1999.ee.johnson.25.35.3 Cylinder.outboards.service.manual

Outboards covered by this Service Manual are designed, built, and equipped to comply with applicable regulations of the U.S. Environmental Protection Agency (EPA), established under the Federal Clean Air Act. The regulations affect the way you maintain and repair these outboards, particularly in the areas of emission-related components and their adjustments. After you have serviced the outboard, it must continue to comply with the same regulations it was manufactured under. Therefore, if any emissionrelated component on these outboards requires repair, replacement, or adjustment, you must use parts and repair procedures that meet OMC specifications. Use this Service Manual as a reference for repair procedures. The regulations provide significant civil penalties for tampering that causes the engine to no longer meet U.S. EPA emission standards. Tampering may include improper repair, replacement, or adjustment of emission-related components.

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Safety Warning

This Service Manual will alert you to certain procedures that must be done very carefully. If you ignore this information, you could . . . • Injure yourself or people around you • Injure the boat operator, boat passengers, or people around the boat • Damage the outboard or its systems Understand the following symbols before proceeding:

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Safety Warning

Alerts you to the possibility of danger and identifies information that will help prevent injuries. Identifies information that will help prevent damage to machinery.

Important

Appears next to information that controls correct assembly and operation of the product.

This Service Manual is written for qualified, factory-trained service technicians familia r w ith the use of OMC Service Tools. This Service Manual tells you how to correctly maintain and service the outboard and its systems. When correctly serviced, the outboard will be reliable and safe to operate. When OMC Service Tools are called for, use them. Where mentioned, the tools are required to perform the service procedure. 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.

Index General Information

Fuel System Ignition System Powerhead Midsection Gearcase Manual Starter

Electrical System Power Trim/Tilt

Safety

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INDEX Topic

Service Manual Title

Page

Alcohol in Gasoline

Fuel Requirements

1-16

Anodes

Anodes - Testing and Replacement

1-28

Anti-Siphon Valve

Boat Fuel System Recommendations

2-12

Battery Cable Extensions

See OIVC Accesso ri es Service Manual

Battery Charging

See OIVC Accessories Service Manual

Battery Recommendations

See OIVC Accessories Service Manual

Battery Testing

See OIVC Accessories Service Manual

• • • •

Break-In Procedure

Break-In Procedu re

1-21

Carburetor Adjustment

Carburetor Mixture Adjustment

2-22

Compression Check

Tune-up Procedure

1-26

Engine Weight

Engine Specifications

1-8

Exhaust Housing Parallelism

Cleaning and Inspection

5-4

Flywheel Nut Torque

Flywheel Servicing

3-7

Fogging Engine

Off-Season Storage

1-22

Fuel Filter

In-Line Fuel Filter Servicing

2-7

Fuel Oil Mixture

Fuel/Oil Ratios

1-14

Fuel Primer

Electric Primer System Servicing

2-10

Fuel Pump Pressure

Pressure Pump Test

2-9

Fuel Pump Vacuum

Suction Pump Test

2-9

Full Throttle Operating Range

Engine Specifications

1-8

Full Throttle Timing

Synchronization and Linkage Adjustments

1-31

Galvanic Corrosion

Anodes - Testing and Replacement

1-28

Gear Ratio

Engine Specifications

1-9

Gearcase Capacity

Engine Specifications

1-9

Heli-Coillnserts

Heli-Coillnserts and Installers

1-43

High Altitude Operation

Weather, Altitude, and Engine Performance

1-20

Idle RPM

Engine Specifications

1-8

Ignition Timing

Synchronization and Linkage Adjustments

1-31

Ignition Specs

Service Specifications

3-3

Ignition Troubleshooting

Output Tests

3-22

Key Switch Check

See OIVC Accessories Service Manual

•

Lubrication Chart

Lubrication Chart

1-12

Ma intenance Va lve

Maintenance Valve Servicing

2-35

Maximum Spark Advance

Synchronization and Linkage Adjustments

1-31

Models Covered

Models Covered

Page 4

Motor Mounts

Exhaust Housing Servicing

5-11

Octane Requirements

Fuel Requirements

1-16

Off-Season Storage

Off-Season Storage

1-22

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Topic

Service Manual Title

Page

Operating Temperature

Engine Temperature Check

4-5

Orifice Plugs - Factory Installed

See OMC Parts Catalog

•

Overheating

Engine Temperature Check

4-5

Preseason Service

Preseason Service

1-25

Pressure Test - Gearcase

Gearcase Servicing - Assembly

6-13

Propeller Selection

Propeller Selection

1-18

Oil Mixing Unit

Oil Tank and Mixing Unit Servicing

2-25

Pyrometer

Engine Temperature Check

4-5

RPM Lim it

Engine Specifications

1-8

Sending Unit - Temperature

Temperature Switch Test

4-7

Shift Cable Installation

Rigging Information

1-38

Spark Plugs

Spark Plug Information

3-8

Starter Rope Length

Starter Servicing

7-5

Storage Mixture

Off-Season Storage

1-22

Submerged Engines

Submerged Engines

1-29

Sync & Link

Synchronization and Linkage Adjustments

1-31

Tachometer Test

Tachometer Circuit Test

8-24

Temperature Switch

Temperature Switch Test

4-7

Test Wheel RPM

Engine Specifications

1-8

Thermomelt Stiks

Engine Temperature Check

4-5

Thermostat

Powerhead Servicing - Assembly

4-19

Throttle Cable Installation

Rigging Information

1-38

Timing

Synchronization and Linkage Adjustments

1-31

Trim Tab

Trim Tab Adjustment

6-20

Tune-up Procedures

Tune-up Procedure

1-28

Vacuum Test - Gearcase

Gearcase Servicing - Assembly

6-13

Oil Tank

Oil Tank and Mixing Unit Servicing

2-25

Voltage Drop Test

Starter System Voltage Drop Test

8-6

Warning Horn Signals Warning Horn Tests

CD ®

• •

Water Pump

Water Pump Servicing

6-5

Winterization

Off-Season Storage

1-22

CD

See ~ Accessories Service Manual - System Check Engine Monitor.

®

See ~ Accessories Service Manual - System Check Engine Monitor - Circuit Verification, Instrument Harness.

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Outboard Models Covered in This Service Manual 25 Models J25R3EE J25RL3EE J25TEL3EE J25PL3EE

35 Models J35EL3EE J35PL3EE J35TEL3EE J35R3EE J35RL3EE

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General Information Table of Contents General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . .. Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .. Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering System Lubrication - Remote Electric Models .. Lubrication Chart ...... . .... . ................... . Fuel/Oil Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fuel Requirements .. .. .... . .......... . ...... . .... New Engine Pre-Delivery Checks .................... Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Weather, Altitude, and Engine Performance ............ Break-In Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Off-Season Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Preseason Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Tune-Up Procedure ............. .. ................ Anodes - Testing and Replacement . . . . . . . . . . . . . . . . .. Submerged Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Synchronization and linkage Adjustments ............ 20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Rigging Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Drill Size Conversion Chart. . . . . . . . . . . . . . . . . . . . . . . .. Heli-Coillnserts and Installers . . . . . . . . . . . . . . . . . . . . ..

1- 2 1- 3 1- 4 1- 7 1- 8 1-11 1-11 1-12 1-14 1-16 1-17 1-18 1-20 1-21 1-22 1-25 1-26 1-28 1-29 1-31 1-37 1-38 1-42 1-43

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General Safety Warnings

Before working on any part of the outboard, read the section called Safety at the end of this manual. When replacement parts are required, use genuine OMC parts or parts with equivalent characteristics including type, strength, and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers. To prevent possible eye injury, always wear SAFETY GLASSES while servicing the unit. Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants, and sealant removers. The engine cover is a machinery guard. Use caution when conducting tests on running engines. Do not wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating flywheel. 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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Service Specifications Standard Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Size

In. Lbs.

Ft. Lbs.

N·m

Size

In. Lbs.

Ft. Lbs.

N ·m

M3

15-22

1,6-2,4

No. 6

7-10

24-36

2,7-4,0

No.8

15-22

• •

0,8-1,2

M4

• •

M5

36-60

3-5

4,0-6,8

No.10

25-35

2-3

2,8-4,0

M6

84-106

7-9

9,5-12,0

No. 12

35-40

3-4

4,0-4,6

M6 (Taptite)

108-132

9-11

12,2-14,9

in .

60-80

5-7

7-9

in .

120-140

10-12

14-16

M8

180-204

15-17

20,3-23,0 220-240

18-20

24-27

M10

312-336

26-28

35,2-38,0 340-360

28-30

38-40

1/ 4

5/ 16

3/s in. 7/ 16

in .

1,6-2,4

INote I These

values only apply when a special torque for a specific fastener is not listed in the Special Torque Chart found at the beginning of each section.

INotel

When tightening two or more screws on the same part, do not tighten screws completely, or one at a time . To avoid distortion, first tighten all screws in sequence to one-third of torque value, then tighten to two-thirds of torque value, then tighten to full value.

Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OMC Ultra-HPF"MGearcase Lube OMC Triple-Guard@Grease Evinrude TC-W3@Outboard Lubricant Johnson TC-W3@Outboard Lubricant OMC Carbon Guard™ Fuel Additive OMC 2+4@ Fuel Conditioner OMC Storage Fogging Oil OMC Starter Pinion Lube OMC Engine Tuner OMC Electrical Grease

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Introduction This manual covers service information on 30.5 cu . in . (500 ccl and 34.5 cu. in. (565 ccl 3-cylinder models. Use this manual together with the proper Parts Catalog for part numbers and for exploded views which are a valuable aid to service. This manual presents the English values and dimensions first and the metric values and dimensions second, inside parentheses ( I. Good Service Practice Service required for ONIC engines is generally one of three kinds: • Normal care and maintenance - which includes putting a new engine into operation, storing engines, lubrication, and care under special operating conditions such as salt water and cold weather. This includes engine servicing procedures to keep the engine in prime operating condition. • Operating malfunctions - due to improper engine mounting, propeller condition or size, boat condition, or the malfunction of some part of the engine. • Complete disassembly and overhaul - such as major service or rebuilding a unit. It is important to you as the service person to determine, before disassembly, just what the trouble is and how to correct it quickly, with minimum expense to the owner. When repairing a component, the most reliable way to ensure a good job is to do a complete overhaul on that component, rather than just replacing the bad part. Wear not readily apparent on other parts could cause a malfunction soon after the repair job. Repair kits and overhaul kits contain all the parts needed to ensure a complete repair, to eliminate guesswork, and to save time . Repair time can also be minimized by the use of special tools. ONIC special tools speed repair work so it can be done within flat rate time . In some cases, the use of substitute tools can damage the part.

INote I Do not operate engine out of water, even

momentarily. If operated in test tank, use proper test wheel. Failure to do so can result in damage to water pump and engine overheating!

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Arrangement of Service Manual This Service Manual includes the specific information you will need to service outboards listed in front of this book. All general procedures are covered in abbreviated form, mostly by reference to procedural illustrations. The specific procedures which apply to this engine are covered in fully-illustrated, detailed, step-bystep instructions. Each of the manual sections contains detailed instructions for disassembly, inspection, assembly, testing, and operating adjustments of the various engine systems. These procedures will help you service a specific system or completely overhaul the outboard. Product Reference and Illustrations Outboard Marine Corporation 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. u.S. EPA Emission Information Outboard Marine Corporation warrants that this marine engine conforms to all applicable U.S. EPA Emission Regulations. Please read the complete warranty statement in the engine's operator's manual. Any authorized Evinrude or Johnson dealer will repair or replace any emission-related part at no cost to the customer during the warranty period. The customer may have non-warranty service performed by any repair establishment that uses certified parts. The regulations provide significant civil penalties for tampering that causes this marine engine to no longer meet U.S. EPA standards. If you have questions about this information or the emission warranty statement, write to the U.S. EPA, Engine Compliance Group, 401 M Street SW, Washington, DC, 20460.

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Service Policy When servicing an outboard which is within its normal warranty period, make repairs using only genuine ()fIIIC replacement components or parts. If ()fIIIC genuine replacement components or parts are not used, ()fIIIC might refuse subsequent warranty claims involving that engine.

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When replacement parts are required, use genuine ()fIIIC parts or parts with equivalent characteristics, including type, strength, and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers.

When reference is made to a brand name, product, or specific tool, an equivalent product may be used in place of the referenced product. Substitute products used must have equivalent characteristics, including type, strength, and material . You must determine if incorrect substitution could result in product mal function and possible injury to the operator and/or passengers. Whether within or following the warranty period, ()fIIIC has a constant interest in its products. It is ()fIIIC's policy to provide dealers with service information so they can give the professional service demanded by today's consumer. The ()fIIIC Training Centers, frequent mailings of Service Bulletins and Advisories, ()fIIIC Special Tools, and this Service Manual repre~ent some of ()fIIIC's efforts to assist dealers in giving consumers the best service possible. The service manual covers all phases of servicing outboards. However, new situations sometimes arise in servicing an engine. If a service question does not appear to be answered in this manual, you are invited to write to the Service Department for additio nal help. Always be sure to give complete information, including engine model number and serial number. Be sure that you are familiar with ()fIIIC warranty policies.

Special Service Tools CIVIC has specially designed tools to simplify some of the disassembly and assembly operations. These tools are illustrated in this service manual, in many cases in actual use. Refer to the ()fIIIC Special Tool Guide for a description and ordering instructions for these tools . Individual purchasers of service manuals must order special tools through an authorized dealer. Outboard Engine Nomenclature Sometimes the words "right" and "left" are very confusing when referring to the sides of an outboard. Therefore, the sides are referred to as STARBOARD or PORT, STARBOARD means on the right hand while facing forward; PORT means left hand.

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DR2066

DR2065

DR4203

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

[JJ

This symbol indicates continuity or very low resistance.

rn This symbol indicates no continuity or very high resistance.

DR4204

Use an ohmmeter calibrated on high ohms scale, or a continuity light, to test continuity.

rn When shows on the meter face, no continuity, or very high resistance, is indicated . The symbol is referred to as infinity. rn When "v" follows a value on the meter face, the procedure is measuring voltage. rn When "fl" follows a value on the meter face, the procedure is measuring resistance. fl is the symbol for ohm, the unit of "00"

DR4205

measurement for resistance. Values

rn When precedes a value on the meter face, it indicates your reading should be less than, or equal to, the value shown. rn When precedes a value on the meter face, it indicates your reading should be greater than, or equal to, the value shown. "s;"

"'2:."

