Evinrude 4906B 4HP 1969 Скачать руководство пользователя страница 238

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and then pull the ratchet

free

of the cable

end.

Take care not to loose the small brass

sleeve.

GOOD WORDS

the

ratchet

removed

from

the

cable end, take notice of exactly

where the

Allen screws made contact

with the cable as

aid

during

installation.

Remove

the

small sleeve from the ratchet.

Shift Half Disassembling

Lift the lever handle asembly free of

the shift box.

Remove

the ratchet

from the end of

shift cable.

This is accomplished

by loosen-

ing

the

Allen

screws

the

sleeve

and

pulling the ratchet

free of the cable.

Take

care not to loose the small brass sleeve.

CLEANING AND INSPECTING

Check to be sure the teeth

on the rocker

of the shift and throttle

handle are not worn

or damaged.

Inspect

the ratchets

removed

from

the

end of

the

cables.

The

teeth

should not be damaged or worn excessively.

Wash the outside

and inside of the shift

box halves with solvent

and dry them thor-

oughly with a cloth or compressed

air.

Throttle Cable Lubrication

6- If the throttle

or shift cables are not

to be replaced,

now is an excellent

time

lubricate

the inner wires.

To lubricate

the

inner

wire,

remove

the

casing

guide

from

TRUNNION

SHIFT

HANDLE

DOUBLE SHIFT LEVER

7-5

the cable at both ends.

Attach

an electric

drill to one end of the wire.

Momentarily

turn the dirll on and off to rotate

the wire

and at the same time allow lubricant

to flow

into the cable, as shown.

ASSEMBLING SHIFT BOX

CRITCAL WORDS

Loca tion

the

cable

end

the

upmost importance.

One Allen screw

must

be tightened

hard, until there

is a definite

crimp in the wire.

If the Allen screw is not

tightened

enough, the cable

will slip in the

sleeve and the adjustment

will be lost.

On some shift and throttle

cables not

manufactured

by Johnson/Evinrude,

the

in-

ner cable

is made of stainless

steel.

When

working

with

one of these

wires,

the

end

must

be heated

to remove

the temper

and

thus allow the Allen screw to make a crimp
in the wire.

If the end of a stainless

steel

wire has a blue color, the temper

has been

removed.

TAKE CARE

not to overheat

the

stainless

steel wire with a torch

because

has a very low melting point.

Throttle Half Assembling

Insert

the small sleeve

onto the end

of the

ratchet

with

the

two Allen

screws

started

in the sleeve.

Notice how the sleeve

has a hole completely

through

it.

The shift

CRIMPED

WIRE

Содержание 4906B 4HP 1969

Страница 1: ...SYNCHRONIZING 2 5 Honing Procedures 3 29 BATTERY SERVICE 2 5 Assembling 3 30 CARBURETOR ADJUSTMENTS 2 7 Piston and Rod Assembly FUEL PUMPS 2 9 Installation 3 30 STAR TER AND SOLENOID 2 10 Crankshaft I...

Страница 2: ...ICAL SYSTEM GENERAL TYPE III CARBURETORS 4 43 INFORMA TION 6 11 Removal 4 4 3 CHARGING CIRCUIT SERVICE 6 12 Cleaning and Inspecting 4 45 Troubleshooting 6 12 Assembling 4 47 Generator Service 6 16 Adj...

Страница 3: ...tions TROUBLESHOOTING MANUAL SHIFT PROPELLER REMOVAL 8 1 8 1 8 2 8 2 8 7 DRAINING LOWER UNIT LOWER UNIT SERVICE 1 5 hp to 4 0 hp NO SHIFT Lower Unit Removal Water Pump Removal Disassembling Cleaning a...

Страница 4: ...31 9 32 9 34 9 34 9 37 9 39 9 39 Removal 9 40 Disassembling 9 40 Cleaning and Inspecting 9 42 Assembling 9 43 Rope Installation 9 43 Starter Installation 9 46 10 MAINTENANCE INTRODUCTION ENGINE SERIAL...

Страница 5: ......

Страница 6: ...ver the boat is stored for long or short periods the bow should be slightly higher than the stern and the drain plug in the transom removed to ensure proper drainage of rain water will be required to...

Страница 7: ...DIAMETER Diameter and pitch are the two basic dimensions of a propeller The diameter is measured across the circumference of a circle scribed by the propeller blades as shown small a zinc plate will c...

Страница 8: ...peller allows the engine to run as near to the rated rpm and horsepower at full throt tle as possible for the boat design The blade area of the propeller deter mines its load carrying capacity A two b...

Страница 9: ...AVITATION BURN o Cavitation air bubbles formed at the propeller Manufacturers are constantly fighting this problem as explained in the text from your boat and engine Therefore take time to make the pr...

Страница 10: ...good working condition and through proper maintenance and lubr i cation Vibration can also be reduced in some cases by increasing the number of blades For this reason many racers use Rubber hub remove...

Страница 11: ...rmance when for ward and rotational speed is high and or the propeller breaks the surface of the water Progressive pitch starts low at the lead ing edge and progressively increases to the trailing edg...

Страница 12: ...protection against leakage Re inforced flexible sections should be installed in fuel lines where there is a lot of motion such as at the engine connection The flaring of copper tubing should be anneal...

Страница 13: ...arpet and then touch a metal object All of these actions cause an elec trical charge In most cases static electri city is generated during very dry weather conditions but when you are filling the fuel...

Страница 14: ...operly grounded to prevent static electricity Static electricity could be extremely dan gerous when taking on fuel LOADING 1 9 opening the fill pipe deck fitting One way to ground yourself is to dip y...

Страница 15: ...buoyancy NEVER use them for cushions or other purposes 5 Coast Guard Approved equipment is equipment which has been approved by the Commandant of the U S Coast Guard and has been determined to be in c...

Страница 16: ...urn its wear er in a vertical or slightly backward position in the water The turning action is not as pronounced as with a Type I The device will not turn as many different type persons under the same...

Страница 17: ...during daytime sunrise to sunset for Recrea tional boats less than 16 ft 5 meters in length Boats participating in organized events such as races regattas or marine parades Open sailboats not equippe...

Страница 18: ...Coast Guard Approved pyrotechnic de vices carry an expiration date This date can NOT exceed 42 months from the date of An adequately stocked first aid kit should be on board for the safety of crew and...

Страница 19: ...one or more of the following conditions as a boat of closed construction subject to fire extinguisher regulations A suitable fire extinguisher should be mounted close to the helmsman for emergency use...

Страница 20: ...ill not knowingly accept a cheap parachute A good boater should not accept a bargain in lifejackets fire ex tinguishers or compass Take the time and spend the few extra dollars to purchase a compass t...

Страница 21: ...one of non magnetic ma terial test to determine whether it is merely magnetic a small piece of iron or steel or some magnetized steel Bring the north pole of the compass near the object then shift an...

Страница 22: ...an alum inum can was placed on one side and the compass read as 204 degrees a good 14 degrees off Next the full can was moved to the opposite side of the compass and again a reading was observed This...

Страница 23: ...lf Bilge Pumps Automatic bilge pumps should be equip ped with an overriding manual switch They should also have an indica tor in the opera tor s position to advise the helmsman when the pump is operat...

Страница 24: ...r and operator If the operator cannot file the report for any reason each person on aboard MUST notify the authorities or determine that the report has been filed 1 15 NAVIGATION Buoys In the United S...

Страница 25: ...in any way as covering the entire subject Powered boats must yield the right of way to all boats without motors except when being overtaken When meeting an other boat head on keep to starboard un les...

Страница 26: ...properly no matter how much time and expense is spent on the tune up Poor Damaged piston probably caused by inaccurate fuel mixture or improper point setting compression must be corrected or the tune...

Страница 27: ...r fine adjustments The time effort and expense of a tune up will not restore an engine to satisfactory performance if the pistons are damaged Major Tune up Remove head Clean carbon from pistons and cy...

Страница 28: ...y also be caused by running the engine out of the water For unknown reasons many opera tors have formed a bad habit of running a small engine without the lower unit being submerged Such a practice wil...

Страница 29: ...e damaged the head should be removed and and a Hell coil insert installed If an at tempt is made to drill out the opening with the head in place some of the filings may fall into the cylinder and caus...

Страница 30: ...nd synchronization are essential for proper engine operation An engine may be in apparent excellent me chanical condition but perform poorly un less the points and synchronization have been adjusted p...

Страница 31: ...sion If the battery has remained under charg ed check for high resistance in the charging circuit If the battery appears to be using too much water the battery may be defec tive or it may be too small...

Страница 32: ...tor Specifi cations in the Appendix With a fully charged battery the ammeter reading will be a bit lower because of the self regulating characteristics of the generating systems A 40 hp engine with a...

Страница 33: ...tion of the idle and high speed adjustments Notice the pressure type fuel con nector CAUTION Water must circulate through the lower unit to the engine any time the en gine is run to prevent damage to...

Страница 34: ...starting a cold engine It is better to have the adjustment on the rich side rather than on the lean side Stating it another way do not make the adjustment A 3 0 hp engine with the low and high speed a...

Страница 35: ...y first removing the cap then the filter element cleaning the parts and drying them with compressed air and finally installing them in their original position A fuel pump pressure test should be made...

Страница 36: ...ed INTERNAL WIRING 2 11 wire to a cutout switch on top of the engine This cutout switch provides a safety to break the ground to the solenoid in the event the engine starts at a high rpm Therefore the...

Страница 37: ...ical connec tor should be inspected and cleaned each season This connector is exposed and vulnerable to dampness and corrosion Resistance Test See the Wiring Diagram in the Appendix Use a magneto anal...

Страница 38: ...entering the power head by way of the drive shaft housing and the exhaust ports during the flush It will also prevent residual water from being trap ped in the drive shaft housing and other passagewa...

Страница 39: ...commercial applications The higher rpm is recommended for light fast boats The wide rpm range will result in greater satisfaction because of maximum performance and greater fuel economy If the engine...

Страница 40: ...AIN ING GEAR Oil The gear oil in the lower unit should be checked on a daily basis during the season of operation The oil should be drained and replenished with new oil every 100 hours of operation BO...

Страница 41: ...drastically hampered if the bottom is damaged the center the bow will be light and the boat will plane more efficiently For this test the boat must be operated in a body of water Check the engine rpm...

