Johnson J2R4SUC 2007 Service Manual

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BRP US Inc. Technical Publications 250 Sea Horse Drive Waukegan, Illinois 60085 United States

† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II

are registered trademarks of Tyco International, Ltd. † Amphenol is a registered trademark of The Amphenol Corporation. † Champion is a registered trademark of Federal-Mogul Corporation. † Deutsch is a registered trademark of The Deutsch Company. † Dexron is a registered trademark of The General Motors Co rporation. † Fluke is a registered trademark of The Fluke Corporation † Frahm is a registered trademark of James G. Biddle Co. † Gasoila is a registered trademark of The Federal Process Corporation. † GE is a registered trademark of The General Electric Company. † GM is a registered trademark of The General Motors Corporation. † Locquic and Loctite are registered trademarks of The Henkel Group. † Lubriplate is a registered trademark of Fiske Brothers Refining Company. † NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc. † NMEA is a registered trademark of the National Marine Electronics Association. † Oetiker is a registered trademark of Hans Oetiker AG Maschinen. † Packard is a registered trademark of Delphi Automotive Systems. † Permatex is a registered trademark of Permatex. † Plastigage is a registered trademark of The Dana Corporation. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. † ThreeBond is a registered trademark of Three Bond Co., Ltd.

Bombardier logo is a registered trademark of Bombardier, Inc., used under license.

The following trademarks are the property of BRP US Inc. or its affiliates:

Carbon Guard™ Nut Lock™ DPL™ Lubricant QuikStart™

Evinrude Evinrude Evinrude Evinrude Evinrude

® ® ®

/ Johnson ® XD30™ Outboard Oil

/ Johnson ® XD50™ Outboard Oil

/ Johnson ® XD100™ Outboard Oil Triple-Guard ® Grease

E-TEC

Extreme Pressure Grease™ Twist-Grip™ FasTrak™ 2+4

Gel-Seal II™ Ultra™ 4-Stroke Outboard Oil Hi-Vis™ Gearcase Lubricant HPF XR™ Gearcase Lubricant

Johnson

Moly Lube™

S.A.F.E.™ S.L.O.W.™ Screw Lock™ SystemCheck™

Fuel Conditioner

Ultra Lock™

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SAFETY INFORMATION

Before working on any part of the outboard, read the SAFETY section at the end of this manual.

This manual is written for qualified, factory-trained technicians who are already familiar with the use

of Evinrude ual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s).

This manual uses the following signal words identifying important safety messages.

/Johnson® Special Tools. This man-

DANGER

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.

Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you.

It is understood that this manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail.

To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual.

DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs.

Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.

IMPORTANT: Identifies information that will

help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product.

These safety alert signal words mean: ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED!

When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction.

Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.

If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.

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DANGER

Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Remove propeller before servicing and when running the outboard on a flushing device.

DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

WARNING

Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).

The motor cover and flywheel cover are machinery guards. Use caution when conducting tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts.

During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

To prevent accidental starting while servicing, twist and remove all spark plug leads. The electrical system presents a serious shock hazard. DO NOT handle prima ry or secondary

ignition components while outboard is running or flywheel is turning. Gasoline is extremely flammable and highly explosive under certain conditions. Use caution

when working on any part of the fuel system. Protect against hazardous fuel spray. Before starting any fuel system service, carefully

relieve fuel system pressure. Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular

phones in the vicinity of a fuel leak or while fueling. Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and

causing an explosion. Always work in a well ventilated area. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.

Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.

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TABLE

CONTENTS

SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS . 15

2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 27

3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4 IGNITION AND ELECTRICAL . . . . . . . . . . . . . . . . . . . . 53

5 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

9 MANUAL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . 139

10 WIRE/HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . 145

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S–1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index–1

Page 7

INTRODUCTION

CONTENTS

MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TYPICAL PAGE – A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TYPICAL PAGE – B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TYPICAL PAGE – C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TYPICAL PAGE – D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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INTRODUCTION

MODELS COVERED IN THIS MANUAL

This manual covers service information on Johnson 2.5 HP 4-Stroke models. Use this manual together with the proper Parts Catalog for part numbers and for exploded views of the outboard, which are a valuable aid to disassembly and reassembly.

Model Number Start Shaft Steer

J2R4SUC Rope 15 in. Tiller

Identifying Model and Serial Numbers

Outboard model and serial numbers are located on the starboard midsection and on the powerhead.

Starboard Midsection

1. Model and serial number

005512

Powerhead

1. Serial number

005513

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MODEL DESIGNATION

STYLE:

J = Johnson E = Evinrude

INTRODUCTION

MODEL DESIGNATION

PREFIX

HORSEPOWER

4-STROKE

B J 2 R 4 SU C

DESIGN FEATURES:

AP = Advanced Propulsion B = Blue Paint C = Counter Rotation D = Evinrude E-TEC E = Electric Start w/Remote Steering F = Direct-Injection G = Graphite Paint H = High Output J = Jet Drive M = Military P = Power Trim and Tilt R = Rope Start w/Tiller Steering S = Saltwater Edition T = Tiller Steering TE = Tiller Electric V = White Paint W = Commercial Model

MODEL YR:

I= 1 N= 2 T= 3 R= 4 O= 5 D= 6 U= 7 C= 8 E= 9 S= 0

Ex: SD = 2006

MODEL RUN

or SUFFIX

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INTRODUCTION

TYPICAL PAGE – A

Italic subheading

above Service Chart

indicates pertaining

models.

Subsection title

indicates beginning of

the subsection.

Bold letter indicates

liquid product to be

applied to a surface

Tightening torque for

a fastener.

Pay attention to

torque specifications.

Some units appear

as in. lbs. Use

appropriate torque.

Exploded view of

Service Chart assists

in identifying parts

and positions

Indicates list

corresponding to

applicable letter in

exploded view of the

Service Chart.

Page Number

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TYPICAL PAGE – B

INTRODUCTION

TYPICAL PAGE – B

Section TitleSection Title

Section TitleSubsection Title

Model specific

illustrations

designated with

image captions

Products and

lubricants italicized

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INTRODUCTION

TYPICAL PAGE – C

Denotes necessary

step or information to

prevent damage or

control correct

procedure

Title in italics indicates

a procedure

concerning a

particular model

Title indicates the

procedure specific to

V4 Models is

finished. From this point, this particular procedure concerns

V6 Models.

Title indicates

from this point,

All Models

are concerned

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TYPICAL PAGE – D

Typical illustration for

lower pulse hose of

V4 or V6 Models

INTRODUCTION

TYPICAL PAGE – D

Illustration components numbered to

correspond to

image

Cross references

direct readers to

related topics

Section tabs allow for

quicker reference

when thumbing through manual

Page 14

INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

Units of Measurement List of Abbreviations

A Amperes amp-hr Ampere hour fl. oz. fluid ounce ft. lbs. foot pounds HP horsepower in. inch in. Hg inches of mercury in. lbs. inch pounds kPa kilopascals ml milliliter mm millimeter N·m Newton meter P/N part number psi pounds per square inch RPM revolutions per minute °C degrees Celsius °F degrees Fahrenheit ms milliseconds µs microseconds Ω Ohms VVolts VAC Volts Alternating Current VDC Volts Direct Current

ABYC American Boat & Yacht Council ATDC after top dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CPS crankshaft position sensor DI Direct-Injection ECU electronic control unit EMM engine management module ICOMIA International Council of Marine

Industry Associations MCA marine cranking amps MWS modular wiring system NMEA National Marine Electronics Assoc. NTC negative temperature coefficient PDP power distribution panel PTC positive temperature coefficient ROM read only memory S.A.F.E.™ speed adjusting failsafe electronics SAC start assist circuit SAE Society of Automotive Engineers S.L.O.W.™ speed limiting operational warning SYNC synchronization TDC top dead center TPS throttle position sensor

WOT wide open throttle WTS water temperature sensor

Page 15

INTRODUCTION

PRODUCT REFERENCE AND ILLUSTRATIONS

BRP US Inc. reserves the right to make changes at any time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts, at any time, without incurring any obligation to equip same on models manufactured prior to date of such change. Specifications used are based on the latest product information available at the time of publication.

The continuing accuracy of this manual cannot be guaranteed.

All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only.

Certain features or systems discussed in this manual might not be found on all models in all marketing areas.

SYMBOLS

Throughout this service manual, symbols are used to interpret electrical troubleshooting results or to assign values in drawings.

Electrical

When “∞” shows on the meter face, no continuity, or very high resistance, is indicated. The symbol is referred to as infinity.

All service technicians must be familiar with nautical orientation. This manual often identifies parts and procedures using these terms.

Nautical Orientation

When “Ω” follows a value on the meter face, the procedure is measuring resistance. Ω is the sym-

DR4203

When “V” follows a value on the meter face, the procedure is measuring voltage.

DR4204

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INTRODUCTION

SYMBOLS

bol for ohm, the unit of measurement for resistance.

DR4205

Values

When “≤” precedes a value on the meter face, the reading should be less than, or equal to, the value shown.

When “≥” precedes a value on the meter face, the reading should be greater than, or equal to, the value shown.

DR4207

DR4206

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SERVICE SPECIFICATIONS AND SPECIAL TOOLS

TABLE OF CONTENTS

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TIGHTENING TORQUE – IMPORTANT FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TIGHTENING TORQUE – GENERAL BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ELECTRICAL / IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SHOP AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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SERVICE SPECIFICATIONS AND SPECIAL TOOLS

TECHNICAL DATA

HP 2.5

Full Throttle

Operating Range RPM

Power 2.5 HP (1.8 kw) @ 5500 RPM

Idle RPM in Gear 1800 to 2000

Weight 30.1 lbs. (14 kg)

Lubrication

ENGINE

Engine Type 4-Stroke OHV 1-cylinder

Displacement

Bore 1.89 in. (48 mm)

Stroke 1.50 in. (38 mm)

Compression ratio 9.0:1

Carburetion One single-throat carburetor, float feed

Main Jet #70

Pilot Jet #32

Starting Enrichment Manual

Float Level Setting 10 ± 2 mm

Preferred Fuel Regular unleaded, plus grade unleaded, premium unleaded gasolines

Acceptable Fuel Any of the above gasolines with 10% Ethanol or 5% Methanol with 5% co-solvents

Minimum Octane 87 AKI (R+M)/2 or 90 RON

FUEL SYSTEM

Additives

Evinrude/Johnson Ultra 4-Stroke outboard oil

Refer to Oil Requirements on p. 32.

Fuel Conditioner, Fuel System Cleaner, Carbon Guard

2+4

Use only Evinrude/Johnson recommended fuel additives.

The use of other additives may result in engine damage.

See Fuel Requirements on p. 31 for additional information.

5250-5750

4.2 cu. in. (68 cm

)

Page 19

Thermostat opens 118 to 126°F (48 to 52°C)

COOLING

IGNITION

Ignition Timing 30° BTDC

GEARCASE

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

HP 2.5

Type Transistorized

RPM Limit 6500 RPM

†

NGK

Spark Plugs

Gear Ratio 13:28 (2.15:1)

Lubricant HPF XR Gearcase Lube

Capacity 2.0 fl. oz. (60 ml)

CR6HSA @ 0.030 in. (0.76 mm)

Gap: 0.024 to 0.028 in. (0.6 to 0.7 mm)

TECHNICAL DATA

Page 20

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

STANDARD TORQUE SPECIFICATIONS

Tightening Torque – Important Fasteners

ITEM

Cylinder head cover bolt 5 mm 7 0.7 5.0

Cylinder head bolt 6 mm 13 1.3 9.5 Crankcase bolt 6 mm 11 1.1 8.0 Connecting rod cap bolt 5 mm 7 0.7 5.0 Valve adjusting lock nut 5 mm 7 0.7 5.0 Intake pipe bolt 6 mm 11 1.1 8.0 Carburetor mounting bolt 6 mm 10 1.0 7.0 Flywheel nut 10 mm 45 4.5 32.5 Igniter unit bolt 6 mm 10 1.0 7.0 Engine oil drain plug 10 mm 10 1.0 7.0 Powerhead mounting bolt 6 mm 10 1.0 7.0 Tiller handle pivot bolt 8 mm 17 1.7 12.5 Lower cover bolt 6 mm 8 0.8 6.0 Swivel shaft nut 8 mm 10 1.0 7.0 Gearcase bolt 6 mm 8 0.8 6.0 Water pump case bolt 6 mm 5 0.5 3.5 Propeller shaft bearing housing bolt 6 mm 8 0.8 6.0

THREAD

DIAM.