DR4206

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DR4207

Engine Specifications 25 and 35 Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Full Throttle Operating Range

5200 to 5800 RPM

Power

25 - 25 HP (18,7 kw) 35 - 35 HP (26,1 kw)

Power Rated @

5500 RPM

Idle RPM in Gear

See Page 1-33

Test Propeller

OMC PI N 434505

Minimum Test RPM

25 - 4200 35 - 5000

Weight:

25R3; 35R3 - 151 Ibs. (68,9 kg) 25RL3; 35RL3 - 156 Ibs. (71,2 kg) 25TEL3; 35TEL3 - 159 Ibs. (72,6 kg) 35EL3 - 160 Ibs. (73 kg) 25PL3; 35PL3 - 170 Ibs. (77 kg)

Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Type

Two-Cycle, In-line 3-Cylinder, Loop-Charged

Displacement

25 - 30.5 cu . in . (500 cc) 35 - 34.5 cu. in. (565 cc)

Bore

25 - 2.350 in. (59,69 mm) 35 - 2.500 in. (63,50 mm)

Stroke

2.344 in. (59,54 mm)

Standard Bore *

25 - 2.3495 - 2.3505 in. (59,68 - 59,70 mm) 35 - 2.4995 - 2.5005 in. (63,49 - 63,51 mm)

Crankshaft Dimensions: Top Journal Center Journals Bottom Journal Rod Crankpin

1.4979 1.3748 1.1810 1.1823

-

1.4984 1.3752 1.1815 1.1828

in. in. in. in.

(38,05 (34,92 (30,00 (30,03

-

38,06 34,93 30,01 30,04

mm) mm) mm) mm)

Piston Diameter, Standard

25 - 2.3440 - 2.3450 (59,54 - 59,56 mm) 35 - 2.4940 - 2.4950 (63,35 - 63,37 mm)

Piston Ring End Gap, Both

0.005 - 0.020 in. (0,13 - 0,51 mm)

* To bore oversize, add piston oversize dimension to standard bore.

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Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

Gear Ratio

13:28 (0.46)

Lubricant

OMC Ultra-HPF Gearcase Lube

Capacity

11 flo oz. (330 ml)

Shift Rod Height

See Page 6-17

Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Type

Magneto Powered Capacitor Discharge

Firing Order

1-2-3

Ignition Features

S.L.D.W. ™and QuikStart ™

Ignition Module RPM Limit

6200

Ignition Coil

OMC PI N 584826 Spark Plug, Champion

INotel

Recommended

Extended Idle

OL86C or L86C

OL87YC or L87YC

All spark plugs are to be gapped at 0.030 in . (0,8 mm)

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._

Battery, Minimum Recommendation

12-Volt, 360 CCA (465 MCA) with 90 minutes Reserve Capacity or 50 Ampere-Hour

Alternator

12-Amp, Fully Regulated

Tachometer Setting

6

Engine Fuse (20-Amp)

OMC PI N 514021

AC Model

71 Watts AC

Warning Signals

No Oil , Low Oil, Water Temperature

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FueISystem ............................................................... . Fuel/Oil Ratios

See Page 1-14

Fuel Requirements

See Page 1-16

Carburetion

Three Single-Throat Carburetors, Float Feed

Calibration

Adjustable Low Speed, Fixed Intermediate and High Speed

Initial Low-Speed Setting

See Page 2-20

Starting Enrichment

Remote Electric - Electric Primer Rope, Tiller Electric - Choke

Float Level Setting

OMC Float Gauge, PIN 324891

Float Drop Setting

1-13/8 in. (25-35 mml

Oil Tank Capacity

2.1 qts. (2 II

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Gearcase Lubrication

fA

To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.

[I]

Remove oil drain/fill plug and oil level plug from gearcase. With motor in normal operating position, allow oil to drain completely.

Important

Do not remove the shift cradle screw @.

To refill, place a tube or pressure can nozzle of OVIC Ultra-HPF gearcase lubricant in drain/fill hole.

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INotellfOVlC Ultra-HPFgearcase lubricant is not available, OVIC Hi-Vis gearcase lube can be used as an alternate. • With motor in normal operating position, fill until lubri cant appears at oil level hole. • Install oil level plug before removing lubricant tube or pressure can nozzle from oil drain/fill hole. Drain/fill plug can then be installed securely without oil loss.

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• Tighten plugs to a torque of 84-86 in. Ibs. (9-10 N·m) .

Steering System Lubrication - Remote Electric Models

w fA

The installer was instructed to grease the steering cable ram during installation. Once the engine is put into use, periodic cleaning and regreasing with OIVIC Triple-Guard grease is required. In fresh water usage, lubricate every 60 days; salt water usage, lubricate every 30 days.

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Lubrication Chart Frequency Figure

Lubrication Point

Lubricant

e

IT]

Gearcase

rn

Steering

rn

Power TrimlTilt Reservoir

W

Electric Start

[]]

Throttle and Shift Linkage

W 1Il

Carburetor Linkage Manual tilt models - Swivel Bracket, Tilt Support, Shallow Water Drive Bracket

[!]

Manual tilt models - Tilt Tube, Clamps, Tilt Lever Shaft

[!]

PT&T models - Tilt Support (port and starboard), Swivel Bracket

[!Q]

PT&T models - Tilt Tube, Upper Tilt Cylinder Rod

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Fresh Water

Salt Water

*

Change after first 20 hours. Check level every 50 operating hours. Change every 100 operating hours or once each season, whichever comes first. 60 Days

30 Days As Required

60 Days

30 Days

60 Days

30 Days

60 Days

30 Days

60 Days

30 Days

60 Days

30 Days

60 Days

30 Days

60 Days

30 Days

* Some areas may require more frequent lubrication. OMC

OMC Ultra-HpprM

OMC Starter

OMC Power TrimlTilt

Triple-Guard® Grease

Gearcase Lube

Pinion Lube

& Power Steering Fluid

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Fuel/Oil Ratios Lubricant

Only the following lubricants should be used:

• Evinrude TC-W3 Outboard Lubricant • Johnson TC-W3 Outboard Lubricant These lubricants are formulated by OMC to give best engine performance while : • Controlling piston and combustion chamber deposits • Providing superior lubrication • Ensuring maximum spark plug life If Evinrude or Johnson Outboard Lubricant is not available, another NMMA certified TC-W3 oil may be used. Look for the certification information on the container label.

INotel

Running or storing an engine on a leaner than recommended fuel/oil mixture may result in powerhead damage.

INote I Avoid the use of the following as they could damage your engine and/or shorten spark plug life: • • • •

Automotive Premix fuel Premix fuel Premix fuel

oils of unknown oil quantity richer than the recommended ratio leaner than the recommended ratio

Some additives in Evinrudel Johnson Outboard Lubricant are subject to evaporation. Always cover partially filled containers to prevent deterioration of lubricant. Normal Service

INotel

Any recreational or commercial engine equipped with an oil mixing unit must use a 50: 1 fuel/oil ratio in the fuel tank if the oil mixing unit IS NOT USED. If the oil mixing unit is not used, follow this procedure: • Run a new fuel line from the in-line fuel filter to the fuel manifold assembly to bypass the oil mixing unit.

High Performance

Any engine, when used for high performance, requires a 50: 1 fuel/oil mixture in the fuel tank along with the oil mixing unit. If the oil mixing unit is not used, a 25: 1 fuel/oil mixture is required in the fuel tank. Severe Service E

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When an oil mixing unit equipped engine is used in commercial, rental, or extended severe service, no additional oiling is necessary.

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Fuel/Oil Mixing Instructions INotel To be used if engine's oil mixing unit is not desired.

&.

Gasoline is extremely flammable and highly explosive under certain conditions. Always stop engine and do not smoke or allow open flames or spark near the boat when refueling or changing fuel tanks. Always mix in well ventilated area.

IT]

Portable tank - Above and below 32° F (00 Cl, add one gallon (4 litres) of fuel. Pour in required amount of oil. Add remaining fuel. Install filler cap and tip tank gently to distribute oil.

[[] rn &. Permanently Installed Tank - Above 32° F pour oil slowly with the fuel as tank is filled . Below 32° F

1

(00 Cl, (00 Cl,

add one gallon (4 litres) of fuel to a separate container. Pour in required amount of oil. Install filler cap and tip container gently to distribute oil. Slowly pour oil /fuel mixture into tank with fuel as tank is filled. To prevent static spark, use a large metal filter funnel as shown in figure. The fuel nozzle must contact the metal funnel when filling the tank.

DR3986

Oil Requirements 3 Gallons (11,4 Litres)

6 Gallons (22,7 Litres)

18 Gallons (68,1 Litres)

100: 1 (1% Lubricant)

4 fl. oz. (118 ml)

8 fl. oz. (236 ml)

24 fl. oz. (708 ml)

50 :1 (2% Lubricant)

8 fl. oz. (236 ml)

16 fl. oz. (473 ml)

48 fl . oz. (1419 mil

25:1

16 fl. oz. (473 ml)

32 fl . oz. (946 ml)

96 fl. oz. (2838 ml)

(4% Lubricant)

PCE0025

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Fuel Requirements

Minimum Octane Models

Recommendations

(R+M)/2 "AKI"

"RON"

All

See fuel classifications below.

87

90

Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having the recommended octane rating. Acceptable Fuel: Any of the above gasolines with up to the following percentage alcohol by volume: • 10% ETHANOL or • 5% METHANOL with 5% cosolvents Unacceptable Fuel: Do not use any gasoline having more than 10% ETHANOL or more than 5% METHANOL even if it contains cosolvents or corrosion inhibitor, regardless of octane rating . OMC products have been designed to operate using the Preferred Fuel or Acceptable Fuel; however, be aware of the following: • The boat fuel system may be different regarding use of alcohol fuels. Refer to boat owner' s manual. • Alcohol attracts and holds moisture which may cause corrosion of metallic parts of the fuel system. • Alcohol extended fuels can cause engine performance 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.

&.

Fuel leakage can contribute to a fire or explosion.

INotel OMC 2+4 fuel conditioner and OMC Carbon Guard fuel additive are the only gasoline additives recommended by Outboard Marine Corporation. Use of other gasoline additives can result in poor performance or engine damage.

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New Engine Pre-Delivery Checks OMC

OWNER IDENTIFICATION CARD

Owner's Name

The careful preparation of an engine before delivery will ensure owner satisfaction.

Address

State_ ZIp _

City

1. Upon • • •

uncrating a new engine, inspect it. If you find: Shipping damage - contact the carrier that delivered it Parts or connections are loose - repair as required Parts are missing - contact OMC

_

Date of Purchase

SERIAL -

MODEL#

........

....

DEALER RECOR D CARD

I

2. Before connecting the instrument harness to the outboard, verify operation of the OMC System Check ™engine monitor and other dash panel functions as described in OMC Accessories Service Manual, Circuit Verification, OMC Tester, PIN 437274.

I

Owner'sHame

Address C~y

State

Z.

City

Stile

Z.

DateofPu'cnase

1911iOrl Key No

SecoodOwner Name

Address

3. Check gearcase lubricant level. Fill to oil level hole.

......

Boat MtI1. ""'''''' _

4. Install test wheel and put engine into test tank.

_ __

BoatLength

IlTIpOI'tIInt: The F..,.I aoet Safety Act reQi.lres registration lists to be mal'llained

on product sales by maoo1acllJ'8r and DEALER. This is a standard card on which a dealer can keep his records.

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5. Momentarily pressurize the fuel system. Check for leaks! Repair any leaks before continuing.

6. Start engine and check cooling system operation. Be sure engine warms to operating temperature at idle.

Name

S 0

Addfess

L

City

ISl81e

Ow ner's Phone

jZIp. 4

D

T

0 Purchase Date

&

7. Check shift operation. Check start-in-gear-prevention feature on engines so equipped. 8. Check electrical and ignition systems for stray spark sources.

Type of Use

Pleasure

Addre ss

L

y

I

Ci ty

B Zip" 4

Slate

_reater

Code

'ng;Mj Mod.,.

Registration

9. Check all adjustments. See Synchronization and Linkage Adjustments, this section.

Oeom", 0 00"

DealerNarne

S 0 D

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Boat Mig

!-lull No.

10. Correct any problems found.

ISM'" .

I

Model

I

Length

Trailer V IN

11. Clean entire engine. 12. When the engine is installed on the boat, check the engine at all trim angles, turn boat's steering wheel fully right and left. Be sure there is no interference of the steering connector, remote control cables, and electrical cables at the boat's motor well.

@ DR 5700

13. Review Operator's Manual information, including owner's responsibilities and engine requirements . 14. Complete the paperwork: @ • Owner's identification card • Dealer's customer record • Registration

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Propeller Selection Selecting the correct propeller for each engine and boat combination will ensure good engine service life and good boat performance. A propeller must be carefully selected to match the engine/boat combination, the application, and the anticipated load in the boat. INotel Selection of the wrong propeller could reduce engine

service life, affect boat performance, or cause serious damage to the powerhead. Procedure

The propeller selection process is very important to the engine service life and to boat performance. Proceed carefully and thoroughly while considering the following points: • During the engine break-in period, only run the engine at wide-open throttle for brief periods of time to verify ' full-throttle RPM. • You must use an accurate tachometer to determine the engine's full-throttle RPM as you test 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 Engine Specifications, this section. • To compensate for changes in boat loading, the engine's full-throttle RPM must be verified periodically. • Occasionally, one propeller will not cover a wide range of boat applications - water skiing to high speed performance boating. In such cases, it might be necessary to have a propeller for each situation .

OJ I Note I 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.

& To avoid accidental starting while changing propellers, twist and remove all spark plug leads.

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®

100% 90% 80%

@

70% 60% 50% 40% 30%

~®

.

@Q

-@@~

1 DR1261

@ Percentage of available horsepower (kwj

® Engine RPM © Horsepower (kwj curve @ Full-throttle operating range

® Rating RPM for horsepower (kwj ® Engine is overloading at W.O .T. @ Engine is overspeeding at W.O.T.

Mirage/eng

1-19

Rated Power

Hot Weather/ ------High Altitude

I

I I I I~

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....

Cl)

~

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RPM

1m a: DR4013

Weather, Altitude, and Engine Performance The horsepower ratings of all engines are those that would be obtained under standard conditions. However, changes in weather and altitude will affect the performance of any outboard. Some factors that will decrease the output of an engine are : • • • •

Low barometric pressure High temperature High humidity High altitude

[ ] ] Performance can decrease noticeably when an engine is run on a hot, humid day. Sometimes the weather or altitude alone can cause the engine RPM to drop below the recommended operating range. In such a case, a lower pitch propeller can be used to bring RPM back into the operating range. In any case, top boat speed will not be as high as on a cool, dry day.

INote I A loss of engine performance can occur if an engine has not been properly modified for high altitude operation. To avoid permanent powerhead damage, be sure that an engine modified for high altitude operation is properly identified and recalibrated when operating at lower altitude.

