach cable casing guide to throttle lever using clevis pin...

Page 43: ...ing the trunnion nut Adjust the shift trunnion The shift lever and gear case must be in NEUTRAL when the remote con trol handle is in NEUTRAL Adjust the throttle trunnion The throttle lever must be at...

Page 44: ...to terminal Position grom met in lower engine cover Secure the battery negative cable to the pow erhead ground terminal Apply Black Neoprene Dip to connection Remote Electrical Harness Refer to acces...

Page 45: ...s IMPORTANT The only fuel additives approved for use in Evinrude outboards are 2 4 fuel condi tioner and Evinrude Johnson Fuel System Cleaner Use of other fuel additives can result in poor performance...

Page 46: ...Johnson XD30 outboard oil is recom mended for use in Johnson 2 Stroke outboards If XD30 oil is not available you must use an oil that meets NMMA TC W3 certification Engine Lubricant Below 32 F 0 C If...

Page 47: ...op Key Switch Check emergency stop function With outboard running at IDLE pull safety lanyard from emer gency stop switch Outboard must stop immedi ately 1 Gearcase lubricant level 000072 1 WARNING DO...

Page 48: ...overboard indicator Operating Temperature An outboard run at idle speed should achieve a temperature based on the engine s thermostatic control In general the powerhead temperature should reach at lea...

Page 49: ...er to the Evinrude Johnson Genuine Parts and Accessories Catalog for propeller styles and sizes Right hand propellers are considered standard rotation propellers When propelling a boat for ward the pr...

Page 50: ...ighten the nut until they are in line Do not loosen Insert a new cotter pin through the propeller nut and shaft Bend its ends over the nut to secure the assembly Remove block of wood IMPORTANT After f...

Page 51: ...YNCHRONIZATION AND LINKAGE ADJUSTMENTS 59 PRELIMINARY ADJUSTMENTS 59 CAM FOLLOWER PICKUP POINT 60 WIDE OPEN THROTTLE ADJUSTMENT 61 MAXIMUM SPARK ADVANCE 61 IDLE SPEED 61 SHIFT LEVER DETENT 62 10 HOUR...

Page 52: ...bricate 1 D Every 60 days Every 30 in Saltwater Swivel bracket tilt support bracket lubricate 1 D Every 60 days Every 30 in Saltwater Shift lever shaft and detent shallow water drive bracket inspect a...

Page 53: ...and lubricate 3 F 3 Propeller shaft splines inspect and lubricate D 3 Spark plugs replace 2 3 Decarbonize G 3 Driveshaft splines inspect and lubricate E 3 Water pump inspect and replace 3 1 Also recom...

Page 54: ...Avoid using metal based antifouling paint on the boat or outboard Testing Procedure Continuity Connect meter leads between engine ground and anode surface The multimeter should indicate little or no...

Page 55: ...te ground drainage during the flushing procedures Keep water inlet pressure between 20 to 40 psi 140 to 275 kPa Flushing Outboard Running Refer to Propeller Hardware Installation on p 47 Place outboar...

Page 56: ...ean or replace as needed Confirm function of overboard water pressure indi cator Clean or replace plug and nozzle as needed LUBRICATION Steering System Remote Models Grease the stainless steel output...

Page 57: ...ckets and the reverse lock mechanism with Triple Guard grease Throttle and Shift Linkage Lubricate the throttle linkage shift linkage starter lockout mechanism and carburetor linkage with Triple Guard...

Page 58: ...l additives for marine applica tions Do not use any automotive gear lubricants 2 stroke or 4 stroke engine oil or any other oil or grease for gearcase applications Propeller Shaft Debris from the wate...

Page 59: ...terminals battery posts and connectors with a solution of baking soda and water Use a wire brush or battery terminal tool to remove cor rosion buildup Rinse and clean all surfaces Reinstall battery a...

Page 60: ...ctions related to the fuel system Visually inspect all components Observe all clamps hoses and connections while outboard is running Replace all damaged components Repair all leaks SPARK PLUGS Spark p...

Page 61: ...e lever Turn the connector clockwise until it seats Turn counterclockwise no more than one half turn to align it with the throttle lever Install the retaining pin The throttle cable bracket must be fl...

