LEHR LP2.5 HP Service Manual Download Page 79

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LEHR LP2.5 HP Rev.A 2013

LP2.5 VALVE SYSTEM

DWG NO

DESCRIPTION

Q'TY

LEHR PART NO

MSRP

Summary of Contents for LP2.5 HP

Page 1: ...0 943 2172 Email support golehr com LP2 5 Service Manual P r o p a n e O u t b o a r d E n g i n e Technical Specifications and Step by Step Guides Your LEHR Authorized Dealer and Service Provider Call Toll Free 1 877 666 8679 ...

Page 2: ...ev A 2013 Service Manual Table of Contents 1 General Information and Specifications 2 Fuel Systems 3 Ignition 4 Powerhead 5 Gearcase 6 Miscellaneous 7 Parts Book Reference 8 Operators Manual Reference 1 2 3 4 5 6 7 8 ...

Page 3: ...chedule Engine Fastener Torque Specifications General Torque Values Quick Notes Fuel Consumption Chart Special Tools Adjusting Engine Idle Speed Checking the Spark Plug Changing the Engine Oil Changing the Gearcase Oil Lubrication Points Valve Lash Notes 16 18 19 20 21 22 24 17 1 General Information and Specifications 4 3 7 10 11 12 13 15 6 ...

Page 4: ... seals Never use with damaged or missing seals Discard cylinder if dirt or rust particles are in valve area 2 Turn engine off 3 Attach cylinder outdoors away from pilot lights flames sparks or other ignition sources These sources can ignite leaking gas 4 Hand tighten only Never use tools to tighten Overtightening can damage seals 5 Check for leaks Put soapy water on connections Look for bubbles Li...

Page 5: ... ratio Control System Starting System Ignition control system Ignition timing Spark plug Cooling system Exhaust system Lubrication System 623 mm 24 5 in 345 mm 13 6 in 1 021 mm 40 2 in 381mm 15 0in 17 2 kg 37 9 lb 1 8 kW 2 5 hp at 5 000 r min 4 000 5 000 r min 0 24 gal hr 0 10 gal hr 4 Stroke single cylinder OHV 1 72 cu cm 4 4 cu in 54 0 mm X 31 5 mm 2 13 in X 1 24 in 9 3 Tiller control Manual sta...

Page 6: ...angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction rear view Propeller identification mark Propane 110 Octane 4 stroke motor oil 10W 30 SE SF SG SH or SJ API 0 35 L 0 37 US Quarts 12 oz Gear Case Lube 90 75 ml 2 5 oz 0 4 8 12 degrees 80 degrees 360 degrees F N 2 08 27 13 Straight bevel gear Dog clutch Spline Cloc...

Page 7: ...N L in mm A 14 50 368 B 25 50 648 C 17 00 432 D 16 50 419 E 4 25 108 F 12 00 305 G 11 00 279 H 14 13 359 I 2 25 57 J 9 00 229 K 23 50 597 L 14 50 368 M 12 50 318 N 11 00 279 O 15 25 387 P LEHR INC PROPANE POWERED OUTBOARD MARINE ENGINE MODEL LP2 5S O 74 74 O ...

Page 8: ...kPa 7 0 kgf cm 102 psi 0 1 mm 0 004 in 54 000 54 015 mm 2 1260 2 1266 in 0 08 mm 0 0031 in 0 05 0 0020 in 53 950 53 965 mm 2 1240 2 1246 in 0 035 0 065 mm 0 0014 0 0026 in 12 009 12 017 mm 0 4728 0 4731 in 11 996 12 000 mm 0 4723 0 4724 in 0 97 0 99 mm 0 0382 0 0390 in 1 95 2 15 mm 0 0768 0 0846 in 0 15 0 30 mm 0 0059 0 0118 in 0 04 0 08 mm 0 0016 0 0031 in 1 17 1 19 mm 0 0461 0 0468 in 2 30 2 50 ...

Page 9: ...rings Free length Tilt limit 1 87 1 95 mm 0 0736 0 0768 in 2 10 2 40 mm 0 0827 0 0945 in 0 20 0 70 mm 0 0079 0 0276 in 0 06 0 16 mm 0 0024 0 0063 in 26 139 26 239 mm 1 0290 1 0330 in 21 950 22 050 mm 0 8642 0 8681 in 14 965 14 990 mm 0 5892 0 5902 in 0 010 0 053 mm 0 5892 0 5902 in 0 03 mm 0 0012 in 0 08 0 15 mm 0 0031 0 006 in 0 08 0 15 mm 0 0031 0 006 in 23 9 24 1 mm 0 941 0 949 in 21 9 22 1 mm ...

Page 10: ... 015 mm 0 9449 0 9455 in 0 2 0 6 0 008 0 024 in 0 016 0 046 mm 0 0006 0 0018 in 21 980 21 993 mm 0 8654 0 8659 in 23 969 23 984 mm 0 9437 0 9443 in 21 0 21 1 mm 0 827 0831 in 0 01 mm 0 0004 in 48 52 C 118 126 F 60 C 140 F 3 mm 0 12 in Ink Stamp Fixed 2150 150 r min Ignition system Ignition timing Ignition spark gap Spark plug cap resistance Ignition Coil unit air gap Ignition Coil unit resistance ...

Page 11: ...INTED SURFACE OF MOTOR 1 Check the motor for scratches nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas NOTE Be sure to turn off the engine when you perform maintenance unless otherwise specified If you or the owner are not familiar with machine servicing this work should be done by your LEHR dealer or other qualified mechanic REPLAC...