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Mirage/eng

Break-In Procedure During the first 10 hours of break-in operation you must use a 50:1 fuel /oil ratio in your fuel tank in addition to the operation of the oil mixing unit. After the 10-hour break-in period, check to see that the oil level in the oil tank has changed, indicating that oil has been used before using unl')1ixed gasoline in the fuel system. If the oil mixing unit is disconnected, you must use a 25: 1 fuel/oil ratio in the fuel tank for the first 10 hours. To help ensure long engine life and prevent serious engine damage, using additional oil in the fuel is mandatory during the first few hours of operation of: • a new engine • a used engine with a new powerhead • a used engine with a newly rebuilt powerhead

INote I DO NOT operate motor out of water. Water pump can be damaged or engine can overheat. INote I DO NOT operate engine at a constant throttle setting. Change engine RPM often. INote I Verify water pump operation by looking for a steady stream of water at the water pump indicator. First 10 Minutes _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ idle ONLY. • Minutes Operate engine Next 50 _ _ _in _gear _ _at _fast __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

• Operate engine in gear below 2700 RPM . • DO NOT hold a constant throttle setting . Change engine speed every 15 minutes.

INote I With

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

• Use full throttle to accelerate boat onto plane, then reduce throttle setting to three-quarters. BE SURE boat remains on plane at this throttle setting. • At intervals, apply full throttle for periods of one to two minutes, returning to three-quarters throttle for a cooling period. • Change engine speed every 15 minutes.

INote I Verify

water pump operation by looking for a steady stream of water at the water pump indicator. Next Eight Hours . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ._ _ __ • Avoid continuous full-throttle operation for extended periods. • Change engine speed every 15 minutes. • DO NOT exceed recommended maximum engine RPM. Refer to Specifications, this section. E

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INote I Retorque cylinder head screws after engine break-in period . Retorque after engine has been run

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and cylinder heads have cooled to the touch .

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Off-Season Storage Use the following procedure to properly prepare Johnson and Evinrude outboards for extended periods of non-use. These steps are intended to protect the engine during storage and simplify the preseason servicing procedure. 1. Stabilize the engine's fuel supply with OIVIC 2+4fuel conditioner, following directions on the bottle.

I

Use a flushing attachment if you operate the engine on a trailer or dolly to prevent engine or water pump damage.

I Note

&.

When using a flushing attachment, always remove engine's propeller before starting engine to prevent accidental contact with moving propeller.

2. Run the engine at approximately 1500 RPM for five minutes to ensure that the entire fuel supply system and the engine's carburetors are full of stabilized fuel. 3. Prepare an engine "storage mixture" in a shop V6 six-gallon tank. The mixture should include: • Five gallons of fuel • Two quarts of OIVIC Storage Fogging Oil • One pint of Evinrude or Johnson Outboard Lubricant • 2112 oz. of OIVIC 2+4 fuel conditioner 4. Connect the tank containing the "storage mixture" to the engine. Run the engine on the "storage mixture" at approximately 1500 RPM for five minutes.

DO NOT disconnect fuel line or run oil mixing unit equipped engines out of fuel. Disconnecting fuel line while engine is running could cause excessive oil consumption and eventual hard starting.

INotel

5. Stop engine and remove all spark plugs. Spray a liberal amount of OIVIC Storage Fogging Oil into the spark plug holes. 6. Turn flywheel in a clockwise direction to distribute the fogging oil throughout the cylinders. Install and torque the spark plugs.

&.

7. Prevent accidental starting during storage; leave spark plug leads off all of the spark plugs.

8. If engine is equipped with a portable fuel tank, disconnect fuel hose from engine and tank.

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Avoid fire or explosion hazard; store all portable fuel tanks in a well ventilated area, away from any open flames .

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Mirage/eng

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9. If the engine is removed from boat, examine all hardware you loosened or removed from the motor and its steering, throttle, and shift system. Replace damaged or missing parts with genuine OIVIC parts, or equivalent. These fasteners are made of special materials to resist weakening and rusting . Do not substitute these fasteners with nuts and bolts which look the same. Using the wrong nuts and bolts may result in sudden unexpected loss of engine control.

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10. Inspect the entire boat steering system for damage due to corrosion, aging, lack of maintenance, or abuse. Inspect mechanical steering cables for deterioration or cracks. Inspect hydraulic steering models for fluid leaks or other external signs or problems. Follow equipment manufacturer's maintenance and lubrication recommendations when servicing the steering system. 11. Remove battery and check its condition, water level, and charge . Store in a cool, dry place, out of direct sunlight. Check the water level and charge periodically during storage. 12. If equipped, service the boat fuel filter following instructions on canister. Clean and inspect the oil tank. 13. Remove propeller and check for damage. A slightly bent propeller blade can hardly be noticed but will affect the performance of the engine. Clean and lubricate the propeller shaft with OIVIC Triple-Guard grease. 14. Drain and refill gearcase . Lubricate engine. See Lubrication, this section . 15. Check engine carefully. Make sure screws and nuts are tight. Replace damaged or worn parts.

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Make sure electrical and fuel system fasteners and clamps are tight and in good condition. Failure to do so may cause electrical sparks and fuel leakage under the engine cover. Fire and explosion could occur. 16. Replace engine cover. Use touch-up paint where needed.

17. Coat all outside painted surfaces of engine with automotive wax.

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NOTES

1-24

Mirage eng

Preseason Service 1. Check gearcase lubrication. If leakage is evident, gearcase seals may need attention . Check lubricant level in power trim /tilt reservoir. See Lubrication, this section.

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2. Apply a light coating of OIVIC Electrical Grease to the ribbed portion of the spark plug ceramics and the opening of the spark plug covers . Connect spark plug leads. Make sure spark plug boots are not cracked or torn.

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3. Check water level in battery, then charge. While the battery is charging, the acid solution inside the battery gives off hydrogen gas which can explode if ignited by a spark or open flame. If hydrogen gas is not able to leave the battery (vents are clogged), the battery itself may explode. Therefore, when charging batteries, make sure that battery is vented to atmosphere and lots of fresh air is in the area. Make sure no sparks or flames are present. Do not short across battery terminals to check battery condition. Install and connect battery.

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4. When engine is reattached to the boat's transom, make sure the steering, shift, and throttle systems are attached to the engine using the factory-specified hardware stored with the engine earlier. Follow the manufacturer's installation instructions! If control systems are attached to the engine using the wrong fasteners or assembled carelessly, sudden unexpected loss of engine control may result.

5. Test functions of the warning system. Refer to OIVIC Accessories Service Manual.

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6. Check fuel system for leaks.

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Tune-Up Procedure 1. Visually inspect engine for leaks, missing or loose parts, or the obvious defects. 2. Compression check - Proper compression is essential for good engine performance . An engine with uneven compression cannot be properly tuned. • Operate the engine until it reaches normal operating temperature. Stop engine. • Remove and inspect all spark plugs. Check their condition. • Install thread-type compression tester in spark plug hole. • With throttle in wide-open position, crank engine with starter through at least four compression strokes. • Variation between cylinders should not exceed 15 PSI (100 kPa) . IF the engine has equal compression, is hard to start, AND operates poorly, check for: • • • •

scored cylinder walls damaged pistons stuck piston rings worn piston rings

IF the engine shows a variation greater than 15 PSI (100 kPa), check for : • • • •

damaged head gasket damaged pistons broken or stuck piston rings scored cylinder walls

IF the engine has equal compression and runs normally, continue the tune-up procedure.

&.

3. Clean and regap or replace spark plugs. Make certain ceramic portion of plug is not cracked. Replace if cracked to prevent sparks.

&.

4. Inspect and test ignition components. See Section 3. Replace deteriorated or damaged parts such as wires, boots, etc., which may emit sparks.

&.

5. Replace in-line fuel filter. Replace deteriorated or damaged fuel system parts such as hoses or gaskets which may result in fuel leaks. Inspect carburetor and primer system. 6. Synchronize the engine. See Synchronization and Linkage Adjustments, this section . E

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7. Inspect propeller shaft seals for evidence of leakage. Replace if necessary. 8. Drain and refill gearcase. Lubricate all components of engine. See Lubrication, this section. 9. Check propeller condition. Replace if damaged. 10. Retorque all screws and nuts to specifications. 11 . Run engine in test tank with correct test propeller. Check cooling system operation . 12. To remove carbon deposits from combustion chambers and pistons, inject OMC Engine Tuner. Let tuner soak in engine between three and sixteen hours. After soaking, run engine at fast idle (1500 RPM) for at least 15 minutes at normal operating temperatu reo

INotel

During engine operation, carbon can build up on internal powerhead components, eventually causing piston rings to "stick." Adding OMC Carbon Guard fuel additive to every tank of fuel is your best protection against such buildup and the resulting mechanical problems. If OMC Carbon Guard is not used consistently in the fuel, OMC Engine Tuner should be applied every 50 operating hours. 13. Check engine operation by verifying minimum test propeller RPM. Refer to Engine Specifications, this section.

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14. Momentarily pressurize fuel system and check for leaks.

15. If engine is to be stored, refer to Off-Season Storage, this section.

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Anodes - Testing and Replacement Erosion or disintegration in salt or brackish water indicates the anodes are performing their function. The anodes should be inspected at intervals and replaced when necessary, or corrosion of the engine will increase.

INotellf any anode has been reduced to 213 its original size (% eroded), it must be replaced! To increase the duration of the anodic protection, the sta rboard stern bracket (on some models) is drilled to accept an additional anode.

m rn

Test for proper installation of the anode. Calibrate an ohmmeter on high ohms scale. Connect one meter lead to a powerhead ground and the other lead to the anode. Be sure the surface of the anode is clean to make good contact. The ohm meter should show a low reading. If not, remove the anode and clean the area where the anode is installed . The mounting screws and the anode itself should also be cleaned. Install and retest.

INote I Do

not paint or coat the anodes or their mounting sur-

faces.

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Submerged Engines Engine Dropped Overboard (Not Running)

If engine is recovered from water immediately, it must be serviced within three hours. See Prolonged Submersion.

INotellf engine cannot be started or serviced immediately, it should be resubmerged in fresh water to avoid exposure to the atmosphere. Make arrangements to have it serviced with the least possible delay. Once the outboard is exposed to air, both fresh and salt water will start etching the highly polished bearing surfaces of the crankshaft, connecting rods, and bearings. The engine must be serviced within three hours of recovery to avoid costly repairs. Proceed as follows: 1. Remove engine cover and rinse powerhead with fresh water. 2. Twist and remove spark plug leads and remove spark plugs.

I Note I To remove or attach leads, pull off or push on with a slight counterclockwise twist. 3. Disconnect fuel line from engine. Drain and clean all fuel lines and fuel tank. Drain and clean oil tank. Purge all contaminated oil from supply lines. 4. Place engine in horizontal position (spark plug openings down) and work out all ofthe water by slowly rotating flywheel approximately 20 times or until there are no signs of water. 5. Drain carburetors - place engine in upright position and remove carburetors for disassembly and draining. 6. Starters, electrical connectors, and all electrical equipment should be completely disassembled, cleaned, flushed with fresh water, treated with a water displacing electrical spray, and thoroughly dried before assembly. 7. Inject outboard lubricant into spark plug holes. 8. Reassemble parts you removed and disconnected. Refill the oil tank with fresh outboard lubricant. Start engine (follow starting instructions) and run '/2 hour using the "break-in" fuel/oil mixture. Run the engine on a "break-in" fuel /oil mixture for approximately three hours after servicing. See Break-in Procedure in this section. 9. If engine fails to start, remove spark plugs again to see if water is present on electrodes. Blowout any water from electrodes and reinstall or replace with new plugs. Repeat starting procedure. E

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INotellf engine shows evidence that sand or silt may have entered it (sand or silt under the engine cover or a slight grinding or scraping when flywheel is rotated), do not attempt to start the engine. It must be disassembled and cleaned. Engine Dropped Overboard (Running) Follow the same procedure as Engine Dropped Overboard (Not Running) . However, if there is any binding when flywheel is rotated , it may indicate a bent connecting rod and no attempt should be made to start the engine. POWERHEAD MUST BE DISASSEMBLED AND SERVICED IMMEDIATELY. Engine Dropped Overboard (In Salt Water) Follow same procedures as Engine Dropped Overboard (Not Running) and (Running). Even if engine can be started, it must be serviced (disassembled and cleaned and electrical components cleaned or replaced where necessary) as salt water can cause excessive corrosion of electrical components and internal parts. Prolonged Submersion (Fresh or Salt Water) If engine has been dropped overboard and not recovered immediately, the engine must be serviced within three hours after recovery. Follow same procedures as Engine Dropped Overboard (Not Running) and (Running). When prolonged submersion occurs in salt water, even if engine can be started, the engine must be disassembled and cleaned and electrical components cleaned or replaced where necessary.

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1 DRC6805

Synchronization and Linkage Adjustments

INote I You must perform this step-by-step procedure exactly as written to ensure consistent engine idling and smooth operation throughout the RPM range. Preli~inaryAdju~~ents~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

INote I Some preliminary adjustments must be made to ensure that the linkage is in the correct position before starting.

&

1. To prevent accidental starting of engine while servicing, twist and

re~ove all spark plug leads.

IT]

2. Set the idle stop screw @ length at % in. (19 mm), measuring from the throttle arm to the idle stop screw boss. Lock the screw in place.

IT]

3. Tiller Models Only: Remove the pivot screw ® securing the throttle cable bracket to the support

arm.

IT]

4. Tiller Models Only: Turn the idle speed adjustment knob counterclockwise to the full SLOW position. Verify that the knob and the throttle twist grip are in the full SLOW position. Verify that the throttle arm © is touching the idle stop screw @.

IJJ

5. Tiller Models Only: Rotate the throttle cable bracket © to align it with the mounting screw hole. Rotate the bracket one revolution toward the cable end to preload the cable. Install the bracket and pivot screw, placing the flat washer ® between the bracket and the cable support arm.

6.

Re~ote

Models Only: Disconnect the throttle cable from the engine. E

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Set Timing Pointer _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

INote I If the timing pointer bracket has been disturbed, check the timing pointer alignment. 1. Remove the three spark plugs from the cylinder head .

IT]

2. Loosen the screw securing the timing pointer. Center the timing pointer. Tighten the screw.

3. Rotate the flywheel clockwise until the cast-in TDC mark is approximately 1 in. (25,4 mm) past the timing pointer. NEVER rotate the flywheel counterclockwise.

W

4. Install OMC Piston Stop Tool, PI N 384887, in the No. 1 cylinder. Adjust the tool to make contact with the piston.

W

5. While holding the piston firmly against the piston stop tool , make a mark ® on the flywheel inline with the timing pointer.

W

6 . Turn the flywheel in a clockwise direction until the piston contacts the tool again. Make a second mark @ on the flywheel inline with the timing pointer. Remove the piston stop tool.

[[] 7. Use the molded-in marks to find the midpoint between marks ® and @. Place a mark © at this location .

W

8. Rotate the flywheel clockwise to line up mark © with the timing pointer. Hold the flywheel in this position. Loosen the timing pointer screw and move it to line up with the cast-in TDC line. Tighten the screw securely. 9. Install the spark plugs and tighten them to 18-20 ft. Ibs. (24-27 N·m).