Page 62: ...is point the center of the roller should align with the indicator mark on cam To adjust use Ball Hex Screwdriver P N 327622 Back out cam follower adjusting screw until the cam and cam follower do not...

Page 63: ...lead must connect to top ignition coil Idle Speed The boat must be in the water under normal oper ating conditions with correct propeller installed The boat s movement must be unrestrained The boat m...

Page 64: ...aged to return their new engines to an authorized dealer for a mechanical check This check should be performed after approxi mately 10 operating hours The cost of this check should be figured at local...

Page 65: ...rude Johnson Storage Fogging Oil into the spark plug holes Turn the flywheel in a clockwise direction to dis tribute the fogging oil throughout the cylinders Install and torque the spark plugs If outb...

Page 66: ...ol ished surfaces of the crankshaft connecting rods and internal powerhead bearings IMPORTANT If outboard cannot be started or serviced immediately it should be resubmerged in fresh water to avoid exp...

Page 67: ...flywheel is rotated it may indicate a bent connecting rod and no attempt should be made to start the outboard Powerhead must be disassembled and serviced immediately Engine Dropped Overboard In Salt W...

Page 68: ...66 MAINTENANCE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 69: ...RECTIFIER RESISTANCE TESTS 70 TACHOMETER CIRCUIT TEST 71 ELECTRIC STARTER TESTS 72 START SWITCH TEST 72 START CIRCUIT VOLTAGE TEST 72 VOLTAGE DROP TESTS 75 STARTER SOLENOID TEST 76 NO LOAD CURRENT DRA...

Page 70: ...flywheel contains permanently charged magnets The magnets supply energy to power the stator windings The magnets must be at their original design strength for full alternator output Stator The altern...

Page 71: ...cessories Service Manual Low electrolyte level Add water and recharge Terminal connections loose or corroded Clean and tighten Excessive electrical load Evaluate accessory loads Wiring Connections loo...

Page 72: ...eter lead to a clean engine ground and the other lead alternately to the yellow blue yellow and yellow gray stator leads Ohmmeter should show a high reading If ohmmeter shows a low reading stator is g...

Page 73: ...stator and do the Stator Resis tance Tests on p 70 Inspect all engine and boat wiring and make sure connectors are in good condition Do the following tests if the tachometer does not operate STEP 1 Se...

Page 74: ...g when switch is pressed High resistance reading when switch is released Replace the start switch if test results are not cor rect Start Circuit Voltage Test IMPORTANT Outboard must be in NEUTRAL thro...

Page 75: ...ws 0 V clean and tighten the rectifier terminal screw STEP 5 Move the voltmeter red lead to the start switch output lead Push the start button Check the volt age between the start switch output lead a...

Page 76: ...RTER TESTS 9 8 7 6 5 1 4 3 2 TYPICAL 1 Battery positive 2 Battery negative 3 Rectifier terminal ground 4 Start switch connection 5 Powerhead ground 6 Start switch output lead 7 Start button 8 Starter...

Page 77: ...eter negative lead to the starter side of the starter solenoid terminal While crank ing engine connect voltmeter positive lead to starter solenoid opposite terminal Voltage reading must not be more th...

Page 78: ...ine wiring must be discon nected from the solenoid before proceeding STEP 1 Connect one ohmmeter lead to terminal A and the other lead to terminal B Ohmmeter must show a high reading If ohmmeter shows...

Page 79: ...etween the battery negative terminal and the starter frame Monitor the starter RPM and current draw Refer to the chart below for the correct specifications IMPORTANT When performing this test the driv...

Page 80: ...commutator surface is unevenly worn or pitted turn on a lathe Remove any trace of oil or metal dust from commutator Check the armature on a growler for shorted turns using a test light or meter Inspec...

Page 81: ...Locate the cause of binding and correct it before completing the assembly Assembly Lubricate the armature shaft bearing surface with Moly Lube Lubricate the armature shaft on and above the pinion hel...

Page 82: ...o 170 in lbs 17 to 19 N m Refer to No Load Current Draw Test on p 77 to check starter operation Installation Install the starter on the bypass cover The elec tric starter motor must be held firmly aga...

Page 83: ...oval Disconnect the black and purple white wires and remove the primer Remove the black and yellow red wires from the top posts Remove the red cables and remove the solenoid with bracket Disconnect th...