TIGHTENING TORQUE

N·m kg-ft lb-ft

Page 21

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

Tightening Torque – General Bolt

STANDARD TORQUE SPECIFICATIONS

IMPORTANT: These values apply only when a specific torque for a specific fastener is not listed in the

appropriate section. When tightening two or more screws on the same part, DO NOT tighten screws completely, one at a time.

ITEM

(Conventional or “4” marked bolt) 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5

(Stainless steel bolt) 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5

(7 marked or marked bolt)

THREAD

DIAM.

5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0 6 mm 4 – 7 0.4 – 0.7 3.0 – 5.0 8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5

5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0 6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0 8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5

5 mm 3 – 6 0.3 – 0.6 2.0 – 4.5 6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5 8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0

10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5

TIGHTENING TORQUE

N·m kg-ft lb-ft

WARNING

Torque wrench tightening specifications must be strictly adhered to. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener.

If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.

Page 22

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SPECIAL TOOLS

Electrical / Ignition

Digital multimeter Ohms resolution 0.01 Purchase through local supplier

Ignition analyzer P/N 501890

DRC7265

49791

CD Peak reading voltmeter P/N 507972

Spark checker P/N 508118

49799

49798

Multimeter, analog P/N 501873

Tachometer/timing light P/N 507980

49793

49789

Page 23

Fuel and Oil

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SPECIAL TOOLS

Fuel/Oil pressure gauge P/N 5000902

Gearcase

Gearcase filler P/N 501882

002275 Fuel vacuum tester

P/N 390954

49790

Universal pinion bearing remover and installer kits P/N 5005927 and P/N 5005928

23286 Oil pressure test adapter

P/N 350930

33974

Installer handle P/N 345822

002623

002575

Gearcase pressure tester P/N 507977 (Stevens P/N S-34) Gearcase vacuum tester P/N 507982 (Stevens P/N V-34)

Dial indicator set

49794

Gearcase fill/drain adapter P/N 5037486

Gearcase fill/drain adaptor P/N 772269

005517

48642

Prop shaft remover P/N 5034237

002630

Page 24

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SPECIAL TOOLS

Powerhead

Crankshaft holder P/N 5034236

Compression gauge adapter P/N 5037485

Crankshaft upper seal remover/installer kit P/N 391060 (9.9-15 HP)

002587

005515

23102

Cylinder bore gauge P/N 771310

Tappet adjusting tool P/N 341444

45303

38202

Valve lifter adapter kit P/N 5000899

Valve spring compressor P/N 346186

002625

DRC50025

Starter

Starter rope threading tool P/N 387784

23682 Starter spring winder/installer

CO3583

P/N 392093

Page 25

Universal

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SPECIAL TOOLS

Puller Bridge P/N 432127 23146

(

Puller jaws (small) P/N 432131 (replacement jaws P/N 437952)

23150

Slide hammer P/N 391008 CO1577

Slide hammer P/N 432128 15345

Universal Puller Set P/N 378103 32885

Puller jaws (large) P/N 432129 (replacement jaws P/N 437954)

Puller jaws (bearing) P/N 432130 (replacement jaws P/N 437953)

23148

23149

Tie strap installation tool P/N 323716

Temperature gun P/N 772018 45240

18105

Page 26

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SHOP AIDS

Cleaning Solvent P/N 771087

“6 in 1” Multi-Purpose Lubricant P/N 777192

Ultra 4-Stroke Outboard Oil, P/N 775594

Engine Tuner P/N 777185

D.P.L. Spray P/N 777183

4-Stroke Outboard Oil, P/N 775597

Anti-Corrosion Spray P/N 777193

Silicone spray P/N 775630

HPF PRO™ Gear Lube P/N 778755

HI-VIS™ Gearcase Lube P/N 775605

Triple-Guard® Grease P/N 508298

Extreme Pressure Grease™ P/N 508303

Page 27

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SHOP AIDS

Moly Lube P/N 175356

Storage Fogging Oil P/N 777186

Needle Bearing Grease, P/N 378642

Power Trim/Tilt and Power Steering Fluid P/N 775612

Starter Bendix Lube P/N 337016

Adhesive 847 P/N 776964

Lubriplate† 777 P/N 317619

2 + 4™ Fuel conditioner P/N 775613

Black Neoprene Dip P/N 909570

Fuel System Cleaner P/N 777184

Electrical Grease P/N 504824

Carbon Guard™ P/N 775629

Page 28

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SHOP AIDS

Gasket Sealing Compound P/N 317201

†

RTV Silicone Sealant P/N 263753

ThreeBond† 1104, P/N351052 ThreeBond 1207B, P/N 351053

Pipe Sealant with Teflon P/N 910048

Permatex† No. 2, P/N 910032

Thermal Joint Compound P/N 322170

†

Gear Mark Compound P/N 772666

Locquic Primer P/N 772032

1 2 3

1. Screw Lock P/N 500417

2. Nut Lock P/N 500421

3. Ultra Lock P/N 500423

†

Purple 222 equivalent

(Loctite (Loctite Blue 242 Equivalent)

(Loctite Red 271 Equivalent)

Page 29

INSTALLATION AND PREDELIVERY

TABLE OF CONTENTS

HULL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

MAXIMUM CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

MOUNTING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TOP EDGE OF TRANSOM OR BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TRANSOM CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

WATER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

MOUNTING HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TRANSOM MEASURING AND DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

HULL CENTERLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

TRANSOM HEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

TRANSOM DRILLING LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

OUTBOARD MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

OIL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

RUNNING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

BREAK-IN (10 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

EMERGENCY STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

OUTBOARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

START-IN-GEAR PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

WATER PUMP OVERBOARD INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

PROPELLER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

PROPELLER HARDWARE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Page 30

INSTALLATION AND PREDELIVERY

HULL PREPARATION

Maximum Capacity

WARNING

Do not overpower the boat by installing an outboard that exceeds the horsepower indicated on the boat’s capacity plate. Overpowering could result in loss of control.

Before installing outboard:

• Refer to the boat manufacturer's certification

label for maximum horsepower rating.

• Refer to ABYC Standards to determine the

maximum horsepower capacity for boats without certification labeling.

Top Edge of Transom or Bracket

Transom thickness or off-sets must also be considered. The top edge of the transom or bracket must provide a proper surface for stern brackets. The stern brackets must contact the flat surface of the transom or bracket. Modify moldings or components that prevent the stern brackets from resting against the transom surface. Do not modify transom brackets.

Transom Clearances

Make sure the transom and splash well area provide adequate clearances.

• The top edge of the transom should be wide

enough to allow full steering travel. The ABYC standard for most single outboard installations is 33 in. (84 cm).

• Check cable and hose routing clearances.

• Make sure there is clearance for mounting bolts

and washers. Check the inside area of the transom for obstructions prior to drilling holes.

Water Flow

1029A

Mounting Surface

Inspect transom surface prior to drilling mounting holes.

• The transom should meet ABYC Standards.

• The transom must be flat and cannot have any

protrusions.

• The transom angle should be approximately 14

degrees.

• Check transom strength and height.

WARNING

DO NOT install an outboard on a curved or irregular surface. Doing so can wear, bind, and damage components, causing loss of control.

Inspect the hull area directly in front of the mounting location.

• Boat-mounted equipment should not create tur-

bulence in the water flow directly in front of the outboard's gearcase. Turbulence or disruptions in the water flow directly in front of the gearcase will affect engine cooling and propeller performance.

Mounting Hardware

WARNING

Use all mounting hardware supplied with the outboard to help ensure a secure installation. Substituting inferior hardware can result in loss of control.

Page 31

INSTALLATION AND PREDELIVERY

TRANSOM MEASURING AND DRILLING

Hull Centerline

Locate the centerline of the boat transom as it relates to the hull (bottom) of the boat.

Use a straightedge to draw a line connecting the port and starboard chines. The chines should be used as reference points for determining the centerline of the hull.

Use a framing square to accurately place a line on the transom. The centerline of the hull should be in line with the keel of the hull and perpendicular to the midpoint of the line connecting the port and starboard chines.

Transom Heights

Make sure the transom height is consistent with the height of the outboard to be installed.

• A 19 to 21 in. (48.3 to 53.3 cm) transom height

uses a 20 in. (50.8 cm) shaft outboard.

• The shaft length of the outboard being installed

should come close to matching the transom height of the boat.

Determine transom height by measuring from the top edge of the transom, along the centerline.

Use a straightedge as a reference to extend the bottom of the boat.

Position the straightedge along centerline. The distance from the top edge of the straightedge to the top edge of the transom is the actual transom height.

1234

1. Chine

2. Strake

3. Keel

4. Hull centerline

DR5568

1. Top edge of transom

2. Actual transom height

DR5541

Page 32

INSTALLATION AND PREDELIVERY

OUTBOARD MOUNTING

Lifting the Outboard

Lift the outboard using the lift grips (NOT the tilt grip or steering handle) and place it in the center of the boat’s transom.

TYPICAL

1. Lift grips

Before Mounting Outboard to T ransom

Some rigging components that attach directly to the outboard should be assembled before the outboard is mounted to the boat's transom. Steering system components and gearcase speedometer pickup hoses are the most common. Determine what equipment will be installed prior to mounting the outboard to the transom or bracket.

DR4661

OUTBOARD MOUNTING

Fastening the Outboard to the Transom

WARNING

The outboard must be correctly installed. Failure to correctly install the outboard could result in serious injury, death, or property damage.

IMPORTANT: Follow all directions carefully.

The outboard’s warranty will not cover product damage or failure resulting from incorrect outboard installation.

WARNING

Even if equipped with clamp screws, the outboard must be bolted to the boat to prevent it from “working off the transom” during operation.

Center the outboard on the boat’s transom (or mounting bracket) and tighten the clamp screws by hand, NOT with tools. An accessory transom plate is recommended to protect the boat’s transom (or mounting bracket).

Page 33

INSTALLATION AND PREDELIVERY

FUEL AND OIL

WARNING

If either side of the transom deforms or cracks when the bolts are tightened to their recommended torque, the transom construction may not be adequate or may be deteriorated. Structural failure of the transom could result in loss of boat control and injury to the occupants.

IMPORTANT:

• Use a marine sealant rated f or above or below

waterline use. RTV silicone is not approved for below waterline use. Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces when removed.

• After 30 minutes of operation, retighten clamp

screws by hand. DO NOT use tools to tighten clamp screws. Check clamp screws regularly.

FUEL AND OIL

Fuel Requirements

WARNING

Gasoline is extremely flammable and highly explosive under certain conditions. Improper handling of fuel could result in property damage, serious injury or death.

Always turn off the outboard before fueling.

Never permit anyone other than an adult to refill the fuel tank.

Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun.

Remove portable fuel tanks from the boat before fueling.