1-32

Mirage eng

Throttle Plate Synchronization _ _ _ _ _ _ _ _ _ _ _ __ 1. Remove the air silencer.

W [[]

2. Use a 5/64 in. ball-hex driver to turn the cam follower adjustment screw counterclockwise until the cam and cam follower @ are NOT touching .

rn 3. Loosen the two carburetor link screws. 4. Verify that all throttle plates are completely closed.

[!Q]

5. Apply light upward pressure to carburetor link tabs and tighten the carburetor link screws. Idle Timing _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

\Notel

The boat and engine must be in the water under normal operating conditions with the correct propeller installed. The boat's movement must be unrestrained. The boat must not be tied to a dock or trailer. Allow engine to reach normal operating temperature before making this adjustment.

[I1]

1. Separate the temperature switch white/black lead connector. Use a jumper to connect the ignition module side of the lead to a clean engine ground. This will disable the QuikStart's cold-start feature, preventing an inaccurate timing reading . 2. Connect the spark plug leads.

~

3. Attach a timing light to the No.1 cylinder spark plug lead. Start the engine. Wait at least 10 seconds for QuikStartto return the timing to normal. Make sure the throttle arm is against its stop. The engine timing pointer must align with correct degree mark on the flywheel grid.

Idle Timing 25,35

4° ATOC

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OJ & 4. Stop the engine. To adjust, loosen the idle stop screw locknut. Rotate the idle stop screw to achieve 4° ATDC idle timing, then tighten locknut.

• Rotating the idle stop screw clockwise advances idle timing. • Rotating the idle stop screw counterclockwise retards idle timing. 5. Repeat Steps 3 and 4.

INote I This procedure should provide the best idle characteristics while allowing engine idle speeds in gear ranging from 700 to 800 RPM, depending on propeller selection. • If idle speed is too high, check induction system for air leaks. • If idle speed is too low when engine condition is correct, decrease idle timing to achieve desired RPM. Example: from 6° ATDC to 4° ATDC. • If idle speed is inconsistent or the engine runs rough or spits lean, refer to Carburetor Mixture Adjustment, Section 2. 6. Reconnect the temperature switch connector. Cam Follower Pickup _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

m

1. Make sure the throttle arm is against the stop screw. Use a sharp grease pencil to make a mark @ on the crankcase, inline with the 4° ATDC mark on the timer base grid.

rn

2. Advance the throttle to line the mark @ on the crankcase with the zero o mark on the timer base grid. Use a 5/6 4 in. ball-hex driver to adjust the cam follower screw so it just touches the cam.

rn

3. Close the throttle, then open the throttle until the mark @ lines up with the zero on the timing grid. Verify that the cam follower is just touching the cam. Maximum Spark Advance _ _ _ _ _ _ _ _ _ _ _ _ _ __

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1. Advance the throttle to wide-open position . The timing pointer must align with the correct degree mark on the timer base grid.

Maximum Spark Advance 25

20° BTDC E

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22° BTDC

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Mirage eng

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[[J

2. To adjust, loosen the timing adjustment screw nut @. Turn the screw to align the mark on the crankcase with the correct number on the timer base grid . • Turning the screw clockwise one turn retards the timing approximately 2° . • Turning the screw counterclockwise one turn advances the timing approximately 2°.

3. Tighten nut @. Verify the adjustment by opening and closing the throttle several times. Make sure the mark on the crankcase consistently aligns with the correct number on the timer base grid when the throttle is in the wide-open position.

Wide-Open Throttle _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

W

1. Remove the air silencer. Advance the throttle to the wide-open position. Verify that the throttle plates are horizontal. If not, check the linkage for correct assembly, mechanical binding, and interference.

rn

2. Attach the drain hose to the air silencer. Install the air silencer on the engine.

Neutral Detent Adjustment _ _ _ _ _ _ _ _ _ _ _ _ __

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1. While rotating the propeller shaft, move the shift lever to NEUTRAL position.

rn 2. Move the shift lever back and forth to verify the neutral detent position . [IQ]

3. Loosen both neutral detent screws.

ITIJ

4. To find the middle of the NEUTRAL position, first move the shift lever forward to the limit of free play. Mark this position with a line © on the neutral detent cam. E

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1-35

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[I]

5. Move the shift lever rearward to the limit of free play. Mark this position with a line @ on the neutral detent cam.

rn 6. Find the middle between the two marks made on the neutral detent cam . Place a mark ® at this position .

rn

7. Move the shift lever to the middle mark ® made in the previous step. Tighten the two screws to 60-84 in . Ibs. (7-9 N·m).

1-36

Mirage eng

20-Hour Check

INote I Outboard Marine Corporation encourages all Johnson and Evinrude owners to return their new engines to an authorized dealer for a mechanical check. This check should be performed after approximately 20 operating hours. The cost of this check should be figured at local dealer labor rates and paid for by the engine owner. The 20-hour check should include: 1. Drain and fill gearcase with recommended lubricant. Pressure and vacuum test gearcase if signs of water are present. 2. On mechanically steered engines, lubricate cable ram with 0'v1C Triple-Guard grease. 3. Check torque on spark plugs. Loosen spark plug 1/4 turn before applying torque. 4. Check all linkage adjustments. 5. Check engine mounting hardware for tightness. 6. Lubricate all grease fittings with grease.

ave

Triple-Guard

7. Check entire boat and engine fuel system for signs of deterioration, damage, or leaks. 8. Check all engine systems for signs of deterioration or problems.

Mirage/eng

1-37

Rigging Information Remote Control

&

To prevent accidental starting of engine, verify that battery cables are disconnected at battery.

t

Control Cable Identification

[JJ

1. Put the control handle into NEUTRAL position. The throttle cable casing guide ® will retract completely and the shift cable casing guide @ will go to the midpoint of its travel.

,®

I,

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([0)

1

[JJ

2. As you move the control handle into FORWARD, the shift cable casing guide @ must retract and the throttle cable casing guide ® must begin to extend.

3. As you move the control handle into REVERSE, both casing guides must extend. 4. Identify each control cable for proper installation .

& Control

cable identification and function must be correct before continuing with installation.

Shift Cable

rn

1. Extend shift cable and lubricate with OMC Triple-Guard

grease.

2. Verify that the fast idle lever is down in the RUN position. 3. Move the remote control handle to NEUTRAL.

&

Before connecting shift cable, verify control handle position and neutral lockout index plate orientation.

rn 4. Move the remote control handle to full throttle in FORWARD. W

5. Rotate the propeller shaft and shift the gearcase into FORWARD.

6. Remove the rubber grommet at the front of the lower motor cover. Remove the anchor pocket cover and screw. Apply a liberal amount of OMC Triple-Guard grease to both anchor block pockets. [ ] ] 7. Install the shift cable on the shift lever pin . Install the retaining clip © supplied with the engine. [ ] ] 8. Pull firmly on cable casing to remove backlash and adjust cable trunnion nut to locate in anchor pocket. 9. Temporarily install the anchor pocket cover and screw. 10. Shift the remote control to NEUTRAL.

&

Safety Related

1-38

Mirage,eng

11 . Temporarily remove the shift cable from the shift lever pin and verify that the gearcase is in its NEUTRAL detent. I Note I If there are not enough threads on the shift cable to allow the adjustment in Step 7, or if the gearcase detent does not correspond with remote control NEUTRAL in Step 10, refer to Section 6 for shift rod height adjustment.

[]] &.

12. Attach shift cable to shift lever pin using the retaining clip ©.

INotelwhen installing OMC Accessory Controls, except for prewired surface mount, the shift cable must be adjusted and installed when the control and engine are in NEUTRAL. Throttle Cable

W

1. Extend throttle cable and lubricate with OMC Triple-Guard grease. 2. Verify that the fast idle lever is down in the RUN position.

3. While rotating the propeller shaft, move the remote control handle from NEUTRAL to the FORWARD detent and then halfway back to NEUTRAL. This positions the control for proper throttle cable adjustment. I Notel Failure to follow this procedure exactly might cause accelerated wear of shift system components and high shifting effort. 4. Move engine throttle lever tightly against idle stop screw.

rn &.

5. Attach cable casing guide to throttle lever pin using retaining clip © supplied with engine.

[ ] ] 6. Remove anchor pocket cover and screw being careful not to disturb the shift cable. Pull firmly on throttle cable to remove backlash and install trunnion nut in anchor pocket.

rn 7. Install the anchor pocket cover and torque screw to 60-84 in. Ibs. (7-9 N·m). 8. Check cable adjustment; if throttle cable adjustment is too loose, idle speed might be high and inconsistent. If throttle cable adjustment is too tight, control effort might be high through the shifting range.

&.

9. Inspect installation to ensure that the control cables are attached to the proper engine levers by lifting the fast idle lever to the START position. If correctly attached, the throttle cable and engine throttle lever will move. INotel When installing a remote control that is not manufactured by Outboard Marine Corporation, you must verify that the shift cable stroke is compatible with this engine. This engine is designed to accept a shift stroke, measured between NEUTRAL and FORWARD, of 1.125-1 .330 in. (28,6-33,8 mm).

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Safety Related

1-39

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42079A

Electrical Cable

&.

Disconnect battery cables from battery before servIcing electrical systems. Failure to do so could result in injury from ignition sources (sparks) or from contact with moving parts if accidental cranking or starting occurs. Provide sufficient slack at motor end to permit steering and tilting of motor without binding cables.

IJJ

1. Route instrument harness into lower engine cover. Position harness so it will not interfere with the upper engine cover when installed. Route harness to a position where the connectors can be attached at the junction box.

[I]

2. Install protective plug ® (supplied with engine) on power trim /tilt 3-pin connector on non-trim models.

rn

3. Before installing connections, check that the seal ® is in place. Clean off any dirt from connectors. Apply a light coat of OIVIC Electrical Grease to the seal. Push connectors together until latched.

rn

4. Secure connectors in junction box by latching connector in slot of junction box.

W 5. Install junction box cover and secure with screws. W &. 6. Route the positive (red) battery cable © to starter solenoid. Secure cable to starter solenoid. Cover terminal with rubber boot.

rn &.

7. Secure the negative (black) battery cable @ to powerhead ground terminal .

[ ] ] 8. Install battery cables, instrument cable, and the trim/tilt cable (if equipped) in grommet.

&.

After installation, verify that there is sufficient clearance for all cables to avoid binding or chafing through all engine steering and tilting angles. E

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Safety Related

1-40

M irage eng

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NOTES

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1-41

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Drill Size Conversion Chart SHOWING MILLIMETER SIZES, FRACTIONAL AND DECIMAL INCH SIZES, AND NUMBER DRILL SIZES

FracMilli - Dec. Meter Equ iv . tional

.1 .15 .2 .25 .3

... .35

... .39 .4

.. . .45

. .. .5

.. . ... .55

... .6

.. . .. .

.65

.. . ... .7

... .75

... .79 .8

...

...

.85

.. . .9

.. . .. . .95

.. . .. . 1.0

... .. . 1.05

. .. .. . 1.1 1.15

.. . 1.19 1. 2 1.25 1.3

.. . 1.35 . ..

1.4 1.45 1.5 . . .

1.55 1.59 1.6

.. . 1.65 1.7 .. .

.0039 .0059 .0079 .0098 .0118 .0 135 .0138 .0415 .0156 .0157 .0160 .0 177 .Q180 .0197 .0200 .0210 .0217 .0225 .0236 .0240 .0250 .0256 .0260 .0280 .0276 .0292 .0295 .0310 .0312 .0315 .0320 .0330 .0335 .0350 .0354 .0360 .0370 .0374 .0380 .0390 .0394 .0400 .0410 .0413 .0420 .0430 .0433 .0452 .0465 .0469 .0472 .0492 .0512 .0520 .0513 .0550 .0551 .0570 .0591 .0595 .0610 .0625 .0629 .0635 .0649 .0669 .0670

Num- Milli- Dec. Fracber Meter Equiv . tional

1.75

.. . 1.8 1.85

.. . 1.9

80

.. . 79

'/ 64

...

1.95 1.98

.. .

78

2.0 2.05

77

... ...

76 75

2.1 2.15

74

2.2 2.25

73 72

...

.. .

2.3 2.35

...

71 70

2.38 2.4

.. .

69

2.45 '/ 32

68

...

. ..

2.5

.. . .. .

67 66

2.6

65

2.7

64 63

2.75 2.78

. .. . .. ...

62 61

2.8

.. . .. . 2.9

60 59

.. .

3.0

...

58 57

3/64

56

3.1 3.18 3.2 3.25

...

... 3.3 3.4

.. . 55 54

3.5 ., . 3.57 3.6

. .. 3.7

...

53

3.75 '/ '6

..

.

. .. 3.8

52

... 3.9

.. . 51

3.97

.0689 .0700 .0709 .0728 .0730 .0748 .0760 .0767 .0781 .0785 .0787 .0807 .0810 .0820 .0827 .0846 .0860 .0866 .0855 .0890 .0905 .0925 .0935 .0937 .0945 .0960 .0964 .0980 .0984 .0995 .1015 .1024 .1040 .1063 .1065 .1082 .1094 .1100 .1102 .1110 .1130 .1141 .1160 .1181 .1200 .1220 .1250 .1260 .1279 .1285 .1299 .1 338 .1360 .1378 .1405 .1406 .1417 .1440 .1457 .1470 .1476 . 1495 .1496 .1520 .1535 .1540 .1562

Num- Milli- Dec. Frac- Num- Milli- Dec. FracMeter Equiv . tional Meter Equiv. tiona I ber ber

... 50

4.0

.. . ... 49

5/64

4.1 4.2

48

.. .

. ..

4.25 4.3

47

.. .

4.37

., . 46 45

4.4

. ..

4.5

... 44 43 42 3132

... 41

4.6

...

4.7 4.75 4.76 4.8

... 4.9

.. . . ..

5.0 40

...

5.1 39 38 37 36 7/ 64

.. .

.. . 5.16

. ..

5.2

...

5.25 5.3

...

35

5.4

34 33

5.5 5.56 5.6

32

. ..

31

5.7 5.75

...

.. . '/ 0

. ..

5.8 5.9

. .. 30

5.95 6.0

... 29

6.1

... 28 9/ 64

. .. 27 26

6.2 6.25 6.3 6.35 6.4 6.5

... 25

6.6

... 24 5/3 2

23

6.7 6.75 6.75

...

. ..

.1 570 .1575 .1590 .1610 .1614 .1654 .1660 .1673 .1693 .1695 .1719 " /64 .1730 .1732 .1770 .1771 .1800 .1811 .1820 .1850 .1870 .1875 3/ '6 .1890 .1910 .1929 .1935 .1960 .1968 .1990 .2008 .2010 .2031 '3/ 64 .2040 .2047 .2055 .2067 .2086 .2090 .2126 .2130 .2165 .2187 7/32 .2205 .2210 .2244 .2263 .2280 .2283 .2323 .2340 .2344 15/64 .2362 .2380 .2401 .2420 .2441 .2460 .2480 .2500 '14 .2520 .2559 .2570 .2598 .2610 .2638 .2657 '7/64 .2657 .2660

22

6.8 6.9

21 20

... 7.0

.. . 7.1 19

. ..