Page 84: ...l bracket with solenoid and tighten screws securely Attach the red cables starter cable to top large post Attach black and yellow red wires to top posts Install primer and connect black and purple whi...

Page 85: ...ows and push together Apply isopropyl alcohol to the terminal cavity Place connectors against solid surface Push terminal into connector until step of insert tool touches connector body Check your wor...

Page 86: ...84 ELECTRICAL NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 87: ...M TESTS 89 TOTAL IGNITION OUTPUT TEST 89 STOP CIRCUIT TESTS 89 CHARGE COIL TEST 91 SENSOR COIL TEST 92 POWER PACK CRANKING OUTPUT 94 POWER PACK RUNNING OUTPUT 94 IGNITION COIL TESTS 95 SPARK PLUGS 97...

Page 88: ...pack to operate the ignition system Sensor Coil The sensor coil contains many windings of wire wrapped around a metal lamination Once the fly wheel exceeds a minimum cranking RPM the fly wheel s magne...

Page 89: ...pack through the engine wiring harness remote electric models When activated this switch directs power pack output to ground stopping the ignition system IMPORTANT This emergency stop switch clip tur...

Page 90: ...oblems could cause a pack to fire erratically or continuously To trouble shoot this situation determine if each cylinder is firing at the correct time and no more than once per revolution Disconnect t...

Page 91: ...wer Pack Cranking Output on p 94 If tester shows no output go to Stop Circuit Tests IMPORTANT It is possible for the ignition sys tem to have a problem but still produce good out put If the engine pop...

Page 92: ...the emergency stop switch clip and lanyard Disconnect the 5 pin Amphenol connector between the power pack and ignition plate Calibrate ohmmeter on appropriate scale Con nect meter leads between igniti...

Page 93: ...either test indicates charge coil or leads are grounded Locate and repair ground or replace charge coil If no reading is indicated go to STEP 2 STEP 2 Set peak reading voltmeter to 9 9 15 NEG and 500...

Page 94: ...ement indicates charge coil or leads are grounded Locate and repair ground or replace charge coil Complete all circuits disconnected during this test Sensor Coil Test STEP 1 Disconnect 5 pin Amphenol...

Page 95: ...ors If wiring and connector condition is good go to STEP 3 STEP 3 IMPORTANT All ohmmeter tests must be per formed with the engine NOT running Insert jumper wires in ignition plate connector ter minals...

Page 96: ...on p 91 If charge coil tests good replace the power pack Power Pack Running Output Twist and remove primary leads from ignition coils Use a clockwise twist to install Stevens Number TS 77 terminal ex...

Page 97: ...must show 0 1 0 05 ohm STEP 2 Calibrate ohmmeter on appropriate scale Con nect meter red lead to coil primary terminal Con nect meter black lead to coil spark plug terminal Meter must show 275 50 ohm...

Page 98: ...age Test The ignition coil and spark plug lead should be tested for leakage or insulation failures using the ignition analyzer Leakage is caused by moisture cracks or holes in the coil housing or spar...

Page 99: ...run an ignition system the flywheel magnets must be of a particular strength Weak flywheel magnets can cause low ignition voltage which would affect engine performance Weak fly wheel magnets can also...

Page 100: ...tighten pressing screw until fly wheel releases Installation Install the flywheel key with its outer edge parallel to taper of crankshaft Clean the crankshaft and flywheel tapers with Cleaning Solven...

Page 101: ...ad Remove the four support plate screws Lift the retainer and support plate from the powerhead Installation Place the retainer plate then the support plate on the powerhead Align support plate with fo...

Page 102: ...5 to 35 in lbs 2 8 to 4 0 N m Connect and adjust spark advance link Refer to SYNCHRONIZATION AND LINKAGE ADJUST MENTS on p 59 Check for sufficient slack on ignition component leads during full advance...

Page 103: ...n component on the ignition plate Connect and route the leads from the spiral wrap and from the ignition component IMPORTANT All component leads must be routed through the clamp and plate in a single...

Page 104: ...nd washer locations before removing any screws Remove the screws coil and washers Installation Assemble the correct sequence of washers and locate the ignition coil on the powerhead Install screws and...