Always wipe off any fuel spillage. Do not smoke, allow open flames or

sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.

Minimum Octane

Evinrude/Johnson outboards are certified to operate on unleaded automotive gasoline with an octane rating equal to or higher than:

• 87 (R+M)/2 AKI, or

• 90 RON

Use unleaded gasoline that contains methyl tertiary butyl ether (MTBE) ONLY if the MTBE con- tent does not exceed 15% by volume.

Use alcohol-extended fuels ONLY if the alcohol content does not exceed:

• 10% ethanol by volume

• 5% methanol with 5% cosolvents by volume

Page 34

INSTALLATION AND PREDELIVERY

FUEL AND OIL

When using alcohol-extended fuels, be aware of the following:

• The boat’s fuel system may have different

requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide.

• Alcohol attracts and holds moisture that can

cause corrosion of metallic parts in the fuel system.

• Alcohol blended fuel can cause engine perfor-

mance problems.

• All parts of the fuel system should be inspected

frequently and replaced if signs of deterioration or fuel leakage are found. Inspect at least annually.

IMPORTANT: Always use fresh gasoline. Gas-

oline will oxidize, resulting in loss of octane and volatile compounds, as well as the production of gum and varnish deposits which can damage the outboard.

Additives IMPORTANT: The only fuel additives approved

for use in Evinrude outboards are 2+4 tioner and Evinrude/Johnson Fuel System Cleaner. Use of other fuel additives can result

in poor performance or engine damage.

fuel condi-

Oil Requirements

IMPORTANT: 4-Stroke outboards are shipped

without oil in the crankcase. Oil must be added before starting the engine for the first time.

IMPORTANT: During the initial 10-hour break-in

period, use Evinrude/Johnson 4-Stroke Outboard Oil or SAE 10W-40, API SE, SF, SG, SH, or SJ rated. DO NOT use synthetic or synthetic blend oils during break-in period.

Evinrude/Johnson Ultra™ 4-Stroke synthetic outboard oil is recommended for normal use in these outboards after break-in.

If Ultra 4-Stroke oil is not available, you must use SAE 10W-40, API SE, SF, SG, SH, or SJ rated.

IMPORTANT: Failure to follow this recommen-

dation could void the outboard warranty if a lubrication-related failure occurs.

If SAE 10W-40 motor oil is not available, select an alternative according to the following chart:

Evinrude/Johnson 2+4 Fuel Conditioner will help prevent gum and varnish deposits from forming in fuel system components and will remove moisture from the fuel system. It can be used continuously and should be used during any period when the outboard is not being operated on a regular basis. Its use will reduce spark plug fouling, fuel system icing, and fuel system component deterioration.

Evinrude/Johnson Fuel System Cleaner will help keep fuel injectors in optimal operating condition.

Evinrude/Johnson Carbon Guard will minimize carbon deposit build-up when used as directed.

Engine Oil

Temperature

004813

Page 35

INSTALLATION AND PREDELIVERY

RUNNING CHECKS

WARNING

DO NOT run outboard without a water supply to the outboard’s cooling system. Cool ing system and/or powerhead damage could occur.

DANGER

IMPORTANT: DO NOT perform break-in using

a flushing device. DO NOT start-up or run the engine out of water. DO NOT leave a running engine unattended.

During the break-in, check water pump operation often. Look for a steady stream of water from the water pump indicator. If the stream of water stops, shut off the engine to prevent damage. Find and correct the cause before continuing.

Change the RPM often. Avoid holding a throttle setting longer than 15 minutes.

Check the crankcase oil level often. Add oil if needed.

First 10 minutes of operation — Operate engine in gear at idle only.

Balance of First 2 hours of operation — Operate in gear below 3000 RPM or 1/2 throttle only.

With easy planing boats, use full throttle to quickly accelerate boat onto plane. Immediately reduce throttle to one-half as soon as the boat is on plane. BE SURE boat remains on plane at this throttle setting.

Third hour of operation — Run the engine in gear at various speeds up to 4000 RPM or 3/4 throttle only.

Break-In (10 Hours)

Follow this procedure to protect the outboard during its initial hours of operation. Careful break-in allows internal engine components to seat properly, resulting in maximum engine life and performance.

Failure to carefully follow the break-in procedures can result in engine damage.

Perform the 10-Hour break-in procedure with the boat and engine in the water, using an appropriate propeller.

Balance of first 10 hours of operation — Run the engine in gear at various engine speeds including full throttle, but remain at full throttle no longer than 5 minutes.

Change the engine speed every 15 minutes. DO NOT exceed recommended maximum engine

RPM. Refer to TECHNICAL DATA on p. 16.

Page 36

INSTALLATION AND PREDELIVERY

RUNNING CHECKS

Fuel System

Perform running checks of the fuel system by following these steps:

• Start outboard. Visually inspect all oil hoses and

connections and fuel hoses and connections. Repair any leaks or misrouted hoses.

Emergency Stop Switch

Check emergency stop function. With outboard running at IDLE, pull safety lanyard from emergency stop switch. Outboard must stop immediately.

Outboard Controls

Confirm that controls can be easily moved into all gear and throttle settings. Do not shift outboard when propeller shaft is not turning.

Start-In-Gear Prevention

WARNING

Make certain that the starter will not operate when the outboard is in gear. The startin-gear prevention feature is required by the United States Coast Guard to help prevent personal injuries.

Water Pump Overboard Indicator

A steady stream of water should flow from the overboard indicator.

1. Water pump overboard indicator DRC4952

Operating Temperature

An outboard running at idle speed should achieve a temperature based on the engine’s thermostatic control. In general, the powerhead temperature should reach at least 100°F (38°C) after five minutes of idling. Confirm that the powerhead reaches idle temperature.

Start outboard and shift outboard into FORWARD. Turn outboard OFF while lever is in FORWARD. Attempt to restart the outboard. Outboard should

not start.

Page 37

INSTALLATION AND PREDELIVERY

PROPELLER SELECTION

Refer to Propeller Hardware Installation on p. 36 before installing propeller.

The correct propeller, under normal load conditions, will allow the engine to run near the midpoint of the RPM operating range at full throttle. Refer to TECHNICAL DATA on p. 16.

1. Percentage of horsepower (kw)

2. Engine RPM

3. Horsepower curve

4. Full throttle operating range

5. Midpoint of full throttle operating range, horsepower rating in kilowatts (kw))

6. Engine is overloaded at full throttle

7. Engine is overspeeding at full throttle

DR1261

Procedure

The propeller selection process is very important to the engine’s service life and to boat performance. Proceed carefully and thoroughly while considering the following points:

• During the engine break-in period, run the out-

board at wide-open throttle for only brief periods of time to check full-throttle RPM.

• Use an accurate tachometer to determine the

engine’s full-throttle RPM while testing various propellers.

• Select a propeller that suits the customer’s

application and allows the engine to run near the midpoint of the full-throttle operating range when the boat has a normal load in it. Refer to

TECHNICAL DATA on p. 16.

• To compensate for changes in boat loading, the

engine’s full-throttle RPM must be verified periodically.

IMPORTANT: If the propeller blades have too

much pitch, the engine is operating below its normal range at full throttle, power is being lost, and powerhead damage could occur. If the propeller blades have too little pitch, the engine is operating above its normal range at full throttle and damage from overspeeding could occur.

WARNING

CAUTION

Selection of the wrong propeller could reduce engine service life, affect boat performance, or cause serious damage to the powerhead.

When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally.

Page 38

INSTALLATION AND PREDELIVERY

PROPELLER SELECTION

Propeller Hardware Installation

WARNING

When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally.

Apply Triple-Guard grease to the entire propeller shaft before installing the propeller.

Install shear pin onto propeller shaft. Install propeller on propeller shaft. Install the cotter pin through the propeller shaft,

then bend its ends to secure the propeller.

1. Shear pin

2. Propeller

3. Cotter pin

005947

IMPORTANT: After fastening cotter pin, make

sure outboard is in NEUTRAL and carefully spin propeller. Propeller must turn freely and should not spin off center. If propeller appears to wobble, check for possible bent propeller shaft.

Page 39

MAINTENANCE

TABLE OF CONTENTS

INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

10-HOUR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SACRIFICIAL ANODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

TESTING PROCEDURE – CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

METALLIC COMPONENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

EXTERIOR FINISHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

WATER INTAKE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

BREATHER AND FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

LINKAGES AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

CRANKCASE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Page 40

MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE

Routine inspection and maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outb oard inspection and maintenance to be performed by an authorized Dealer.

IMPORTANT: Outboards used for rental operations, commercial applications, or other high hour use

applications require more frequent inspections and maintenance. Inspection and maintenance should be adjusted according to operating conditions and use; and environmental conditions.

Engine Maintenance and Inspection Schedule

Description

Swivel bracket, inspect and lubricate Clamp screws, inspect and lubricate Throttle linkage, inspect and lubricate Steering bracket, lubricate Shift lever, lubricate Lubrication and corrosion protection for metallic components

Anticorrosion anodes, check operation Water intake screens, check condition Overboard water pump indicator, check operation Steering friction, check/adjust Throttle and shift operation, check function Emergency stop circuit and lanyard, check function Clamp screws, tighten Starter, inspect cord Crankcase oil level, check H Flush cooling system Operator’s Guide, onboard Fuel system components, inspect and repair leaks Fastener inspection, tighten loosened components Thermostat, inspect and check operation Fuel filter inspection, eliminate contamination Electrical and ignition wires and connections, inspect Gearcase lubricant, replace B Powerhead synchronization and linkage, inspect

Frequency

Engine

(1)

Care

Product

D D D D D

Each Use

10-Hour

Inspection

Every 50 Hours

or 6 months

Every 60 days / Every 30 in Saltwater Every 60 days / Every 30 in Saltwater Every 60 days / Every 30 in Saltwater Every 60 days / Every 30 in Saltwater Every 60 days / Every 30 in Saltwater Every 60 days / Every 30 in Saltwater

Every 100 Hours

or Annually

Every 200 Hours

or Biannually

33 33 33 33 33 33 33 33 33 3 3

(3)

33 33 33 33

(3)

Page 41

INSPECTION AND MAINTENANCE SCHEDULE

Engine Maintenance and Inspection Schedule

Engine

Description

Crankcase oil, replace Oil filter, replace Valve tappet clearance, inspect Engine upper and lower motor covers, clean and wax Starter pinion shaft, inspect and lubricate F Gearcase lubricant, inspect fill level and condition of lube B Propeller shaft, inspect and lubricate D Spark plugs, replace Decarbonize G Operator’s Guide, review Breather and fuel line, replace Carburetor, inspect Driveshaft splines, inspect and lubricate E Fuel filter, replace Ignition timing, inspect Water pump, inspect and replace

(2)

(3)

Care

Product

MAINTENANCE

Frequency

Each Use

10-Hour

Inspection

Every 50 Hours

or 6 months

Every 100 Hours

or Annually

Every 200 Hours

or Biannually

33 33 33

3 3 3

3 3 3 3

3 3 3 3 3 3

(1) Also recommended at 10-Hour Inspection (2) Replace every 100 hours or annually if Ultra 4-Stroke oil is not used. (3) Emission-related component

A B C D E F G H

Evinrude/Johnson Anti-Corrosion Spray or Evinrude/Johnson “6 in 1” Multi-Purpose Lubricant HPF XR Gearcase Lubricant

Power Trim/Tilt and Power Steering Fluid

Triple-Guard Grease Evinrude/Johnson Moly Lube

Starter Bendix Lube Only

Evinrude/Johnson Engine Tuner Evinrude/Johnson Ultra 4-Stroke synthetic blend oil

Page 42

MAINTENANCE

10-HOUR INSPECTION

IMPORTANT: All Johnson outboard owners are

encouraged to return their new engines to an authorized dealer for a mechanical check.