.. .

7.14 7.2 7.25 7.3

17

. ..

18

7.4 16

. ..

15

7.5 7.54 7.6

14 13

.. .

7.7 7.75 7.8 7.9 7.94 8.0

. .. 12 11 10 9

...

8

...

8.1 8.2 8.25 8.3 8.33 8.4

7

.. . 6

. ..

8.5 8.6

5

.. . 4

8.7 8.73 8.75 8.8

3

.. .

... 8.9 9.0

2

.. . 9.1 9.13 9.2 9.25 9.3

1

A

...

...

B

9.4 9.5 9.53

C

... 9.6 9.7 9.75 9.8

D E

. .. F

G

9.9 9.92 10.0

.. .. . .

.. .

10.32

H

10.5

.. .

.2677 .2716 .2720 .2756 .2770 .2795 .2811 .2812 .2835 .2854 .2874 .2900 .2913 .2950 .2953 .2968 .2992 .3020 .3031 .3051 .3071 .3110 .3125 .3150 .3160 .3189 .3228 .3230 .3248 .3268 .3281 .3307 .3320 .3346 .3386 .3390 .3425 .3437 .3445 .3465 .3480 .3504 .3543 .3580 .3583 .3594 .3622 .3641 .3661 .3680 .3701 .3740 .3750 .3770 .3780 .3819 .3838 .3858 .3860 .3839 .3906 .3937 .3970 .4040 .4062 .4130 .4134

FracNum- Milli- Dec. Meter Equiv. t iona I ber

I

J K

9/ 32

...

L M 19/ 64

. .. N

5/ ,6

. .. 0

P 2 '/ 64

.. . Q

R " 132

. .. S T

23/ 64

...

U

3/ 0

. .. V

W 25/64

... X Y

' 3/32

. ..

Z

10.72 .4219 11 .0 .4330 11.11 .4375 11 .5 .4528 11 .51 .4531 11.91 .4687 .4724 12.0 12.30 .4843 .4921 12.5 12.7 .5000 13.0 .5118 13.10 .5156 13.49 .5312 13.5 .5315 13.89 .5469 14.0 .5512 14.29 .5624 14.5 .5709 14.68 .5781 15.0 .5906 15.08 .5937 15.48 .6094 15.5 .6102 15.88 .6250 16.0 .6299 16.27 .6406 .6496 16.5 16.67 .6562 17.0 .6693 17.06 .6719 17.46 .6875 17.5 .6890 17.86 .7031 18.0 .7087 18.26 .7187 18.5 .7283 18.65 .7344 19.0 .7480 19.05 .7500 19.45 .7656 19.5 .7677 19.84 .7812 20.0 .7874 20.24 .7969 20.5 .8071 20.64 .8125 21 .0 .8268 21 .04 .8218 21.43 .8437 21 .5 .8465 21.83 .8594 .8661 22.0 22.23 .8750 22.5 .8858 22.62 .8906 23.0 .9055 23.02 .9062 23.42 .9219 23.5 .9252 23.81 .9375 24.0 .9449 24.21 .9531 24.5 .9646 24.61 .9687 25.0 .9843 25.03 .9844 25.4 1.0000

27/64

7/' 6 29/ 64 '5/32 3 '/64

'12 33/64 17/32 35/64 9/ ' 6 37/64 ' 9132 39/ 64

5fs 4 '/64 2'/ 32 43/ 64 " / '6 45/64 23/ 32 47/6,

% 49/64 25/32 5 '/ 64 '3/' 6 53/ 64 27/32 55/64 7/0 57/64 29/32 59/64 '5/' 6 6'/64 3 '/32 63/6,

1

DR2949·E NG

1-42

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Heli-Coillnserts and Installers

IJJ

Use these Heli-Coil inserts on all models to repair damaged threads. The installation kit consists of drill, tap, and insertion tools.

INotel

The 14 mm spark plug inserts are specially made for use in aluminum cylinder heads. Do not use substitutes.

\ \> · 1

Installation Instructions

\

-,1

'j

C03603

1. Drill to adequate depth using drill size supplied with kit. 2. Use Heli-Coil tap supplied with pack. Check thread size on shank to make certain proper size is used. 3. Screw insert onto mandrel until tang is fully engaged in driving contour. 4. Screw insert into tapped hole . Top of insert must be onequarter to one-half turn below top surface. 5. The tang must be removed to allow full passage of screw into the insert. The tang may be broken off cleanly at the notch in the bottom coil with a punch or rod having a diameter that just fits into the assembled insert. Make sure that the punch or rod has a square end (no chamfer). Place punch or rod into assembled insert until it rests on tang. Holding tool squarely, strike it sharply with a hammer.

PIN 391436 391438 391439 391440 391441 391450 984963 391437 437276 437277 437278 437279

Mirage/eng

Name of Part Heli-Coillnstaller Heli-Coillnstaller Heli-Coillnstaller Heli-Coillnstaller Heli-Coillnstaller Heli-Coillnstaller Heli-Coillnstaller Heli-Coillnstaller Heli-Coillnstaller He Ii-Coil Installer Heli-Coillnstaller Heli-Coillnstaller

Kit, Kit, Kit, Kit, Kit, Kit, Kit, Kit, Kit, Kit, Kit, Kit,

8-32 10-24 %-20 5/ 16 -18 %-16 1/2-13 3/4-16 14 mm M5 x 0.8 M6 x 1.0 M8 x 1.25 M10 x 1.50

1-43

PIN

Name of Part

391448 391447 391446 391445 391444 391449 913412 437948 437949 437280 437950 391443 391442

Heli-Coillnserts, 8-32 Heli-Coillnserts, 10-24 Heli-Coillnserts, %-20 Heli-Coillnserts,5/ 16 -18 Heli-Coillnserts, 3/ 8 -16 Heli-Coillnserts, 1/2- 13 Heli-Coillnserts, 3/4-16 Heli-Coillnserts, M5 x 0.8 Heli-Coillnserts, M6 x 1.0 Heli-Coillnserts , M8 x 1.25 Heli-Coillnserts , M10 x 1.50 Heli-Coillnserts, 14 mm (% in . Reach) Heli-Coillnserts, 14 mm (1/2 in . Reach)

Fuel System Table of Contents General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . In-Line Fuel Filter Servicing . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Primer System Servicing ...... . ............. Boat Fuel System Recommendations ................. Carburetor Servicing .... ...... ................... . Carburetor Mixture Adjustment. . . . . . . . . . . . . . . . . . . . . Intake Manifold Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . Oil Tank and Mixing Unit Servicing . . . . . . . . . . . . . . . . . . Low Oil Light Test - Tiller Model. . . . . . . . . . . . . . . . . . . . Maintenance Valve Servicing . . . . . . . . . . . . . . . . . . . . . . . Fuel System Trouble Check Chart . . . . . . . . . . . . . . . . . . .

2- 2 2- 3 2- 5 2- 6 2- 7 2- 8 2-10 2-12 2-15 2-22 2-23 2-25 2-35 2-36 END

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General Safety Warnings

Before working on any part of the fuel system, read the section called Safety at the end of this manual. The engine cover is a machinery guard. Use caution when conducting tests on running engines. Do not wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating flywheel. To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Check nonmetallic fuel system parts for signs of deterioration, cuts, cracking, or abrasion. Always replace with specified parts. Do not attempt to run engine with any fuel system component disconnected or removed. Fuel leakage could contribute to a fire or explosion. After completing any service procedure, momentarily pressurize fuel system and check for leaks! Fuel leakage could contribute to a fire or explosion. When using shop air for cleaning or drying parts: • Be sure air supply is regulated to not more than 25 PSI (172 kPa). • Be sure you use appropriate eye protection to avoid personal injury. 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.

2-2

M irage en

Service Specifications Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

In. Lbs.

N'm

Adhesive

Leaf Valve Screws

25-35

2,8-4,0

0tVtC Ultra Lock

Intake Manifold Screws

60-84

7-9

0tVtC Ultra Lock

Cover and Bowl Screws

17-19

1,9-2,1

•

Fuel Pump to Crankcase Screws

24-36

3-4

0tVtC Nut Lock

Primer Solenoid Screws

Powerhead

84-106

10-12

0tVtC Nut Lock

Upper Oil Tank Mounting Bracket Screws

216-240

25-27

0tVtC Ultra Lock

Lower Oil Tank Mounting Bracket Screws

180-204

21-23

0tVtC Nut Lock

Oil Mixing Unit Mounting Bracket Screws

180-204

21-23

0tVtC Nut Lock

60-84

7-9

0tVtC Nut Lock

Description

to

Carburetor to Intake Mounting Screws

Manifold

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2-3

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a,nc Special Tools Required

PIN

Tool Panel

317002 324891 326623 390954 323716 325043 322698 322697

E

E E

•E E E E

Description

Orifice Plug Screwdriver Float Gauge Fuel Nipple Cleaning Tool Fuel Line Vacuum Tester Tie Strap Installation Tool Hose Clamp Wrench Pin Removal Tool Insert Tool

Service Aids Required

Monoject 412 Syringe, or equivalent Clear Tubing, Va in. I.D. x 12 in. (3 mm I.D. x 305 mm) long Brass or Copper Tubing, 3132 in. x 4 in. (2 mm x 102 mm) long Ohmmeter Machinist's Straightedge Inch Pound Torque Wrench

Sealants and Lubricants Required

a,nc Cleaning Solvent Johnson or Evinrude TC-W3@Outboard Lubricant OIVIC Locquic Primer OIVIC Screw Lock OIVIC Nut Lock OIVIC Ultra Lock Gasoila Sealer Isopropyl Alcohol OIVIC 2+4@Fuel Conditioner OIVIC Carbon Guard ™ Fuel Additive OIVIC Carburetor and Choke Cleaner

2-4

Mirage/eng

Fuel Requirements

Minimum Octane Models

Recommendation

(R+M)/2 "AKI"

"RON"

All

See fuel classifications below.

87

69 PCE0020

Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having the recommended octane rating. Acceptable Fuel: Any of the above gasolines with up to the following percentage by volume:

• 10% ETHANOL or • 5% METHANOL with 5% cosolvents Unacceptable Fuel: Do not use any gasoline having more than 10% ETHANOL or more than 5% METHANOL, even if it contains cosolvents or corrosion inhibitor, regardless of octane rating.

OMC products have been designed to operate using the Preferred Fuel or Acceptable Fuel; however, be aware of the following: • The boat's fuel system may be different regarding use of alcohol fuels. Refer to boat owner's manual. • Alcohol attracts and holds moisture which may cause corrosion of metallic parts of the fuel system. • Alcohol extended fuels can cause engine performance 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.

&

Fuel leakage can contribute to a fire or explosion.

INote I OMC 2+4 fuel

conditioner and OMC Carbon Guard fuel additive are the only gasoline additives recommended by Outboard Marine Corporation. Use of other gasoline additives can result in poor performance or engine damage.

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Description of Fuel System

IJJ

1. The two fuel pumps are of the diaphragm-displacement type and are operated by changes in crankcase pressure. Alternately, suction and pressure in the crankcase are transmitted to the pump diaphragms. The pumps are designed to operate together. One pump draws fuel from the fuel tank. The other pumps the fuel through the oil mixing unit and on to the three carburetors.

INote I The

fuel pumps are different and react differently to crankcase suction and pressure pulses. They must not be interchanged as inadequate fuel and oil will reach the engine causing poor performance and possible powerhead failure.

W

2. The carburetors meter the fuel to their individual cylinders. They control engine speed and power output by varying the intake charge density. To react correctly to a wide range of operating conditions, the carburetors have multiple fuel mixing circuits.

rn [!] Mixture enrichment for cold starting is controlled by either a choke @ or a fuel primer solenoid @.

4 30393

2-6

Mirage eng

In-Line Fuel Filter Servicing

INotel

Removal of the starboard side lower motor cover may be necessary to allow access to the in-line fuel filter. Follow instructions found in the Powerhead section of this manual.

rn 1. Loosen both clamps © and move them away from the fuel filter. rn &. 2. Remove both the inlet@ and outlet ® fuel hoses from the filter. Catch any fuel that may leak from the hoses or filter. Discard the filter.

rn 3. Install a new fuel filter and connect both hoses @ and ® to the filter. rn &. 4. Move the clamps © into position to secure the filter. &.

5. Run the engine and check for leaks.

6. Install the starboard side lower motor cover if it was removed following instructions found in the Powerhead section of this manual.

Mirage/eng

&

Safety Related

2-7

Fuel Pump Servicing

OJ INote I This engine uses two fuel pumps to deliverfuel to the carburetors. One pump @ is designed to draw fuel from the tank. The other pump ® delivers fuel under pressure to the fuel mixing unit and then to the carburetors. Switching the pumps around will result in poor performance and possible engine damage. Before replacing a suspect fuel pump, remove and clean the fuel filters or install new filter elements. Also, remove the fuel hose from the fuel tank and blow through all passages and hoses with low-pressure compressed air to be sure they are open. This might be the cause of inadequate fuel delivery. If this procedure does not correct the trouble, test the fuel pumps.

&.

To prevent excessive fuel spillage, disconnect hose connector at motor before disassembly. After servicing, check for leaks by connecting fuel hose to motor and squeezing primer bulb until definite resistance is felt in bulb.

W

To service filter, loosen screw and remove cover @. Do not lose small O-ring @ from around center post or large O-ring ® from outer edge of cover.

W • Wash filter element ® with clean solvent and a brush.

2 DR3000

• Install filter with lip facing fuel pump body.

W • Make sure the large O-ring ® is seated in its groove in the cover and the small O-ring @ is in place around center post.

W •

Install cover @' Position inlet nipple between screw heads .

• Tighten the cover screw securely.

&

Safety Related

2-8

M ir age em;}

Function Test

Two tests must be conducted to ensure proper fuel delivery. The first test will check the suction pumps' ability to draw fuel from the fuel tank. The second test will check the pressure pumps' ability to supply fuel to the oiling unit and the carburetors. Conduct these tests with the motor in a test tank or on the boat. Before testing, loosen fuel tank gas cap momentarily to release any pressure that may have built up. Fuel tank must not be more than 30 in. (76 em) below fuel pump.

Suction Pump Test

W

1. Remove the fuel inlet fitting to suction fuel pump hose. Connect a fuel vacuum gauge (obtained locally) between the fuel inlet fitting and the suction pump.

2. Start motor and run it at wide-open throttle . Observe the gauge. Pump vacuum gauge should read no more than 4 inches (102 mm) Hg. 3. If fuel pump does not meet this specification, check fuel delivery system for a restriction . • If no restriction is found, repair or replace the suction fuel pump. When installing a new fuel pump, apply OMC Nut Lock to threads of screws. Install screws and torque to 24-36 in. Ibs. (2,8-4,0 N·m).