Page 105: ...MP PRESSURE TEST 106 FUEL PUMP SERVICE 106 DISASSEMBLY 106 CLEANING 106 ASSEMBLY 107 CARBURETOR SERVICE 107 EMISSIONS COMPLIANCE 107 REMOVAL 107 DISASSEMBLY 108 CLEANING AND INSPECTION 109 ASSEMBLY 11...

Page 106: ...W M I S A D J U S T E D W O T S T O P S C R E W M I S A D J U S T E D T H R O T T L E C A B L E M I S A D J U S T E D F L O A T V A L V E S T U C K C L O S E D F L O A T V A L V E S T U C K O P E N F...

Page 107: ...range of operating condi tions the carburetor has multiple fuel mixing cir cuits Fuel mixture enrichment for cold starting is con trolled by a choke IMPORTANT The 9 9 15 models use a tamper resistant...

Page 108: ...all a new filter ele ment Also remove the fuel hose from the fuel tank and blow through all passages and hoses with low pressure compressed air to be sure they are open This might be the cause of inad...

Page 109: ...ected resulting in fire or explosion 2 3 4 1 Emissions Compliance Johnson 9 9 15 models are manufactured in accordance with United States of America Envi ronmental Protection Agency EPA standards for...

Page 110: ...ion of federal law Changes to the original design or adjustment limits become the responsibilty of the servicing technician and or the owner The following proce dures must be followed EXACTLY to ensur...

Page 111: ...m pounds Before inspection all carburetor components must be thoroughly clean Carburetor must be completely disassembled Clean parts with Carburetor and Choke Cleaner Use a clean bristle brush to remo...

Page 112: ...excessive throttle shaft play Check for throttle valve misalignment If necessary remove the calibration pocket core plug to inspect the pocket for damage or restric tions Drive a small punch not more...

Page 113: ...ure that all parts are perfectly clean Be sure that all replacement parts match original ones in size and shape Replace all gaskets O rings and sealing washers each time you assemble a carburetor If r...

Page 114: ...or body to setting shown Bend the float lever tab to adjust float drop Install the float chamber and a new gasket Tighten the screws to a torque of 8 to 10 in lbs 0 8 to 1 2 N m following sequence emb...

Page 115: ...ning nuts securely Install cam follower on post Position O ring on the post to secure cam follower Install the choke lever Install the air silencer cover and tighten screws securely Install the manual...

Page 116: ...ace the steering handle Turn the idle speed adjustment knob counterclockwise to lowest SLOW speed position Run the engine at slow speed 700 to 800 RPM and adjust the low speed needle until the highest...

Page 117: ...Inspect the leaf plate assemblies for damage The leaf valves and plate must not be distorted The leaf valve tips must not be cracked or chipped The leaf stops must not be distorted or loose Test leaf...

Page 118: ...9 9 and 15 leaf valves are not interchangeable The thickness of the valves is not the same Assembly IMPORTANT All intake manifold components must be perfectly clean before assembly Do not use a strong...

Page 119: ...p Install screws finger tight Center the leaf valves on the plate using index marks Tighten screws securely Installation Position leaf plate assembly and new gaskets on powerhead Install gaskets dry U...

Page 120: ...118 FUEL SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 121: ...K 122 UPPER CRANKCASE SEAL 123 GENERAL 123 REMOVAL 123 INSTALLATION 123 SHIFT LINKAGE 124 REMOVAL 124 INSTALLATION 125 START SWITCH 126 NEUTRAL START PROTECTION 127 MANUAL STARTER 127 ELECTRIC STARTER...

Page 122: ...Screws 216 to 240 in lbs 25 to 27 N m Install screws dry Do not use sealants on threads Powerhead Retaining Screws 60 to 84 in lbs 7 to 9 N m Apply Gasket Sealing Com pound to threads Main Bearing Scr...

Page 123: ...board with starter note maxi mum pressure reading on gauge Repeat proce dure for each cylinder Return throttle to idle position and reconnect power pack connector Replace spark plugs Retaining Ring Pl...

Page 124: ...00 RPM the digital pyrometer or Temperature Gun should indicate 140 15 F 60 7 C when checking at top of the cylinder head If engine temperature is not within this range trou bleshoot cooling system to...

Page 125: ...o remover installer body P N 326271 Thread remover installer body with tip into seal to engage metal case While holding remover installer body turn press ing screw P N 342227 and remove seal Installat...