Page 12: ... cowling screw Tiller handle bolt Carrying handle screw Engine shut off switch nut Grease nipple Swivel bracket bolt Throttle grip screw Clamp bracket inner nut Clamp bracket outer nut Throttle grip shift bolt Trim rod nut M6 M6 M6 M6 M8 M8 M6 M6 M5 M8 M8 M6 M6 M8 M6 M6 M6 M3 M6 M5 M6 M6 M5 M8 M4 M6 M5 M5 Item Thread Size Tightening Torques N m 5 0 9 0 5 0 11 14 30 5 0 12 2 0 18 20 44 10 10 18 11 ...

Page 13: ...standard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided in applicable sections for this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components shou...

Page 14: ...level as measured from the water surface to the top of the test tank transom 2150 150 rpm Spark Plug end gap BR6HS 0 5 0 6mm or 0 020 0 024 in Ignition Coil to Flywheel Air Gap 0 4 0 6mm or 0 016 0 024 in Valve Lash Performed with cold valves Intake 0 08 0 15mm or 0 003 0 006 in Exhaust 0 08 0 15mm or 0 08 0 15 in Thermostat Temperatures Starts to open at and fully open at 48 52C 118 126F 3mm 0 12...

Page 15: ... to read engine Serial Number Code Example LP2 5S 13C00031 LP2 5L 13 C 00031 Model Year Month Engine Number A Lehr Propane 2 5 HP Short Shaft B Year built 2013 C Month built March Month built uses alpha A thru L for Jan thru Dec D Last five digits are production number or 31 A B C D ...

Page 16: ...LEHR LP2 5 HP Rev A 2013 15 1 ...

Page 17: ...meter B Compression Pressure Gauge C Universal Puller D Spark Tester E Inductive Tachometer F Calipers G Paper Clip H Feeler Gauge Assorted Metric Hand Tools I J K L M N A basic assortment of shop equipment and hand tools are all that s required to support basic maintenance activities 1 ...

Page 18: ...ve tachometer B suitable for a single cylinder four stroke engine Start the engine and allow it to warm up to proper oper ating temperature about 3 minutes 3 Once engine temperature and RPM s are stable use a small screwdriver to adjust the idle speed adjustment screw 1 to attain 2150 150 RPM The idle speed screw is accesible with a long phillips head screwdriver inserted through an access hole in...

Page 19: ...n torgue to 25 0 N m or 18 4 ft lbs 5 Install the spark plug lead securely to the plug The boot should touch the hex of the plug when on all the way 1 Remove the upper engine cover Remove the rubber access grommet from the lower motor cover Remove spark plug through the access port Spark Plug BR6HS NGK Spark Plug Gap A 0 5 0 6 mm 0 020 0 024 in Spark Plug Torque 25 0 N m 18 4 ft lbs S Checking the...

Page 20: ...e oil filler cap and then start the engine and warm it up for 5 minutes 6 Turn the engine off and then check the oil level and correct it if necessary Changing the Engine Oil 1 Remove the oil filler cap 2 Place a drain pan under the drain hole 1 and then remove the drain bolt and let the oil drain completely 1 2 Be sure to clean up any oil spills Engine oil drain bolt 2 18 N m 1 8 kgf m 13 3 ft lb...

Page 21: ... the oil Ievel plug to allow the oil to drain completely Inspect the used oil after it has been drained If the oil is milky water is getting into the gear case which can cause gear and bearing damage Consult your LEHR dealer for repair of the lower unit seals 5 With the outboard motor in a vertical position and using a flexible or pressurized filling device inject the gear oil into the gear oil dr...

Page 22: ...LEHR LP2 5 HP Rev A 2013 21 1 Apply water resistant anit corrosion grease to the areas shown Apply grease to the grease nipple until it flows from the bushings Lubrication Points 1 ...

Page 23: ...ttle bracket B Remove the 4 bottle bracket bolts being careful to not lose the spacers under the bracket Remove the 6 valve cover bolts and the valve cover C Valve Lash Check Engine must be cold Perform at 10 Hours and every 100 hours after that D E C F 1 2 4 3 1 1 3 5 6 4 2 2 D Intake Valve E Exhaust Valve F Locking Nut The rocker arm pivot nut adjuster nut is located underneath the locking nut 1...

Page 24: ...n and torque the locking nut 10 N m 7 4 ft lb Re check the clearance 1 ensuring the adjustment did not change Re adjust if necessary until proper clearance is attained with the locking nut torqued 7 To properly seat the valves and check your work rotate the crankshaft two complete revolutions returning to TDC Check valve clearance 1 again to confirm proper clearance Re adjust if necessary 8 Replac...

Page 25: ...LEHR LP2 5 HP Rev A 2013 24 NOTES ...

Page 26: ...ev A 2013 25 Propane Fuel Sytem Removing and Replacing the Carburetor Installing the Slide Throttle Cable Cap Adjusting the Idle Speed Removing the Fuel Line Assembly Assembling the Fuel Line Notes 2 26 28 29 30 32 33 ...

Page 27: ...with the mesh screen going in the inlet first followed by the bronze filter 3 Unscrew the throttle cable cap D out of the top of the carburetor and remove the cable C cap D and slide assembly E To provide clearance to remove the assembly twist the throttle grip to the wide open throttle WOT position This will retract the slide and provide clearance for the throttle cable to clear the bottle bracke...

Page 28: ...e throttle spring slide and needle assembly are now free from the throttle cable and cap Reverse the order to reassemble the new slide assembly to the throttle cable A Orient the slide with the brass retainer pin F pointing down then compress the spring with the slide G and jiggle it until the pin drops out releasing the throttle cable core wire F G 2 The clearance between the 1st stage of the car...