Страница 42: ...ivered to the combustion chamber 2 The complete lubrication system 3 In most cases the ignition system 4 The frequency of the power stroke These differences will be discussed briefly and compared with...

Страница 43: ...MOSPHERIC AIR PRESSURE Air flow principle for a modern carburetor with each revolution of the crankshaft Compare this system with a four cycle en gine A stroke of the piston is required to accomplish...

Страница 44: ...nd the fresh fuel charge is compressed inside the combustion chamber DEFLECTOR INTAKE COMPRESS ION INTRODUCTION 3 3 Pressure in the crankcase decreases as the piston moves upward and a fresh charge of...

Страница 45: ...ifferent type of crankshaft installa tions The illustrations accompanying the text are from different size units and the cap tions clearly identify which model is cover ed Exploded drawings showing pr...

Страница 46: ...in salt water or has not had proper maintenance or shelter or any number of other factors then separating the powerhead from the exhaust housing may not be a simple task An air hammer may be required...

Страница 47: ...k plug opening if the threads have been damaged On many engines a sending unit is in stalled in the head to warn the operator if Removing the thermostat from the head the engine begins to run too hot...

Страница 48: ...storted If the reed is broken the loose piece MUST be located and removed before the engine is returned to service The piece of reed may have found its way into the crankcase behind the bypass cover I...

Страница 49: ...the reed tip and the reed plate Close view showing the dimple on the reed plate The reed leaves must straddle the dimple and be centered over the openings for proper operation The reeds must NEVER be...

Страница 50: ...y used with a pressure fuel tank REED SERVICE 3 9 Back side of the same plate shown at the bottom of the previous column Notice how the reed stops are centered over the reeds reed from the front side...

Страница 51: ...reeds unless they are to be replaced AL WAYS replace reeds in sets NEVER turn used reeds over to be used a second time Lay the reeds on a flat surface and measure all the reed stops If there is a grea...

Страница 52: ...S COVERS 3 11 the powerhead and be transferred to the exhaust housing If the cover was the only item over the exhaust ports they would become so hot from the exhaust gases they might cause a fire or a...

Страница 53: ...Block Service under Bypass Cover and Exhaust Cover Installation The exhaust area of the powerhead open for inspec tion and cleaning 3 8 TOP SEAL The top seal maintains vacuum and pres sure in the cran...

Страница 54: ...sing the proper tools to install the top seal BOTTOM SEAL 3 13 is installed through the driveshaft and holds the seal upward and in place As the powerhead is lowered down over the driveshaft during in...

Страница 55: ...crankshaft where the truarc ring fits If the Quadrant ring installed in its retainer at the bottom seal Removing the quadrant seal and retainer from the crankshaft groove is not clean the ring will s...

Страница 56: ...od hard forceful blow DO NOT keep beating on the end of the pin because such action would round the pin head until it would not be possible to drive it out of the cover Centering pins are the first it...

Страница 57: ...f the cover is distorted it will fail to make a proper seal when it is installed Cylinder block after the crankcase cover has been removed Once the crankshaft has been tapped as described and the prop...

Страница 58: ...ice the hole in the rod near where the wrist pin passes through the piston On many rods there is also a hole in the rod at the crank end These two holes MUST AL WAYS face upward during installation Ro...

Страница 59: ...of the cylinder and the sharp edge toward the intake side during installation When the rod is installed to the piston the relationship of the rod can only be one way The rod holes must face upward and...

Страница 60: ...n must be driven out FROM the loose side This may not seem reason able but there is a very simple explanation By placing the piston in the arbor press cradle with the tight side down and the arbor ram...

Страница 61: ...above your knees Set the piston between your legs with the LOOSE side of the piston facing upward Now drive the wrist pin free using a drift pin with a shoulder The drift pin will fit into the hole th...

Страница 62: ...ring surface being subjected to water contamination which causes etching The etching re sembles the size of the bearing as shown in the accompanying illustration Inspect the bearing surface of the rod...

Страница 63: ...Align the etched marks on the knob side of the connecting rod with the etched marks on the connecting rod cap b Tighten the connecting rod cap at taching bolts securely Installing the rod cap onto th...

Страница 64: ...ring may break but if it is difficult to remove it MUST be replaced OBSERVE the pin in each ring groove of the piston The ends of the ring MUST straddle this pin The pin prevents the ring from rotatin...

Страница 65: ...on ring locating pins to be sure they are tight There is one locating pin in each ring groove If one locating pin is loose the piston must be replaced Never attempt to replace the pin it is NEVER succ...

Страница 66: ...ugh the piston and rod Continue to press the wrist pin through until the groove in the wrist pin for the lock ring is visible on both ends of the pin Remove the assembly from the arbor press Install t...

Страница 67: ...through the wrist pin and the shoulder will ride on the end of the wrist pin Use sharp hard blows with a hammer Your legs will absorb the shock without damaging the piston If this method is used on a...

Страница 68: ...e Crankshaft with the upper center and lower main bearings ready to be removed CRANKSHAFT 3 27 Crankcase cover with the labyrinth seal area clearly visible the locating pins in the cylinder block The...

Страница 69: ...to remove the seal A crankshaft cleaned and ready for installation Crankshaft with a badly corroded throw This crankshaft is unfit for further service from the top main bearing If the same type of sea...

Страница 70: ...cating during the honing operation b Pump a continuous flow of honing oil into the work area If pumping is not practical use an oil can Apply the oil generously and frequently on both the stones and w...

Страница 71: ...for the do i t yourselfer working at home without the advantage of special tools First purchase a special hose clamp with a strip of metal inside the clamp as shown Checking the ring gap clearance by...

Страница 72: ...ermitted to rotate at one point the opening between the ring ends would align with either the intake or ex haust port in the cylinder the ring would expand very slightly catch on the edge of the port...

Страница 73: ...ough intake port the clamp is against the piston skirt At this point the ring ends will be together and the cutout on each ring end will be against the pin Tap the piston with the end of a wooden tool...

Страница 74: ...e block and at the same time align the hole in each bearing to enable the pin in the block to Bearing locating pins in the cylinder block Each pin must index into a hole in the bearing shown in the il...

Страница 75: ...tight and then just a bit more Use a scratchall pick or similar tool and move it back and forth on the outside surface of the rod and cap Make the movement across the mating line of the rod and cap T...

Страница 76: ...on slightly because all of the rings will not be visible at one time If there is no spring tension the ring was broken during installation The piston must be removed and a new ring installed Repeat th...

Страница 77: ...lled in the rod cap This pin will index into a hole in the rod for proper alignment Tighten the rod cap bolts alternately and evenly in three rounds to the torque value given in the Specifications in...

Страница 78: ...washers Bring the bolts up fingertight and then just a bit more Tighten the rod cap bolts alternately and evenly in three rounds to the torque value Tightening the rod cap bolts to the proper torque...

Страница 79: ...ylinder block in stallation work should be performed WITH OUT interruption Do not begin the work if a break in the sequence is expected coffee lunch whatever The sealer will begin to set almost immedi...

Страница 80: ...gh the crank case cover into the cylinder block CYLINDER BLOCK 3 39 Tighten the bolts to 1 2 the total torque value on the first round to 3 4 the total torque value on the second round and to the full...

Страница 81: ...ion on the cylinder block Install the bypass covers and secure them in place with the attaching hardware If a fuel pump is used be sure the same bypass cover is installed in the position from which it...

Страница 82: ...ee rounds to the torque value specified in the Appen dix Tighten the bolts to 1 2 the torque value on the first round to 3 4 the total torque value on the second round and to the full torque value on...

Страница 83: ...e at any speed after 2 hours BUT NOT at sustained full throttle until another 8 hours of operation Testing a 35 horsepower unit with a pressure fuel tank c Mix gasoline and oil during the break in per...

Страница 84: ...BLOCK 3 43 AIR E rp oded drawing of a 3 0 hp powerhead 1956 and the 4 0 hp powerhead 1969 70 with principle parts identified The 4 0 hp unit uses a bearing and seal on the crankshaft instead of the oi...

Страница 85: ...3 44 POWERHEAD EXHAUST COVER I LEVER Exploded drawing of a 5 5 hp powerhead 1956 60 principle parts identified...

Страница 86: ...45 GASKET FUEL PUMP GASKET Exploded drawing of a powerhead with principle parts identified for the following units 5 5 hp 1961 64 5 0 hp 1965 68 6 0 hp 1965 70 The 6 0 hp unit uses an oil slinger ins...

Страница 87: ...3 46 POWERHEAD Exploded drawing of a 7 5 hp powerhead 1956 58 with principle parts identified...

Страница 88: ...CYLINDER BLOCK 3 47 HEAD GASKET RING...

Страница 89: ...3 48 POWERHEAD HEAD BYPASS COVER Exploded drawing of a 10 hp powerhead 1956 63 with principle parts identified...

Страница 90: ...CYLINDER BLOCK 3 49 THERMOSTAT EXHAUST COVER The...

Страница 91: ...Exploded drawing of the crankshaft and associated parts for the powerhead shown on the previous page 3 50 POWERHEAD...

Страница 92: ...r under heavy duty service the mixture may change to as much as 12 parts air to 1 part fuel Float Systems A small chamber in the carburetor serves as a fuel reservoir A float valve admits fuel into th...

Страница 93: ...fuel tank arrangement the filter is actually an intergral part of the fuel pickup Obsolete pressure type fuel tank used extensively until about 1958 The system was replaced by the squeeze bulb arrang...

Страница 94: ...needle valves are installed On late model engines the high speed needle valve was replaced with a high speed orifice There is no adjustment with the orifice type These needle valves are used to compe...

Страница 95: ...mobile using regu lar gasoline If a sudden increase in gas consumption is noticed or if the engine does not perform Commercial additives such as Sta bii may be used to keep the fuel in the tank fresh...

Страница 96: ...he carburetor The ONLY guaranteed method of removing ALL fuel is to take the time to remove the carburetor and drain the fuel Secondly if the engine is operated with the fuel supply shut off until it...

Страница 97: ...edle or to a defective float which would cause an extra high level of fuel in the bowl and overflow into the intake mani fold FUEL PUMP TESTS CAUTION Gasoline will be flowing in the engine area during...

Страница 98: ...el line connec tor into the engine 4 Defective fuel pump 5 The line from the fuel tank to the fuel pump may be plugged the line may be leaking air or the squeeze bulb may be defective 6 Defective fuel...