Pressure Pump Test

W

1. Remove pressure fuel pump to in-line fuel filter hose. Connect a fuel pressure gauge (obtain locally) between the pressure fuel pump and the in-line fuel filter. 2. Start motor and run it at wide-open throttle. Observe the gauge. Pump pressure should read a minimum of 3 PSI (21 kPa). 3. If pressure fuel pump does not meet this specification, repair or re place the pressure fuel pump . • When installing a new fuel pump, apply OMC Nut Lockto threads of screws. Install screws and torque to 24-36 in . Ibs. (2,8-4,0 N·m) .

Mirage eng

2-9

Electric Primer System Servicing Function Test

1. Start engine and allow it to reach normal operating temperature. Set engine speed at 2000 RPM.

[IJ

2. While engine is running, push key in. Engine should run richly and drop 1000 RPM.

W

3. Remove primer hose from any primer fitting that you suspect is clogged. Connect a '/8 in. I.D. clear vinyl hose between the fitting and a syringe filled with isopropyl alcohol. 4. Press lightly on the syringe plunger . • If fluid moves through the fitting, it is okay.

rn • OMC If fluid does not move through the fitting, clean it with Fuel Nipple Cleaning Tool, PI N 326623. 40684

23655

2-10

MIrage eng

rn 5. To test the solenoid windings, calibrate an ohmmeter on low ohms scale and connect between the purple/white and black leads . • Meter should indicate 5.5 ± 1.5 ohms. 6. To test solenoid valve and seat: [[]

• Lightly pressurize inlet fitting with alcohol and syringe.

[]]

• With lever in run position @, no fluid should enter inlet fitting.

[]]

• With lever in prime position @ , fluid should come out both outlet fittings .

rn 7. To inspect or replace internal components, remove the four solenoid cover screws. [ [ ] 8. When assembling solenoid, back out screws in their holes to engage original threads - then, tighten securely. Installation

COAl138

-@

1. Attach purple/white leads and three hoses. Secure large hose with tie strap. 2. Install solenoid and bracket. Position ground lead under the inside bracket screw.

&.

3. Check for leaks by connecting fuel tank hose to motor and squeezing primer bulb until definite pressure is felt in the bulb.

6 DR3814

30239 DR1417

Mirage/eng

&

Safety Related

2-11

Boat Fuel System Recommendations Purpose

This information is provided to assist you in evaluating a boat's permanently installed fuel system. Large outboards require a boat fuel system that has a high fuel flow rate and a low pressure drop across the entire system. It is very important that all boat fuel system components are of the correct capacity and that they are properly installed. ABYC's Standard H-24 and ICOMIA's Standard No. 17 are accepted as industry standards and should be referred to for additional information.

INote I A permanently installed fuel system with excessive restrictions could exceed the fuel pump's pumping capacity and cause poor engine performance or serious powerhead damage. To evaluate the restrictiveness of a permanently installed fuel system, refer to Fuel Pump Servicing, this section. Recommendations

1. Fuel Tank Pickup Tube - a minimum inside diameter of 3/8 in. (9,5 mm) is required for V6 and larger engines. 3/8 in. (9,5 mm) is preferred for V4 and smaller engines, while a minimum of 5/16 in. (7,9 mm) is required. Dual 70 3-cylinder and larger outboards each require a separate fuel pickup tube.

IT]

2. Pickup Tube Filter - to be constructed from stainless steel No. 304 wire cloth, 100 mesh, with wire diameter of 0.0045 in. A cylindrical screen ® equal to pickup tube outside diameter and 1 in. (25,4 mm) long will provide adequate surface area. The screen should be horizontal and slightly above the tank bottom.

2-12

1 DR5980

Mirage/eng

3. Anti-Siphon Valve - safety standards require permanently installed fuel systems to have anti-siphon protection. This protect ion can be afforded in two ways: • All fuel distribution lines must be secured above the highest fuel level when the boat is in its normal, unloaded, static floating position . • Each fuel pickup tube must have an anti-siphon valve installed . Anti-siphon valves used must have a pressure drop of no more than 2.5 inches Hg at a flow rate of 20 gallons per hour. The following OMC valves meet this requirement: • PIN 173273 for • PIN 173274 for • PIN 173275 for

5/ 16 3/8 3/8

in . 1.0. hose in. 1.0. hose in. 0.0. copper

4. Fuel Distribution Lines - a minimum inside diameter of 3/ 8 in. (9,5 mm) is required for V6 and larger engines. 3/8 in . (9,5 mm) is preferred for V4 and smaller engines, while a minimum of 5/ 16 in . (7 ,9 mm) is required. Distribution lines must be USCG Type "A1" or "B1". Vinyl hose must not be used in a permanently installed fuel distribution system. 5. Fuel Distribution Fittings - all fittings must have a minimum inside diameter of 1/4 in. (6,4 mm), while 9/ 32 in. (7,1 mm) is preferred. 6. Fuel Filter - fuel filters must have a pressure drop of no more than 0.4 inch Hg at a flow rate of 20 gallons per hour. The filter should have a minimum filtered area of 200 square inches (1290 cm 2 ). OMC Fuel Filter Kit, PI N 174176, meets these requirements. 7. Fuel System Priming - OMC Electric Fuel Primer Kit, PIN 174651, is available for built-in fuel systems. The kit mounts near the fuel supply and, when activated, fills the fuel distribution lines and engine fuel system for quicker starting. OMC Manual Filter Primer Assembly, PIN 398540, is available for engines below 120 HP.

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2-13

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NOTES

2-14

Mirage eng

Carburetor Servicing Removal

In.

1. Avoid accidental start-up while servicing engine; twist and remove all spark plug leads.

OJ

2. Turn the retainer knob located in the middle of the air silencer and remove the silencer from the engine. Disconnect the drain hose from the nipple at the bottom of the silencer.

rn 3. Remove the choke link ® from carburetor choke lever. rn 4. Remove the throttle linkage @ from the throttle arm.

m

5. Loosen two mounting screws

© and remove carburetor .

[ ] ] 6. Cut tie strap @ securing fuel hose to carburetor.

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Safety Related

2-15

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~"'~ --r--Ft=-t ~® Q

@~

____

~o e ___

®

~

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(J) ~

1 DR5958

OJ

Disassembly

1. Remove two screws securing the adapter @ to the carburetor. Discard the gasket @. 2. Remove the low-speed needle carburetor body cover.

© and spring @ from the

3. Remove the eight cover screws. Lift the cover off the carburetor body. Discard the gasket.

® and gasket ®

4. Remove the seven float chamber screws. Remove the float chamber © and gasket @. Discard the gasket. 5. Remove the hinge pin

CD, float Q),

6. Remove the valve seat

© and

and float valve @.

gasket @. Discard the gasket.

7. Remove the high-speed orifice @.

2-16

Mirage eng

Cleaning and Inspection

INote I Never clean a carburetor by submerging or soaking it in a hot tank or carburetor cleaner. Do not expose plastic or rubber parts to any carburetor cleaner.

1. Before inspection, all carburetor components must be perfectly clean : • Carburetor must be completely disassembled . • Clean parts with OMC Carburetor and Choke Cleaner.

rn • deposits. Use a clean bristle brush to remove gum or varnish • Blow dry with shop air of not more than 25 PSI (172 kPa) . When drying passages, direct the flow of shop air opposite to the direction of fuel flow. Float Valve Assembly

3

1. Inspect the inlet needle and float valve seat:

rn • rn •

DR3584

Check the inlet needle tip for grooves, nicks, scratches, or distortion. Check the float valve seat for nicks, scratches, or distortion .

• Check the float for signs of oil or gasoline saturation .

INotel

The inlet needle and float valve seat must be replaced as a

set.

4 DR5981

Needle Valves

W

Inspect the tapered end of the needle valve for nicks, scratches, grooves, or signs of distortion.

M irage/eng

2-17

y

Carburetor Body

[IJ

1. Check all drillings and passages with a syringe filled with isopropyl alcohol.

2. Visually inspect all gasket surfaces for nicks or irregularities. 3. Check for excessive throttle shaft play. Check for throttle valve misalignment.

W 4. Check for leaks between emulsion pickup tube and carburetor body:

• Invert carburetor body and fill idle circuit with isopropyl alcohol. • Check for leaks at point @. • If a leak occurs, blow dry and apply a drop of OMC Ultra Lock at point @.

2 7626

2-18

Mirage eng

3 DR5958

rn

Assembly

INote I Before

proceeding, be sure that all parts are perfectly clean . Be sure that all replacement parts match original ones in size and shape. Replace all gaskets, O-rings, and sealing washers each time you assemble a carburetor. 1. Install the high-speed orifice @. 2. Install the gasket

© and valve seat @.

3. Install the hinge pin @, float

®, and float valve @.

4. Check for correct positioning of the float level. The float level controls the height of fuel in the float chamber and is critical with regard to carburetor calibration and function. 5. Install the adapter ® with a new gasket CD onto the carburetor and secure with two screws. Tighten the screws securely.

Mirage/eng

2-19

OJ • Turn

carburetor body upside down and hold so gasket surface is horizontal. The weight of the float will close the float valve needle. Rest OVIC Float Gauge, PI N 324891, on gasket surface and slide gauge up, next to float. Top of float should be between notches on gauge. g.g 81 5 H.P.

2 THRU 6 H .P.

OJ

Use notch that is indicated "9.9 & 15 HP." Be certain gauge is not holding down the float. • If float level is not between the notches of gauge, lightly bend metal float arm to adjust level. Be careful not to force float needle valve into seat.

DA5982

6. Check for correct float drop dimension. This dimension affects the full opening of the inlet needle and is critical to correct operation of the carburetor. With carburetor body in normal running position, the float must drop open to dimension shown. To adjust, bend tab on float arm where tab contacts float seat.

W

@ Base of carburetor body ® Bend float lever tab to achieve proper dimension © 1 in . to 13/8 in. (25-35 mm)

7. Install the float bowl and bowl gasket. Tighten the screws to a torque of 17-19 in . Ibs. (1,9-2,1 N·m), following sequence embossed on float chamber.

2 DA5983

8. Install the carburetor body cover and gasket. Tighten the screws to a torque of 17-19 in. Ibs. (1,9-2,1 N·m), following sequence embossed on cover.

W

9. Install the low-speed needle and spring . Turn needle carefully until the dimension between the cover @ and back ® of the needle is 0.390 in . (9,9 mm).

2-20

Mirage/eng

Installation

W

1. Attach the fuel supply hose, and secure with a tie strap

®.

[ ] ] 2. Position a new gasket @ on the intake manifold. [ [ ] 3. Apply CIVIC Locquic Primer and OIVIC Nut Lock to the two carburetor mounting screws @. Install the carburetor and secure with two screws. Tighten the screws to 60-84 in. Ibs. (7-9 N·m).

rn 4. Snap the throttle linkage CD into the throttle arm. Check for a secure attachment. W

5. Install the choke linkage Q) on the choke lever.

[ [ ] 6. Attach the drain hose to the nipple on the bottom of the air silencer. Attach the air silencer to the powerhead and secure by twisting the silencer lock.

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2-21

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Carburetor Mixture Adjustment

INotel

Before proceeding, verify the low-speed needle initial setting. Refer to Page 2-20, Step 9.

1. Start the engine and run it in FORWARD at one-half throttle. Allow the engine to reach normal operating temperature.

[JJ

2. Tiller Models - as you face the steering handle, turn the idle speed adjustment knob counterclockwise to full SLOW speed position.

W

3. Run the engine at slow speed (700-800 RPM) and adjust the low-speed needle @ until the highest consistent RPM is atta ined . Allow 15 seconds after each adjustment for the engine to respond. 4. After the final adjustment is completed, turn the low-speed needle counterclockwise Va turn to prevent a lean condition, particularly in NEUTRAL. 5. Reduce engine speed and turn the idle speed adjustment to allow the engine to run at a minimum of 650 RPM in FORWARD.

6. Run the engine in gear near full throttle for one minute. Quickly reduce speed to SLOW (700-800 RPM) and shift into NEUTRAL. The engine should continue to run smoothly. 7. If the engine stalls or pops, the mixture is too lean . Turn the needle counterclockwise 1/ 16 turn. Allow 15 seconds after each adjustment for the engine to respond. Repeat Step 6 to verify that the mixture adjustment is correct. 8. If the engine does not respond to adjustments, check it for other problems. Make sure gasoline is of good quality and mixed with the proper amount of oil.

2-22

Mirage/eng

Intake Manifold Servicing Removal

1. Follow steps listed in Carburetor Removal, this section.

2. Remove manifold screws and remove manifold. Disassembly

1. Remove the two screws per leaf plate assembly, and remove the leaf plate assemblies as required. INotel Do not disassemble leaf plate assemblies. Leaf plate assemblies are not serviced in detail.

2. When handling leaf plate assemblies, do not lift or bend leaf valves. Inspection

4

1. Inspect the leaf plate assemblies for damage:

rn •

40412

The leaf valve tips must not be cracked or chipped.

• The leaf stops must not be distorted or loose. • Test leaf plate screw tightness. If loose, retighten screws using OMC Screw Lock to 25-35 in. Ibs. (3-4 N·m).

2. Inspect the intake manifold: • All gasket surfaces must be smooth and free of nicks.

W • Use a machinist's straightedge to check for flatness in all directions. The mounting ± 0.004 in. (0,10 mm).

surface

must

be

flat,

INotel All intake manifold components must be perfectly clean before assembly. Do not use a strong carburetor cleaner or hot soaking tank.

Mirage/eng

2-23

Assembly

1. Apply OMC Locquic Primer and OMC Ultra Lock to the leaf plate assembly to manifold screws.

IT]

2. Peal the backing off a new intake manifold gasket. Position the gasket on the leaf plate assembly side of the intake manifold.

rn

3. Position each leaf plate assembly onto the intake manifold and secure with two screws each. Torque the screws to 25-35 in. Ibs. (3-4 N·m).

2-24

1

Mirage eng

Installation

1. Apply OMC Locquic Primer and OMC Ultra Lock to the eight intake manifold mounting screws.

m

2. Install the intake manifold and secure with the eight screws. Torque the screws evenly to 60-84 in. Ibs. (7-9 N·m).

3. Refer to Synchronization and Linkage Adjustments, Section 1, for adjustment information.

Oil Tank and Mixing Unit Servicing Removal INotel The oil tank can be removed from the engine with the mixing unit without removing the oil from the tank. If just the tank is to be removed, siphon the oil from the opening at the top of the tank.

1. Remove the starboard side lower motor cover following the instructions in the Powerhead section in this manual.

rn 2. Remove the retainer from the oil level sender 3-pin Amphenol connector @. Disconnect the sender leads from the engine wiring harness.