Page 29: ... by the slide assembly Use the slide to compress the spring against the cap and watch for the throttle cable end come into view in the retainer pin hole in the slide When the end is in place carefully orient and insert the retainer pin over the end of the cable The pin should be flush with or below the body of the slide Check for security 3 Twist the throttle grip to WOT position to improve workin...

Page 30: ...ould be approximately 9 from the top of the transom 2 Hook up an inductive tachometer B suitable for a single cylinder four stroke engine Start the engine and allow it to warm up to proper oper ating temperature about 3 minutes 3 Once engine temperature and RPM s are stable use a small screw driver to adjust the idle speed adjustment screw 1 to attain 2150 150 RPM in neutral Turning the screw cloc...

Page 31: ... of hose Hold the brass connector stationary with a 14 mm wrench and unscrew the tube nut with a 10 mm wrench On reassembly do not use teflon tape or sealant Removing the Fuel Line 2 Behind the banjo bolt is a filter and mesh screen Be careful not to lose these 1 2 14 mm 10 mm 4 Remove the screws and clamps that hold the top of the two bottom covers together located in the inside of the top of the...

Page 32: ...ng clamp to have room to access these bolts Once the cover is free remove it from the engine with the fuel line attached Note the position and routing of the fuel line for correct re assembly 6 Remove the fuel line from the bottom cover by holding the banjo bolt with a 16mm wrench and turning the remote connector with a 10mm deep socket from the hex or 16mm thin wrench as shown ...

Page 33: ...mbly Attachment of the cover is the reverse of disassembly sequence 3 Attach the fuel line to the carburetor with the banjo bolt Torque to 8 N m 5 9 ft lbs 4 Insert the end of the rubber hose through the hole in the bottle brack et and install the brass connector Torque to 18 N m 13 2 ft lbs Do not use teflon tape or sealant 5 Check for leaks when fuel line re assembly is complete Banjo Bolt Banjo...

Page 34: ...LEHR LP2 5 HP Rev A 2013 33 NOTES ...

Page 35: ...P Rev A 2013 34 Ignition System Ignition System Components and Schematic Checking Ignition Spark Testing Engine Stop Switch Checking Ignition Coil Adjusting or Replacing the Ignition Coil Notes 3 35 36 37 38 39 40 ...

Page 36: ...ctronic circuit board inside the coil controls spark advance 1 Ignition Coil 2 Flywheel 3 Flywheel Magnet 4 Air gap 0 4 0 6 mm 0 016 0 024 in 1 2 4 3 3 Ignition System Schematic ELEC Electrical systems Wiring harness CD Flywheel magnet TCI unit Engine shut off switch Ground w B B Black W White S69M8020 A B C D E W W B B A Flywheel Magnet B Ignition Coil C Spark Plug D Stop Emergency Stop Switch E ...

Page 37: ...ark plug Connect spark checker to ground 4 Set spark tester to jump a 6 5 mm 0 25 in gap If good spark no further testing necessary If no spark check to ensure the emergency stop switch lanyard clip is connected See following page for procedure Still no spark check the ignition coil See following page for procedure 1 Remove the upper engine cover A Checking the Ignition Spark 3 B C A ...

Page 38: ...he other meter lead to the black stop switch ground wire where it is attached to ground on the engine Checking the Engine Stop Switch R Continuity YES NO YES ctrical systems t plug cap from the rning the cap coun unit resistance cification e ack B Q 0 S69M8090 Q 0 S69M8100 park plug wire Q Checking the engine shut off switch 1 Check the engine shut off switch for con tinuity Replace if there is no...

Page 39: ...ch one ohm meter lead to the ignition coil white wire Attach the other ohm meter lead to the ignition coil black wire Record your reading 3 Replace coil if either circuit is out of specification Secondary Spark Plug Wire Resistance Attach one ohm meter lead to the ignition coil white wire Attach the other ohm meter lead to the ignition coil spark plug wire Record your reading Testing the Ignition ...

Page 40: ...d the ground wire and the two attaching bolts D and remove the coil 2 Install the new coil and adjust the flywheel to coil leg air gap C to 0 4 0 6 mm 0 016 0 024 3 Torque the bolts D to 10 Nm 7 2 ft lbs 4 Reassemble starter assembly bottle bracket and spark plug hi tension lead Adjusting or Replacing Ignition Coil C D D 1 2 4 3 3 Carburetor removed for reference ...

Page 41: ...LEHR LP2 5 HP Rev A 2013 40 NOTES ...

Page 42: ... 2013 41 Powerhead Checking the Cooling System Cooling System Flow Chart Inspect Replace Thermostat or Sacrificial Anode Replacing the Head Gasket Valve Lash Adjustment Installing a Powerhead Notes 4 42 43 44 45 48 47 50 ...

Page 43: ...w remove the thermostat hose from the thermostat cover If no water is present at the thermostat cover nipple and there is no combustion chamber pressure present in the nipple then re move and check the thermostat for debris or damage If thermostat is clean and functioning and and housing is clear of de bris it is probable that the water pump needs servicing See Inspect and Service the Water Pump C...

Page 44: ...Gas and water Cooling System Flowchart Crankcase Cylinder Block Upper Midsection Inside Lower Midsection Exhaust Port Atmosphere Upper Midsection Top Starboard Side Cooling Water Pilot Hole Water Pump Cooling Water Inlet Atmosphere Cylinder Head Thermostat 4 ...

Page 45: ...ing the temperature Check to see if thermostat lifts and opens at the proper temperature and clean or replace if necessary Thermostat begins to lift at 48C 52C 118F 126F and should be fully open to 3mm 0 120 at 60C 140F 6 Reassemble with a new gasket and test run for water leaks A C C A B B Water Temperature Valve Lift 48 52 C 118 126 F 0 mm 0 in Above 60 C 140 F above 3 mm 0 12 in V 1 Remove the ...

Page 46: ...arate the cylinder head from the cylinder block 7 Clean both mating surfaces and install a new head gasket No sealer is necessary 8 Install the cylinder head making sure the rocker arms and pushrods are oiled and properly located and torque the cylinder head bolts in 2 steps Step one torque is 14 Nm 10 3 ft lb and second step is 30 Nm 22 1 ft lbs 9 Place the rockers over the pushrods oiling the en...

Page 47: ...eat the valves rotate the crankshaft two full revolutions returning to TDC Check the valve lash again and adjust if necessary and lock the adjustment check ing to make sure the locking procedure does not change the setting 11 Replace the valve cover gasket and install the valve cover torqueing in two steps First torque step is 5 Nm 3 7 ft lbs and the second step is 12 Nm 8 9 ft lbs 12 Reassemble t...

Page 48: ...2 Remove the rear carrying handle the lower engine cover spark plug and the propane bottle bracket 3 Remove the thermostat water hose 4 Remove the 6 valve cover retainer bolts and the 2 crankcase bolts be low the head and remove the valve cover D E C F 1 3 5 6 4 2 1 2 D Intake Valve E Exhaust Valve F Locking Nut The rocker arm pivot nut adjuster nut is located underneath the locking nut 1 2 4 3 ...

Page 49: ...xt to seat the valves rotate the crankshaft two full revolutions returning to TDC Check the valve lash again and adjust if necessary and lock the adjustment check ing to make sure the locking procedure does not change the setting 6 Replace the valve cover gasket and install the valve cover torqueing in two steps First torque step is 5 Nm 3 7 ft lbs and the second step is 12 Nm 8 9 ft lbs 7 Reassem...

Page 50: ...ove the throttle cable and slide assembly refer to Carburetor Re moval Section 2 4 Remove the propane fuel line refer to Fuel Line Removal Section 2 5 Remove the six powerhead retainer bolts and remove the powerhead 6 Clean the power head mating surfaces install the dowels and the new powerhead base gasket 7 Install the powerhead onto the midsection and secure with the powerhead bolts 8 Install bo...

Page 51: ...LEHR LP2 5 HP Rev A 2013 50 NOTES ...

Page 52: ...case Checking Gearcase for Oil and Water Leaks Removing the Gearcase from the Mid Section Gearcase Line Drawing Reference Pictures Water Pump Disassembly Installation of Water Pump Installing the Gearcase Notes 5 52 53 54 55 57 56 58 ...

Page 53: ... shaft oils seals for damage and fill drain plugs 3 Relieve the pressure on the tester before removing from the gearcase Check the Gearcase for Leaks 1 1 Check the propeller blades and splines for cracks damage or wear Replace if necessary Checking the Propeller 1 Check the anodes for scales grease or oil Clean if necessary Do not oil grease or paint the anodes otherwise they will be ineffective 2...

Page 54: ... Remove the spark plug wire from the spark plug and place the engine in neutral 2 Remove the shift rod connector plug on the exhaust housing and loosen the shift rod connector bolt A 3 Remove the three bolts attaching the gearcase to the midsec tion and remove the gearcase 1 3 2 A 5 ...

Page 55: ...a e h x e h 9 4 LP2 5 LOWER UNIT DRIVE PARTS DWG NO DESCRIPTION Q TY LEHR PART NO MSRP 0 9 6 1 1 0 0 3 2 7 0 B O 1 e p i p r e t a w 1 0 5 7 2 0 0 3 2 7 0 B O 2 g u l p l i o e v i r d 2 0 8 0 3 0 0 3 2 7 0 B O 2 w e r c s g u l p f o d a p g n i l a e s 3 0 3 1 4 6 0 1 2 7 0 B O 3 0 3 X 6 M t l o b d a e h x e h 4 0 6 0 7 0 0 1 2 7 0 B O 3 r e h s a w 6 M 5 0 7 0 6 0 0 3 2 7 0 B O 2 n i p g n i t...

Page 56: ... 1 2 3 4 1 2 2 Slide the pump housing up the shaft noting the condition and assembly order of the water pump parts 3 Inspect and repair worn parts A Shift Rod B Gasket C Lower Plate D Dowel Pins E Impeller Drive Pin F O Ring G Stainless Steel Plate H Impeller I Impeller Cup J Impeller Pump Housing A A D D G F D C B J I D E A H J I H E F G A 5 Water Pump Disassembly ...

Page 57: ...ng Orient the cup tab extension into the recess in the impeller cup 5 Align the impeller housing with the water pump impeller and push the housing down onto the impeller while rotating the driveshaft in a clockwise direction until it is completely seated against the stainless steel plate 6 Install the 4 impeller housing bolts and tighten 7 Install gearcase onto midsection See installing gearcase p...

Page 58: ... i h s 6 3 c s i d h c t u l c 7 3 g n i r p s n o i s s e r p m o c 8 3 g n i r p a n s 9 3 r a e g g n i v i r d 0 4 m i h s r a e g g n i v i r d 1 4 t f a h s e v i r d 2 4 p i l c r i c 3 4 e v e e l s t f a h s e v i r d 4 4 l a e s l i o 5 4 g n i h s u b t f a h s e v i r d 6 4 t i n u r a e g d r a w r o f 7 4 t f a h s p o r p g n i r a e b 8 4 0 2 x 6 M t l o b d a e h x e h 9 4 LP2 5 L...

Page 59: ...LEHR LP2 5 HP Rev A 2013 58 NOTES ...