Page 126: ...scribed in REMOVAL on p 128 Remove the clip and drive pin from shift handle Remove the screw retaining the shift handle Remove the lockout rod Remove the choke lever and grommet Remove the pin shift r...

Page 127: ...tallation Install the two shift arm bushings Install the pin and shift lever and secure with cotter pin Install the shift arm and spacer Position lock tab on shift arm and install screw securely Bend...

Page 128: ...to any additional task that may be required for installation Install switch wires through grommet Connect the red wires to the starter motor and electrical box Apply Black Neoprene Dip to the connecti...

Page 129: ...arter wire and the start switch wire at the electri cal box and press start button The continuity light or ohmmeter should show continuity Shift outboard into FORWARD and REVERSE and press start butto...

Page 130: ...ponents Refer to ELEC TRICAL section Remove the fuel components Refer to FUEL SYSTEM section Remove the ignition components Refer to IGNI TION section Remove the shift lever and linkage Refer to SHIFT...

Page 131: ...ocation Remove the three screws retaining the crankcase head to the powerhead Using a mallet and a punch drive the seals from the crankcase head Discard the O ring and seals Remove the exhaust cover s...

Page 132: ...hes mark the top piston dome number 1 and the bot tom piston dome number 2 Remove the intake bypass cover from the cylinder block Clean the gasket surfaces Remove the six intake manifold screws intake...

Page 133: ...t up and remove the crankcase IMPORTANT Pistons connecting rods needle bearings and liners are wearing parts and seat with the operation of the engine Because of this it is essential to maintain their...

Page 134: ...er main bearing only if it needs to be replaced Use external retaining ring pliers to remove the lower bearing retaining ring and a bearing separa tor to support the bearing Place the separator flats...

Page 135: ...s on reassembly CLEANING IMPORTANT Before inspecting or assembling powerhead all internal components must be per fectly clean and free of contaminants Remove any carbon accumulation from exhaust port...

Page 136: ...Before any inspection process can begin all inter nal components must be clean and free of excess oil Refer to CLEANING on p 133 Make a visual inspection of all internal compo nents Check for unusual...

Page 137: ...5 mm IMPORTANT If any cylinder is outside these tolerances it must be bored oversize One over size piston is available for this engine 0 020 in 0 508 mm To determine oversize bore add 0 020 in 0 508 m...

Page 138: ...l checks around the piston If straightedge does not touch piston remove the ring and clean ring groove ASSEMBLY IMPORTANT Proceed slowly Make no forced assemblies unless a pressing operation is called...

Page 139: ...ing careful not to disturb the bearings Place the connecting rod and the two wrist pin washers in position in the piston cavity aligned with the wrist pin boss Finish installing the wrist pin through...

Page 140: ...to prevent the pistons from falling out If removed oil and press a new lower main bear ing onto the crankshaft When pressing on the bearing support the crankshaft between the two lower counterweights...

Page 141: ...e rods on the crankpins at this time Place other retainer halves and bearings on crankpins Oil threads of rod cap screws and install each rod cap on the proper connecting rod Make sure alignment mark...

Page 142: ...ithin 1 4 in 6 4 mm of the labyrinth seals and bearings IMPORTANT Gel Seal II has a shelf life of at least one year when stored at room temperature Test the Gel Seal II or replace it if the age of the...

Page 143: ...When installed both seal lips will face toward each other Apply approximately 3 cc of Moly Lube between the seals Oil and place a new O ring on the crankcase head Install the crankcase head Apply Gask...

Page 144: ...ure switch if equipped in the cylinder head Install thermostat cover and O ring Torque screws 60 to 84 in lbs 7 to 9 N m Apply Gasket Sealing Compound to both sides of two new exhaust cover gaskets In...

Page 145: ...uch inner exhaust tube Position inner exhaust tube on powerhead Tighten the screws and torque 60 to 84 in lbs 7 to 9 N m Apply a liberal amount of Permatex No 2 sealer to the machined diameter of lowe...

Page 146: ...to 84 in lbs 7 to 9 N m IMPORTANT Adjust the start button assembly See Start Switch on p 126 To avoid permanent powerhead damage instruct operator to repeat the original outboard break in procedure as...

Page 147: ...POWERHEAD POWERHEAD VIEWS 145 7 POWERHEAD VIEWS Port Starboard View Manual Start DP0019 DP0020...