W

3. Remove screw @ securing the oil tank to the top bracket.

Mirage/eng

2-25

IT]

&

4. Remove the fuel outlet clamp ® from the fuel filter. Remove the outlet hose from the filter. Catch any fuel that might leak from the filter.

W

5. Remove the screw @ securing the lower oil tank and mixing unit brackets to the powerhead. Pull the brackets away from the powerhead slightly.

rn &

6. Cut the tie strap © securing the fuel outlet hose to the mixing unit. Remove the hose from the mixing unit nipple. Catch any fuel that might leak out.

40555

Mixing Unit Disassembly

rn

1. Separate the oil tank from the mixing unit by cutting the tie strap ©. Pull the hose off the oil tank nipple. Plug the nipple to prevent loss of oil. 2. Cut the tie strap and remove the short fuel hose from the inlet nipple .

[ ] ] 3. Remove the two screws @ securing the oil inlet housing to the intermediate housing and remove the assembly. [ ] ] 4. Remove and discard the large

® and small ® O-rings.

[IJ

5. Remove the two screws @ securing the oil inlet housing cover to the housing.

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2-26

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Mirage e ng

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39990

39992

[ [ ] 6. Remove and discard the a-ring seal from the cover.

rn 7. Remove the three screws ® securing the fitting retainer CD to the oil inlet housing . Remove the retainer. [IQ]

8. Remove the oil inlet Q) and fuel inlet housing. Discard the a -rings.

® fittings from the

ill]

9. Remove and discard the oil filter (1).

[J1]

10. Remove and discard the oil inlet valve @.

[J1] IJ1]

11. Push out the oil outlet valve

® and

a-ring seal @.

INote I Do not attempt to pull the outlet valve out of the housing. This could damage the seat.

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2-27

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IT]

12. Remove the two screws ® securing the fuel outlet fitting retainer to the oil mixing unit cover. Remove the retainer, fitting, and O-ring. Discard the O-ring.

W

13. Pinch the piston seal and roll it off the piston. Discard the piston seal.

rn 14. Remove six screws @ securing the mixing unit bracket to the mixing unit. Note the position of the bracket, then remove it.

rn []J

15. Remove the remaining two screws and washers @. Separate the oil mixing cover @ from the intermediate housing @. Remove the piston and diaphragm assembly @, the small spring ®, and the large spring CD. Discard the piston and diaphragm assembly.

4

Cleaning, Inspection, and Lubrication

INote \ The following

must be done in a clean and dust free area.

1. Wash all components of the oil inlet housing in clean solvent and blow dry.

W []] 2.

Clean mounting threads for cover and oil inlet housing with OIVIC Cleaning Solvent.

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2-28

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Mirage,eng

E

[ ] ] 3. Lubricate all contact points and replacement components with Johnson or Evinrude Outboard Lubricant.

Assembly

rn 1. Position the small spring ® on the end of the short stub of the piston and diaphragm assembly @. Place the large spring CD inside of the diaphragm .

[!Q]

W

2. Position the large spring CD inside the oil mixing unit cover @. Compress the large spring with the cover. Make sure the small spring ® is located over the button Q) inside the cover. Rotate the cover to align the cover and housing exactly as during disassembly. Press the two together and secure with two screws and washers ©.

8 39935

[I1]

3. Install the mixing unit bracket and secure with six screws @. Tighten all eight screws @ and © to 5-7 in. Ibs. (0,6-0,8 N·m).

~

4. Carefully install the oil piston seal into the groove in the oil piston.

9

10

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2-29

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39995

rn W

5. Place the oil outlet valve Secure it with a new O-ring seal @.

® into the oil inlet housing.

rn 6. Install a new oil inlet valve @.

rn

7. Place a new O-ring @ into the groove in the oil pump cover.

[}J

W

8. Position the oil pump cover with the area ® facing the oil inlet valve @. Install the cover and secure with two smaller screws ®. Tighten the screws to 5-7 in. Ibs. (0,6-0,8 N·m).

[ [ ] 9. Install the oil inlet filter @.

2-30

M irage eng

40012

[ [ ] 10. Place a new a-ring

® in both the oil and fuel inlet ports.

rn I1Q] 11. Install the oil CD and fuel Q) inlet fittings. Secure the fittings with retainer ® and three screws CD. Tighten the screws to 5-7 in. Ibs. (0,6-0,8 N·m).

[I!J

12. Install small a-ring housing.

~ and

large a -ring

® into the pump

[11]

[11]13. Place the oil inlet housing @ onto the intermediate housing. Secure with two larger screws ®. Tighten the screws to 7-9 in. Ibs. (0,8-1,0 N·m).

40003

40005

40006

Mirage/eng

2-31

40685

OJ

14. Place a new O-ring

® into the fuel outlet po rt.

rn W

15. Install the outlet fitting and retainer @. Secure with two screws @ . Tighten the screws to 5-7 in. Ibs. (0,6-0,8 N·m).

&

16. Attach the short fuel inlet hose to the fuel inlet nipple and secure with a tie strap.

W&

17. Attach the oil outlet hose @to the oil tank nipple and secure with a tie strap @.

Installation

[]] &

1. Attach the fuel outlet hose nipple and secure with a tie strap @.

® to

the oil mixing unit

W

2. Apply OMC Locquic Primer and OMC Nut Lock to the oil mixing unit and lower oil tank mounting bracket screw. Mount the mixing unit and tank on the engine and secure with mounting bracket screw @. Tighten the screw to 180-204 in. Ibs. (20,3-23,0 N·m) .

Safety Related

2-32

Mirage/eng

[]] &.

3. Attach the fuel hose filter and secure with clamp Q).

CD

to the outlet side of the fuel

rn 4. Route the oil tank sending unit lead ® behind the upper oil tank bracket (h). rn 5. Apply OMC Locquic Primer and OMC Ultra Lock to the upper oil tank mounting bracket screw. Secure the tank to the upper bracket with the screw Ibs. (24,4-27,1 N·m).

iW. Tighten the screw to 216-240 in.

[!Q]

6. Connect the oil tank sending unit lead to the engine wiring harness and secure with retainer @.

7. Install the starboard side lower motor cover following the instructions in the Powerhead section in this manual. Oil Tank Sending Unit Removal

[!Q] [!Il

1. Remove retainer @ from 3-pin Amphenol connector. Disconnect the oil sending unit lead @ from the engine wiring harness.

~

2. Remove the screw mounting bracket.

iW

40544

securing the oil tank to the upper

[TI]

3. Use two wrenches to remove the nut securing the sending unit to the oil tank.

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Safety Related

2-33

40563

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[I]

4. Remove the sending unit from the oil tank.

W

5. Note the position of the sending unit wires in the Amphenol connector. Remove the wires from the connector using OMC Pin Removal Tool, PI N 322698. Remove the nut@, washer@, and grommet © from the sending unit lead. Discard the grommet.

.~

Oil Tank Sending Unit Test

W

Low Oil Test - Calibrate ohmmeter on appropriate scale. Connect meter leads between black wire terminal "8" and tan/ black wire terminal "C".

40564

-

• Position @ - Meter should show a high reading • Position ® - Meter should show a low reading • Position ® - Meter should show a low reading

©\

@

Replace the oil tank sending unit if your results vary.

W

No Oil Test - Connect meter leads between black wire terminal "8" and tan/yellow wire terminal "A". • Position @ - Meter should show a high reading • Position ® - Meter should show a high reading • Position ® - Meter should show a low reading

2 40565

Replace the oil tank sending unit if your results vary. Oil Tank Sending Unit Installation

m

1. Place a new grommet ©, washer @, then nut @ onto the sending unit leads. Install the wires into the Amphenol connector in their original position using OMC Insert Tool, PI N 322697.

W

2. Place the sending unit into the oil tank. Let the sending unit rest on the bottom of the tank.

[]J []J

3. Place the grommet © down into the tank. Place the washer @ on top of the grommet, then thread the nut @ onto the sending unit. Tighten the nut securely.

ITJ 4. Route the oil tank sending unit lead @ behind the upper oil tank bracket @.

2-34

Mirage/eng

[ ] ] 5. Apply OVIC Locquic Primer and OVIC Ultra Lock to the upper oil tank mounting bracket screw. Secure the tank to the upper bracket with the screw Q). Tighten the screw to 216-240 in. Ibs. (24,4-27,1 N·m).

W

6. Connect the oil tank sending unit lead to the engine wiring harness and secure with retainer Q).

Low Oil Light Test - Tiller Model 1. Disconnect oil tank sending unit plug

[1Q]

® from receptacle CD.

A. Connect a jumper wire from the black/tan wire in plug

®

to the black wire in plug ®. Crank or run engine. LOW OIL light should illuminate.

B. Connect jumper wire from the black/tan wire in plug ® to an engine ground. Crank or run engine. LOW OIL light should illuminate. C. If light goes on in test No.1 B but there was no light in test No. 1A, check black wire in plug ® for continuity and a good ground connection. 2. If there was no light in tests No. 1A or 1B:

A. Disconnect red/tan and tan/black LOW OIL light receptacle

~

from plug @ at ignition module .

B. Crank or run engine and check for 12-14 Volts at red/tan wire connector in plug @. C.lf low or no voltage in test No. 2B; replace ignition module. 3. If voltage OK in test No. 2B:

A. Connect battery 12V + to red/tan and 12V- to tan/black wires in

receptacle~.

Light should illuminate.

B. If no light in test No. 3A, replace bulb. 4. If light was OK in test No. 1A and 1B, check oil tank sending unit. See Oil Tank Sending Unit Removal, this section. E

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2-35

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40596

Maintenance Valve Servicing Removal

rn

1. Remove the valve cap @ from the maintenance valve.

W

2. Remove the valve core @ using a valve repair tool purchased from a local hardware or auto parts supplier.

©

3. Thread the appropriate size tip of an automotive dent puller into the valve core housing. Use the dent puller to pull the valve core housing straight out of the intake manifold.

INote I The old valve core housing must be pulled straight out of the intake manifold, or the manifold will be damaged. Installation

rn

1. Install a new O-ring @ onto the valve core housing. Apply OMC Locquic Primer and OMC Screw Lock to the unthreaded end of the housing.

W

2. Thread the valve repair tool half of the way onto the end of the valve core housing .

INote I Do not thread the valve

repair tool more than half of the way onto the valve core housing. You will not be able to remove the tool from the housing after installation.

[ [ ] 3. Place a small socket over the end of the valve core tool and drive the valve core housing straight into the intake manifold until it seats. Remove the valve core tool.

INote I The valve core housing must be driven straight in to the intake manifold, or the manifold will be damaged . [ ] ] 4. Install the valve core into the valve core housing . Tighten securely.

rn

5. Install the valve cap @. Tighten securely. E

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500/565cc 25, 3

FUEL SYSTEf

FUEL TANK AND FILTER

REFER TO OWNER MANUAL

REFER TO PAGES 2-5 THRU 13

REFER TO PAGE 2-10

REFER TO SECTION 1

RE PA

VI TROUBLE CHECK CHART

CARBURETOR

FER TO GE 2-15 THRU 22

REFER TO PAGE 2-23

Ignition System Table of Contents General Safety Warnings ......................... . Service Specifications ............................ . About This Section .............................. . Flywheel Holding Tool ........................... . Flywheel Servicing .............................. . Spark Plug Information ........................... . RPM Limiting Ignition Module ..................... . General Information - CD Ignition .................. . Ignition Coil Tests ............................... . Principles of Operation ........................... . Ignition Component Servicing ..................... . Amphenol Connector Servicing .................... . Packard Connector Servicing ...................... . Troubleshooting Test Equipment ................... . QuikStart Electronic Starting ...................... . SL 0. W Warning System ......................... . Troubleshooting Sequence Chart ................... . Output Tests ................................... .

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3- 2 3- 3 3- 5 3- 6 3- 7 3- 8 3- 9 3- 9 3-10 3-11 3-14 3-16 3-17 3-18 3-19 3-20 3-21 3-22

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General Safety Warnings

Before working on any part of the ignition system, read the section called Safety at the end of this manual. The engine cover is a machinery guard. Use caution when conducting tests on running engines. Do not wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating flywheel. Perform all ignition coil tests on a wooden or insulated bench top to prevent leakage or shock hazards. To avoid possible shock hazards, do not handle ignition coil or tester leads during output test. Do not touch high voltage ignition coils or spark plug wires when engine is being started or when running. Shock can cause serious personal injury under certain conditions. To prevent possible fire and explosion under the engine cover, make sure electrical wires are routed and clamped in original position away from rotating parts which could cut or abrade wire insulation. If necessary to remove the spark plugs, be sure to keep the spark tester away from open spark plug holes. 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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Service Specifications Component Specifications

Rope and Electric Start Models Charge Coil

Power Coil

Ignition Coil

Ignition Module Min . Output Voltage

Primary Ohms

Secondary Ohms

Ohms

Min . Output Voltage Cranking

Ohms

Min . Output Voltage Cranking

Cranking

Running

0.28 ± 0.05

2300 ± 300

57 ± 5

30

800 ± 80

220

100

240 PCE0074D

Special Torque Chart

In. Lbs.

Description

• •

Spark Plug Flywheel Nut

Ignition Coil Screws

84-106

Ignition Module Screws

84-106

Stator Screws Sensor Screws Encoder Screws

J

I

Ft. Lbs.

N·m

Adhesive

18-20

24-27

•

100-105

136-142

OMC Gasket Sealing Compound

• • • • •

9-12

OMC Nut Lock

9-12

OMC Nut Lock

9-12

OMC Nut Lock

2,7-4,1

OMC Nut Lock

2,7-4,1

OMC Nut Lock

84-106 24-36 24-36

PCE0050

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PIN

Tool Panel

378103

B E E E E

322699 322698 322697 322696 342228 342226 342225 771311

•F F

•

Description

Universal Puller Kit Socket Removal Tool Pin Removal Tool Insert Tool Crimping Pliers Wiring Harness Adapter Ball Socket Remover Ball Socket Installer Flywheel Holder

Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OMC Gasket Sealing Compound OMC Moly Lube OMC Cleaning Solvent OMC Nut Lock OMC Locquic Primer OMC Triple-Guard@Grease OMC Electrical Grease Isopropyl Alcohol Specialized Test Equipment _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Stevens Flywheel Strap Wrench No. S-17, or equivalent Spark Tester Peak-reading Voltmeter Stevens Terminal Extenders No. TS-77, or equivalent Stevens Load Adapter No. PL-88, or equivalent Ohmmeter Jumper Wire Ignition Analyzer

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About This Section The information in this section of the Service Manual has been organ ized into a format that will allow the technician to make maximum use of his troubleshooting time . To be most effective, the technician should read and understand these statements before proceeding. 1. To save time , routine service information has been covered in the first pages of this section. They include: • A brief review of the principles of operation for OMC's CD ignition systems, Page 3-11. • A list of available troubleshooting test equipment, Page 3-19. • A brief review of spark plug information, Page 3-8. • Instructions for servicing the flywheel, Page 3-7. • A review of all testing procedures for ignition coil, Page 3-10. • An Ignition Coil Specifications chart, Page 3-10. 2. If you are working on an engine where the ignition problem makes the engine very hard to start or impossible to start, begin your testing with Output Tests, Page 3-22. 3. If you are working on an engine where the ignition problem creates an intermittent high-speed misfire or inconsistent run ning qualities above cranking RPM, refer to Running Output Test, Page 3-30.