This check should be performed after approximately 10 operating hours. The cost of this check should be figured at local dealer labor rates and paid for by the engine owner.

The 10-hour inspection should check:

• Anticorrosion anodes functionality

• Water intake screens

• Overboard water pump indicator

• Steering operation

• Throttle and shift operation

• Emergency stop circuit and lanyard functionality

• Fuel system components, repair any leaks

• Fuel filter, eliminate any contamination

• Fasteners, tighten loose components

• Thermostat operation

• Engine to transom mounting hardware

• Electrical and ignition wires and connections

ANTI-CORROSION PROTECTION

Sacrificial Anodes

Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to protect the underwater metal components of the outboard from galvanic corrosion.

Outboards are equipped with sacrificial anodes.

1. Gearcase housing anode 005882

Powerhead Anode 005883

Visually inspect anodes and metal components below water level. Erosion of anodes is normal and indicates the anodes are functioning properly.

IMPORTANT: Anodes that are not eroding may

indicate that the anodes are not properly grounded. Anodes and the mounting screws must be clean and tight for effective corrosion protection.

Page 43

MAINTENANCE

ANTI-CORROSION PROTECTION

For best anode performance:

• Replace all anodes that have eroded or disinte-

grated to two-thirds of their original size.

• Do not paint or apply protective coatings to

anodes or anode fasteners.

• Avoid using metal-based antifouling paint on the

boat or outboard.

IMPORTANT: The anode securing screw

should be covered with silicone sealant.

1. Anode

2. Silicone sealant

004779

Metallic Component Protection

Protect metal components on outboards from corrosion. Use the following products to minimize corrosion.

• Anti-Corrosion Spray provides a heavy, waxy

coating to protect components.

• “6 in 1” Multi-Purpose Lubricant provides a thin

film of anti-corrosion protection.

Exterior Finishes

Maintain the outboard’s exterior finish to prevent corrosion and reduce oxidation.

• Use automotive wax to protect the outboard’s

exterior finish from oxidation.

• Clean regularly using clean water and mild

detergent soap.

• Touch-up damage to painted surfaces promptly.

• Protect moving components with appropriate

lubricants.

Testing Procedure – Continuity

Calibrate multimeter on “HIGH” ohm scale. Connect meter leads between engine ground and

anode surface. The multimeter should indicate little or no resis-

tance. If resistance is high, check the following:

• Remove the anode and clean the area where

the anode is installed.

• Clean the mounting screws.

• Install the anode and test again.

Page 44

MAINTENANCE

COOLING SYSTEM

Check the condition of cooling system components regularly. The outboard cooling system consists of:

• water intake screens

• overboard water pump indicator

• water pump

• all internal water passages

• thermostat

Flushing

Flush the outboard with fresh water following each use in brackish, salt, or polluted water to minimize the accumulation of scale and silt deposits in coo ling system passages.

WARNING

Prevent injury from contact with rotating propeller; remove the propeller before flushing.

IMPORTANT: To prevent damage, do not run

outboard above fast idle. Water must flow from the water pump indicator. If it does not, shut off the outboard and repair as needed.

Shut OFF the outboard. Leave the outboard in VERTICAL (DOWN) position long enough for the water to drain from the powerhead completely.

1. Water pump indicator 005884

Remove outboard from tank and install propeller.

Procedure

Remove propeller and shift the outboard to NEUTRAL.

Run the outboard in a large container of water, such as a 30-gallon garbage can. If needed, insert a board between the rim of the can and the outboard’s clamp screws for thickness. Be sure water covers the water intakes.

TYPICAL dr6434

Water Intake Screen

Inspect condition of water intake screen. Clean or replace as needed.

1. Water intake screen 005885

Water Pump

Inspect water pump every 200 hours of operation. Refer to Water Pump on p. 127.

START outboard. Run outboard at IDLE only for at least five minutes.

Page 45

MAINTENANCE

FUEL SYSTEM

Breather and Fuel Line

If leakage, cracks, swelling, or other damage is found, replace the breather and/or the fuel line.

005886

Fuel Filter

If water accumulation, sediment, leakage, cracks, or other damage is found, replace the fuel filter.

LUBRICATION

Engine Oil

Refer to INSPECTION AND MAINTENANCE SCHEDULE on p. 38 for oil change schedule.

IMPORTANT: Engine oil should be changed

while engine is warm. Place outboard upright on a level surface. Remove the oil filler cap.

Carburetor

If damage is found, replace the carburetor.

1. Oil filler cap 005888

Place a container under engine oil drain plug (underside of lower engine cover), then remove plug and gasket to drain engine oil.

005887

1. Oil drain plug 005889

Install new gasket and oil drain plug. Tighten plug to 7 ft. lbs. (10 N·m).

IMPORTANT: Do not re-use gasket once

removed. Always use a new gasket.

005945

Page 46

MAINTENANCE

LUBRICATION

Pour recommended oil into oil filler opening, then install filler cap.

Recommended oil:

•

Evinrude/Johnson Ultra 4-Stroke oil, or

• SAE 10W-40, API classification SE, SF, SG,

SH, SJ.

Oil amount:

•

Oil change only: 0.33 Qt. (0.38 L)

St art the engin e and allow it to run for several minutes at idle speed.

Turn off engine and wait for approximately two minutes.

Check oil level.

Oil level window

Gearcase Lubricant

IMPORTANT: Always check the fill level of the

gearcase lubricant prior to removing drain/fill plug. A tie strap can be used to check lubricant level.

TYPICAL

1. Tie strap

Examine drained lubricant for excessive metal fragments and for any indication of water in oil (cloudy or milky appearance). Lubricant that is black in color with a burnt odor indicates worn, overheated oil. Pressure and vacuum check gearcases with apparent leaks. Repair all leaks.

000072

005890

Oil level should be between full level and low level in the oil level window.

Refer to INSPECTION AND MAINTENANCE SCHEDULE on p. 38 for service frequency and recommended lubricants.

Refer to LUBRICANT on p. 122 for complete gearcase lubricant filling procedures.

004363

Page 47

Linkages and Fittings

Apply Triple-Guard grease to the points shown.

Throttle cable

MAINTENANCE

LUBRICATION

Swivel bracket

Propeller shaft

Clamp screws

WARNING

When servicing the propeller, always shift the outboard to NEUTRAL position, and twist and remove all spark plug leads so the engine cannot be started accidentally.

Page 48

MAINTENANCE

SPARK PLUG

The spark plug should be removed and examined periodically. Replace worn, fouled or damaged spark plug.

• Remove spark plug and inspect condition.

• Set spark plug gap on new, replacement spark

plug.

• Apply Electrical Grease to the ribbed portion of

the spark plug ceramic and to the opening of the spark plug cover to prevent corrosion.

Recommended spark plug and gap setting:

• NGK CR6HSA @ 0.026 in. (0.65 mm).

Tighten spark plug 8 ft. lbs. (11 N·m).

VALVE CLEARANCE

Measurement

Remove engine cover. Remove recoil starter. Refer to starter REMOVAL

on p. 141. Remove spark plug. Remove four screws and cylinder head cover.

1 2

1. Screw (4)

2. Cylinder head cover

005896

005895

Rotate the flywheel clockwise to bring the piston to Top Dead Center (TDC) on compression stroke.

IMPORTANT: Rotate the crankshaft in the nor-

mal running direction only (clockwise) to prevent water pump impeller damage.

To confirm whether the piston is at the TDC position on a compression stroke or on a exhaust stroke, rotate the flywheel within ±15° beyond the TDC position:

• If both rocker arms do not move at all, the piston

is at the position on a compression stroke.

• If any rocker arm moves, the piston is at the

TDC position on an exhaust stroke. Rotate the flywheel one more turn.

IMPORTANT: The piston must be at its TDC

position on a compression stroke to check or adjust valve clearance.

Page 49

MAINTENANCE

VALVE CLEARANCE

Use a feeler gauge to measure clearance between valve stem end and valve adjusting screw on rocker arm.

valve clearance

005897

Valve clearance: (cold engine)

• IN: 0.005 to 0.007 in. (0.13 to 0.17 mm)

• EX: 0.005 to 0.007 in. (0.13 to 0.17 mm)

If measurement is out of specification, adjust valve clearance.

IMPORTANT: The valve clearance specification

is for COLD engine condition.

Adjustment

Loosen the valve adjusting lock nut while holding the valve adjusting screw.

Turn valve adjusting screw using to bring valve clearance within specification.

1. Lock nut

2. Adjusting screw

Tighten valve adjusting lock nut while holding valve adjusting screw. Tighten lock nut to 5 ft. lbs. (7 N·m).

005899

005898

005900

Recheck valve clearance.

Page 50

MAINTENANCE

IDLE SPEED

Tighten the four cylinder head screws to 5 ft. lbs. (7 N·m).

1. Screw (4) 005896

IMPORTANT: Do not re-use gasket once

removed. Always use a new gasket.

IDLE SPEED

Check throttle link mechanism and carburetor throttle valve for smooth operation.

Untie the knot in grip holder and remove the grip holder and starter grip.

005942

Completely remove the engine cover. Reinstall the starter grip and grip holder. Loosen

the knot previously tied in the rope.

The starter grip must be removed before the engine cover can be completely removed. Tie a knot in the rope inside the engine cover in order to prevent the rope from winding onto the recoil reel when the starter grip is removed.

005902

005943

Connect a shop tachometer to the engine.

005901

Page 51

MAINTENANCE

IGNITION TIMING

Start and warm the engine.

Engine idle speed:

• 1800 to 2000 RPM

IMPORTANT: Check and/or adjust idle speed

after the engine speed has stabilized. If idle speed is out of specification, adjust as fol-

lows: Turn the throttle stop screw:

• Clockwise: Engine speed increases

• Counterclockwise: Engine speed decreases.

IGNITION TIMING

IMPORTANT: Before checking ignition timing,

make sure idle speed is adjusted within specification.

Start and warm the engine. Connect a shop tachometer and timing light to the

engine.

Check the ignition timing while operating the engine at 1900 RPM (idle speed).

Ignition timing:

• 30° BTDC @ 1900 RPM

1. Throttle stop screw 005944

005946

Page 52

MAINTENANCE

STORAGE

WARNING

To prevent injury from contact with rotating propeller, remove the propeller before flushing.

IMPORTANT: DO NOT start outboard without a

water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur.

Fuel System Treatment

Stabilize the boat’s fuel supply with Evinrude/Johnson 2+4 Fuel Conditioner following the instructions on the container.

START outboard and RUN at IDLE speed for five minutes to ensure that the entire fuel system is filled with the storage mixture.

Proceed with Internal Engine Treatment.

Internal Engine Treatment

Turn the flywheel in a clockwise direction to distribute the fogging oil throughout the cylinder. Install and torque the spark plug.

IMPORTANT: DO NOT restart outboard until it

goes back into service. If the outboard is removed from boat, examine all

loosened and removed hardware. Replace damaged or missing parts with genuine Evinrude/Johnson parts or equivalent.

Additional Recommendations

• Replace gearcase lubricant.

• Remove and inspect propeller.

• Clean and grease propeller shaft.

• Lubricate all grease fittings and linkages.

• Clean or replace fuel filter element.

• Inspect outboard. Replace all damaged and

worn components. Refer to manufacturer’s maintenance and lubrication recommendations.

• Touch up painted surfaces as needed. Coat

outer painted surfaces with automotive wax.

• Store outboard in upright (vertical) position.

• Check for fuel leakage.