Page 148: ...146 POWERHEAD POWERHEAD VIEWS Rear View Manual Start DP0021...

Page 149: ...0 INSPECTION 151 ASSEMBLY 151 INSTALLATION 153 EXHAUST HOUSING 155 DISASSEMBLY 155 CLEANING AND INSPECTION 156 ASSEMBLY 157 SWIVEL BRACKET 159 DISASSEMBLY 159 ASSEMBLY 160 ADJUSTMENTS 162 TILT FRICTIO...

Page 150: ...Lock Upper Mount to Steering Bracket 18 to 20 ft lbs 24 to 27 N m Nut Lock Lower Mount to Exhaust Housing Nut Lock Lower Mount Bracket Screws 60 to 84 in lbs 7 to 9 N m Nut Lock Steering Bracket to Pi...

Page 151: ...stop button ground lead from the igni tion coil Cut tie strap and separate the 5 pin Amphenol connector Remove the stop button black wire from the plug using Socket Removal Tool P N 322699 Remove the...

Page 152: ...lix halves rollers and guides Pull the throttle pin out of the cable Remove throttle end cap from inner handle Remove stop switch cover screws and cover stop switch assembly Remove the throttle contro...

Page 153: ...lace parts if necessary Refer to Stop Circuit Tests on p 89 to test stop switch Assembly Install the throttle cable seal in inner handle Snap the stop switch assembly with the throttle cable into the...

Page 154: ...es over the roller pin and into the slots of the inner handle Place the rollers on the ends of the roller pin Assemble helix halves on the handle and slide the grip over the helix Be sure the twist gr...

Page 155: ...the steering bracket Attach the steering handle to the steering bracket Tighten the screw and nut so the steering handle can pivot and maintain any position Tighten the nut so the steering handle can...

Page 156: ...cable connector into throttle lever and insert pin Position throttle cable anchor on powerhead and secure with shoulder screw and washer Hook cable retainer around throttle cable and install air silen...

Page 157: ...ift arm pin to disengage the shift rod from the shift arm and remove the rod Remove the five screws and lift the lower engine cover support off the exhaust housing Remove the two lower mount bracket s...

Page 158: ...s or kinks which may restrict water flow Inspect shift components for wear Replace if deteriorated or damaged Clamp Screw Inspect clamp screw assembly s Replace swivel plate and retainer if bent or lo...

Page 159: ...7 to 9 N m Place the upper thrust mount and plate in position on the swivel bracket assembly Clean all sealant from the threads on the two upper mount to steering bracket screws Apply Nut Lock to thr...

Page 160: ...ghten the screws to a torque of 48 to 60 in lbs 5 to 7 N m Position the lower engine cover support on the exhaust housing and torque the five screws to 60 to 84 in lbs 7 to 9 N m Lubricate the upper s...

Page 161: ...rom top of the swivel bracket Remove the thrust washer O ring and bushing from bottom of swivel bracket If necessary disassemble the steering bracket from the pilot shaft by removing the three screws...

Page 162: ...ssembly IMPORTANT Lubricate pilot shaft and bush ings with Triple Guard grease If any of the swivel bracket components were removed refer to the two reference pictures for correct reassembly If remove...

Page 163: ...le Guard grease to the lower bushing Install the lower bushing O ring and lower thrust washer Apply Triple Guard grease to the pivot tube Install the pivot tube and steering bracket into the swivel br...

Page 164: ...eases idle speed Make certain that throttle is in SLOW position and the outboard is at normal operating temperature before making the idle speed adjustment Outboard should idle at recom mended RPM in...

Page 165: ...AL 172 DRIVESHAFT SEALS 172 DRIVESHAFT BEARING 172 PINION BEARINGS 173 FORWARD BEARING 173 SHIFT ROD BUSHING AND O RING 173 PROP SHAFT BEARING HOUSING SEALS AND O RING 174 PROP SHAFT BEARING HOUSING B...

Page 166: ...B A B A B D 84 to 86 in lb 9 to 10 N m 96 to 120 in lb 11 to 14 N m F A 84 to 86 in lb 9 to 10 N m 48 to 84 in lb 5 to 9 N m A A A B R 60 to 84 in lb 7 to 9 N m F B A Triple Guard Grease B Gasket Seal...