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25/16 in. (59 mm) Dia. Bolt Circle

3/4 in. (19 mm) Dia. Holes (3) 120 Apart

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1 5/8 in. (41 mm) Dia. Bolt Circle

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1 5/16 in. (33 mm) Dia.

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Flywheel Servicing

INote I In

order to produce the voltage necessary to run an ignition system, the flywheel magnets must be of a particular strength. Weak flywheel magnets can cause low ignition voltage, which could affect motor performance. Weak flywheel magnets can also cause low readings on ignition test equipment, such as the peak-reading voltmeter, which may cause unnecessary replacement of ignition components. Flywheels rarely go bad and would only be replaced as a last resort in solving an ignition problem. Removal

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1. To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. 2. Remove the manual starter or flywheel cover from the engine.

IT]

3. Remove the flywheel nut. Use a flywheel holding tool as drawn on Page 3-6 and three PI N 309492 screws from OMC Universal Puller Set, PIN 378103, or other suitable tool to hold the flywheel.

INote I Use

care when threading screws into the flywheel. The screws can be threaded too far into the flywheel and can damage components mounted on the inside. Thread the screws carefully into the flywheel until resistance is felt. There should be enough thread engagement to loosen the flywheel nut or pull the flywheel.

[ ] ] 4. Apply CIVIC Moly Lube to threads of pressing screw and center hole of crankshaft.

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5. Assemble the following components from OMC Universal Puller Set, PI N 378103:

® Body, PI N 307636 ® Pressing Screw, PI N 307637 © Handle, PIN 307638 @ 3 Screws, PI N 309492 ® 3 Washers, PIN 307639 6. Install the puller on flywheel with body flat side up. Seat the shoulder screws completely. Hold puller by its handle, and tighten pressing screw until flywheel releases. 7. Remove the flywheel.

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Installation

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1. Install the flywheel key with its outer edge parallel to centerline of crankshaft and single upset mark facing down. 2. Clean the crankshaft and flywheel tapers with OI\IK: Cleaning Solvent and let dry. These surfaces must be clean and dry to allow proper locking of the tapers.

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3. Align the flywheel keyway and install flywheel. Coat the threads of the flywheel nut with OI\IK: Gasket Sealing Compound. Install the nut and torque to 100-105 ft. Ibs. (136-142 N·m) using the flywheel holding tool as drawn on Page 3-6 and three PI N 309492 screws from OI\IK: Universal Puller Set, PIN 378103, or other suitable tool to hold the flywheel.

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'-----'-_ _--..:...._~_ _ ____=_,__,.,..J

INote I After replacing any major ignition component, verify correct maximum spark advance using the procedure outlined in Section 1. Encoder Servicing

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Check all the window styles @ of the encoder for broken cracked corners or an accumulation of dirt. Clean or replace the encoder if needed. Apply ow:: Locquic Primer and OMC Nut Lock to the three retaining screws @. Tighten the screws to 24-36 in. Ibs. (2,7-4,1 N·m).

Spark Plug Information The spark plugs should be removed and examined. A spark plug should be replaced if the electrodes are badly worn , if it has a cracked insulator, or is badly fouled. Before installing the spark plug lead cover on the spark plug, apply a light coating of OI\IK: Electrical Grease to the ribbed portion of the spark plug ceramic and to the opening of the spark plug cover. This will help prevent corrosion between the spring terminal and the spark plug which can cause high tension arcing.

INotel

Recommended

Extended Idle

OL86C or L86C

OL87YC or L87YC

All spark plugs are to be gapped at 0.030 in. (0,8 mm).

3-8

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RPM Limiting Ignition Module Some ignition modules have a built-in RPM limiting device. Certain models are equipped with a limiting ignition module to guard against possible powerhead failures caused by improper propeller selection (under propping)' excessive wear on propeller blades, improper motor installation, propeller ventilation, or unusually light boat loading. Be sure to use the correct ignition module when servicing the models listed below to control the engine's operating RPM range and protect it from possible powerhead damage due to overspeeding. RPM Limit

6200

General Information - CD Ignition Troubleshooting the Ignition System The magneto powered capacitor discharge ignition system is easy to troubleshoot. Remember these tips to obtain fast, accurate test resu Its: 1. Visual Inspection - Check wiring for broken, pinched, or loose leads. Connectors should be securely fastened and free from moisture or water accumulation. 2. Test Equipment Condition - Be sure testers are in working order. Many hours can be wasted by replacing working components needlessly. 3. Follow Procedure - Troubleshooting can seem difficult if you vary your technique for each problem . Many times items in the system are overlooked because you "thought" you tested them. By following the same procedure each time you troubleshoot, all items in the ignition system will be tested. 4. Test the Complete System - There may be occasions when more than one component is defective. If this condition is undetected, repeat ignition system failure may occur, or damage to replacement parts could result. Test everything .

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Ignition Coil Tests A wide variety of ignition testers are available from various manufacturers. In addition, some automotive testers having the proper specifications can be used. Detailed instructions for the use of any tester are provided with the unit, therefore, only general information is given here. Refer to t he manual of the ignition tester you are using for coil specifications . Specifications will vary among testers . Ignition coil must be removed from powerhead for power and leakage testing.

1 DRC6004

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avoid possible shock hazards and to prevent leakage, perform all tests to the coil on a wooden or insulated bench top. Specifications Primary

Secondary

Operating

Resistance

Resistance

Amps (Max)

Analyzer Polarity

2

Merc-O- Tronic Coil

DRC6003

1.5 amps

Magneto C.D. 0.28 ± 0.05

n

2300 ± 300

n

Normal Stevens

PIN 584826

1.1 amps PCE 0043

Ohmmeter Test Resistance tests can be performed while the ignition coil is still mounted to the powerhead. 1. Twist and remove the spark plug and primary leads from the ignition coil.

DR4081

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2. Calibrate ohmmeter on appropriate scale. Connect meter black lead to clean engine ground. If the coil is not mounted on the engine, connect meter black lead to ground tab on the coil. Connect meter red lead to coil primary terminal. • Meter must show 0.28 ± 0.05 ohm .

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3. Calibrate ohmmeter on appropriate scale. Connect meter red lead to coil primary terminal. Connect meter black lead to coil spark plug terminal. • Meter must show 2300 ± 300 ohms.

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4. Test spark plug leads for continuity. Calibrate ohmmeter on low ohms scale. Attach one ohmmeter lead to each spring terminal. While wiggling both spark plug covers and entire length of the spark plug lead, the resistance should remain near zero. Replace spark plug lead if your test results vary.

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Tests Using Ignition Analyzer INotel When conducting coil tests using an ignition analyzer, do not exceed the coils' maximum specified amperage. Power Test

rn The ignition coil is tested with "normal" polarity connections. Connect tester red lead to the primary terminal @ of the coil and the tester black lead to the ground tab @. Connect the high tension lead of the tester to the coil spark plug lead @. A steady spark, in the tester at or before maximum specified amperage, indicates a good coil. Refer to Ignition Coil Specifications. Surface Leakage Test The ignition coil and spark plug lead should be tested for leakage and insulation failures using the ignition tester. Leakage is caused by moisture, cracks, or holes in the coil housing or spark plug leads.

5

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__________________~~ 40852

[ ] ] With the tester's small black and red leads still connected, remove the tester's high tension lead from the coil. Turn on the tester and probe entire surface of the coil, spark plug lead, and spark plug cover. Flash over will be apparent wherever insulation has broken down. Replace any coil or spark plug lead that shows leakage.

Principles of Operation

6 40787

Flywheel [ ] ] The flywheel contains the permanent magnets necessary to energize the charge coil and power coil. Once the flywheel exceeds a minimum cranking RPM, the flywheel's magnetic lines of force passing through the charge coil and power coil windings produce voltage in those circuits. The charge coil and power coil magnets are located around the flywheel's inner rim. [ ] ] An encoder @ is mounted on the inside of the flywheel. The encoder determines crankshaft position and ignition timing.

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Stator Assembly

OJ The charge coil is located on the stator assembly. It contains many windings (strands of wire wrapped around a metal lamination). Once the flywheel exceeds a minimum cranking RPM, the flywheel's magnetic lines offorce cut through the coil windings to produce voltage. The voltage is supplied to the ignition module to operate the ignition system .

OJ The power coil is located on the stator assembly. It contains many windings (strands of wire wrapped around a metal lamination). Once the flywheel exceeds a minimum cranking RPM, the flywheel's magnetic lines of force cut through the coil windings to produce voltage. The voltage is supplied to the ignition module to operate the following systems:

• S.L.D. W.

TAl

warning system

• QuikStart TAI electronic starting • Sensor assembly • Ignition functions Sensor Assembly

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The sensor assembly consists of two individual optical sensors @. The assembly uses the windows of the encoder to determine crankshaft position, provide anti-reverse protection, and control when the spark plugs fire. Because this is an optical system, the sensors must be kept clean and free of dirt and oil.

Ignition Module

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The ignition module ® has several basic functions. It stores and distributes the voltage received from the charge coil. The ignition module uses electronic switches, activated by the sensor assembly, to energize the three ignition coils' primary windings.

The ignition module has an RPM limiting circuit which helps protect against powerhead damage due to overrevving. RPM will be limited to 6200 RPM. Overrevving can result from: • Installing the motor too high • Carrying less weight than the motor is propped for • Using a propeller that is too small, has very worn blades, or ventilates excessively. The ignition module incorporates the S.L.D. W. warning system. This system gradually limits engine speed to approximately 2500 RPM when either the: • Engine temperature exceeds 240 0 F (1160 C). E

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• Oil level in the oil tank drops below a predetermined level.

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Once the S.L.O. W. warning system has activated, the engine must cool to allow the temperature switch to open or outboard lubricant must be added to the oil tank. The engine must be operated below 1500 RPM before normal operation can be resumed. The ignition module also incorporates QuikStart electronic starting, which automatically advances the ignition timing when the engine temperature is less than 1050 F (41 0 el, and for approximately 7 seconds each time the engine is started, to ensure reliable starts.

Stop Circuit - Rope and TE Models

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The stop button ©, key switch @, and emergency stop switch ® are connected to the ignition module through the engine wiring harness. When activated, these switches direct the ignition module output to ground, stopping the ignition system.

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The steering handle contains a combination stop switch/ emergency stop device. • When the clip and lanyard assembly is removed, the emergency stop device is in the STOP position. • When the clip and lanyard assembly is installed, the emergency stop device is in the RUN position. • To stop the engine when the clip and lanyard assembly is in place, press the stop button inward until the engine stops.

Key Switch [ ] ] A combination key switch @ and emergency stop switch is connected to the power pack through the engine wiring harness. When activated, these switches direct the power pack output to ground, stopping the ignition system.

Important This emergency stop switch

clip turns the key from ON to OFF as it is removed . It does not electrically disarm the ignition system. The key switch, ignition system, and starting circuit are all fully functional after the emergency stop switch clip has been removed.

Ignition Coil

W The ignition coil ® consists of two windings of wire around a laminated steel core. The coil has one primary and one secondary terminal connections and a ground tab.

Through mutual induction, the ignition coil transforms ignition module output to as much as 40,000 volts to fire the spark plug.

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Ignition Component Servicing Removal

1. Remove flywheel.

IT]

2. Disconnect stator plug @ and sensor plug @ at the ignition module, and stator to rectifier/regulator wires at the connector @.

[I]

3. Remove three screws @ retaining the stator. Remove stator.

rn 4. Disconnect sensor assembly ball socket using

QNK; Ball

Socket Remover, PI N 342226.

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5. Remove three screws ® securing the sensor assembly to the powerhead . Remove the assembly.

[ [ ] 6. Remove the primary wires

® from ignition co ils.

[]] 7. Remove the tan/black no-oil sender lead from the ignition module 2-pin Amphenol connector using QNK; Pin Removal Tool, PIN 322698. Remove and disconnect the ignition module 4-pin Amphenol connector @. [ ] ] 8. Remove three screws ® retaining the ignition module. Remove ignition module ground screw CD, then remove the module.

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[ ] ] 9. Remove screw retaining the ignition coil to powerhead. Remove coil with spark plug wire . Installation [ ] ] 1. Apply OMC Locquic Primer and OMC Nut Lock to the ignition coil mounting screw. Place ignition coil in position and torque screw to 84-106 in. Ibs. (9-12 N·m).

[IQ]

2. Apply OMC Locquic Primer and OMC Nut Lock to three ignition module mounting screws. Place ground wire Q) and lock washer under module mounting boss. Position the ignition module and torque screws ® to 84-106 in. Ibs. (9-12 N·m). Place ground wire ® and lock washer into position and secure with screw CD tightened to 84-106 in. Ibs. (9-12 N·m).

[!1]

3. Install tan/black no-oil sender lead into 2-pin Ampheno/ connector using OMC Insert Tool, PI N 322697. Connect 4-pin Ampheno/ connector © to engine harness and secure on ignition module .

~

4. Attach three primary wires to ignition coils: ~

orange/blue - top coil

® orange/purple - center coil @ orange/green - bottom coil

~ 5. Position sensor assembly. Apply OIVIC Locquic Primer and OMC Nut Lock to three sensor screws. Install the screws and tighten to 24-36 in . Ibs. (2,7-4,1 N·m). Attach the sensor assembly lead ® to ignition module.

[1!]

6. Attach sensor assembly ball to link using OMC Ball Socket Installer, PIN 342225.

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42201

Amphenol Connector Servicing

INote I The Ampheno/@pin and socket terminals are not the same size as Deutsch @ pin and socket terminals . You cannot interchange them. Terminal Removal

1. To remove a terminal from the plug or receptacle, lubricate both ends of the cavity with isopropyl alcohol.

OJ Pick the proper tool for the service being performed : @ OMC Pin Remover, PIN 322698 @ OMC Socket Remover, PI N 322699 © OMC Crimping Pliers, PIN 322696 @ OMC Insert Tool, PI N 322697

rn OJ 2. Place the plug or receptacle against the edge of a flat surface with clearance behind connector for terminal to be pushed out. Push terminal from connector with tool @ or @.

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3. Pin and socket terminals may be replaced if damaged. Strip 1/4 in. (6 mm) insulation from wire and crimp new terminal onto wire at point ® with crimping pliers.

Terminal Installation

1. Connect the plug and receptacle before installing terminal. