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TABLE OF CONTENTS

Table of Contents

5 HP Outboard • Troubleshooting & Repair Manual

INTRODUCTION

TROUBLESHOOTING

DISASSEMBLY

In the Interest of Safety

Safety Alert Symbols

Fuel Recommendations

Gasoline

Oil Recommendations

Lubrication System

Engine Oil

Oil Drain Plug, Oil Fill and Dipstick

Gear Selector

Operation

Reverse

Neutral

Forward

Changing Gear Case Oil

Check Lower Unit

No Start - Hard Start

Vibration

Power Loss

Noise

Cooling

Check Ignition

Armature Test

Tests for No Spark

Neutral Switch Test

Check Compression

Cylinder Leak Down Test

Check Carburetion

Steering Tension

Propeller Service

Cooling Shroud

Removal

Power Head

Blower Housing

Magnetron™ Ignition

Flywheel

Inspect Flywheel Key, Keyway,
Flywheel and Crankshaft

Carburetor

Disassemble Carburetor

Carburetor Cleaning

Cylinder Head

Prepare Cylinder Head for Removal

Remove Valve Cover

Disassemble Cylinder Head

Crankshaft & Camshaft

Oil Slinger Lubrication

Piston and Connecting Rod

Gear Case Disassembly

Sliding Clutch

Midsection

Disassembly

Throttle Cable

Replacement

Rewind Starter

Remove Rope

Inspect Rope

Remove Pulley and Spring

Inspect Spring, Starter Housing and Pulley 35

Содержание 5 HP

Страница 1: ...air Manual Electronic Version 275110 3 03 Please click the Bookmarks tab at left to enable the search and navigational features of this document For Briggs Stratton Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Страница 2: ...y possible hazards and or results of each procedure or method We have not undertaken any such wide evaluation Therefore anyone who uses a procedure or method not described by the manufacturer must first satisfy himself that neither his safety nor the safety of the product will be endangered by the service or operating procedure selected All information illustrations and specifications contained in...

Страница 3: ...Switch Test 16 Check Compression 17 Cylinder Leak Down Test 17 Check Carburetion 18 Steering Tension 18 Propeller Service 19 Cooling Shroud 23 Removal 23 Power Head 23 Blower Housing 24 Magnetron Ignition 24 Flywheel 25 Inspect Flywheel Key Keyway Flywheel and Crankshaft 26 Carburetor 26 Disassemble Carburetor 27 Carburetor Cleaning 27 Cylinder Head 28 Prepare Cylinder Head for Removal 28 Remove V...

Страница 4: ...t Installation 50 Install Connecting Rod Piston 50 Install Camshaft 51 Install Sump 51 Crankshaft End Play 51 Install Flywheel 52 Install Armature 52 Armature Air Gap 52 Cylinder Head Assembly 53 Install Cylinder Head Plate and Rocker Arm Studs 53 Install Valves 53 Install Valve Springs and Retainers 53 Install Cylinder Head 54 Install Rocker Arms 54 Adjust Valve Clearance 55 Install Valve Cover 5...

Страница 5: ...ntroduction In the Interest of Safety 5 Safety Alert Symbols 5 Fuel Recommendations 6 Gasoline 6 Oil Recommendations 6 Lubrication System 6 Engine Oil 6 Oil Drain Plug Oil Fill and Dipstick 6 Gear Selector 7 Operation 7 Reverse 8 Neutral 8 Forward 8 Changing Gear Case Oil 9 ...

Страница 6: ...yte fluid contains acid and is extremely caustic Contact with battery fluid will cause severe chemical burns WARNING Be sur e the shift selector is in NEUTRAL position before attempting to start the outboard When starting engine pull cord slowly until resistance is felt then pull rapidly Allow the cord to retract slowly Rapid retraction of starter cord kickback will pull hand and arm toward engine...

Страница 7: ...fler Inspect periodically and replace if worn or leaking If engine is equipped with muffler deflector inspect periodically and replace if necessary Replacement parts must be same as on original equipment DO NOT run the outboard unless the propeller is either removed from the outboard or in water Remove the spark plug lead and select NEUTRAL when servicing the outboard Remove the propeller whenever...