Страница 99: ...orked to pump fuel to the engine After engine start air pressure forces fuel from the tank to the engine situation simply immerse the ends of the hose in boiling water for a few minutes to soften the...

Страница 100: ...periods and then shuts down from lack of fuel the problem may be lack of air pressure in the tank To check for air pressure after the engine has run for just a short period open the fill cap very sli...

Страница 101: ...principle parts with important comments for satisfac tory service A set of points unfit for service due to oxidation ROUGH ENGINE IDLE If an engine does not idle smoothly the most reasonable approach...

Страница 102: ...the owners pride of ownership and good care While you are checking the bottom take note of the propeller condition A bent blade or other damage will definitely cause poor boat performance If the hull...

Страница 103: ...the horsepower and model engines equipped with each CARBURETOR INSTALLATIONS Type I Single barrel front draft with adjustable low speed and high speed needle valves 1 5 hp 3 0 hp 5 0 hp 5 5 hp 1968 70...

Страница 104: ...s and then remove the copper fuel line between the shut off valve and the carburetor 4 On engines utilizing a separate fuel tank remove the tie strap or clamp secur ing the rubber hose connecting the...

Страница 105: ...igh speed orifice and covered with a plug in approximately the same location in the carburetor as the high speed needle valve Therefore if there is a plug instead of the high speed needle valve remove...

Страница 106: ...tween the bowl and the carburetor showing the opening to allow fuel to leave the bowl and enter the idle passage of the carburetor CLEANING AND INSPECTING NEVER dip rubber parts plastic parts diaphrag...

Страница 107: ...alled on the carburetor being serviced check the orifice for cleanliness The orifice has a stamped number This number represents a drill size Check the orifice with the shank of the proper size drill...

Страница 108: ...AF AIR SILENCER Exploded vtew of a Type I carburetor installed on small Johnson Evinrude engines This carburetor is used with the old style pressure type fuel tank Therefore the filter bowl is incorpo...

Страница 109: ...4 18 FUEL Exploded view of a Type I carburetor installed on small Johnson Evinrude engines equipped with the fuel tank attached to the engine The filter on these units is in the tank...

Страница 110: ...arburetor Check to be sure the float is square with the carburetor cavity one side is not further away than the other 16 Place the bowl gasket in position on the carburetor and then position the bowl...

Страница 111: ...o allow the needle valves to be installed 22 Install the high speed needle valve into the bottom cavity by rotating it CLOCKWISE Allow the needle valve to sea t LIGHTLY then back it out COUNTER CLOCKW...

Страница 112: ...gasket material Place a NEW gasket in position on the intake manifold 27 Connect the fuel line to the carbu retor or on engines equipped with a self contained fuel tank replace the line be tween the s...

Страница 113: ...ust the high speed by rotating the high speed needle valve CLOCKWISE until the number of rpm begins to drop then rotate the high speed valve COUNTERCLOCK WISE until the highest rpm is reached Re turn...

Страница 114: ...erform one of the fol lowing three procedures depending on the choke system installed on the carburetor of the engine being serviced CHOKE SYSTEM 4 23 HEA T ELECTRIC CHOKE REMOVAL 1 Observe the compre...

Страница 115: ...r Remove the solenoid and take care to retain the spring inside the solenoid Remove the choke solenoid gasket LEVER SPRING 6 Using a pair of needle nose pliers reach inside the choke base and remove t...

Страница 116: ...ing the clamp to the carburetor Remove the choke solenoid from the carburetor The choke solenoid CANNOT be serviced The boot should be in good condition It may be re moved by sliding it off the soleno...

Страница 117: ...em A check valve and orifice is installed in the water system to prevent flooding of the diaphragm when the manifold pressure fluc tuates during slow speed operation A punc ture or other damage to the...

Страница 118: ...through the chamber 4 After the cover has been removed it is not necessary to remove the choke base from the carburetor Remove the four screws securing the choke head and then remove the head 5 Notice...

Страница 119: ...the carburetor being ser viced has a front shield installed remove the top screw 2 Remove the two screws on the front side of the carburetor cover Remove the cover from the front of the carburetor 3...

Страница 120: ...eedle valve 7 Loosen the packing nut securing the high speed needle valve to the carburetor bowl Turn the high speed needle valve COUNTERCLOCKWISE until it is free then remove it from the carburetor b...

Страница 121: ...eed nozzle Remove the high speed nozzle from the carburetor using the proper size screwdriver to prevent possible damage to the nozzle If difficulty is experienced in removing the high speed nozzle le...

Страница 122: ...ges in the castings with compressed air Check all of the parts TYPE II CARBURETOR 4 31 GOOD Compare this new needle valve with the worn needle to the left and passages to be sure they are not dogged o...

Страница 123: ...rrs which might cause a leak Check the float for deterioration Check to be sure the float spring has not been stretched If any part of the float is damaged the unit must be replaced Check the float ar...

Страница 124: ...askets are contained TYPE II CARBURETOR 4 33 In the kit V ost repair kits contain more parts and gaskets than are needed because the kit may be used to service a wide range of carburetor models 1 Inst...

Страница 125: ...r the nozzle Force the gasket down onto the carburetor stem 5 Place a NEW gasket in position on the the carburetor base NEVER attempt to install a used gasket at this location As the gasket is used th...

Страница 126: ...s not level use a pair of needle nose pliers and CAREFULLY bend the foat tab SQUARELY until the float is in the correct position level with the carbu retor Check to be sure the float is square with th...

Страница 127: ...d by hand but with just a little difficulty 13 Install the high speed orifice into the carburetor bowl using the proper size screwdr iver 14 Install a NEW drain plug gasket and then thread the drain p...

Страница 128: ...stall a NEW gasket and screen onto the front of the carburetor 19 If a front cover is used on the unit being serviced install the front cover and secure it in place with the two attaching screws 20 In...

Страница 129: ...ger and spring by hooking the spring into the choke lever 2 Insert a NEW gasket into the cavity of the choke base 3 Insert the spring into the bore of the choke solenoid 4 Work the choke solenoid up t...

Страница 130: ...buretor Connect the choke quick disconnect on the choke wire leading to the dash Install the starter and genera tor if the engine being serviced is equipped with these two units 8 Connect the heat tub...

Страница 131: ...d and into the lever attached to the carburetor Install the washer and cotter pin 4 Clean the surface of the intake mani fold thoroughly Check to be sure all old gasket material has been removed Place...

Страница 132: ...PHRAGM TYPE II CARBURETOR 4 41 4 Lower the stem down through the spring and diaphragm and onto the base 5 Install the cover and secure it in place with the attaching screws Tighten the screws ALTERNAT...

Страница 133: ...CARBURETOR ADJUSTMENTS GOOD WORD Under all conditions the ignition and fuel system MUST be synchronized before the fine adjustments to the carburetor are made See Chapter 5 After the synchroni zation...

Страница 134: ...the car buretor On later models the reeds were removed from this location and installed between the engine block and the intake manifold TYPE III CARBURETOR 4 43 The early model idle needle valves ex...

Страница 135: ...The O ring may be discarded 4 Remove the five screws securing the carburetor to the intake manifold Notice that four of the screws have slots and one is a countersunk screw Lift the carburetor from th...

Страница 136: ...ip rubber parts plastic parts nylon parts diaphragms or pump plungers in carburetor cleaner These parts should be cleaned ONLY in solvent and then blown dry with compressed air Place all metal parts i...

Страница 137: ...4 46 FUEL LEVER AND LOW SPEED...

Страница 138: ...replace any that have developed a groove GOOD WORN WORN GOOD Needle and seat arrangement showing a worn and new needle for comparison TYPE III CARBURETOR 4 47 Parts included in a carburetor repair kit...

Страница 139: ...ding condi tion in the carburetor 4 Apply just a drop of oil into the seat and then insert the inlet needle into seat 5 Position a NEW float over the needle and then slide a NEW hinge pin into place 6...

Страница 140: ...gasket mater ial Place a NEW gasket in position on the manifold Set the carburetor into place on the manifold and secure it with the five TYPE III CARBURETOR 4 49 attaching screws OBSERVE that one of...

Страница 141: ...arm to operating temperature Adjust the low speed idle by turning the low speed needle valve CLOCKWISE until the engine begins to misfire or the rpm drops noticeably From this point rotate the needle...

Страница 142: ...anges will be identified in the text All other fuel pumps must be replaced as a unit However the pump cover can be SEAT DIAPHRAGM INLET VALVE OUTLET VALVE Functional diagram to illustrate operation of...

Страница 143: ...to removing the cover and cleaning the screen from the engine operate the squeeze bulb in the fuel line until it is firm and then to carefully observe the end of the vacuum hose to detect any fuel le...

Страница 144: ...all disc washer because it will be used again 6 Some model pumps may have a small disc washer and long spring installed under the diaphragm Other models may have a large nylon washer and spring DISCAR...

Страница 145: ...internal parts necessary to rebuild the pump including diaphragm check valves gaskets etc will be included in the pump repair kit At one time these kits were available from the local O l C dealer at...

Страница 146: ...o attaching screws 5 Install the NEW LONG spring over the boss of the retainer and then place the nylon disc washer on top of the spring that was provided in the kit NEVER use the small disc on top of...

Страница 147: ...hion the vacuum im pulses from the engine 8 Ease the fuel pump cover down over the diaphragm and then thread the six cover attaching screws into the pump body As each screw is started pull on the edge...

Страница 148: ...LINE SERVICE The procedures outlined in this section cover service of or iginal equipment produc ed by Johnson Evinrude Pressurized Fuel System A pressure type fuel tank was used with the early model...

Страница 149: ...xtending its ull length the cylinders Installation of new hoses to the carburetor is not a difficult or expensive task The accompanying illustration clearly shows the two hoses connected to the fuel t...

Страница 150: ...rom inside of the fuel cap The chain may hang free inside the fuel tank 4 If the chain cannot be disconnected from the cap by removing the retaining screw then remove the cotter pin from inside the ta...

Страница 151: ...check valve should allow air to pass up through the tube but prevent the movement of air in the opposite direction If the check valve fails the tests clean the assembly in carburetor cleaner and then...

Страница 152: ...because highly flam able fumes dre present and the danger of fire or explosion is present Demand and observe NO SMOKING or open flame in the work area Clean the tank in the out of doors Wash the inter...

Страница 153: ...4 62 FUEL Exploded view of a pressure tyoe fuel tank with major parts identified...

Страница 154: ...wn through the spring and the housing with the dia phragm seated on the housing Install the relief spring and washer into the housing and hole of the diaphragm 7 Install the spring over the top of the...

Страница 155: ...ith the matching holes in the gasket and tank 13 Securing the pump in place with the attaching screws Use NEW tiny gaskets on each screw to prevent fuel linkage through the screw holes 14 Slide the pu...

Страница 156: ...catch fuel being discharged from the end of the hose Fuel Line Service The only service work to be performed on the fuel lines is replacement of the 0 rings in the fuel line connectors and re placemen...

Страница 157: ...4 66 fUEL...

Страница 158: ...the screen for damage It is possible to bend a new piece of screen material around the pickup and solder it in place without purchasing a complete new unit Attach the fuel gauge to the new pickup unit...

Страница 159: ...t may have become hardened causing difficulty in working it over the check valve To remedy this situation simply immerse the ends of the hose i boiling water for a few minutes to soften the rubber and...

Страница 160: ...uld be started and run per iodicall y up on an outboard motor If you have any doubts concerning your understanding of two cyle engine operation it would be best to study the operation theory section i...

Страница 161: ...or of the porcelain which is an indication this plug has been running at the correct tempera ture This means the plug is one with the correct heat range and also that the air fuel mixture is correct R...

Страница 162: ...Wear Electrode wear results in a wide gap and if the electrode becomes carbonized it will form a high resistance path for the spark to jump across Such a condition will cause the engine to misfire du...

Страница 163: ...nnector side the polarity is reversed 3 The firing end of a used spark plug can give a clue to coil polarity If the ground electrode is dished it may mean polarity is reversed 5 4 WIRING HARNESS CRITI...

Страница 164: ...k the engine DOES NOT mean the engine is equipped with a battery type igni tion system A magneto system uses the battery only to crank the engine Once the engine is running the battery has absolutely...

Страница 165: ...he spark plug s and continue through the system until the source of trou ble is located Remember a magneto system is a self contained unit Therefore if the engine has a key switch and wire harness rem...

Страница 166: ...en the boat is operating in the water If the propeller is released from the TROUBLESHOOTING 5 7 shaft because of an accident striking an underwater object whatever the engine would then be operating u...

Страница 167: ...L WORDS These next two paragraphs may well be the most important words in this chapter Misuse of the wiring harness is the most single cause of electri cal problems with outboard power plants A wiring...

Страница 168: ...rk plug s by hand This is a rough test to determine if the plug is tightened properly You should not be able to remove the plug without using the proper socket size tool Remove the spark plug s and ke...

Страница 169: ...ngs are not stuck in the piston fail to expand properly Therefore it is essential that any compres sion problem be corrected before proceeding with the tune up procedure See Chapter 3 If the power hea...

Страница 170: ...ondition Condenser In simple terms a condenser is composed of two sheets of tin or aluminum foil laid TROUBLESHOOTING 5 11 ALTERNATE LAYERS OF INSULATION WAXED PAPER ALTERNATE LAYERS OF FOIL TI N OR A...

Страница 171: ...e crankshaft Both points are constructed with a steel base and a tungsten cap fused to the base To properly diagnose magneto spark problems the theory of electricity flow must be understood The flow o...

Страница 172: ...wheel type magnetos REMOVAL 1 Remove the hood or enough of the engine cover to expose the flywheel Dis connect the battery connections from the SERVICING 5 13 battery terminals if a battery is used to...

Страница 173: ...couple from the sides showing the wiring and ar rangement of parts Breaker Points Condenser Service The armature plate does not have to be removed to service the magneto If it is necessary to remove t...

Страница 174: ...d down screw secur ing the non moveable half of the point set to the armature plate 11 Remove the hold down screw securing the condenser to the armature plate Ob serve how the condenser sets into a re...

Страница 175: ...Replacement of the top seal on a John son E vinrude engine is NOT a difficult task with the proper tools a seal remover and seal installer NEVER attempt to remove the seal with screwdrivers punch pic...

Страница 176: ...tly with the wrong side up SERVICING 5 17 Slide the cam down the crankshaft with the word TOP facing upward Continue working the cam down the crankshaft until it is in place over the Woodruff key or p...

Страница 177: ...5 18 IGNITION FLYWHEEL Exploded drawing of a typical magneto system Only one coil and set of points is shown...

Страница 178: ...dence the seal has been leaking it MUST be re placed as outlined earlier in this section A coil burned where the high tension lead enters the coil on the bottom side Arcing caused the damcge CLEANING...

Страница 179: ...ee screws through the laminated core into the armature plate but DO NOT tighten them If the engine being serviced has a second coil install the other coil in the same manner 4 Check to be sure the spa...

Страница 180: ...Armature Plate Installation 8 Slide the armature plate down over the crankshaft and onto the engine Align the screw holes in the armature plate with the holes in the power head retainer After the arm...

Страница 181: ...the spring arm to the inside of the post of the base points Continue to work the points on down into the base 13 Observe the points The points should be together and the spring part of the moveable ar...

Страница 182: ...n ed at the factory and does not require adjustment Once the point set is properly installed all should be well In most cases breaker contact and alignment will not be necessary If a slight alignment...

Страница 183: ...he key in the crankshaft key way Check to be sure the inside taper of the flywheel and the taper on the crankshaft are clean of dirt or oil to prevent the flywheel from walking on the crankshaft while...

Страница 184: ...to the torque value given in the following table Connect the battery leads to the battery terminals if a battery is used with a starter motor to crank the engine This particular engine differs from t...

Страница 185: ...pendix two numbers will be obtained One for the location of the primary adjustment and the other indicating the method of making the adjustment GOOD WORDS When making the synchronization adjust ment i...

Страница 186: ...ctual adjustment is accomplished by ONLY ONE method depending on the engine being ser viced Check the Appendix for the ad justment to be performed The reference numbers are listed in the Appendix unde...

Страница 187: ...ced is to be adjusted until pickup is at the proper location and the throttle shaft just begins to move 7 Movement of the shaft can be exag gerated by attaching a short piece of stiff wire to an allig...

Страница 188: ...e clip to the throttle shaft as shown The wire jiggling will instantly indi cate movement of the shaft The actual adjustment is accomplished by ONLY ONE of two means depending on the engine being serv...

Страница 189: ...n The wire jiggling will instantly indi cate movement of the shaft The actual adjustment is accomplished by ONLY ONE of three means depending on the engine being serviced Check the Appendix for the ad...

Страница 190: ...mp for a bait tank Because of its job and the consequences failure to perform in an emergency the best advice is to purchase a well known brand with an extended warranty period from a reputable dealer...

Страница 191: ...ting at OOF This second figure indicates the cranking load capacitv and is referred to as the Peak Wa tt Rating of a battery This Peak Watt Rating PWR has been developed to measure the cold cranking a...

Страница 192: ...evel should drop below normal the lower tip of the rod is exposed and the upper end glows as a warn ing to add water Such a device is only necessary on one cell cap because if the electrolyte is low i...

Страница 193: ...ertically and suck up liquid only until the float is free and floating A pair of pliers should be used to tighten the wingnuts when they are used Securing the wingnuts by hand is not adequate the conn...

Страница 194: ...ance at the connections Such corrosion places a strain on all electrically operated devices on the boat and causes hard engine starting BATTERY SERVICE 6 5 attention rr ust be giver to the battery to...

Страница 195: ...s and the advantage of the dual installation is lost The switch may be dosed intentionally to take advantage of Schematic drawing for a two battery one engine hookup Sche matic drawing for Q two batte...

Страница 196: ...cons tant voltage system is used to reduce the 12 14 volts of the electrical system to an average of 5 vol ts This steady 5 vol ts ensures the gauges will read accurately un der varying conditions fr...

Страница 197: ...UGE The fuel gauge is intended to indicate the quantity of fuel in the tank As the experienced boatman has learned the gauge reading is seldom an accurate report of the fuel available in the tank The...

Страница 198: ...nections are on a negative grounded system If the pointer fails to move from the FULL position the problem could be one of three faul ts 1 The tank sending unit is not properly grounded 2 Improper con...

Страница 199: ...ter readings range from 0 to 6 000 rpm in increments of 100 Tachome ters have solid state electronic circuits which eliminates the need for relays or Maximum engine performance can only be obtained th...

Страница 200: ...es are still started only by pulling on a rope On the larger hp engines an electric starter motor coupled with a mechanical gear mesh between the cranking motor and the engine flywheel similar to the...

Страница 201: ...0 watts and a radio rated at 30 watts Amps 48 Watts 12 volts 4 Amps In this case if all the lights are on and the radio is being used the total draw on the battery would be 4 amps If the engine is run...

Страница 202: ...re the engine MUST be mounted in a body of water to prevent a RUNAWAY condition and serious damage to internal parts or destruction of the unit NEVER attempt to operate the engine above idle speed wit...

Страница 203: ...rator will run wild If the amp meter registers a high reading while the generator field is grounded the circuit has a broken wire or the voltage regulator is defective If the amp meter reading does no...

Страница 204: ...When a new voltage regulator is instal led the generator must be polarized BE FCRE the cover is installed CHARGING CIRCUIT 6 15 3 Polarize the new regulator by first connecting the posi tive lead to...

Страница 205: ...ewdriver or other similar tool and pry the puller up and free of the generator shaft Hold the generator and at the same time remove the nuts from the top of the generator support bracket and the gener...

Страница 206: ...IT 6 17 between the commutator bars on the arma ture Perform the test again If the hack saw blade still vibrates during the test the armature has a short and MUST be replaced Testing for a Ground 7 Ob...

Страница 207: ...meter indicates continuity the positive terminal insulation through the generator frame is broken down and MUST be replac ed Positive Brush Test for Ground 11 Using a test lamp or ohmmeter make contac...

Страница 208: ...THRU BOLT UPPER HEAD ARMATURE BEARING FRAME CHARGING CIRCUIT 6 19 Exploded view of a typical generator showing arrangement of major parts BRUSH 2 LOWER HEAD...

Страница 209: ...n the commutator bars should be 1 3 4 This undercut must be the full width of the insulation and flat at the bottom A triangular groove is NOT satisfactory After the undercut work is completed the slo...

Страница 210: ...t personal INJURY or damage to the generator 1 Connect a jumper wire between the field terminal and a good ground on the case Connect a second jumper wire be tween the positive battery terminal and th...

Страница 211: ...h to connect or disconnect the starter from the battery The operator controls the switch with a pushbutton or key switch A cutout switch is installed in the sys tem to prevent starting the engine if t...

Страница 212: ...ill strike the splin es and the rubber cushion will not absorb the shock STARTER MOTOR 6 23 The sound of the motor during cranking is a good indication of whether the starter motor is operating proper...

Страница 213: ...harged b Throttle advanced too far beyond fast idle speed Typical Bendix spring arrangement on a starter motor A small amount or 011 on the Shaft in the spring area will prolong satisfactory operation...

Страница 214: ...6 to identify exactly where the connection or test is to made Starter Motor Turns Slowly a Battery charge is low Charge the battery to full capacity b Electrical connections corroded or loose Clean an...

Страница 215: ...jump er wire at No 8 the starter solenoid and the other lead to a good ground Connect a second jumper wire at No 2 the positive terminal of the battery to No 6 the starter solenoid The voltmeter shou...

Страница 216: ...E GEAR 6 27 CASTELLATED NUT Two different type drive nuts used on outboard starter motors The nut on the left is a self locking type and the right one is a castellated nut with a cotter pin Type I Dri...

Страница 217: ...e sta rter motor pro ceed directly to Section 6 16 To install the starter motor onto the engine if no further work is to be perform ed proceed directly to Section 6 17 DISASSEMBLING Type II Drive Gear...

Страница 218: ...CO REM Y STARTER 6 29 the three 7 16 bolts or nuts in some cases securing the starter motor bracket to the engine Remove the starter motor and bracket together G X D NEWS If the only motor repair nece...

Страница 219: ...nuity the arma ture is grounded and MUST be replaced Checking the Commutator Bar 5 Check between or check bar to bar as shown in the accompanying illustration The test light should light or the meter...

Страница 220: ...ter frame If the meter does not indicate continuity the brush or brush retainer is not grounded to the frame If the unit being tested has a double set of negative and positive brushes move the test le...

Страница 221: ...this chapter for detailed procedures to test the starter motor ASSEMBLING THE DELCO REMY Negative Brushes and Retainer The following procedures apply to brush es mounted to the field frame assembly 1...

Страница 222: ...in the right position to reach the brush holders Do not Installing the negative brush into the frame assemb ly A new bolt and washer is provided in the replace ment kit DELCO REMY STARTER 6 33 overhea...

Страница 223: ...engine proceed directly to Section 6 17 6 14 AUTOLITE STARTER MOTOR SERVICE REMOVAL 1 Before beginning any work on the starter motor disconnect the positive lead from the battery terminal Remove the...

Страница 224: ...ly Remove the positive brush from its holder ARMATURE TESTING Testing for a Short 5 Position the armature on a growler then hold a hacksaw blade over the arma ture core Turn the growler switch to the...

Страница 225: ...mmeter Connect one lead of the meter to the end of the brush and the other lead to the terminal The ohmmeter MUST indicate continuity between the brush and the terminal If the meter indi cates any res...

Страница 226: ...ny suspect ed defective part according to the pro cedures outlined ear lier in this Section Check the commutator for run out In spect the armature shaft and both bearings for scoring Turn the commutat...

Страница 227: ...cap over the frame assembly Install the positive brush into the retainer and push the brush backward until the spring part of the retain er is on the side of the brush 2 Work the cap over the end of...

Страница 228: ...ement of the brushes the drive gear does not have to be removed All starter motors have thru bolts securing the upper and lower cap to the field frame assembly In all cases both caps have some type of...

Страница 229: ...from their holders and then remove the brush springs Lift the white plastic retainer free from the frame Observe the location of the notch on the retainer in relation to the frame The retainer must be...

Страница 230: ...ion and flat at the bottom A triang ular groove is not satisfactory After the under cutting work is completed clean out the slots carefully to remove dirt and cop per dust Sand the commutator lightly...

Страница 231: ...d CLEANING AND INSPECTING Clean the field coils armature commu tator armature shaft brush end plate and drive end housing with a brush or compress ed air Wash all ot her parts in solvent and blow them...

Страница 232: ...ough the cut a way in the plate 2 Install the spring into the retainer Push the negative brush into its retainer and then wrap a fine piece of wire around the front side of the brush and the back side...

Страница 233: ...ook up to test an assembled starter motor motor NEVER make the momemtary con tact with the positive lead to the terminal because any arcing at the terminal may damage the terminal threads and the nut...

Страница 234: ...updated manual shift electr ic shift and the push button shift mechanism These shift boxes are all considered original Johnson Evinrude equipment 7 2 SHIFT BOXES DESCRIPTION Undoubtedly the most used...

Страница 235: ...rip on the lever handle without the throttle changing position An idle stop is also built into the shift box This feature prevents the throttle from being retracted past normal idle to the point where...

Страница 236: ...ever moves smoothly without difficulty the problem is immediately isolated to the Connecting ruon with adjustable trun DOUBLE SHIFT LEVER 7 3 engine Attempt to identify if the problem is in the thrott...

Страница 237: ...mechanism jumping a tooth and loosing its timing DISASSEMBLING Removing Single and Double Lever Shift Boxes 1 Remove the attaching hardware se curing the shift box to the side of the boat Once the shi...

Страница 238: ...te the inner wires To lubricate the inner wire remove the casing guide from TRUNNION SHIFT HANDLE DOUBLE SHIFT LEVER 7 5 the cable at both ends Attach an electric drill to one end of the wire Momentar...

Страница 239: ...t ratchet in position in side the shift half of the box Place the shift lever down over the top of the ratchet with the last tooth on the lever rocker engaged with the last tooth of the slider Apply a...

Страница 240: ...Normally this type of problem is the result of improper shift box installation This area includes connection of the shift and throttle cables in the shift box If the stainless steel inner wire was no...

Страница 241: ...ift side of the box does not have any adjustments except for the low idle stop Observe how the shift lever pivots at the bottom and the throttle lever pivots at the top DISASSEMBLING Throttle Half 2 R...

Страница 242: ...which the screws were attached Push out the center square button and then remove the rack from the shift lever CLEANING AND INSPECTING Check the nylon wear block on the end of the anti friction cap Th...

Страница 243: ...a bluish appearance it has been heated at an earlier date and the temper removed The temper MUST be removed to permit the holding screw to make a crimp in the wire to hold an adjustment If the wire ha...

Страница 244: ...mine if the temper has been removed If the end has a bluish appearance it has been heated at an earlier date and the temper removed The temper MUST be removed to permit the holding screw to make a cri...

Страница 245: ...performing the work 1 Difficult Shift Operation Many times this type of problem is the result of incorrect cable installation the NO SLACK SLACK 1 f cable is not the proper length or there are too man...

Страница 246: ...circuit If the results of this test indicate a short in the cirucit the lower unit must be disassembled and inspected See Chapter 8 4 Testing Shift Switch Forward To test the switch for the FORWARD po...

Страница 247: ...BLING GOOD WORDS On Johnson units a friction screw is installed in the bottom side of the shift box This screw allows friction adjustment of the throttle handle This arrangement prevents the throttle...

Страница 248: ...idle link as an assembly 5 Remove the screws from the end of the sleeve on the end of the cable and then pull the throttle cable free of the link and sleeve 6 If the switch fails to check out as desc...

Страница 249: ...p in the wire THROTTLE CD to hold an adjustment If the wire has not been tempered heat the end but not enough to melt the wire Tighten the top screw in the sleeve until the screw makes a crimp in the...

Страница 250: ...ts SHOULD ALWAYS BE USED because a loose shift box during high speed operation could be extremely dangerous Connect the shift wire under the dash SINGLE LEVER SHIFT BOX 7 17 EXTREME OPPOSITE pas ITION...

Страница 251: ...ockwise one half turn Move the auxiliary throttle to the START position and then turn the ignition switch to the START position again If the starter still fails to crank the engine with the warm up le...

Страница 252: ...button for the FORWARD position and then for the REVERSE posi tion Note how much the ammeter reading increased each time a shift button was de pressed If the reading was more than 2 5 amperes for eit...

Страница 253: ...ple or red lead and to the reverse terminal blue lead with the other probe Again depress the FORWARD NEUTRAL and RE VERSE pushbuttons The meter should indicate continuity or the test light come on for...

Страница 254: ...er 2 Notice the screw and retainer at the forward end of the casing guide and just below the throttle lever Remove the screw and retainer Pull the throttle cable and casting guide free of the shift bo...

Страница 255: ...he drill on and off to rotate the wire and at the same time allow lubricant to flow into the cable as shown ASSEMBLING Switch Installation 1 Position the switch box inside the shift box underneath the...

Страница 256: ...he selector bracket Move the bracket forward or aft until the buttons can be depressed Tighten the screws to secure the bracket in the proper position 7 Install the shift box cover and secure it in pl...

Страница 257: ...onds without water will damage the water pump Now adjust the slide yoke to allow the pushbuttons to be depressed at 700 rpm but not at 750 rpm If it is not possible to depress the buttons at 700 rpm r...

Страница 258: ...e throttle cable into the trunnion at the engine end CABLE END FITTING 7 25 Detailed draWing of the shift trunnion at the engine in the casting guide tighten the top screw until a definite crimp is ma...

Страница 259: ...n earlier date and the temper removed The temper MUST be removed to permit the holding screw to make a crimp in the wire to hold an adjustment If the screw is not tightened to this degree the wire wil...

Страница 260: ...uple inches and the shift coupler removed Non shift lower unit with the drive gear cap and propeller shaft shown 4 The lower unit does not have shifting capabilities therefore removal of the unit is n...

Страница 261: ...wer unit or metal particles are discovered in the gear lubricant the lower unit should be com pletely disassembled cleaned and inspected Gear arrangement used on the 40 hp manual Shift lower unit Gear...

Страница 262: ...indow must be removed Hold the shift rod with a pair of pliers and at the same time attempt to move the shift lever on the starboard side of the engine If it is possible to move the shift lever the be...

Страница 263: ...ustration at the top of this column The propeller should be removed frequently and debris removed from the rpropelier shaft to prevent such costly repairs Cut a way view of a propeller showing the pro...