Page 60: ...HR LP2 5 HP Rev A 2013 59 Miscellaneous Service Removing the Bottle Bracket Removing the Engine Rear Lower Cover Tiller Arm Assembly Tiller Arm Assembly Reference Manual Starter Notes 6 59 60 61 62 63 64 ...

Page 61: ...pacers retaining it to the engine Loosen the bolts and remove them one at a time along with the washers and spacer bushings located underneath the bottle bracket 3 Swing the fuel line and bottle bracket out of the way and secure Removing the Bottle Bracket 6 Carburetor removed to better show bracket bushings underneath ...

Page 62: ...clip nuts located inside the cover on each side where the front and rear covers join 2 Remove the 2 Phillips heads screws and flat clip nuts inside the cover 3 Using a 10mm socket remove the 4 bolts located on the bottom of the rear where they attach to the engine 4 The cover is now free and may be removed Removing the Rear Engine Cover 6 ...

Page 63: ... on the upper case 2 2 Locate the engine shut off switch lead inside the the tiller arm so that it does not contact the throttle lever 3 Insert the tiller handle assembly into the upper case housing and secure it with the attachment bolt 3 Snug up and then torque to the 26Nm or 19 2 ft lbs 4 The engine shut off switch lead 4 and the throttle cable 5 should be oriented as shown Assembling the Tille...

Page 64: ... 2 1 0 6 2 7 0 B O 1 e l d n a h e l t t o r h t 2 1 0 7 0 3 1 0 6 2 7 0 B O 1 6 2 T S w e r c s g n i p p a t d a e h n a p s p i l l i h p 3 1 0 9 6 4 1 0 6 2 7 0 B O 1 d n a b r o t a c i d n i 4 1 0 0 1 5 1 0 6 2 7 0 B O 1 0 1 M r e h s a w 5 1 0 0 5 6 1 0 6 2 7 0 B O 1 g n i r p s 6 1 0 8 2 7 1 0 6 2 7 0 B O 1 k c o l b g n i h s u b 7 1 0 2 5 6 8 1 0 6 2 7 0 B O 1 e l d n a h r e l l i t 8 1...

Page 65: ...en the bracket and the engine block Carefully Swing the bottle bracket to the side and out of the way 2 Next remove the 3 starter housing attaching bolts and lift the starter off the engine block 3 Reverse the procedure to reassemble LP2 5 POWER SYSTEM 1 2 25 26 27 29 3 39 40 42 45 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 67 49 68 49 41 84 7 6 81 82 6 ...

Page 66: ...LEHR LP2 5 HP Rev A 2013 65 NOTES 6 ...

Page 67: ...LEHR LP2 5 HP Rev A 2013 66 DETAILED PARTS LIST AND DIAGRAMS MODEL LP2 5S ...

Page 68: ...LEHR LP2 5 HP Rev A 2013 67 7 LP2 5 LOWER UNIT PARTS 1 2 3 4 5 6 7 8 9 10 11 12 9 13 15 16 17 19 20 21 23 22 24 18 25 26 27 14 16 17 ...

Page 69: ... i t c e n n o c t f i h s 1 1 0 0 1 3 1 0 7 2 7 0 B O 1 n i p r e t t o c 2 1 5 4 7 4 1 0 7 2 7 0 B O 1 B t n e m g e s p m a l c 3 1 0 8 6 1 0 2 0 3 2 7 0 B O 1 d o r m a c t f i h s 4 1 5 4 7 5 1 0 7 2 7 0 B O 1 A t n e m g e s p m a l c 5 1 0 6 0 7 0 0 1 2 7 0 B O 3 6 M r e h s a w 6 1 0 2 1 6 0 0 1 2 7 0 B O 3 0 2 x 6 M t l o b d a e h x e h 7 1 5 7 4 8 1 0 7 2 7 0 B O 1 g n i t t i f e s a e...

Page 70: ...LP2 5 HP Rev A 2013 69 7 LP2 5 LOWER UNIT DRIVE PARTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3 2 32 41 42 43 44 45 46 47 48 49 51 52 50 22 ...

Page 71: ...t a l f 4 2 9 9 6 7 5 2 P P L 5 2 0 3 2 7 0 B O 1 r e l l e p o r p 5 2 9 9 9 2 5 2 W P L 6 2 0 3 2 7 0 B O 1 t i k p m u p r e t a w 6 2 0 5 4 1 7 2 0 3 2 7 0 B O 1 r e h s a w t s u r h t 7 2 5 1 1 8 2 0 3 2 7 0 B O 2 6 1 6 M t l o b d a e h x e h 8 2 0 6 0 7 0 0 1 2 7 0 B O 2 r e h s a w 6 M 9 2 5 1 5 4 0 3 0 3 2 7 0 B O 1 r e v o c e v i r d t i n u r e w o l 0 3 0 0 6 1 3 0 3 2 7 0 B O 1 e v ...

Page 72: ...LEHR LP2 5 HP Rev A 2013 71 7 LP2 5 STEERING PARTS 1 2 3 4 5 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 7 9 10 6 ...

Page 73: ...e l t t o r h t 2 1 0 7 0 3 1 0 6 2 7 0 B O 1 6 2 T S w e r c s g n i p p a t d a e h n a p s p i l l i h p 3 1 0 9 6 4 1 0 6 2 7 0 B O 1 d n a b r o t a c i d n i 4 1 0 0 1 5 1 0 6 2 7 0 B O 1 0 1 M r e h s a w 5 1 0 0 5 6 1 0 6 2 7 0 B O 1 g n i r p s 6 1 0 8 2 7 1 0 6 2 7 0 B O 1 k c o l b g n i h s u b 7 1 0 2 5 6 8 1 0 6 2 7 0 B O 1 e l d n a h r e l l i t 8 1 0 8 0 9 1 0 6 2 7 0 B O 2 2 1 X ...

Page 74: ...LEHR LP2 5 HP Rev A 2013 73 7 OB072 CLAMP PARTS 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 41 42 2 5 28 29 ...

Page 75: ... r o t 9 1 0 2 3 0 2 0 4 2 7 0 B O 1 k c o l b g n i h s u b 0 2 0 1 8 3 1 2 0 4 2 7 0 B O 1 r e v e l k c o l t l i t 1 2 0 6 0 2 2 0 4 2 7 0 B O 1 0 1 X 4 t e v i r 2 2 0 6 6 3 2 0 4 2 7 0 B O 1 r e v e l n o i t c i r f g n i n r u t 3 2 0 5 2 1 4 2 0 4 2 7 0 B O 1 n o i t c i r f g n i n r u t w e r c s 4 2 0 0 1 5 2 0 4 2 7 0 B O 1 r e h s a w 5 2 0 1 5 6 2 0 4 2 7 0 B O 1 g n i r p s d e s s...

Page 76: ... 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 60 60 64 65 66 67 49 68 69 70 71 72 73 74 75 49 49 49 75 41 84 74 75 77 78 78 79 80 76 83 7 6 81 82 ...

Page 77: ...0 2 x 8 M t l o b d a e h x e h 4 2 0 5 8 1 5 2 0 1 2 7 0 B O 1 y l b m e s s a s s a l g t h g i s l i o e n i g n e 5 2 0 5 5 6 2 0 1 2 7 0 B O 1 p a c l l i f l i o 6 2 0 7 3 7 2 0 1 2 7 0 B O 1 l l i f l i o g n i r O 7 2 0 5 7 1 8 2 0 1 2 7 0 B O 1 t e k s a g d a e h 8 2 0 5 2 9 2 0 1 2 7 0 B O 2 l e w o d 9 2 0 2 0 1 2 0 3 0 1 2 7 0 B O 1 d a e h r e d n i l y c 0 3 0 7 4 1 3 0 1 2 7 0 B O ...

Page 78: ...1 6 0 0 1 2 7 0 B O 1 0 2 x 6 M t l o b d a e h x e h 5 6 0 8 1 6 6 0 1 2 7 0 B O 1 0 6 X 6 M t l o b d e d a e h n o g a x e h 6 6 0 0 2 7 6 0 1 2 7 0 B O 1 m m 2 8 r e c a p s 7 6 0 2 2 8 6 0 1 2 7 0 B O 1 m m 2 0 1 r e c a p s 8 6 0 0 2 9 6 0 1 2 7 0 B O 1 m m 1 2 9 r e c a p s 9 6 0 1 4 0 7 0 1 2 7 0 B O 1 m m 5 9 4 r e c a p s 0 7 71 3mm nut 5 7 0 1 7 0 1 2 7 0 B O 1 0 7 0 2 7 0 1 2 7 0 B O 1...

Page 79: ...e s l i o e v l a v 4 0 0 7 9 8 0 1 2 7 0 B O 2 g n i r p s e v l a v 5 0 1 3 0 9 0 1 2 7 0 B O 2 r e n i a t e r g n i r p s e v l a v 6 0 0 1 1 9 0 1 2 7 0 B O 2 r e p e e k k c o l e v l a v 7 0 5 9 2 9 0 1 2 7 0 B O 2 m r a r e k c o r 8 0 8 4 3 9 0 1 2 7 0 B O 2 r e t s u j d a t a e s l l a b m r a k c o r 9 0 7 3 4 9 0 1 2 7 0 B O 2 t u n n o g a x e h 0 1 0 8 2 5 9 0 1 2 7 0 B O 2 d u t s ...

Page 80: ...B O 1 y l b m e s s a d o r g n i t c e n n o c 3 0 8 1 2 0 1 1 2 7 0 B O 1 y e k f f u r d o o w 4 0 0 9 3 0 1 1 2 7 0 B O 1 n i p n o t s i p 5 0 9 0 4 0 1 1 2 7 0 B O 2 r e n i a t e r n i p n o t s i p 6 5 2 0 5 5 0 1 1 2 7 0 B O 1 n o t s i p 7 0 5 1 1 6 0 1 1 2 7 0 B O 1 g n i r l i o 8 0 5 1 1 7 0 1 1 2 7 0 B O 1 g n i r p s n o i s s e r p m o c d n 2 9 0 5 1 1 8 0 1 1 2 7 0 B O 1 g n i r ...

Page 81: ...16 50 1 1 1 2 7 0 B O 1 l e e r r e t r a t s 4 0 21 20 0 2 5 1 1 1 1 2 7 0 B O 2 l w a p g n i v i r d 5 0 8 1 2 1 1 1 2 7 0 B O 1 p i l c g n i r p s 6 7 guide plate 1 1 1 2 7 0 B O 1 3 5 50 8 guide plate bolt 1 1 1 2 7 0 B O 1 4 3 50 1 1 1 2 7 0 B O 1 e p o r r e t r a t s 9 5 6 00 10 starter pull handle 1 1 1 2 7 0 B O 1 6 9 25 11 handle cap 1 1 1 2 7 0 B O 1 7 1 25 1 1 1 2 7 0 B O 1 l a e s r...

Page 82: ...over 1 OB072 5 009 40 50 10 rear lower cover 1 OB072 5 010 35 80 11 top cover 0 7 5 6 1 1 1 0 5 2 7 0 B O 1 12 decal sheet 0 0 8 4 2 1 0 5 2 7 0 B O 1 1 0 5 2 7 0 B O 1 l a e s r e v o c 3 1 3 4 80 14 rubber ring gasket oil drain 1 OB072 5 014 3 70 15 jam small rubber plug 1 OB072 5 015 6 00 16 jam mid rubber plug 1 OB072 5 016 6 20 17 jam big rubber plug phillips 1 OB072 5 017 7 10 18 pan head ta...

Page 83: ... 2 7 0 B O 1 l a u n a m s r o t a r e p o 1 9 9 3 1 0 1 K P L 2 0 0 8 2 7 0 B O 1 d r a y n a l h c t i w s p o t s e n i g n e 2 5 2 0 2 0 5 T P L 3 0 0 8 2 7 0 B O 1 h c u o p t i k l o o t 3 0 0 5 4 0 0 8 2 1 1 B O 1 e l d n a h d n a e p o r r e t r a t s y c n e g r e m e 4 5 4 ft propane connector hose 1 OB072 8 006 LPH4 29 99 ...

Page 84: ... BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM WARNING Important Manual Information 1 General Information 2 Installation 7 Operation 8 Maintenance 13 Troubleshooting 21 Specifications 24 Warranty 25 TABLE OF CONTENTS FOR SERVICE Call 1 866 941 LEHR 5347 2 5 HP MODEL LP 2 5S READ AND FOLLOW ALL SAFETY RULES AND OPERATING INSTRUCTIONS CAUTION BEFORE OPERATING THIS PRODUCT ...

Page 85: ...r from any unit that has a suspected leak WARNING PROPANE IS HIGHLY FLAMMABLE AND ITS VAPORS CAN EXPLODE IF IGNITED SAFETY WARNINGS FOR PROPANE UNITS CARBON MONOXIDE HAZARD Burning propane makes Carbon Monoxide CO CO is invisible has no smell and can kill you Operating your outboard engine in an enclosed area can be dangerous 1 Use only in well ventilated areas If you experience headache drowsines...

Page 86: ... your LEHR dealer or call 1 866 941 LEHR 5347 WARNING Warning symbol indicates ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor NOTE A NOTE provides information to make procedures easier or clearer To ensure long product life LEHR recommends that...

Page 87: ... which contain carbon monoxide a colorless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets Check throttle shift and steering for proper operation before starting the engine Attach the engine stop switch lanyard cord to a secure place on your clothing or your ...

Page 88: ... 8 7 1 TOP COVER 2 TOP COVER LOCK LEVER 3 CARRYING HANDLE 4 STEERING FRICTION SCREW 5 ANTI CAVITATION PLATE 6 PROPELLER 7 COOLING WATER INLET 8 TRIM ROD 9 CLAMP BRACKET 10 THROTTLE FRICTION ADJUSTER 11 THROTTLE LEVER TILLER HANDLE 12 BOTTLE BRACKET CLAMP 13 PULL START HANDLE 14 ENGINE SHUT OFF SWITCH 15 REMOTE PROPANE CONNECTOR 16 CLAMP SCREWS 17 ROPE ATTACHMENT 18 GEAR SHIFT LEVER 19 RUBBER TANK ...

Page 89: ...ositions to provide operation Forward F and Neutral N Reduce throttle speed to idle speed Always shift outboard into gear with a quick motion THROTTLE GRIP The throttle grip is on the tiller handle Turn the grip counterclockwise to increase speed and clockwise to decrease speed THROTTLE FRICTION ADJUSTER A friction device provides adjustable resistance to movement of the throttle grip or the remot...

Page 90: ...ing Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward NOTE The engine cannot be started with the stop switch lock removed ENGINE STOP BUTTON To stop the engine push and hold the engine stop button or pul...

Page 91: ... the engine is all the way up lift up on the lock lever to disengage it while lowering the engine WARNING Do not use the tilt support bar when trailering the boat The outboard motor could shake loose from the tilt support and fall If the motor cannot be trailered in the normal running position use an additional support device to secure it in the tilt position TOP COVER LOCK LEVER CARRYING HANDLE A...

Page 92: ...ncy the water resistance drag of the boat and outboard motor must be made as little as possible The mounting height of the outboard motor greatly affects the water resistance If the mounting height is too high cavitation tends to occur thus reducing the propulsion and if the propeller tips cut the air the engine speed will rise abnormally and cause the engine to over heat If the mounting height is...

Page 93: ... glass lens but not so high as to touch the inside of the glass Recommended engine oil 4 stroke motor oil with a combination of the following SAE and API oil classifications Engine oil type SAE 10W 30 Engine oil grade API SE S F SG SH SJ SL Engine oil quantity 0 37USqt 0 35L WARNING ALL ENGINES ARE SHIPPED FROM THE FACTORY WITHOUT ENGINE OIL ADD OIL BEFORE STARTING ENGINE FUEL Check to be sure you...

Page 94: ...nister clamp pull the canister out and remove the propane connector by turning it counterclockwise 3 Remove the empty canister 4 Dispose of empty propane canisters in accordance to Federal State and Local regulations CONNECTING REMOTE PROPANE TANK 1 Make sure the engine is off and the propane tank is closed 2 Connect the remote hose to the remote propane tank Use only a high pressure propane hose ...

Page 95: ...a small amount between 1 8 1 4 throttle and try again Also if the engine is warm and fails to start open the throttle a small amount and try to start the engine again If the weather is below 45 degrees F open the throttle to 1 4 1 2 to start cold WARMING UP ENGINE 1 Warm up the engine by operating at 1 2 throttle or less for the first 4 minutes Failure to do so will cause the engine to stall in co...

Page 96: ...he boat with the trim set to different angles to find the position that works best for your boat and operating conditions NOTE The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim bolt one hole When the boat is on plane a bow up attitude results in less drag greater stability and efficiency This is generally when the keel line of the boat is up about 3 to 5 deg...

Page 97: ...iction adjuster by turning it clockwise to prevent the motor from turning freely 3 Hold the carrying handle and tilt the engine up fully until the tilt support lever automatically locks PROCEDURE FOR TILTING DOWN 1 Slightly tilt the outboard motor up 2 Slowly tilt the outboard motor down while pulling the tilt support lever up 3 Loosen the steering friction adjuster by turning it counterclockwise ...

Page 98: ...ccidentally falls Do not use the tilt support lever when trailering the boat The outboard motor could shake loose from the tilt support and fall If the motor can not be trailered in the normal running position use an additional support device to secure it in the tilt position The outboard motor should be trailered and stored in the normal running position If there is insufficient road clearance in...

Page 99: ...er each use before being stored Do not run the engine without supplying it with cooling water Either the engine water pump will be damaged or the engine will be damaged from overheating Before starting the engine be sure to supply water to the cooling water passages 1 Wash the outboard motor body using fresh water 2 Remove the engine top cover 3 Install the outboard motor on a test tank or submerg...

Page 100: ...r CHECKING PAINTED SURFACE OF MOTOR 1 Check the motor for scratches nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas NOTE Be sure to turn off the engine when you perform maintenance unless otherwise specified If you or the owner are not familiar with machine servicing this work should be done by your LEHR dealer or other qualified me...

Page 101: ...bon and other deposits are excessive you should replace the spark plug with another of the correct type Before fitting the spark plug measure the electrode gap with a wire thickness gauge Adjust the gap to specification if necessary When fitting the plug always clean the gasket surface and use a new gasket Wipe off any dirt from the threads and screw in the spark plug to the correct torque NOTE If...

Page 102: ...e idle speed screw at the proper angle Remove the rubber plug to use this hole CHANGING ENGINE OIL WARNING Avoid draining the engine oil immediately after stopping the engine The oil is hot and should be handled with care to avoid burns Be sure the outboard motor is securely fastened to the transom or a stable stand Do not overfill the oil and be sure the outboard motor is upright not tilted when ...

Page 103: ...over cylinder head and cylinder WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head cylinder thermostat housing and thermostat hose CHECKING PROPELLER WARNING You could be seriously injured if the engine accidentally starts when you are near the propeller Before inspecting removing or installing the propeller remove the spark plug ca...

Page 104: ...the propeller from turning PROPELLER SELECTION Your LEHR outboard engine is supplied with a propeller that matches the needs of a boat most suited to an engine of its size If you feel you are not getting optimal performance from the engine on your boat a different pitch propeller could help The performance of your outboard motor will be affected if you choose a different propeller as an incorrect ...

Page 105: ...he used oil after it has been drained If the oil is milky water is getting into the gear case which can cause gear and bearing damage Consult your LEHR dealer for repair of the lower unit seals 5 With the outboard motor in a vertical position and using a flexible or pressurized filling device inject the gear oil into the gear oil drain screw hole 6 When the oil begins to flow out of the oil level ...

Page 106: ...ssible faulty internal engine parts A Have serviced by a LEHR dealer ENGINE IDLES IRREGULARLY OR STALLS Q Is propane tank empty A Check tank fluid level by shaking it Q Is spark plug fouled or incorrect type or gap A Inspect spark plug Clean or replace with recommended type Q Is the Idle speed set correctly A Adjust Idle screw or have serviced by LEHR dealer Q Are fuel joints connected correctly A...

Page 107: ...damage is found or not return to the nearest harbor slowly and carefully 4 Have the outboard motor inspected before operating it again STARTER WILL NOT OPERATE If the start mechanism does not operate the engine cannot be cranked with the starter the engine can be started with an emergency starter rope WARNING Use this procedure only in an emergency and only to return to the port for repairs Make s...

Page 108: ... if necessary PROCEDURE FOR SUBMERGED MOTOR If the outboard motor has been submerged immediately take it to a LEHR dealer Some corrosion may begin almost immediately If you cannot immediately take the outboard to a dealer follow the procedures below in order to minimize engine damage 1 Wash away mud salt seaweed and debris with fresh water 2 Remove the spark plug then face the spark plug hole down...

Page 109: ... 08 GEAR SHIFT F N TRANSOM HEIGHT 15 381 mm MAX OPERATING R P M 3000 3500 R P M IDLE SPEED 2000 R P M IGNITION TYPE ELECTRONIC IGNITION SWITCH TETHER VALVE CLEARANCE IN and EX COLD SPARK PLUG GAP 0 020 0 024 INCH 0 5 0 6 mm LUBRICATION CRANKCASE OIL CAPACITY 0 37 US qt 0 35L FUEL STARTER PULL CHORD AUTO REWIND 003 005 in 0 08 0 12mm PROPANE 4 STROKE 10W 30 SPARK PLUG TORQUE SPEC 18 4 ft lb 25 0 N ...

Page 110: ... any time without notice or obligation to any purchaser HOW TO OBTAIN SERVICE Warranty service is available with proof of purchase through your local authorized service dealer To locate the dealer in your area visit our website at www golehr com or call 1 866 941 LEHR or write to 8922 Ellis Ave LA CA 90034 CALIFORNIA EMISSIONS EPA CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The...

Page 111: ...ed part that is scheduled only for regular inspection in the written instructions required by Subsection d must be warranted for the warranty period defined in Subsection b 2 A statement in such written instructions to the effect of repair or replace as necessary will not reduce the period of warranty coverage Any such part repaired or replaced under warranty must be warranted for the remaining wa...

Page 112: ...LEHR LP2 5 HP Rev A 2013 111 8 NOTES ...

Page 113: ...tandards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low Emission The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards Engines meeting these standards have 65 lower emissions than One Star ...

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