Страница 8: ...ssists in cooling Old oil gradually becomes thick and loses its cooling ability and lubricating qualities Engine Oil Use a high quality detergent oil classified For Service SF SG SH SJ or higher Briggs Stratton strongly recommends the use of synthetic oil such as Briggs Stratton 100030C or equivalent If not available SAE 30 weight oil is an acceptable substitute No special additives should be used...

Страница 9: ... assembly The shift lever is connected to the shift cam rod by an upper rod The rods are connected with a clamp that also provides for NEUTRAL adjustment The forward gear Figure 5 and reverse gear are driven simultaneously by the pinion gear and spin freely on the propeller shaft The spring inside the propeller shaft applies forward pressure on the roll pin sliding clutch and shift cam follower Th...

Страница 10: ...follower is on the middle detent of the shifter cam The sliding clutch is not engaged to either the FORWARD or the REVERSE gears Forward When the shifter is set to the FORWARD position the shift cam Figure 8 is pulled to its highest position in the gear case The spring inside the propeller shaft pushes the sliding clutch and cam follower forward engaging the sliding clutch to the FORWARD gear 8 6 ...

Страница 11: ...nsert the tip of the oil bottle into the oil fill lower hole Squeeze the bottle until the oil is just to the point of overflowing at the vent upper hole 4 Install vent plug in top hole Torque to 20 in lbs 2 Nm 5 Install oil drain fill plug in lower hole Torque to 45 in lbs 5 Nm 1 2 Section 1 Introduction 5 HP Outboard Troubleshooting Repair Manual Figure 9 Gear Case Oil 2 1 ...

Страница 12: ...10 Section 1 Introduction 5 HP Outboard Troubleshooting Repair Manual 1 ...

Страница 13: ...Check Lower Unit 13 No Start Hard Start 13 Vibration 13 Power Loss 13 Noise 13 Cooling 13 Check Ignition 14 Armature Test 15 Tests for No Spark 15 Neutral Switch Test 16 Check Compression 17 Cylinder Leak Down Test 17 Check Carburetion 18 Steering Tension 18 Propeller Service 19 Troubleshooting ...

Страница 14: ...12 Section 2 Troubleshooting 5 HP Outboard Troubleshooting Repair Manual 2 ...

Страница 15: ...for lower unit damage Power Loss 1 Bind or drag in unit place engine in NEUTRAL Operate lower unit manually to check for binding 2 No lubrication in lower unit Noise 1 No lubricant in lower unit 2 Worn bearings or gears Cooling Chaff or dirt can clog the cooling system especially after prolonged service in very dusty conditions Continued operation with a clogged cooling system can cause severe ove...

Страница 16: ...is performing satisfactorily If spark does not occur look for Incorrect ignition armature air gap Shorted stop switch wire Shorted safety engine stop switch Ignition armature failure Defective Speed Limiter NOTE If engine runs but misses during operation a quick check to determine if ignition is faulty can be made by inserting the spark plug tester between the ignition cable and the spark plug A s...

Страница 17: ...e is good and there is still no spark 1 Remove the cowl from the power head 2 Disconnect the armature ground lead 3 Remove safety engine stop switch clip Figure 13 4 Disconnect the wiring harness connector Figure 14 from the engine speed limiter 5 Insert the test probe to the wire harness side of the armature ground wire connector 6 Test the switch for continuity at the engine ground There should ...

Страница 18: ... harness connector Figure 16 from the engine speed limiter 2 Place the shift lever to NEUTRAL Test for continuity between the wiring harness connector and the engine ground 3 Repeat the test with the shift lever in the FORWARD and REVERSE positions There should be continuity with the shift lever NEUTRAL and no continuity in the FORWARD and REVERSE positions 4 Remove the power head See Section 3 5 ...

Страница 19: ...shaft in direction of operation until piston is at top dead center TDC of compression stroke 4 Hold flywheel nut with 15 16 socket and 1 2 breaker bar Figure 18 5 Connect tester 19545 to a shop air source with minimum air pressure of 70 psi 480 KPA 6 Install outlet hose into spark plug hole of cylinder being tested Insure o ring is seated to prevent air leak at spark plug hole Connect other end to...

Страница 20: ...hoking Excessively rich fuel mixture Water in fuel Inlet needle stuck open Fouled spark plug If plug is dry look for Leaking carburetor mounting gaskets Dirt or gum deposits in carburetor fuel filter fuel lines transport valve or fuel tank Inlet needle stuck shut Inoperative fuel pump A simple check to determine if the fuel is getting to the combustion chamber through the carburetor is to remove t...

Страница 21: ...rtion show wear or damage replace the shaft 5 Inspect the propeller Figure 21 for broken or damaged blades and for wear or damage to the hub Replace or repair the propeller as required 6 Install the coupling to the propeller 7 Apply anti seize to the propeller shaft Install the propeller stainless steel washer and stainless steel lock nut to the propeller shaft Torque to 90 in lbs 10 Nm 2 3 4 1 2 ...

Страница 22: ...20 Section 2 Troubleshooting 5 HP Outboard Troubleshooting Repair Manual 2 ...

Страница 23: ...6 Disassemble Carburetor 27 Carburetor Cleaning 27 Cylinder Head 28 Prepare Cylinder Head for Removal 28 Remove Valve Cover 28 Disassemble Cylinder Head 28 Crankshaft Camshaft 29 Oil Slinger Lubrication 29 Piston and Connecting Rod 30 Gear Case Disassembly 30 Sliding Clutch 32 Midsection 33 Disassembly 33 Throttle Cable 34 Replacement 34 Rewind Starter 34 Remove Rope 34 Inspect Rope 34 Remove Pull...

Страница 24: ...22 Section 3 Disassembly 5 HP Outboard Troubleshooting Repair Manual 3 ...

Страница 25: ...andle insert from handle and pull the knot from the handle insert Untie knot remove insert and handle from rope 6 Remove the starter rope from the shroud Remove the shroud from the engine Power Head 1 Cut wire ties holding the throttle cable to the starboard right side of the rear handle 2 Remove nuts Figure 26 washers and bolts NOTE The bolt on the starboard side of the engine is longer than the ...

Страница 26: ...A and B two from front and two from rear of blower housing as shown Magnetron Ignition NOTE The flywheel does not need to be removed to service Magnetron ignition except to check the keyway flywheel key and oil seal Replace any damaged parts 1 Remove blower housing 2 Remove the spark plug wire from the spark plug 3 Remove armature mounting screws Figure 30 disconnect stop wire Lift off armature 2 ...

Страница 27: ...t until top of nut is flush with end of crankshaft threads 5 Install the flywheel puller to the flywheel 6 Turn puller screws into flywheel puller holes until screws bottom or puller contacts flywheel nut Figure 34 7 Tighten puller nuts or screws equally until flywheel loosens NOTE If the screws on Flywheel Puller Tool are too short use two cylinder head bolts 94622 or two cylinder head studs 9477...

Страница 28: ...in the fuel hose to stop fuel leakage Screw threads will loosen rubber particles which will get into the fuel system 2 Disconnect choke Figure 36 and throttle linkages 3 Remove fuel pump retaining strap 3 Remove speed limiter retaining strap 4 Remove screws Figure 37 Set aside air horn and gasket Disconnect breather tube 5 Disconnect fuel line at carburetor 6 Remove screws Figure 38 carburetor and...

Страница 29: ...Carburetor Cleaning 1 Disassemble carburetor 2 Remove all old gaskets seals and sealing material 3 Use commercial carburetor cleaning solvents such as Briggs Stratton Spray Cleaner 100041 or 100042 to clean carburetor parts and body 4 Do not leave non metallic parts plastic nylon minlon etc in commercial carburetor cleaner bath more than 15 minutes NOTE Parts containing rubber such as seals o ring...

Страница 30: ...usting nuts and rocker arms 2 Pull the push rods from the push rod guides Label the push rods for correct assembly 3 Remove cylinder head plate with rocker arm studs 4 Remove valve caps 5 Place cylinder head on work surface 6 Press down on spring retainer Figure 44 with thumbs to compress valve spring Compress spring until large end of slot in retainer can be lined up with end of valve stem 6 4 3 ...

Страница 31: ...e dowel pins 3 Tip engine over onto flywheel side of crankcase 4 Support engine to prevent end of crankshaft from resting on workbench 5 Rotate crankshaft until timing mark on crankshaft Figure 46 aligns with timing mark on camshaft 6 With camshaft in this position the valve tappets will remain clear of cam lobes Lift out camshaft 7 Remove tappets Oil Slinger Lubrication The oil slinger Figure 47 ...