Страница 264: ...finally the unit will not stay in gear for even a short time The following areas must be checked to locate the cause 1 Check the bellcrank under the power head This is accomplished by first checking i...

Страница 265: ...r cable should slip on the end cable guide the adjustment would be lost 3 Move the shift lever at the engine into the neutral position and the shift lever at the control box to the neutral position No...

Страница 266: ...the lower unit If the attempt to crank the engine is still unsuccessful the problem is in the powerhead 8 3 PROPELLER REMOVAL The shear pin on most outboard units is installed through the propeller s...

Страница 267: ...to its proper location Allow the gear lubricant to drain into the container As the lubricant drains catch some with your fingers from time to time and rub it between your thumb and finger to determin...

Страница 268: ...the driveshaft installed SERVICE NO SHIFT 8 9 1 Disconnect the spark plug wire from the plug Remove the retaining bolts secur ing the lower unit to the exhaust housing CAREFULLY pull directly downwar...

Страница 269: ...ss type lower unit a thrust bearing is installed under the pinion gear This thrust bearing can only be re moved by tapping it out in the following manner Turn the lower unit so the propeller shaft ope...

Страница 270: ...ears and wear Check for a glazed or melted appearance caused from operat ing without sufficient water If any ques tion exists and as previously stated install a new impeller if at all possible Clean a...

Страница 271: ...8 12 LOWER UNIT PROPELLER Exploded drawing of the Weedless lower unit gear case with major parts identified...

Страница 272: ...splines on the shaft to index with the splines in the gear SPECIAL WORDS After the drives haft is installed care must be exercised NOT to allow the drive shaft to slip out of position in the pinion ge...

Страница 273: ...when the head is install ed WATER PUMP INSTALLATION 5 Lay down a bead of sealer No 1000 onto the lower unit surface Slide the water pump plate down the driveshaft and onto the lower unit surface 6 In...

Страница 274: ...o the grommet in the water pump housing as a further aid to installation This tube is very small in size and will bend easily during installation if it has even a little difficulty passing through the...

Страница 275: ...from the propeller However if they have been removed for any number of reasons they should be coated with OMC Type A lubricant prior to installation The bushing is installed first then the clutch hub...

Страница 276: ...the direct drive engines without a reverse gear The engine is rotated 1800 with the steering lever to move the boat sternward Because a shift rod is not used naturally there is no re quirement to dis...

Страница 277: ...inch and then remove the bottom bolt in the shift Window removed from a lower unit to gain access to the shift connector as explained in the text The detail drpwing upper left illustrates the relatio...

Страница 278: ...t piece of 211 x 6 wood to accommodate the lower unit with the cavitation plate resting on top of the wood Clamp the wood in a vise and service work may then be performed with the lower unit erect On...

Страница 279: ...will not come free it is the type with the key and keyway Therefore the driveshaft will be removed later when the lower unit is disassembled If the driveshaft comes free remove it at this time 6 Turn...

Страница 280: ...in the slot during installation With the reverse gear some bearing heads have a hole and a matching pin installed in the housing indexes in this hole Some other reverse gears have a tab protruding fro...

Страница 281: ...t A special tapered punch is required to remove the bushing from the lower unit housing Obtain the special punch and then remove the bushing and the O ring Using a slide hammer to pull the bearing car...

Страница 282: ...per and finish with No 180 Check the water intake screen and pas sages by removing the bypass cover if one is used Inspect the clutch dog drive gears pinion gear and thrust washers Replace these items...

Страница 283: ...e the prongs are not worn or rounded Dam age or wear to the prongs indicates the lever must be replaced C aged ball bearing set destroyed due to lack of lubrication vibration corrosion metal particles...

Страница 284: ...o the hole and make another test Continue to drop solder into the hole and test until the pin is flush with the housing when it is installed If more soldered is inserted into the hole than necessary t...

Страница 285: ...8 26 LOWER UNIT Exploded drawing of a lower unit with a window for access to the shift connector...

Страница 286: ...MANUAL SHIFT 5 HP TO 25 HP 8 27 Exploded drawing of a lower unit requiring the powerhead to be removed to gain access to the shift disconnect...

Страница 287: ...e the clutch dog onto the propel ler shaft splines Apply a light coating of lubricant to the washer and then insert it into the center of the forward gear Slide the forward gear onto the end of the pr...

Страница 288: ...the gear case 6 Slide the propeller shaft assembly in to the lower unit housing Check to be sure the slot in the forward gear bearing indexes with the pin in the lower unit and the protrusion on the...

Страница 289: ...If the cap and shift lever are not aligned exactly the screw will seek and make the alignment as it passes through However do not make a long point or the screw will not have enough support and would...

Страница 290: ...rop of sealer to the threads and then tighten the screw securely 15 Turn the lower unit rightside up Install a NEW gasket onto the upper surface of the lower unit MANUAL SHIFT 5 HP TO 25 HP 8 31 16 In...

Страница 291: ...the driveshaft CLOCKWISE as the wa ter pump housing is lowered to allow the impeller blades to assume their natural and proper position inside the housing Continue to rotate the drives haft and work...

Страница 292: ...stalled the cutout area on the shift rod MUST be aligned in such a manner to allow the bolt to be properly installed Therefore as the lower unit is mated with the exhaust hous ing exercise patience as...

Страница 293: ...ge of the shift handle Install the power head 25 Check to be sure the water pickup tube is clean smooth and free of any corrosion Coat the water pickup tube and grommet with lubricant as an aid to ins...

Страница 294: ...e vent plug MANUAL SHIFT 5 HP TO 25 HP 8 35 A FEW GOOD WORDS The propeller washer if used and drive pin play an extremely important role When shifting gears during normal operation or if the propeller...

Страница 295: ...sed NEVER oper ate the engine above an idle speed because the no load condition on the propeller would allow the engine to RUNA WAY resulting in Location of the shear pin through the propeller shaft j...

Страница 296: ...ing It is not uncommon for the water tube s to be stuck in the water pump making separation of the lower unit from the exhaust housing diffi cult However with patience and persist ence the tube s will...

Страница 297: ...screw heads to break off when an attempt to remove them is made If this should happen use a chisel and breakaway the water pump housing from the lower unit EXERCISE CARE not to damage the lower unit h...

Страница 298: ...ke time to make a sketch or take Q photograph showing the arrangement of parts as en assist during the installation work years Therefore the positioning of the gears shims bearings and other parts may...

Страница 299: ...The babbitt side MUST face toward the reverse gear during installation The washer also has two dog ears one facing upward and the other downward By taking note at this time of these items and exactly...

Страница 300: ...er unit housing These two items prevent water from entering the lower unit A special tapered Caged ball bearing set installed on some newer model lower units instead of the babbitt bearing MANUAL SHIF...

Страница 301: ...aft if the splines are worn Inspect the gearcase and exhaust housing for dam age 1 0 the machined surfaces Remove any nicks and refurbish the surfaces on a surface plate Start with a No 120 Emery pape...

Страница 302: ...dutch dog The sides of the The web area indicated should be inspected careful ly for the slightest sign of a hairline crack The smallest evidence of a crack is cause to replace the housing because ex...

Страница 303: ...ed on 35 hp and 40 hp engines Two propeller shafts are shown The second shaft with the two balls and spring may be installed as a conversion This new type shaft arranqment holds the shift dog more sec...

Страница 304: ...typical manual shift lower unit installed on late mode 40 hp engines This lower unit is almost identical to the one shown on Page 8 44 except the water pump has a two line recirculating system The pr...

Страница 305: ...heck to be sure the shift rod is clean and smooth free of any burrs or corrosion Coat the shift rod and the 0 ring with oil as an aid to installation Slide the shift rod down through the a ring and bu...

Страница 306: ...in MUST index into the hole in the retainer when the propeller shaft is instal led If the pin is not seated properly in the hole the seal retainer will work part way out of the housing and the lubrica...

Страница 307: ...mmer If the caged needle bearing is installed tap on the numbered side of the bearing 14 Coat the outside edge of a NEW seal with No 1000 sealer and then tap the seal into place in the top of the uppe...

Страница 308: ...face of the water pump with light weight oil 18 Lower the water pump housing down the driveshaft and over the impeller Ro tate the driveshaft CLOCKWISE as the wa ter pump housing is lowered to allow t...

Страница 309: ...to allow the bolt to be properly installed Therefore as the lower unit is mated with the exhaust housing exercise patience as the two units come together to enable the bolt to be installed at the prop...

Страница 310: ...Words just before Step 20 before MANUAL SHIFT 28 HP TO 40 HP 8 51 making this connection After the bolt is in place install and secure the window with the attaching hardware Start the bolts securing t...

Страница 311: ...ive pin Slide the propeller cap into place and secure it with the cotter pin 27 Final adjustment for remote control units Shift the lower unit into NEUTRAL gear At the shift box move the shift lever t...

Страница 312: ...used on the 40 hp electromatic shift lower unit ELECTROMATIC SHIFT 8 53 generator to maintain battery amperage and voltage for efficient operation of the shift mechanism When the key is in the ON posi...

Страница 313: ...ing the full length of the hub Hold the shaft from turning and then rotate the propeller 1 4 turn to position the grooves over the drive pin holes The propeller can then be pulled straight off the sha...

Страница 314: ...m eter is not installed on the dash one must be temporarily connect ed to the system for this test by first removing the wire marked BAT from the key switch and then connecting the ammeter in ELECTROM...

Страница 315: ...switch OFF move the shift lever to the NEUTRAL position and connect one lead of an ohmmeter to the green forward wire leading from the rear of the engine to the lower unit and the other lead to a goo...

Страница 316: ...haust housing or extension The water tubes may be stuck in the water pump Therefore if difficul ty is encountered in freeing the ELECTROMATIC SHIFT 8 57 lower unit force a wide blade chisel stiff scra...

Страница 317: ...damaged Use a 9 16 deep well socket and remove the lower unit gear case stud nuts then the washers and shift cable retainer DISCARD the nuts because they are the self locking type and MUST NOT be use...

Страница 318: ...er portions of the lower unit after the retaining bolts have been cut 12 Clamp the lower unit by the skeg in a vise equipped with soft jaws as shown Remove the retainer screw and washer then lift the...

Страница 319: ...other suitable container before releasing the pliers 15 Obtain a pair of Truarc pliers In sert the tips of the pliers into the holes of the retaining ring Now CAREFULLY re move the retaining ring fro...

Страница 320: ...ired After the housing is heated grasp the studs with a gloved hand and at the same time tap the housing on a board The forward coil and bearing race will be released from the hous ing If the tools ar...

Страница 321: ...s can be made to determine the condition of the bearing One is to feel the driveshaft in the area where it passes through the bearing If the shaft is smooth with no indication of roughness the bearing...

Страница 322: ...he clutch has been slipping the modest cost of the spring and hub is justi fied in eliminating this area as a possible source of shifting problems 26 Obtain and wear a pair of SAFETY GLASSES while wor...

Страница 323: ...8 64 LOWER UNIT Exploded drawing of a typical electric shift lower unit installed on 40 hp engines with major parts identified...

Страница 324: ...turns freely without any evi dence of rough spots or binding Inspect the rollers and balls for any sign of pits or flat spots Lower unit with a broken stud This type of damage is usually the result of...

Страница 325: ...te direction to the normal winding of the spring coils Place the spring in the gear with the spring key beside the spacer key Now shift both keys to the side of the slot against which they will pull 2...

Страница 326: ...ith its key ELECTROMATIC SHIFT 8 67 in the slot of the bevel gear The spacer MUST be positioned to encircle the cupped area in the opposite direction to the normal winding of the spring coil Install t...

Страница 327: ...seal was removed press a new seal into the head The seal can be installed using a block of wood and a mallet If the bearing was removed install a new bearing from the back side of the head A special b...

Страница 328: ...o the bearing race Naturally the tapered end of the bear ing enters the race first 15 Install the forward coil in the hous ing using special tool No 379230 Feed the coil wire into the groove in the bo...

Страница 329: ...e feed the blue lead through the opening in the lower housing The lead on the back side of the coil MUST be on TOP WARNING This next step can be dangerous The snap ring is placed under tremendous tens...

Страница 330: ...e four screws alternately and evenly Rotate the propeller shaft and check to be sure it turns without excessive drag 25 Set the wires into the retainer and secure them in place with the screw and wash...

Страница 331: ...er the hole as the stud passes through the retainer washer Continue to lower the upper housing and at the same time work the shift wires up into the cavity of the upper housing to prevent the wires fr...

Страница 332: ...driveshaft CLOCKWISE as the water pump housing is lowered to allow the impeller blades to Comparison of a new left water pump impeller with one unfit for service right ELECTROMATIC SHIFT 8 73 assume...

Страница 333: ...O ring onto the top of the driveshaft just below the splines O RING GOOD WORDS Clean both lower unit water tubes with sandpaper These tubes should be clean and shiny as an aid to mating the lower unit...

Страница 334: ...the rear housing cover with the exhaust relief boot fitting into the re cess of the cover Secure the cover in place with the attaching hardware 42 Position the outer exhaust cover in place on the por...

Страница 335: ...tank in a body of water or with a flush attachm ent connected to the lower unit If the flush attachment is used NEVER oper ate the engine above an idle speed because the no load condition on the prope...

Страница 336: ...lon drive gear Starter installation on the 5 hp and 6 hp engines This starter is similar in operation to an automotive type starter slides upward and engages the flywheel ring gear Once the engine sta...

Страница 337: ...turn springs a center cone and a set of spring release dogs that engage with the Ilywheel ring gear when the starter rope is pulled Service procedures are presented in Section 9 5 The second model do...

Страница 338: ...ard con tinues to perform year after year the age of the spring steel will finally take its toll This single pawl starter may be installed on 3 hp to 25 hp engines PINION GEAR 5 6 HP 9 3 The rewind sp...

Страница 339: ...ending on the size horsepower engine being serviced Therefore check the Hand Starter Rope Specifications in the Appendix and then purchase a quality nylon piece of the proper length and diameter size...

Страница 340: ...r the starter spring is weak and should be replaced STARTER REMOVAL AUTHOR S NOTE For photographic clarity the accomp anying pictures were taken servicing a star ter from a powerhead removed from the...

Страница 341: ...the pliers and allow the spool to slip a little at a time until the spring is completely unwound 4 Remove the two retaining bolts on top of the starter 5 Loosen but DO NOT remove the bolts on the bot...

Страница 342: ...e the starter is disassembled Inspect the teeth of the pinion gear The teeth will show some signs of normal wear A broken tooth or excessive wear on one side of the teeth is justification for replace...

Страница 343: ...on the engine HELPFUL WORD As an assist to installation first soak the bushing in hot water for about ten minutes and then lubricate it with just a drop of outboard oil 5 The tang on the outer spring...

Страница 344: ...ng into the bottom collar on the engine HELPFUL WORD As an assist to installation first soak the bushing in hot water for about ten minutes and then lubricate it with just a dorp of outboard oil 2A In...

Страница 345: ...wo bottom retainer screws 7 Insert a large size screwdriver into the top of the spool and then rotate the spool by count exactly 16 1 2 complete turns Lift the pinion gear to engage the flywheel ring...

Страница 346: ...YPE I STAR TER CYLINDER WITH PINION GEAR ALL 9 5 HP ENGINES This gear drive starter is a new design employing the principle of an automotive type starter motor When the starter rope is pulled the star...

Страница 347: ...fused and while they are still hot use a piece of cloth as protection and pull the end out flat to prevent a glob from forming 3 Tie a figure 8 knot in one end of the new rope Feed the rope through th...

Страница 348: ...starter Lift the starter assembly from the power head OBSERVE As the starter is removed take special note of how the upper bearing retainer ex tends over a hole in the powerhead This hole is a water...

Страница 349: ...these parts will attract dirt causing the gear to bind on the spool Lubricate the upper and lower spool bearing surfaces with just a drop of outboard lubricant Apply outboard oil to the spring on the...

Страница 350: ...ear down over the spool shaft 7 Align the hole in the upper spring retainer with the hole in the starter spool and with the slot in the pinion gear INSTALLA TION AUTHOR S WORD For the following illust...

Страница 351: ...of cloth as protection and pull the end out flat to prevent a glob from forming 11 Insert a large screwdriver blade into the top of the spool and then rotate the spool COUNTERCLOCKWISE by count 20 1 2...

Страница 352: ...arefully during disassembling and asembling work with the starter SAFETY WORDS Work on the starter can be very danger ous Because approximately 12 feet of spring steel is tightly wound into about a 4...

Страница 353: ...r of needle nose pliers and then pull the spring out as far as possible to relieve tension on the spring 4 Remove the 3 8 bolt from the brac ket between the starter and the exhaust housing 5 Hold the...

Страница 354: ...rope from the pulley Notice how the rope unwinds from t he pulley COUNTERCLOCKWISE 9 Remove the bushings from the idler gear arm A bushing is installed on each side of the pulley 10 Two different meth...

Страница 355: ...e horsepower engine being serviced Therefore check the Hand Starter Rope Specifications in the Appendix and then purchase a quality nylon piece of the proper length and diameter size Only with the pro...

Страница 356: ...ly The remainder of the spring will be installed later 6 Assemble the idler gear with the shoulder against the idler gear arm Install the idler gear arm and spring to the pulley and cup with the stop...

Страница 357: ...f the engine pull on the rope and the idler gear will engage with the flywheel ring gear Continue to pull the rope and at the same time work the spring down into the cup If the rope becomes fully exte...

Страница 358: ...he Appen dix ATOP FLYWHEEL WITH SPRINGS 9 23 9 5 TYPE In MOUNTED ATOP FLYWHEEL MODEL WITH RETURN SPRINGS 28 HP 1962 63 30 HP 1956 35 HP 1957 59 40 HP 1960 63 This type starter is installed as original...

Страница 359: ...t Work the rope anchor out of the rubber covered handle then remove the rope f rom the anchor Remove the handle from the rope Untie the knot in the rope and then hold the disc pulley but permit it to...

Страница 360: ...n a cage If the spring should accidently be released severe personal injury could result from being struck by the spring with force Therefore the following step MUST be performed with care to prevent...

Страница 361: ...ppears to be weak or frayed If the rope is The rope on this unit broke causing the spring to rewind with incredible speed The end of the spring was bent back in the wrong direction New pawl return spr...

Страница 362: ...direction Work the first turn into the housing and then hold the spring down with one hand and continue to wind the ATOP FLYWHEEL WITH SPRINGS 9 27 spring into the housing Patience and time are requir...

Страница 363: ...indle housing and then install the bolt through the washer into the housing Tighten the bolt securely Housing left with the spring properly installed and the spring end bent toward the center The pin...

Страница 364: ...sepower engine being serviced Therefore check the Hand Starter Rope Specifications in the Appendix and then purchase a quality nylon piece of the proper length and diameter size Only with the proper r...

Страница 365: ...e handle thread it through the rope apply just a little oil to the rope then pull the wire and rope through the handle 10 Work the end of the rope into the handle anchor Secure the rope in place by pu...

Страница 366: ...th force Therefore the service instructions MUST and we say again MUST be followed closely to prevent release of the spring at the wrong time Such action would be a BAD SCENE a very BAD SCENE because...

Страница 367: ...thus allow the rope to wind back onto the pulley SLOWLY Contin ue to allow the spring in the pulley to unwind SLOWLY until all tension has been released 3 Remove the center bolt nut from the top side...

Страница 368: ...hers in the area If the spring should be accidently released at the wrong time such action would be a BAD SCENE a very BAD SCENE because serious personal injury could result 8 Lift the pulley straight...

Страница 369: ...incredible speed The end of the spring was bent back in the wrong direction Inspect the starter spring end loops Re place the spring if it is weak corroded or cracked Check the spring pin located at...

Страница 370: ...ng After the last portion is in place bend the end of the spring towards the center of the housing This position will allow the pulley pin to align with the loop in the end of the spring when the pull...

Страница 371: ...index the pin into the hole in the housing 7 Place the washer inside the spindle housing and then install the bolt through the washer into the housing Tighten the bolt securely 8 Install the three pa...

Страница 372: ...een fused and while they are still hot use a piece of doth as protection and pull the end out flat to prevent a glob from forming 11 Tie a figure g knot in one end of the rope Settheropeaside but hand...

Страница 373: ...ightly pull on the rope to relieve tension on the pin installed through the pulley and housing in Step 12 Maintain some tension on the rope remove the pin and allow the spring to SLOWLY wind the rope...

Страница 374: ...ause ser ious personal injury could result The starter rope should NEVER be re leased from the extended position Such action would allow the spring to wind with incredible speed resulting in serious d...