Page 167: ...lug then the lubricant drain fill plug and drain the lube from the gear case into a container Inspect the lubricant for metal chips The presence of metal fuzz can indicate normal wear of the gears bea...

Page 168: ...ears at the oil level hole Filling the gearcase too quickly can cause air pockets and the gearcase may not fill completely Clean plug seal area and install the lubricant level plug and new seal then t...

Page 169: ...g Separate gearcase and exhaust housing to expose the shift rod connector Remove the upper connector screw Remove gearcase from the exhaust housing and place in a suitable holding fixture WARNING Duri...

Page 170: ...ngages the crank shaft Rotate the flywheel if necessary Make sure the upper shift rod enters the shift rod connector Align the groove in the lower shift rod with the screw hole in the connector Apply...

Page 171: ...and visible signs of wear or damage Check impeller cup and plate for scoring distortion and impeller material transfer Inspect housing for cracks or melting Assembly Apply Gasket Sealing Compound to t...

Page 172: ...ce on the top of the gearcase that contacts the impeller plate Slide the plate down over the driveshaft and position it Apply Needle Bearing grease to the impeller drive pin and position it on the fla...

Page 173: ...e the propeller shaft with thrust washers and reverse gear components If forward thrust washer is not on propeller shaft check for it in the relieved area of the forward gear Use a magnetic tool to lo...

Page 174: ...and thrust bearing BEARING AND SEAL REMOVAL IMPORTANT Inspect bearings for damage while in place If bearing is damaged remove and discard If the bearing is removed for any reason it must be replaced...

Page 175: ...cup Use Wrench P N 334359 to hold the puller while tightening the jaws Shift Rod Bushing and O ring Position Shift Rod Bushing Remover P N 327693 under the shift rod bushing Thread the adapter of the...

Page 176: ...idge P N 432127 and Small Puller Jaws P N 432131 remove seal s Discard seal s Prop Shaft Bearing Housing Bearings Using Bearing Remover P N 319880 and a mal let remove the smaller propeller shaft bear...

Page 177: ...to Anode Testing Procedure Continuity on p 52 Driveshaft check splines for chips wear and cracks Bearing and gear surfaces must not show signs of metal transfer corrosion or dis coloration Severe spl...

Page 178: ...Seals and O ring Use Seal Installer P N 342663 to install a new seal in the rear of the bearing housing Apply DPL Penetrating Lubricant to the casing of the seal before installing Install the seal wit...

Page 179: ...e specific out board model IMPORTANT To ensure accurate bearing loca tion washer must be flat and screw must be tight Install lower pinion bearing Assemble tool using short spacer P N 326585 and remov...

Page 180: ...riveshaft Seals Install new seals back to back in the driveshaft bore using the appropriate seal installer Apply Gasket Sealing Compound to the metal casing of the seals before installing Install the...

Page 181: ...t the bottom of the gearcase Position one pinion thrust washer on the pinion Oil and install the thrust bearing Install the other thrust washer on the pinion Install the pinion in the gearcase IMPORTA...

Page 182: ...d gear Hold propeller shaft in place and move shift rod to NEUTRAL position Apply Needle Bearing grease to the thrust washer propeller shaft spring and two detent balls install thrust washer behind sp...

Page 183: ...bearing housing screws Install the screws and tighten to a torque of 60 to 80 in lbs 7 to 9 N m Install the driveshaft Rotate the driveshaft to allow the splines in the pinion to engage the splines o...

Page 184: ...182 GEARCASE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 185: ...STARTER 183 10 MANUAL STARTER TABLE OF CONTENTS GENERAL 184 STARTER ROPE LENGTH 184 TORQUE CHART 184 REMOVAL 184 ROPE REPLACEMENT 185 DISASSEMBLY 186 CLEANING AND INSPECTION 187 ASSEMBLY 187 INSTALLAT...

Page 186: ...ons Remove the three starter retaining screws Model Rope Length 9 9 15 59 in 150 cm Model Description In lbs Ft lbs N m 9 9 15 Starter Retaining Screw 60 84 5 7 7 9 9 9 15 Starter Spindle Screw and Nu...

Page 187: ...t P N 342682 Remove rope from pulley channel untie knot and remove rope from starter assembly Remove cap from handle untie knot and remove rope from handle Cut new rope 59 in 150 cm long Fuse 1 2 in 1...