Страница 32: ...Socket 19557 to loosen the propeller shaft carrier Figure 50 NOTE Always loosen the shaft carrier with the gear case attached to the midsection The shaft carrier is LEFT HANDTHREAD 4 Remove the drive shaft housing plug Loosen do not remove the shift rod clamp set screw Figure 51 5 Remove the nut Figure 52 and screw Remove the gear case from the midsection 6 7 6 4 1 2 3 1 Section 3 Disassembly 5 HP...

Страница 33: ...for the shift shaft If any gear is worn or damaged replace all gears as a set Inspect the bearing on the forward gear If the bearing shows wear or damage inspect the bearing race inside the gear case If the bearing race is worn or damaged replace the gear case If the bearing is damaged replace the gear set Replace the drive shaft if it is bent damaged or worn 14 12 13 11 10 9 8 4 Section 3 Disasse...

Страница 34: ...y installed to the tool remove and discard the roll pin Figure 56 from the sliding clutch Disassemble the tool and the propeller shaft sliding clutch assembly Replace the shaft if it is bent or if the clutch splines are worn Replace the roll pin Inspect the sliding clutch and spring Replace worn or damaged components 4 Install the shaft spring and sliding clutch to the tool Assemble the shaft in r...

Страница 35: ...lose the brake shoe The reverse hook may come off with either tilt bracket 4 Inspect the steering brake shoe and the reverse hook actuator Figure 58 Replace if worn or damaged 5 Remove and inspect the sleeves and rubber bushings Figure 59 Replace if worn or damaged NOTE Be aware of the stack up of bushing and sleeves 2 1 4 5 3 2 1 Section 3 Disassembly 5 HP Outboard Troubleshooting Repair Manual 3...

Страница 36: ... far as it will go 2 While holding pulley and starter housing pull pulley end of rope out and untie knot at end of rope 3 Remove rope and handle from starter 4 Slowly release pulley to release spring tension Inspect Rope 1 Inspect rope Replace if frayed or broken strands are found 2 If re using old rope burn each end of rope with an open flame and wipe rope ends with waste cloth while still hot to...

Страница 37: ...s kinks and burrs Replace assembly if any of the above conditions exist 4 Inspect starter housing for wear or sharp edges at rope eyelet Figure 64 center pivot post and inner spring anchor tab 5 Replace assembly if worn or damaged 4 6 5 3 2 1 3 Section 3 Disassembly 5 HP Outboard Troubleshooting Repair Manual 3 Figure 61 Rewind Starter Pulley Figure 62 Pulley With Spring Figure 64 Starter Housing ...

Страница 38: ...36 Section 3 Disassembly 5 HP Outboard Troubleshooting Repair Manual 3 ...

Страница 39: ...9 Check Piston Ring Groove Wear 40 Check Piston Ring End Gap 40 Check Connecting Rod 40 Undersized Connecting Rods 40 Check Piston Pin and Piston Pin Bore 41 Inspect Crankshaft 41 Inspect Camshaft 42 Check Cylinder 42 Cylinder Resizing 42 Set Up For Honing 42 Hone Cylinder 43 Cylinder Finish Cross Hatch 43 Cylinder Cleaning 44 Check Camshaft Bearings 44 Check Crankshaft Bearings 44 Remove DU Magne...

Страница 40: ...38 Section 4 Overhaul 5 HP Outboard Troubleshooting Repair Manual 4 ...

Страница 41: ...commercially available valve grinding tool Briggs Stratton does not recommend this practice as a high quality repair procedure Valve replacement is recommended for damaged or worn valves Valve seats Figure 65B are cut to 45 using Tool 19237 or 19343 Neway Valve Seat Cutter Kit Valve and seat are lapped in using Valve Lapping Tool 19258 and Valve Lapping Compound 94150 to assure a good seal between...

Страница 42: ...ace the piston ring if the ring end gap is greater than Top Compression Ring 020 in 51mm Center Compression Ring 030 in 76mm Oil Control Ring 035 in 89mm Check Connecting Rod If the crankpin bearing is scored the rod must be replaced Reject size of the crankpin bearing Figure 69 is 1 102 in 27 99mm or greater Reject size of the piston pin bearing is 627 in 15 93mm or greater Undersized Connecting ...

Страница 43: ...t Discard crankshaft if worn smaller than the following minimum diameter specifications Mag journal Figure 72 873 in 22 17mm PTO journal 1 060 in 26 92mm 2 Resize the crankpin journal if worn smaller than the following minimum diameter Crankpin journal 1 097 in 27 86mm 3 Inspect keyway Replace the crankshaft if the keyways show wear or spreading Remove burrs from keyway edges to prevent bearing da...

Страница 44: ...thin specification and shows no sign of scoring or other damage When installing new piston rings the cylinder bore should be reconditioned using a rigid hone with finishing stones to restore the proper cross hatch angle in the cylinder bore Cylinder Resizing Always resize bore to exactly 010 020 or 030 25mm 50mm or 76mm over standard size If this is done accurately the stock oversize rings and pis...

Страница 45: ...l hone travels full length of bore and extends past the cylinder bore ends Do not extend hone more than 3 4 1 19mm 25mm at either end of cylinder bore 6 As cutting tension decreases stop hone and tighten adjusting knob 7 Check cylinder bore frequently with an accurate micrometer Cylinder Finish Cross Hatch The finishing stones are used after the cylinder bore has been resized to within 0015 04mm o...

Страница 46: ...rings Replace cylinder or sump if cam gear bearings are worn more than specification Replace cylinder or sump if Plug Gauge 19164 can be inserted in bearing 1 4 6 35mm or more Figure 77 If gauge is not available replace cylinder or sump if bearings are worn over 503 12 78mm Check Crankshaft Bearings Check the crankshaft bearings in the cylinder and sump whenever the engine is apart Gauge or measur...

Страница 47: ...thrust face side of cylinder 3 Stake bearing to cylinder as shown Figure 81 Oil Seals Install new oil seals whenever engine is disassembled When installing crankcase cover or sump always use the correct seal protector to prevent damaging oil seal 3 2 Section 4 Overhaul 5 HP Outboard Troubleshooting Repair Manual 4 Figure 79 Remove DU Magneto Bearing Figure 80 Install DU Magneto Bearing Figure 81 S...

Страница 48: ...46 Section 4 Overhaul 5 HP Outboard Troubleshooting Repair Manual 4 ...

Страница 49: ...Rocker Arm Studs 53 Install Valves 53 Install Valve Springs and Retainers 53 Install Cylinder Head 54 Install Rocker Arms 54 Adjust Valve Clearance 55 Install Valve Cover 55 Carburetor Assembly 55 Install Welch Plug 55 Install Choke Shaft 56 Install Throttle Shaft 56 Install Inlet Needle and Float 56 Install Carburetor 57 Install Pulley and Spring 57 Install Pawls Pawl Springs Retainer Assembly 58...

Страница 50: ...48 Section 5 Assembly 5 HP Outboard Troubleshooting Repair Manual 5 ...

Страница 51: ...ollowed by the center ring and top ring 2 Install the center and top rings with the ID mark facing the top of the piston Compress Piston Rings 1 Oil the piston rings and piston skirt 2 Compress the piston rings with Ring Compressor 19230 Figure 84 3 Place piston and compressor upside down on bench and push piston down until head of piston is even with edge of compressor 4 Tighten compressor until ...

Страница 52: ...n journal or connecting rod journal 4 Pull connecting rod against crankpin 5 Install connecting rod cap with notch in rod cap aligned with tab in connecting rod NOTE The notch in the connecting rod cap Figure 87 must engage the tab on the connecting rod 6 Install connecting rod cap screws NOTE Torque the screw closest to the piston Figure 88 first Torque the screw farthest from piston second The c...

Страница 53: ...not force sump 2 Install screws torque in sequence as shown Figure 90 Torque to 110 in lbs 12 Nm Crankshaft End Play When sump is installed with a standard gasket end play should be 002 028 in 05 71mm Always measure end play with a standard gasket in place If end play is more than specification replace crankcase cover or sump or use 220624 shim Figure 91 on magneto end of crankshaft If end play is...

Страница 54: ...inger tight Armature Air Gap 1 Pull left side of armature away from flywheel and tighten left screw 2 Rotate flywheel until magnet is under armature laminations 3 Place thickness gauge blade Figure 94 between magnet and armature NOTE Use a 010 014 25 36mm gauge 4 Loosen left armature screw and let magnet pull armature down onto flywheel magnet Torque screws to 25 in lb 3 Nm 3 2 1 Section 5 Assembl...