Страница 375: ...able for starting AND that one of the pistons will return to TOC when the pull is completed if the engine fails to start If an excessive amount of pull is necessary before the fly wheel begins to rota...

Страница 376: ...bolt lockwasher and washer from the center of the pulley spin dle Lift the spindle out of the pulley and ATOP FLYWHEEL WITH NYLON PAWL 9 41 at the same time hold the pulley firmly together with the ho...

Страница 377: ...ext illustration clearly shows a spring end properly positioned in the housing Wash all parts except the rope in solvent and then blow them dry with compressed air Remove any trace of corrosion and wi...

Страница 378: ...used and while they are still hot use a piece of cloth as protection and pull the end out flat to prevent a glob from forming Knot tied in the end of the starter rope to prevent the rope from being pu...

Страница 379: ...ee end of the spring around the coiled portion 3A CAREFULL Y lower the coiled spring into the starter housing with the loop on the free end of the spring indexed over the peg in the housing and the sp...

Страница 380: ...nylon pawl onto the starter hub The friction spring fits into a groove in the spindle Pull just a little on the pawl and set it over the stud on the flywheel pulley 6 Snap the E clip over the top of t...

Страница 381: ...r E for Evinrude On the Evinrude engines the arrow must fall between the two marks on the pulley If the arrow is not properly aligned the starter rope is not the proper length It is either too long or...

Страница 382: ...long life and satisfactory performance at mini mum cost Many times if an outboard is not per forming properly the owner will nurse it through the season with good intentions of working on the unit on...

Страница 383: ...r is the stern and the direction is aft Manufacturer s identification plate installed be tween the transom brackets the right side when facing forward is the starboard side and the left side is the po...

Страница 384: ...f this type boat will probably carry it atop his vehicle and be saved the expense and trouble of tro ilering to the water the hull sustains a severe blow the impact will be either absorbed by deflecti...

Страница 385: ...ull and a leak develops the only emer gency action possible is to make an attempt to reduce the amount of water being taken on by stuffing any type of available material into the opening until the boa...

Страница 386: ...d after the following procedures have been performed the engine should be disas sembled cleaned assembled using new gas kets seals and Oeririzs and then st2 rted as soon as possible Submerged engine t...

Страница 387: ...gine in a horizontal position with the spark plug holes DOWN and then cranking the engine with the rewind starter or with a socket wrench on the flywheel nut 6 Alcohol will absorb water There fore pou...

Страница 388: ...is used to describe a boat that has filled with rain water and ruined the interior because the plug was not removed or the bow was not high enough to allow the water to drain properly Proper storage f...

Страница 389: ...e of additive will maintain the fuel in a fresh condition for up to a full year 3 Clean the with benzol see pair Section carburetor fuel filter s Chapter 4 Carburetor Re Rust preventative to be used w...

Страница 390: ...h the lower unit down If hanging is not practical lay the outboard on its back This will place the lower unit below the power head Adding lubricant to the lower unit on a small horsepower engine The l...

Страница 391: ...nd cause burrs on the hole These burrs may make removing the propeller difficult To overcome this Propeller installation with a washer and shear pin The cotter pin is installed through the propeller n...

Страница 392: ...ant drains Draining lubricant from a lower I1nit TAKE CARE not to remove the Phillips screw by mistake This screw secures the Shift fork in position LOWER UNIT 10 11 catch some with your fingers from...

Страница 393: ...vent hole A squirt type oil can must be used to allow the trapped air in the lower unit to escape at the same time the final lubricant is added Once the unit is com pletely full install and tighten t...

Страница 394: ...ndicates the battery is in satisfactory condition If the reading is 1 150 or in the red band the battery needs to be charged Observe the six safety points given in the text when using a hydrometer PRE...

Страница 395: ...the fuel vias not drained at the end of the previous season make a careful inspection for gum formation If a six gallon fuel tank is used Method of removing an O ring from a connector The connector is...

Страница 396: ...ump Check the idle exhaust port for water discharge At idle speed only a fine water mist will be visible Check for leaks Check operation of the thermostat After the engine has reached operating temper...

Страница 397: ...e type that cannot cause an explosive mixture to ignite ONE FINAL WORD Before putting the boat in the water TAKE TIME to VERIFY the drain plugs are installed Countless number of boating ex cursions ha...

Страница 398: ...ec2 m S2 X 0 0254 metres sec2 m s2 foot pounds calories Btu watt hours kilowatt hr s ENERGY OR WORK watt second joule newton metre X 1 3558 X 4 187 X 1055 X 3500 X 3 600 joules j joules j joules j jou...

Страница 399: ...7 0 6693 8 0315 0995 39 2010 7 8 3 3268 17 06 6719 43 64 0320 67 1015 38 5 16 2031 13 64 8 33 3281 21 64 17 46 6875 11 16 0330 66 2 6 1024 2040 6 8 4 3307 17 5 6890 85 0335 1040 37 5 2 2047 3320 0 17...

Страница 400: ...0015 0 0030 9 5 1968 1 81 2 31 0 020 0 004 5 0 0030 9 5 1969 70 1 81 2 32 0 020 0 0050 0 0035 10 1956 63 1 875 2 37 N A 0 0035 0 0030 15 1956 2 50 2 37 N A 0 0035 0 0030 18 1957 64 2 25 2 50 0 025 0...

Страница 401: ...935 0 0925 0 015 0 005 7 5 1956 57 0 0035 0 0010 0 015 0 005 9 5 1968 0 0035 0 0010 0 0935 0 0925 0 017 0 007 9 5 1969 70 0 0035 0 0010 0 0935 0 0925 0 017 0 007 10 1956 63 0 0015 0 0030 0 017 0 007 1...

Страница 402: ...ll 7522 2 7 5 12 4 4000 J6J B C 7 1 QO 18 10014 2 10 16 6 4000 J6J 0 7 1 FD FDE l1 15020 15922 2 18 22 0 4500 J4J 0 7 1 RO ROE RJE 19 25028 25930 25532 2 35 40 5 4500 J4J 0 9 1 1958 1958 1958 JW 14 3...

Страница 403: ...J4J D 7 1 FD 15 15034 2 18 22 4500 J4J D 7 1 RD RDS 23 35022 35524 2 40 43 9 4500 J4J D 9 3 1962 1962 1962 JW 17 3042 3044 2 3 5 28 4000 J6J A 7 1 CD 19 5524 2 5 5 8 84 4000 J6J B C 7 1 QD 23 10024 2...

Страница 404: ...4500 J4J D 7 1 RX RXW 13BE 33502 52 2 33 40 5 4500 J4J D 9 3 RD RDS RK AM 27 40502 52 40562 72 2 40 43 9 4500 J4J D 9 4 1966 1966 1966 JW JWL JH JHL 21 3602 03 3612 32 3G33 2 3 5 28 4000 J6J A 7 1 LD...

Страница 405: ...8 84 4500 J6J B E 6 1 MQ MQL 14 9822 23 2 9 5 15 2 4500 J4J E 7 2 18802 03 2 18 22 0 4500 J4J 0 8 1 FO FOL 22 2 20 22 0 4500 J4J 0 8 1 RX RXL RXE RXEL 16 33802 03 33852 53 2 33 40 5 4500 J4J 0 9 3 RD...

Страница 406: ...J4J D 9 4 lIOES 40ESL 70 GENERAL NOTES All engines flywheel magneto Top cylinder No 1 Bottom cylinder No 2 All points 020 All spark plugs 030 Timing NOT adjustable SPECIAL NOTES Primary Pickup Locati...

Страница 407: ...18 hp 20 hp 25 hp 28 hp 30 hp 33 hp 35 hp 40 hp ltOE hp MODEL 1968 70 1956 70 1969 70 1969 70 1965 68 1956 6lt 1965 70 1956 58 1961t 70 1956 63 1956 1956 70 1966 68 1969 70 1962 65 1956 1965 68 1957...

Страница 408: ...tage Ground Polarity Armature Air Gap Circuit Breaker Voltage Reg Current Regulator Current Regulator Setting Amps GENERATOR SPECI FICATIONS VRU 610lA 12 Negative Generator GJG 4 001M GJG 4 002M Rot D...

Страница 409: ...2 5 5 hp All 580321 18 22 6 0 hp All 580321 18 22 7 5 hp All 580321 18 22 9 5 hp All 580321 18 22 10 hp All 580321 18 22 15 hp All 580321 18 22 18 hp 1957 61 580321 18 22 30 hp All 580321 18 22 35 hp...

Страница 410: ...2 71 1 2 6 0 hp 1965 67 0 130 64 6 0 hp 1968 70 0 130 56 7 5 hp 1956 5 5 32 70 9 5 hp 1964 70 5 32 71 1 2 10 hp 1956 61 7 32 70 3 16 10 hp 1962 63 7 32 75 3 4 15 hp 1956 7 32 70 3 16 18 hp 1957 61 7 3...

Страница 411: ...GREEN CHOKE SWITCH BLACK WIRE RED WIRE o BLACK BATTERY CABLE NEG SWITCH CABLE RED BATTERY CABLE POS SOLENOID TO GROUND RED CARBURETOR CHOKE SOLENOID WHITE GREEN PORT MOTOR BRACKET LOWER SCREW GROUND W...

Страница 412: ...A 16 APPENDIX Wire Identification 33 hp with Generator 1965 67...

Страница 413: ...APPENDIX A 17 o C...

Страница 414: ...Wire Identification 33 hp with Generator 1969 70...

Страница 415: ...APPENDIX A 19 Wire Identification 35 hp 1957 59...

Страница 416: ...A 20 APPENDIX Wire Identification 40 hp Standard Shift with Generator 1960 66...

Страница 417: ...APPENDIX A 21 UJ cc b Wire Identification 40 hp Standard Shift with Generator 1967 68...

Страница 418: ...A 22 APPENDIX ee I U Vl Z Z o U I I Wire Identification 40 hp Standard Shift With Generator 1969 10...

Страница 419: ...APPENDIX Wire Identification 40 hp Electric Shift with Generator 1961 66 A 23...

Страница 420: ...A 24 APPENDIX C 00 Wire Identification 40 hp Electric Shift with Generator 1967 68...

Страница 421: ...Wire Identification 40 hp Electric Shift with Generator 1969 70...

Страница 422: ...NOTES NUMBERS...

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