Page 188: ...old the pulley down in housing and lift out spin dle Carefully lift out pulley leaving spring in hous ing Turn starter housing over and jar on bench to remove spring WARNING Wear safety glasses while...

Page 189: ...ousing Look for sharp edges and rough surfaces that could fray the starter rope File and polish to remove ASSEMBLY Install mandrel from Starter Spring Installer Kit P N 342682 in vice and place spring...

Page 190: ...se approximately 3 1 2 turns until opening for rope in housing aligns with rope channel in pulley Secure pulley in place by installing stop tool into pulley and housing holes Inspect starter rope Repl...

Page 191: ...44 in lbs 14 to 16 N m Examine lockout parts Replace any worn or dam aged parts Install pawl linkage and retaining ring sharp edge up Check the operation of the pawl The pawl should extend when the st...

Page 192: ...carefully until screw head contacts cam Do not overtighten Install starter screws Tighten screws 60 to 84 in lbs 7 to 9 N m Check operation of starter and starter lockout Starter should crank outboard...

Page 193: ...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 194: ...S 2...

Page 195: ...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 196: ...ORWARD 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 can loss of...

Page 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ...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 214: ...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 215: ...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 216: ...ual as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you received training related to c...

Page 217: ...aft 172 Forward 173 Pinion 173 Propeller Shaft Bearing Housing 174 Break In Oiling 44 Procedure 46 C Cable Hose and Wire Routing 42 Cables Battery Cables 42 Cam Follower Pickup Point 9 9 15 60 Carbure...

Page 218: ...ation 178 Removal 172 E Electric Starter Adjustment 127 Assembly 79 Cleaning and Inspection 78 Disassembly 77 Installation 80 Lubrication 57 No Load Current Draw Test 77 Removal 77 Test 127 Electrical...

Page 219: ...Maintenance 58 I Idle Speed Adjustment 9 9 15 61 Ignition Charge Coil Test 91 Components 86 Ignition Coil 19 Ignition Coil Tests 95 Maximum Spark Advance 9 9 15 61 Power Pack Cranking Output Test 94...

Page 220: ...Assembly 9 9 15 136 Cleaning 134 Inspection 9 9 15 135 Removal 9 9 15 132 Power Pack 86 Cranking Output Test 94 Description 86 Running Output Test 94 Powerhead Assembly 25 30 143 Assembly 9 9 15 136...

Page 221: ...54 Requirements 38 Stern Bracket 159 Stop Button 87 Stop Circuit Test 89 Storing the Engine 63 Submerged Engines 64 Swivel Bracket Components 160 Synchronization and Linkage Adjustments 9 9 15 59 T T...

Page 222: ...693 173 Slide Hammer P N 391008 173 Slide Hammer P N 432128 173 Small Puller Jaws P N 432131 172 174 Socket Removal Tool P N 322699 82 149 Starter Spring Installer Kit P N 342682 184 185 186 187 188 T...

Page 223: ...DR4698 Water Flow Diagram 9 9 15HP...

Page 224: ...A B C 5 1 2 3 6 4 5 1 2 3 6 4 5 1 2 3 6 4 DRC6165R MWS Instrument Wiring Harness 1 2 5 1 2 3 6 7 4 8 A B C...

Page 225: ...Dual Outboards B M M C A S 3 4 2 5 1 6 5 2 3 4 6 1 Lanyard Switch Emergency Stop Circuits B M M C A S 5 2 3 4 6 1 Single Outboard 000705 B M M C A S...

Page 226: ...B M M C A S OFF M B S A C M ON M B S A C M START M B S A C M 4 5 6 1 2 3 MWS Key Switch and Neutral Safety Switch 000954 CHOKE PRIMER M B S A C M...

Page 227: ...REV 5 6 4 3 2 S I G S I G S I G S I G 5 1 2 3 7 4 8 6 TO OUTBOARD W ARNING HORN S YS TEM CHECK S PEEDOMETER TACHOMETER TRIM TILT FUEL W ATER PRES LIGHT S W ITCH V OLTMETER DRC6278R FUEL TANK SENDER T...

Page 228: ...A B C D E B C D E A 9 9 15HP DRC 6217 2 1...

Page 229: ......

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