Страница 55: ...with Valve Guide Lubricant 93963 and install in valve guides 3 Oil the inside diameter of the valve stem seal with engine oil and install on the valve stem 4 Slide seal down against head plate NOTE Be sure Valve Guide Lubricant is not on valve face valve seat or exposed end of valve stem Install Valve Springs and Retainers 1 Place a shop rag or wood blocks on work surface to support valves Place c...

Страница 56: ...ed to the second step Uneven tightening may cause a warped cylinder head First step 70 in lbs 8 Nm Second step 140 in lbs 16 Nm Final step 210 in lbs 24 Nm Install Rocker Arms 1 Install push rods Figure 99 through push rod guide making sure push rods are in valve tappets 2 Remove all lubricant from end of valve stems 3 Place valve caps Figure 100 on end of valve stems Do not use lubricant on the v...

Страница 57: ...and exhaust valves 5 To adjust loosen set screw Figure 102 Turn rocker nut until valve clearance is correct 6 When valves are adjusted hold rocker nut Tighten set screw to 35 in lbs 4 Nm 7 Recheck clearance and adjust if required Install Valve Cover 1 Install valve cover with new gasket Install four screws Torque screws to 85 in lbs 10 Nm 2 Install muffler exhaust manifold air guides shields and o...

Страница 58: ...is facing out 3 Lay throttle plate on shaft with numbers facing out and install screw Install Inlet Needle and Float 1 Install inlet needle Figure 106 to float and install assembly to carburetor body 2 Insert float hinge pin and center pin between float pin bosses Float height is non adjustable 3 Install rubber gasket on carburetor and lay float bowl on body 4 Place fiber washer over main jet and ...

Страница 59: ...sealant to prevent screws from vibrating loose 5 Install a new air horn gasket and the air horn to the carburetor 6 Install fuel pump and connect fuel lines 7 Install speed limiter Install Pulley and Spring 1 Lay starter housing on workbench 2 Assemble starter pulley Figure 108 to center pivot post in housing 3 Rotate pulley counterclockwise until slight resistance is felt indicating that spring i...

Страница 60: ...stall Rope 1 Tie knot on one end of the rope NOTE Knot must be the original Figure 8 style Figure 112 so it will not pull through pulley or rope handle hole 2 Turn pulley counterclockwise until spring is wound tight 3 Rotate pulley clockwise until rope hole Figure 113 in pulley is in line with starter housing eyelet and hold pulley 4 Insert unknotted end of rope through rope hole in pulley then th...

Страница 61: ...Torque screws to 85 in lbs 10 Nm Gear Case Assembly 1 Install the shift cam rod Figure 116 to the gear case 2 Install the shift shaft support with seal and the O rings to the input shaft carrier 3 Install the input shaft carrier to the gear case Torque stainless steel screws and stud to 55 in lbs 6 Nm 1 8 7 4 2 3 6 5 4 Section 5 Assembly 5 HP Outboard Troubleshooting Repair Manual Figure 114 Secur...

Страница 62: ...arrier until the flange contacts the face of the gear case Do not torque the carrier at this time The carrier is Left Hand Thread NOTE It may be necessary to turn the drive shaft and or the propeller shaft to mesh gears 10 Install the drive shaft through the top plate into the pinion gear 11 Depress the shift cam rod Figure 119 approximately 5 16 8 mm to select NEUTRAL NOTE Turn the drive shaft an...

Страница 63: ...to 60 in lbs 7 Nm Torque the nut to 80 in lbs 9 Nm 16 Verify that the gear lever and gear case are both in NEUTRAL and that the shift rod and shift cam rod are both engaged to the clamp Tighten the clamp through the hole in the gear case Figure 123 Torque the clamp screw to 35 in lbs 4 Nm Again verify NEUTRAL 17 Use Briggs Stratton Socket 19557 to torque the carrier to the gear case Torque the car...

Страница 64: ...se hook to port side tilt bracket with pin 4 Place the tilt bracket with the reverse hook onto the midsection Align the bushings already in position on the mid section Figure 125 with the grooves in the tilt brackets Figure 126 5 Place the remaining tilt bracket onto the midsection 6 Secure the tilt brackets with four Figure 127 screws Torque screws to 55 in lbs 6 Nm 7 Install the transom brackets...