Check level and condition of crankcase oil. Change oil and filter if required. Refer to INSPEC- TION AND MAINTENANCE SCHEDULE on p. 38.

Use Evinrude/Johnson Storage Fogging Oil to prevent corrosion of internal engine components during periods of storage.

Remove spark plugs and spray a liberal amount of Evinrude/Johnson Storage Fogging Oil into the spark plug hole.

WARNING

Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

Page 53

MAINTENANCE

PRE-SEASON SERVICE

If the outboard was removed from the boat for storage, make certain it has been reinstalled with factory specified hardware.

Crankcase Oil

• Check oil level

• Add oil as needed

Gearcase Lubricant

• Check the lubricant level.

• Inspect gearcase for leaks. If leak is apparent,

pressure and vacuum test gearcase.

• Repair gearcase as needed.

Operational Checks

• Steering

• Throttle and shift

• All other accessories

Fuel System

• Inspect entire fuel system for leaks prior to start-

ing outboard. Repair all leaks.

• Start outboard and reinspect.

WARNING

Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

SUBMERGED ENGINES

Once an outboard has been submerged in fresh or salt water, it must be serviced within three (3) hours of recovery. Immediate service can minimize the corrosive affect that air has on the polished surfaces of the crankshaft, connecting rods, and internal powerhead bearings.

IMPORTANT: If outboard cannot be started or

serviced immediately, it should be resubmerged in fresh water to avoid exposure to the atmosphere.

Engine Dropped Overboard (Not Running)

Disconnect battery cables at the battery. Rinse powerhead with clean water. Remove spark plug leads and spark plugs. Place outboard in horizontal position (cylinder

heads down). Slowly rotate flywheel in a clockwise rotation to work all water out of powerhead.

IMPORTANT: If sand or silt may have entered

the outboard, DO NOT attempt to start the it. Disassemble and clean.

Place engine in upright position. Drain, disassemble, and clean carburetor.

Disassemble all electrical connectors. Clean connectors and terminals, and treat with water displacing electrical spray. Apply Electrical Grease to terminals prior to reassembly. Coat all exposed solenoid terminals and engine grounds with Black

Neoprene Dip.

Clean and inspect all electrical components. Replace damaged or corroded components prior to returning the outboard to service. Electric starters should be disassembled, cleaned, flushed with clean water , and trea ted with water displacin g electrical spray prior to reassembly.

Change oil and filter. Remove carburetor for draining, disassembly and

cleaning.

Page 54

MAINTENANCE

SUBMERGED ENGINES

Disconnect fuel supply hose from outboard. Drain and clean all fuel hoses, filters, and fuel tanks. Refill fuel tank with fresh fuel.

Inject a small amount of outboard lubricant into spark plug holes and install new spark plugs.

Reinstall all removed or disconnected parts. Run the outboard below 1500 RPM for one-half

hour. Change oil and filter again.

Engine Dropped Overboard (Running)

Follow the same procedures as Engine Dropped Overboard (Not Running). However, if there is

any binding when the flywheel is rotated, it may indicate a bent connecting rod and no attempt should be made to start the outboard. Powerhead must be disassembled and serviced immediately.

Engine Dropped Overboard (In Salt Water)

Follow the same procedures used for Engine Dropped Overboard (Not Running) and Engine Dropped Overboard (Running). Disassemble

and clean outboards that have been submerged in salt water for prolonged periods of time. Clean or replace electrical components as necessary.

Prolonged Submersion (Fresh or Salt Water)

Outboards that have been dropped overboard and not recovered immediately, must be serviced within three hours of recovery. Follow the same procedures used for Engine Dropped Overboard

(Not Running) and Engine Dropped Overboard (Running).

Page 55

IGNITION AND ELECTRICAL

TABLE OF CONTENTS

SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

IGNITER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SPARK PLUG CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

IGNITER AIR GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Page 56

IGNITION AND ELECTRICAL

SERVICE CHART

1. Flywheel

2. Ignition coil

3. Bolt

4. Nut

5. Key

6. Cap, spark plug

7. Seal, spark plug

8. Seal, high tension cord

9. Switch assembly, emergency

10. Plate, lock

11. Nut

12. Label, stop

13. Clamp

14. Holder, throttle cable

A Triple-Guard Grease B Gasket Sealing Compound C Adhesive 847

F Blue Nut Lock R DPL Penetrating Lube W HPF XR Gear Oil

D Moly Lube

EPC4223

Page 57

IGNITION AND ELECTRICAL

OPERATION

The outboard uses a transistorized ignition circuit. The ignition system consists of a flywheel magneto, an igniter unit, a spark plug and an emergency stop switch.

Flywheel magneto

Emergency stop switch

Igniter unit

Spark plug

Page 58

IGNITION AND ELECTRICAL

OPERATION

When the recoil starter is pulled, the flywheel is turned. An electromotive force generated in the primary winding (n primary circuit (indicated by dashed lines).

As the flywheel turns further, the primary current increases, and the terminal voltage of the circuit consisting of the resistor (R nection of the series circuit (R further, the terminal vo lt age of the resistor (R ing voltage of the transistor (TR turned on. As a result, the base current of (TR transistor (TR

1) of the ignition coil makes the transistor (TR1) conduct through the resistor (R1) and forms the

1) and transistor (TR1) increases. This increases the working voltage at the con- 2 and R3) connected in parallel to the primary circuit. As the flywheel turns

3) in the resistor circuit (R2 and R3) rises to the level of work-

2) when the ignition timing approaches, and thus the transistor (TR2) is

1) flowing through the resistor (R1) is bypassed, and the

1) is turned off from the conductive state.

The current flowing through the primary winding (n

1) is thus interrupted, and a rapid change occurs in the

magnetic flux across the ignition coil. The result is a high surge voltage in the secondary winding (n

Transistor

Ignition coil

Spark plug

Emergency stop switch

Flywheel magneto

2).

Page 59

IGNITION AND ELECTRICAL

TROUBLESHOOTING

Perform the following ignition system tests when engine is hard to start to determine if the cause is in the ignition or other system.

START

Check spark condition.

No or weak sparks

Check if spark plug is in good condition (Refer to SPARK PLUG on page 46).

Disconnect the emergency stop switch lead wire (black).

No or weak sparks

Check the air gap between the igniter unit core and the flywheel.

Air gap: 0.02 in. (0.5 mm)

Check the igniter unit resistance (Refer to Igniter Unit on page 58).

Primary: 0.5 to 0.9 kΩ Secondary: 10 to 16 kΩ

Sparks

Check ignition timing by using timing light. (30° BTDC at 1900 RPM)

Sparks

Out of Spec.

Replace spark plug with a new one

Check and/or replace the emergency stop switch (Refer to Engine Stop Switch on page 58).

Adjust the air gap (Refer to Igniter Air Gap on page 59).

The cause is not in the ignition system

Check the spark plug cap for any evidence of a high-tension leak.

Check the spark plug cap resistance (Refer to Spark Plug Cap on page 58).

Cap resistance: 4 to 6 kΩ

Out of Spec.

Replace the spark plug cap.

Replace the igniter unit.

Page 60

IGNITION AND ELECTRICAL

IGNITION TESTS

Igniter Unit

Resistance Test

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

Connect Ohmmeter test probes to igniter unit coils as shown:

Tester probe connection

Probe Other Probe

Primary coil Terminal Core

Secondary coil High-tension cord Core

Igniter unit coil resistance:

• Primary coil resistance: 0.5 to 0.9 kΩ

• Secondary coil resistance: 10 to 16 kΩ

Spark Plug Cap

Resistance Test

Measure spark plug cap resistance. Spark plug cap resistance:

• 8 to 12 kΩ

004698

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

Primary Coil 005950

Secondary Coil 005953

If measurement is out of specification, replace the igniter unit.

Engine Stop Switch

Check continuity of the emergency stop switch:

Switch condition Continuity

Lock plate IN No

Lock plate OUT Yes

Lock plate IN &

button depressed

1 2

CONT

If the result is out of specification, replace the emergency stop switch.

Yes

005954

Page 61

IGNITION AND ELECTRICAL

COMPONENT SERVICING

Igniter Air Gap

Use a thickness gauge to measure the air gap between the flywheel and the igniter unit:

• Air gap: 0.02 in. (0.5 mm)

005955

Removal

Use strap-type flywheel holder, P/N 507976, or equivalent to loosen the flywheel nut.

IMPORTANT: Do not remove the flywheel nut.

It prevents damage to the crankshaft when using flywheel remover tools.

1. Flywheel holder 005957

Install the puller on flywheel. Hold puller by its handle, and tighten pressing screw until flywheel releases.

WARNING

Before removing ignition parts, twist and remove spark lead.

Flywheel

Remove the manual starter. Refer to starter REMOVAL on p. 141.

Disconnect the emergency stop switch lead wire from the igniter unit, and remove the two bolts securing the igniter unit.

Universal Puller 005958

1. Emergency stop switch lead wire

2. Bolts

005956

Page 62

IGNITION AND ELECTRICAL

COMPONENT SERVICING

Remove the flywheel nut, starter pulley, flywheel, and key.

1. Flywheel nut

2. Starter pulley

3. Flywheel

4. Key

005959

Igniter Unit

Install the igniter unit with an air gap of 0.02 in. (0.5 mm) between both core ends and the flywheel. Check the gaps as shown.

005955

Tighten igniter unit bolts to 7.0 ft. lbs. (10 N·m). Reconnect emergency stop switch lead wire.

Installation

Installation is reverse order of removal with special attention to the following steps:

Flywheel

Clean flywheel and crankshaft mating surfaces with cleaning solvent.

Use strap-type flywheel holder, P/N 507976, or equivalent to hold the flywheel. Tigh ten nut to 32.5 ft. lbs. (45 N·m).

1. Bolts

2. Emergency stop switch lead wire

005956

Final Assembly Check

Perform the following checks to ensure proper and safe operation:

All parts removed have been returned to their original positions.

Wire routings are correct. Refer to WIRE/HOSE ROUTING on p. 145.

1. Flywheel holder 005957

Page 63

FUEL SYSTEM

TABLE OF CONTENTS

SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

LEAKAGE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

THROTTLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Page 64

FUEL SYSTEM

SERVICE CHART

1. Carburetor

2. Nozzle, main

3. Jet, main (68) Jet, main (70) Jet, main (72)

4. Valve, needle

5. Float

6. Pin, float

7. Spring

8. Gasket

9. Chamber, float

10. Gasket

11. Screw

12. Spring

13. Screw

14. Screw

15. Jet, pilot (30) Jet, pilot (32) Jet, pilot (34)

16. Screw

17. Jet, air (170)

18. Jet, pilot air (145)

19. Gasket

20. Plate

21. Spring

22. Screw

23. Screw

24. Gasket, carburetor

25. Rod, choke

26. Connector, choke rod

27. Knob, choke

28. Bolt

EPC4225

Page 65

1. Tank, fuel

2. Bracket, fuel tank

3. Cap assembly, fuel tank

4. Gasket, tank cap

5. Cushion

6. Grommet, fuel tank

7. Rubber, fuel tank grommet

8. Valve assembly, fuel

9. Clip, fuel hose

10. Hose, fuel (valve to carb)

FUEL SYSTEM

EPC4224

Page 66

FUEL SYSTEM

REMOVAL

WARNING

Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.

Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.

Remove the engine cover. Remove the recoil starter. Refer to MANUAL STARTER on p. 139.

Turn the fuel cock lever to the “OFF” position. Loosen the screw securing the throttle control

inner cable and detach the choke rod from the carburetor.

Remove the two bolts securing the carburetor.

1. Bolts 005963

Remove the carburetor and air silencer.

1. Screw

2. Choke rod

Remove the fuel hose from the fuel cock.

005960

1. Carburetor

2. Air silencer

005969

Remove fuel hose from the carburetor.

1. Fuel hose 005964

Inspect the fuel hose. If cracks, swelling, or other damage is found, replace the fuel hose.

1. Fuel hose

2. Fuel cock

005962

Page 67

FUEL SYSTEM

CARBURETOR

Disassembly

Remove the idle adjusting screw and the four screws securing the plate.

2 1 3

1. Idle adjusting screw

2. Screw (4)

3. Plate

Remove the main air jet, the pilot air jet and the screw.

005973

Remove the pilot jet.

1. Pilot jet 005975

Remove the bolt and the float chamber.

3 2

1. Main air jet

2. Pilot air jet

3. Screw

005974

1. Bolt

2. Float chamber

005976

Remove the float pin, the float and the float spring.

1. Float pin

2. Float

3. Float spring

005977 005978

IMPORTANT: Always remove the float pin from

the right side to the left side.

Page 68

FUEL SYSTEM

CARBURETOR

Remove the needle valve from the float.

1. Needle valve 005979

Remove the main jet.

Cleaning and Inspection

Clean carburetor components thoroughly with cleaning solvent and compressed air before inspection.

WARNING

Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).

IMPORTANT: Do not place any rubber, plastic

or non-metallic parts in cleaning solvent, as severe damage or deterioration will result. Do not use a wire or a small drill bit in order to clean the orifices and jets of the carburetor.

Carburetor Body and Float Chamber

Inspect the carburetor body and the float chamber. If damage is found, replace component.

1. Main jet 005980

Remove the main nozzle.

1. Main nozzle 005981

005982

Jet and Nozzle

Inspect the jets and nozzles. If crack or other damage is found, replace the component.

005983

Page 69

FUEL SYSTEM

CARBURETOR

Needle Valve

Inspect the needle valve. If broken tip or wear is found, replace the valve.

005984

Float

Inspect the float. If crack or other damage is found, replace the float.

Install the main nozzle to the carburetor body before installing the main jet.

1. Main nozzle

2. Main jet

Install the float with needle valve.

005986 005987

005985

Reassembly

Reassembly is reverse order of disassembly with special attention to the following steps.

1. Float

2. Needle valve

Install the float pin.

005988

IMPORTANT: Always install the float pin from

the left side to the right side.

005989

Install the float pin spring.

Page 70

FUEL SYSTEM

INSTALLATION

IMPORTANT: After installing float, inspect for

smooth movement of float.

1. Spring 005978

Checking Float Height

Measure the float height.

• Float height: 10 ± 2 mm

INSTALLATION

Installation is reverse order of removal with special attention to the following steps.

005970

IMPORTANT: Do not re-use the removed gas-

ket. Always use a new gasket. Tighten the carburetor mounting bolts to 7.0 ft.

lbs. (10 N·m).

Float Height 005990

IMPORTANT: Float weight cannot be applied to

needle valve. Install the pilot jet, pilot air jet, and main air jet.

1. Pilot jet

2. Pilot air jet

3. Main air jet

005991

1. Bolts 005963

Refer to Throttle Adjustment on p. 69.

Page 71

FUEL SYSTEM

INSTALLATION

Leakage Check

Twist the air-vent screw o n the fuel tank cap counterclockwise to open the vent.

005966

Turn the fuel cock lever “ON” position.

Throttle Adjustment

Fully close the throttle control grip. Turn the idle adjusting screw counterclockwise

until the screw does not touch the stopper plate.

1. Screw

2. Stopper plate

Insert the throttle control inner cable into the linkage hole. While pulling the cable, tighten the screw in order to secure the cable.

005971

005967

Check the fuel line for leaks.

1. Fuel line 005968

1. Cable

2. Screw

Adjust the idle speed. Refer to IDLE SPEED on p. 48.

005972

Page 72

FUEL SYSTEM

FUEL TANK

Removal

Remove the motor cover. Remove the recoil starter. Refer to MANUAL

STARTER on p. 139.

1. Recoil starter 005992

Turn the fuel cock lever to the “OFF” position.

Remove the fuel tank.

1. Fuel tank 005995

Loosen the connecting screw and remove the fuel cock from the fuel tank.

1. Fuel cock lever — OFF position 005993

Remove the fuel hose from the fuel cock.

1. Screw

2. Fuel cock

005996

Inspection

Check the filter. If clogged, or damaged is found, clean the filter, or replace the fuel cock.

Inspect the fuel cock. If leakage, deterioration, or other damage is found, replace the assembly.

1. Fuel hose

2. Fuel cock

005994

Fuel Cock and Filter 005997

Page 73

FUEL SYSTEM

FUEL TANK

Inspect the fuel tank. If crack, leakage, or deterioration is found, replace the tank.

If water or other contamination is found, drain and clean the tank.

Fuel Tank 005998

Check that the fuel tank vent opens and relieves internal tank pressure properly.

If vent does not work, replace the tank cap.

Installation

Installation is reverse order of removal with special attention to the following steps.

Place the fuel tank bracket in position.

1. Fuel tank bracket 006000

Install the fuel tank and recoil starter. Check the fuel hose routing. Refer to WIRE/HOSE

ROUTING on p. 145.

Fuel Tank Cap and Vent 005999

Check for fuel leakage.

WARNING

Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

Page 74

FUEL SYSTEM

NOTES

Technician’s Notes Related Documents

Bulletins

Instruction Sheets

Other

Page 75

POWERHEAD

TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

CYLINDER/CRANKCASE/PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

IGNITER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

FINAL ASSEMBLY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

WATER COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Page 76

POWERHEAD

SPECIFICATIONS

Item Unit

Data

2.5 HP

CYLINDER HEAD / CAMSHAFT

Cylinder head distortion Limit mm (in) 0.05 (0.002) Cam height

Rocker arm shaft hole diameter

Rocker arm shaft outside diameter

IN, EX

STD mm (in) 28.480 – 28.680 (1.1213 – 1.1291) Limit mm (in) 28.180 (1.1094)

STD mm (in) 4.015 – 4.027 (0.1581 – 0.1585)

STD mm (in) 3.990 – 4.005 (0.1571 – 0.1577)

VALVE / VALVE GUIDE

Valve diameter IN mm (in) 20.0 (0.79)

EX mm (in) 18.0 (0.71)

V a l ve cl earance (Cold engine condition)

Valve seat angle IN — 45°

V alve guide to valve stem clearance

V alve guide inside diameter

Va lve stem outside diameter

V alve stem deflection

V alve stem runout

IN STD mm (in) 0.13 – 0.17 (0.005 – 0.007)

EX STD mm (in) 0.13 – 0.17 (0.005 – 0.007)

EX — 45°

IN, EX STD mm (in) 4.000 – 4.012 (0.1575 – 0.1580) Valve guide inside diameter

IN STD mm (in) 3.975 – 3.990 (0.1565 – 0.1571)

EX STD mm (in) 3.960 – 3.975 (0.1559 – 0.1565)

IN, EX Limit mm (in) 0.35 (0.014) Valve stem deflection

IN, EX Limit mm (in) 0.05 (0.002) Valve stem runout

STD mm (in) 0.010 – 0.037 (0.0004 – 0.0015) Limit mm (in) 0.075 (0.0030) STD mm (in) 0.025 – 0.052 (0.0010 – 0.0020) Limit mm (in) 0.090 (0.0035)

Valve diameter

V a l ve cl earance (Cold engine condition)

V a l v e se at ang l e

Va lve guide to valve stem clearance

Valve stem outs ide diameter

Page 77

POWERHEAD

SPECIFICATIONS

Item Unit

Data

2.5 HP

CYLINDER / PISTON / PISTON RING

Cylinder distortion Limit mm (in) 0.05 (0.002) Piston to cylinder

clearance Cylinder bore STD mm (in) 48.000 – 48.015 (1.8898 – 1.8904)

Cylinder measuring position mm (in) 20 (0.8) from cylinder top surface Piston skirt diameter STD mm (in) 47.975 – 47.990 (1.8888 – 1.8894) Piston measuring position mm (in) 5 (0.2) from piston skirt end Cylinder bore wear Limit mm (in) 0.100 (0.0039) Piston ring end

gap Piston ring free

end gap

Piston ring to groove clearance

Piston ring groove width

Pin clearance in piston pin hole

Piston pin outside diameter

Piston pin hole diameter STD mm (in) 12.002 – 12.008 (0.4725 – 0.4728)

Pin clearance in connecting rod small end

1st,

2nd

1st

2nd

1st,

2nd

1st,

2nd

STD mm (in) 0.018 – 0.033 (0.0007 – 0.0013)

Limit mm (in) 0.100 (0.0039)

STD mm (in) 0.15 – 0.35 (0.006 – 0.014)

Limit mm (in) 0.50 (0.020)

STD mm (in) Approximately 6.1 (0.24)

Limit mm (in) 4.9 (0.19)

STD mm (in) Approx. 5.7 (0.22)

Limit mm (in) 4.6 (0.18)

STD mm (in) 0.020 – 0.060 (0.0008 – 0.0024)

Limit mm (in) 0.120 (0.0047)

STD mm (in) 1.21 – 1.23 (0.048 – 0.049) STD mm (in) 0.002 – 0.013 (0.0001 – 0.0005)

Limit mm (in) 0.040 (0.0016)

STD mm (in) 11.995 – 12.000 (0.4722 – 0.4724)

Limit mm (in) 11.980 (0.4717)

Limit mm (in) 12.030 (0.4736)

STD mm (in) 0.006 – 0.019 (0.0002 – 0.0007)

Limit mm (in) 0.050 (0.0020)

CRANKSHAFT / CONNECTING ROD

Connecting rod small end inside diameter

Connecting rod big end oil clearance

Connecting rod big end inside diameter

Crank pin outside diameter

Crank pin outside diameter difference (out-ofround and taper)

Connecting rod big end side clearance

Connecting rod big end width

Crank pin width STD mm (in) 18.00 – 18.20 (0.709 – 0.717) Crankshaft runout Limit mm (in) 0.05 (0.002)

STD mm (in) 12.006 – 12.014 (0.4727 – 0.4730)

Limit mm (in) 12.040 (0.4740)

STD mm (in) 0.015 – 0.035 (0.0006 – 0.0014)

Limit mm (in) 0.080 (0.0031)

STD mm (in) 19.015 – 19.025 (0.7486 – 0.7490)

STD mm (in) 18.990 – 19.000 (0.7476 – 0.7480)

Limit mm (in) 0.010 (0.0004)

STD mm (in) 0.20 – 0.70 (0.008 – 0.028)

Limit mm (in) 1.00 (0.039)

STD mm (in) 17.50 – 17.80 (0.689 – 0.701)

Page 78

POWERHEAD

COMPRESSION TESTING

Start and run outboard until it achieves operating temperature, then shut OFF.

Remove spark plug. Advance throttle linkage to WOT. Install compression tester’s hose attachment into

spark plug hole.

WARNING

Disconnect the safety lanyard from the emergency stop switch prior to starting the engine. This will prevent any residual fuel from the cylinder from being ignited by a spark from the spark plug cap.

While starting the outboard with starter, note maximum pressure reading on gauge.

IMPORTANT: The values shown are guidelines

only, not absolute service limits.

Cylinder Compression Test

Standard

If engine shows a variation in test, check for:

137 to 199 psi

(960 to 1400 kPa)

• Excessively worn cylinder wall

• Worn piston

• Worn or stuck piston ring

• Poor seating of valves

• Ruptured or damaged cylinder head gasket

Install all parts that were removed.

Page 79

POWERHEAD

REMOVAL

Before removing the powerhead:

• Drain the engine oil. Refer to Engine Oil on

p. 43.

• Shift into “NEUTRAL” position.

• Remove the recoil starter assembly. Refer to

MANUAL STARTER on p. 139.

• Remove the fuel tank. Refer to FUEL TANK on

p. 70.

• Remove the carburetor assembly. Refer to

CARBURETOR on p. 65.

• Remove the igniter unit and flywheel magneto.

Refer to Removal on p. 59.

• Remove the tiller handle assembly. Refer to

Tiller Handle on p. 112.

Remove the four engine mounting bolts.

Detach the powerhead and lower cover. Remove the four lower cover bolts, then detach

the powerhead from the lower cover.

1. Bolt (4) 006003

Remove the bolt and oil seal protector.

1. Bolt (4) 006002 006001

2 1

1. Bolt

2. Oil seal protector

006004

Page 80

POWERHEAD

CYLINDER HEAD

Disassembly

Remove the two bolts, intake manifold, and insulator.

1. Bolt (2)

2. Intake manifold

3. Insulator

Remove the four cylinder head cover four bolts and cover.

006010

Remove the valve adjusting lock nuts, then the valve adjusting screw. Remove the rocker arm shaft and the rocker arms.

1. Lock nut (2)

2. Screw (2)

3. Rocker arm shaft

4. Rocker arm (2)

Remove the push rods.

006012

1. Bolt (4)

2. Cover

006011

1. Push rod (2) 006013

Remove the cylinder head gasket and the five cylinder head bolts from the cylinder block.

1. Gasket

2. Bolt (5)

006014

Page 81

POWERHEAD

CYLINDER HEAD

Remove the retainers.

1. Retainer (2) 006023

IMPORTANT: To remove the retainer, move it

in the direction shown, and force it off the valve shaft.

Remove the intake valve and exhaust valve.

1 2

1. Intake valve

2. Exhaust valve

Remove the valve stem seals.

006026

006024

Remove the valve springs.

1. Valve spring (2) 006025

IMPORTANT: Reassemble each valve spring to

its original position.

1. Valve stem seal (2) 006027

IMPORTANT: Do not re-use the removed valve

stem seal.

Page 82

POWERHEAD

CYLINDER HEAD

Cleaning and Inspection

IMPORTANT: If any excessive wear, cracks,

defects, or other damage is found on any component, replace.

Cylinder Head

Remove all carbon from the combustion chamber.

IMPORTANT: Do not use any sharp edged tool

to scrape carbon off the cylinder head or components. DO NOT scuff or nick the metal surfaces when decarboning.

Cylinder Head Distortion

Using a straightedge and thickness gauge, measure the gasket surface of the cylinder head at six locations as shown.

Cylinder head distortion:

• Service limit: 0.002 in. (0.05 mm)

006030

If the measurement exceeds the service limit, resurface or replace the cylinder head.

006028

Inspect the cylinder head for crack in the intake and the exhaust ports, the combustion chamber and the head surface.

006029

Valve Seat

Inspect the valve seats for cracks or other damage.

006031

IMPORTANT: The cylinder head can be resur-

faced using a surface plate and a #400 grit wet sandpaper. Move the cylinder head in a figure eight pattern when sanding.

Page 83

POWERHEAD

CYLINDER HEAD

Water Jacket

Inspect the water jacket for clogs or obstructions. Clean the water jackets if necessary.

006032

Rocker Arm and Shaft

Inspect the rocker arms and shaft for wear, bends, cracks, or other damage. Replace if necessary.

Rocker arm shaft hole diameter:

• 0.1581 to 0.1585 in. (4.015 to 4.027 mm)

006034

Measure the rocker arm shaft diameter.

Rocker arm shaft outside diameter:

• 0.1571 to 0.1577 in. (3.990 to 4.005 mm)

006033

Measure the rocker arm shaft hole diameter using a small bore gauge.

006035

Push Rod

Inspect the push rods for bends or other damage. Replace it necessary.

006036

Page 84

POWERHEAD

CYLINDER HEAD

Valve and Valve Guide

Using a micrometer and a small bore gauge, measure the diameters on the valve stems and the guides in order to check the guide to stem clearance. Measure at more than one place along length of each stem and guide.

Valve stem outside diameter:

• IN: 0.1565 to 0.1571 in. (3.975 to 3.990 mm)

• EX: 0.1559 to 0.1565 in. (3.960 to 3.975 mm)

006037

Measure the valve guide inside diameter using a small bore gauge.

If the measurement exceeds the service limit, replace the valve and/or the cylinder head.

If unable to measure the valve guide inside diameter, measure the valve stem deflection.

006039

Install valves into the valve guide. Lift valves 8 to 10 mm off seat. Move the valve head in the direction “X – Y” and

measure the deflection.

Valve stem deflection:

• IN / EX: 0.014 in. (0.35 mm)

006038

Valve guide inside diameter:

• IN / EX: 0.1575 to 0.1580 in. (4.000 to 4.012

mm)

Valve guide to valve stem clearance:

• IN: 0.0004 to 0.0015 in. (0.010 to 0.037 mm)

• EX: 0.0010 to 0.0020 in. (0.025 to 0.052 mm)

Service limit:

• IN: 0.0030 in. (0.075 mm)

• EX: 0.0035 in. (0.090 mm)

If the measurement exceeds the service limit, replace the valve and/or the cylinder head.

Valve Stem End

Inspect the valve stem end face for pitting and wear. If pitting or wear is found, the valve stem end may be resurfaced. If the chamfer of stem end has been worn away, replace the valve.

006040

Page 85

POWERHEAD

CYLINDER HEAD

Valve Stem Runout

Measure the valve stem runout.

006041

Valve stem runout:

• 0.002 in. (0.05 mm)

If the measurement exceeds the service limit, replace the valve.

Valve Head Radial Runout

Measure the valve head radial runout.

Valve Head Thickness

Measure the thickness of the valve head.

Valve head thickness:

• IN / EX: 0.02 in. (0.5 mm)

If the measurement exceeds the service limit, replace the valve.

Valve Seat Contact Width

Measure the valve seat contact width.

Valve head radial runout:

• 0.003 in. (0.08 mm)

If the measurement exceeds the service limit, replace the valve.

006042

006044

Remove all carbon from the valve and seat. Coat the valve seat evenly with Prussian Blue (or

equivalent). Install the valve into the valve guide. Put the valve lapper on the valve head. Rotate the valve while gently tapping the valve

contact area against the seat. Continue coating the valve seating face with Prus-

sian Blue.

Page 86

POWERHEAD

CYLINDER HEAD

Measure the valve seat contact width.

1. Valve seat contact area 006045

Valve seat contact width:

• IN / EX: 0.03 to 0.04 in. (0.8 to 1.0 mm)

If measurement exceeds specification, repair valve seat.

Clean and assemble the cylinder head and valve components.

IMPORTANT: Fill the intake and the exhaust

ports with solvent in order to check for leaks between the valve seat and the valve.

If any leaks occur, inspect the valve seat and the face for burrs or debris which could prevent the valve from sealing.

Valve Spring

Measure the valve spring free length.

If the measurement exceeds the service limit, replace the valve spring.

Valve Spring Preload

Measure the valve spring preload.

006048

Valve spring preload:

• Standard – IN / EX: 8.05 to 9.24 lbs. (3.65 to

4.19 kg) for 0.6 in. (15 mm)

• Service limit – IN / EX: 7.34 lbs. (3.3 kg) for 0.6

in. (15 mm)

If the measurement exceeds the service limit, replace the valve spring.

Assembly

Assembly is reverse order of disassembly with special attention to the following steps.

Apply engine oil to the valve stem seals.

Valve spring free length:

• Standard – IN / EX: 0.883 in. (22.42 mm)

• Service limit – IN / EX: 0.847 in. (21.52 mm)

Install the valve stem seals to the valve guide.

006047

1. Valve stem seal (2) 006049

IMPORTANT: Do not re-use the removed valve

stem seal. Always use a new stem seal.

Page 87

POWERHEAD

CYLINDER HEAD

Apply engine oil to the valve guide bore and valve stem.

Install the valves in the valve guides.

1. Valve (2) 006050

Install the valve spring and the retainer.

the retainer, and let it slide sidewise into the center hole.

1. Side hole 006052

Make sure the retainers are properly seated in groove.

Groove

1. Valve spring

2. Retainer

006051

IMPORTANT: Reassemble each valve spring to

its original position. Push down the retainer with both thumbs so the

valve stem can be inserted into the side hole of

006053

IMPORTANT: Do not re-use cylinder head gas-

ket. Always use a new gasket. Before installing cylinder head gasket, apply

ThreeBond 1207B sealant to both surfaces of the shaded areas shown.

006015

Page 88

POWERHEAD

CYLINDER HEAD

Installation

Insert the dowel pins and place a new cylinder head gasket into position on cylinder.

1. Dowel pins

2. Gasket

Position cylinder head assembly on cylinder. Apply engine oil to cylinder head bolts. Lightly

seat all cylinder head bolts. Tighten bolts in two steps according to tightening

order.

• First torque: 5.0 ft. lbs. (7 N·m)

• Final torque: 9.5 ft. lbs. (13 N·m)

006016

Install the push rods onto the cam rocker arms.

1. Push rod (2)

2. Cam rocker arms

Install the rocker arms and the rocker arm shaft. Adjust the valve clearance. Refer to VALVE

CLEARANCE on p. 46.

006019 006020

Torque Sequence 006017

1. Rocker arm (2)

2. Rocker arm shaft

Install the cylinder head cover and the gasket, then tighten the four cylinder head cover bolts according to tightening order to torque of 5.0 ft. lbs. (7 N ·m).

Torque Sequence 006022

006021

Page 89

POWERHEAD

CYLINDER/CRANKCASE/PISTON

CYLINDER/CRANKCASE/ PISTON

Disassembly

Remove the powerhead. Refer to REMOVAL on p. 77.

Remove the cylinder head. Refer to CYLINDER HEAD on p. 78.

Remove the bolt and the under oil seal plate.

Remove the thrust washer.

1. Thrust washer 006056

Remove the cam rocker arm, washer, cam rocker arm, spring, washer, and shaft.

1. Bolt

2. Seal plate

Remove the eight bolts and the crankcase.

006054

1. Crankcase 006055

1. Cam rocker arm

2. Washer

3. Spring

4. Washer

5. Shaft

Remove the oil pump shaft, camshaft, and shaft.

1. Oil pump shaft

2. Camshaft

3. Shaft

006057

006058

1 2

Page 90

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Remove the two connecting rod bolts and the connecting rod cap.

1. Bolt (2)

2. Connecting rod cap

Remove the piston with the connecting rod through the top of the cylinder bore.

006059

Remove the circlips, the piston pin, the connecting rod, and the piston rings from the piston.

1. Circlips

2. Piston pin

3. Connecting rod

4. Piston rings

5. Piston

Remove the screw and the oil pump outer plate.

006062

006060

Remove the crankshaft from the cylinder block.

1. Crankshaft 006061

1. Screw

2. Plate

Remove the inner rotor and the outer rotor.

1. Inner rotor

2. Outer rotor

006063

006064

Page 91

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Remove the four bolts and the thermostat cover.

1. Thermostat cover 006065

Remove the thermostat.

Remove a screw and the reed valve.

1. Screw

2. Reed valve

006068

Inspection

IMPORTANT: If excessive wear, crack, defec-

tive or other damage is found on any component, replace.

Camshaft

Inspect the camshaft face for scratches and wear.

1. Thermostat 006066

Remove the three screws and the breather plate.

1. Breather plate 006067

Measure the camshaft height.

006069

Cam height:

• Standard – IN / EX: 1.1213 to 1.1291 in.

(28.480 to 28.680 mm)

• Service limit – IN / EX: 1.1094 in. (28.180 mm)

If the measurement exceeds the service limit, replace the camshaft.

Page 92

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Inspect the camshaft gear for wear or other damage. Replace, if necessary.

006070

Cam Rocker Arm

Inspect the cam rocker arm for wear or other damage. Replace, if necessary.

Cylinder distortion:

• Service limit: 0.002 in. (0.05 mm)

If the measurement exceeds the service limit, resurface or replace the cylinder.

006073

IMPORTANT: The cylinder can be resurfaced,

using a surface plate and a #400 grit wet sandpaper. Move the cylinder in a figure eight pattern when sanding.

006071

Cylinder / Piston / Piston Ring

Measure the gasket surface of the cylinder at locations shown.

Water Jacket

Inspect the water passages for clogs or obstructions. Clean, if necessary.

006074

Cylinder Bore

Inspect the cylinder wall for scratches, roughness, or ridges which indicate excessive wear. If the cylinder bore is very rough or deeply scratched or ridged, rebore the cylinder and use a oversize piston.

006072

Page 93

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Measure the cylinder bore in the thrust and axial directions at the three position depths.

1 2

006075 006076

Check for the following:

• Difference between the measurements at the

three positions (taper).

• Difference between the thrust and axial mea-

surements (out-of-round).

Cylinder bore wear (difference):

• Service limit – 0.0039 in. (0.100 mm)

Cylinder bore:

• 1.8898 to 1.8904 in. (48.000 to 48.015 mm)

Piston skirt diameter:

• 1.8888 to 1.8894 in. (47.975 to 47.990 mm)

Oversize piston and piston rings are marked as shown.

Piston

Oversize I.D. Mark

0.50 mm 50

Oversize Piston I.D. Mark

First and Second Ring

If the wear (difference) exceeds the service limit, rebore or replace the cylinder.

To check the piston to cylinder clearance, measure the following items:

• Cylinder bore at 20 mm elevation from the gas-

ket surface at a right angle to the crankshaft pin.

• Piston skirt diameter at 5 mm elevation from the

skirt end.

Piston to cylinder clearance:

• Standard – 0.0007 to 0.0013 in. (0.018 to 0.033

mm)

• Service limit – 0.0039 in. (0.100 mm)

If the clearance exceeds the service limit, replace the piston and/or the cylinder, or rebore cylinder.

Oversize I.D. Mark

0.50 mm 50

Oversize First and Second Ring I.D. Mark 006080

Oil Ring

Oversize I.D. Mark

0.50 mm Blue paint

Oversize Oil Ring I.D. Mark 006081

006078

Page 94

POWERHEAD

CYLINDER/CRANKCASE/PISTON

IMPORTANT: The piston grooves must be

clean, dry and free of carbon before checking clearance.

Fit the piston ring into the piston groove, and measure the clearance between the ring and the ring groove using the thickness gauge.

Piston ring to groove clearance:

• Standard – First and Second Ring: 0.0008 to

0.0024 in. (0.020 to 0.060 mm)

• Service limit – First and Second Ring: 0.0047 in.

(0.120 mm)

Measure the piston ring end gap with the piston ring in the lowest position of the cylinder bore.

1. Piston ring

Piston ring end gap:

• Standard – First and Second Ring: 0.006 to

0.014 in. (0.15 to 0.35 mm)

• Service limit – First and Second Ring: 0.020 in.

(0.50 mm)

If the measurement exceeds the service limit, replace the position ring.

1. First ring

2. Second ring

006082 006083

If the measurement exceeds the service limits, replace the piston and/or the piston ring.

Piston ring groove width:

• Standard – First and Second Ring: 0.048 to

0.049 in. (1.21 to 1.23 mm)

• Standard – Oil: 0.059 to 0.060 in. (1.51 to 1.53

mm)

Piston ring thickness:

• Standard – First and Second Ring: 0.046 to

0.047 in. (1.17 to 1.19 mm)

Measure the piston ring free end gap.

006085

Piston ring free end gap: Standard

• First Ring: Approximately 0.24 in. (6.1 mm)

• Standard – Second Ring: Approximately 0.22

in. (5.7 mm)

Service limit

• First Ring – 0.19 in. (4.9 mm)

• Second Ring – 0.18 in. (4.6 mm)

If the measurement exceeds the service limits, replace the piston ring.

Page 95

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Piston Pin Clearance

To check the clearance, measure:

• Piston pin outside diameter in the thrust and

axial directions.

• Piston pin hole diameter in the thrust and axial

directions.

006086-8

Connecting Rod Big End Side Clearance

Measure the clearance with the connecting rod installed on the crank pin as shown in the figure.

006089

Connecting rod big end side clearance:

• Standard – 0.008 to 0.028 in. (0.20 to 0.70 mm)

• Service limit – 0.039 in. (1.00 mm)

If the measurement exceeds the service limit, replace the connecting rod assembly and/or crankshaft.

Pin clearance in piston pin hole:

• Standard – 0.0001 to 0.0005 in. (0.002 to 0.013

mm)

• Service limit – 0.0016 in. (0.040 mm)

Pin clearance in connecting rod small end:

• Standard – 0.0002 to 0.0007 in. (0.006 to 0.019

mm)

• Service limit – 0.0020 in. (0.050 mm)

If the clearance exceeds the service limit, replace the piston, the piston pin and/or the connecting rod assembly.

Piston pin outside diameter:

• Standard – 0.4722 to 0.4724 in. (11.995 to

12.000 mm)

• Service limit – 0.4717 in. (11.980 mm)

Piston pin hole diameter:

• Standard – 0.4725 to 0.4728 in. (12.002 to

12.008 mm)

• Service limit – 0.4736 in. (12.030 mm)

Connecting rod small end inside diameter:

• Standard – 0.4727 to 0.4730 in. (12.006 to

12.014 mm)

• Service limit – 0.4740 in. (12.040 mm)

Connecting rod big end width:

• 0.689 to 0.701 in. (17.50 to 17.80 mm)

Crank pin width:

• 0.709 to 0.717 in. (18.00 to 18.20 mm)

Inspect the crank pin for uneven wear or damage. Measure the crank pin outside diameter for out-ofround or taper.

006090

• Out-of-round: A – B

• Taper: a – b

Page 96

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Crank pin outside diameter difference (out-ofround and taper):

• Service limit – 0.0004 in. (0.010 mm)

If the out-of-round or the taper exceeds the service limit, replace the crankshaft.

Crank pin outside diameter:

• 0.7476 to 0.7480 in. (18.990 to 19.000 mm)

Check the big end oil clearance. Clean the surface of the connecting rod, the connecting rod cap, and the crank pin. Place a piece of a plastigauge on the crank pin parallel to the crankshaft, avoiding the oil hole.

Remove the connecting rod and the connecting rod cap from the crank pin. Measure the clearance.

Connecting rod big end oil clearance:

• Standard – 0.0006 to 0.0014 in. (0.15 to 0.035

mm)

• Service limit – 0.0031 in. (0.080 mm)

If the measurement exceeds the service limit, replace the connecting rod assembly and/or crankshaft.

Connecting rod big end inside diameter:

• 0.7486 to 0.7490 in. (19.015 to 19.025 mm) Crankshaft Runout

Measure the crankshaft runout.

006091

Install the connecting rod and the connecting rod cap on the crank pin. Install the two connecting rod bolts and tighten the bolts in two steps:

• First torque: 2.5 ft. lbs. (5 N·m)

• Final torque: 5.0 ft. lbs. (7 N·m)

1. Bolt (2) 006092

IMPORTANT: Do not rotate the connecting rod

with the plastigauge in place.

006094

Crankshaft runout:

• 0.002 in. (0.05 mm)

If the measurement exceeds the service limit, replace the crankshaft.

Oil Seal and Bearing

Visually check the oil seals inst alled in the cylinder block and crankcase for cuts, nicks, excessive wear, or other damage.

006095

Page 97

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Visually check the crankshaft upper bearing for pitting, roughness, or other damage.

006096

If no damage is found on the oil seals or bearing, do not remove either.

Drive the oil seal down into position as shown.

Inside crankcase

1. Crankshaft upper oil seal 006099 006100

Seals 006097

006098

IMPORTANT: Do not re-use the oil seal once

removed. Always use a new oil seal.

Inside crankcase

1. Crankshaft lower oil seal

2. Driveshaft oil seal

006101 006102

Oil Pump

Inspect the outer rotor, the inner rotor and the rotor plate for excessive wear or other damage. Replace if necessary.

006103

Page 98

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Assembly

Assembly is reverse order of disassembly with special attention to the following steps.

If the original components are not replaced, each piston, piston pin, and connecting rod is to be assembled and installed in the original order and position.

IMPORTANT: Do not re-use gaskets, oil seals,

O-rings, or circlips once removed. Always use new parts.

Piston to Connecting Rod

Apply engine oil to the piston pin, the piston pin bore, and the connecting rod.

Fit the connecting rod to the piston as shown, and insert the piston pin through the piston and the connecting rod.

Install the piston pin circlips.

Make sure that the connecting rod is installed in the direction shown. Install the circlips with a gap facing either up or down as shown.

Mark

Gap

1. Piston pin

2. Connecting rod

3. Piston

4. Circlips

006104

Piston Ring to Piston

Oil Ring

Apply engine oil to the piston rings. Install the spacer first, then the side rails.

1. Spacer

2. Side rail

006105 006106

2 1

006107

Page 99

POWERHEAD

CYLINDER/CRANKCASE/PISTON

IMPORTANT: When installing the spacer, do

not allow the ends to overlap in the groove.

incorrect

correct

006108

First Ring and Second Ring

Apply engine oil to the piston rings. Install the second ring and the first ring to the pis-

ton with the “R” mark toward the piston head side.

“R”

Ring Gap Direction

Position the piston rings so the ring gaps are staggered at approximately 90 degree angles.

Mark

1. First ring

2. Second ring

3. Oil ring lower side rail

4. Oil ring upper side rail

006111

IMPORTANT: Failure to stagger the piston ring

gaps may result in the crankcase oil dilution.

Crankshaft and Piston to Cylinder

Apply engine oil to the crankshaft journals, crank pin, and bearing.

Mark

1. First ring

2. Second ring

3. Oil ring

006109

IMPORTANT: The first ring differs from the sec-

ond ring in shape. Distinguish the first ring from the second ring by referring to the figure.

1st ring

2nd ring

006110

Apply Triple-Guard grease to the lip of the upper oil seal.

Install the crankshaft to the cylinder block.

1. Crankshaft 006115

Apply engine oil to the piston and cylinder wall.

Page 100

POWERHEAD

CYLINDER/CRANKCASE/PISTON

Insert the piston/connecting rod assembly into the cylinder bore from the cylinder head side using a piston ring compressor.

006116

Position the “O” mark on the piston head to the flywheel side.

Flywheel side

Install the connecting rod cap in the direction shown.

006119

Apply engine oil lightly to the connecting rod bolts. Tighten the two connecting rod bolts in two steps:

• First torque: 2.5 ft. lbs. (3.5 N·m)

• Final torque: 5.0 ft. lbs. (7.0 N·m)

006117

Connecting Rod Cap

Apply engine oil to the crank pin, the connecting rod, and the connecting rod cap.

1. Connecting rod cap 006118

1. Bolt (2) 006120

Camshaft

Apply engine oil to the shaft. Inst all the shaft in the cylinder block. Apply engine oil to the cam faces, the cam journals and the timing gear.

1. Camshaft 006121