Страница 65: ...ead 1 Grease the shift lever pockets under the neutral switch Figure 129 and the shift lever retaining plate Grease the hex end of drive shaft and spring as shown 2 Torque screws to 35 in lbs 4 Nm 3 Connect the neutral switch wire to the wiring harness Lower the power head onto the midsection Align the hex socket in the crankshaft adapter to the hex end of the drive shaft Be certain that the wire ...

Страница 66: ...o the rear handle 6 Connect the choke control rod to the choke lever Cooling Shroud Installation 1 Insert the starter rope through the opening in the shroud 2 Pull the rope through the openings in the handle and handle insert 3 Knot the end of the rope with a figure 8 knot Figure 131 as shown 4 Pull the handle out and hold 5 Remove temporary knot 6 Install the shroud safety engine stop switch dips...

Страница 67: ...r 3 Move throttle control to FAST position Engine should accelerate smoothly 4 Turn the idle mixture screw clockwise slowly until the engine just begins to slow and note or mark the position of the screw 5 Then turn the screw counterclockwise until the engine just begins to slow Again note or mark the position of the screw 6 Turn the idle mixture screw to the midpoint between the two positions 7 I...

Страница 68: ...66 Section 5 Assembly 5 HP Outboard Troubleshooting Repair Manual 5 ...

Страница 69: ...rd Troubleshooting Repair Manual 6 Appendix Appendix 67 Outboard Engine Fastener Specifications 68 Lower Unit Fastener Specifications 68 Ignition System Wiring Diagram 69 Component Location Gear Case 71 Component Location Midsection 73 ...

Страница 70: ... Valve Cover 3 8 85 in lbs 10 Nm Lower Unit Fastener Specifications Casing Clamp Cylinder 1 35 in lbs 4 Nm Choke Nut 1 30 in lbs 3 Nm Clamp Bracket Screw 2 35 in lbs 4 Nm Cowl Mounting Screw 10 32 4 25 in lbs 3 Nm Cowl Screw Standoff 4 35 in lbs 4 Nm Cowl Cover Screw 10 24 4 25 in lbs 3 Nm Engine Mounting Bolts 3 210 in lbs 24 Nm Front Handle Casing Clamp Screw 1 35 in lbs 4 Nm Front Handle Screw ...

Страница 71: ...eners Always use Anti Seize compound on any external screws and nuts that are stainless to stainless Ignition System Wiring Diagram Section 6 Appendix 5 HP Outboard Troubleshooting Repair Manual 6 Ignition System 1 Safety Engine Stop Switch 2 BLACK Wire to Safety Engine Stop Switch 3 Connector 4 BLACK Wire Armature Ground 5 Armature 6 Spark Plug 7 BLACK Wire to Speed Limiter 8 Not Used 9 Neutral S...

Страница 72: ...70 Section 6 Appendix 5 HP Outboard Troubleshooting Repair Manual 6 Component Location Gear Case 11 1 2 3 4 5 7 8 9 6 12 13 14 15 16 17 18 19 20 22 23 21 10 ...

Страница 73: ... 7 Sliding Clutch 8 Roll Pin 9 Vent Plug 10 Screw 2 SS 11 Seal 12 O Ring 13 Pinion Gear 14 Stud 15 Input Shaft Carrier 16 Quad Ring Seal 17 Seal 18 O Ring 19 Shift Cam Rod 20 Gear Case 21 Oil Drain Fill Plug 22 Forward Gear Bearing Assembly 23 Shift Cam Follower Section 6 Appendix 5 HP Outboard Troubleshooting Repair Manual 6 ...

Страница 74: ...72 Section 6 Appendix 5 HP Outboard Troubleshooting Repair Manual 6 Component Location Midsection 11 1 2 3 4 5 7 8 9 6 12 13 14 15 16 17 18 19 20 21 22 23 10 ...

Страница 75: ...d 6 Housing 7 Tilt Bracket LH Port 8 Brake Shoe 9 Washer 10 Washer 11 Lock Nut 12 Transom Bracket 13 Clamp Handle 14 Washer 15 Screw 16 Actuator 17 Reverse Hook 18 Pin 19 Bolt 20 Sleeve 21 Bushing 22 Tilt Bracket RH Starboard 23 Neutral Switch Section 6 Appendix 5 HP Outboard Troubleshooting Repair Manual 6 ...

Страница 76: ...74 Section 6 Appendix 5 HP Outboard Troubleshooting Repair Manual 6 ...

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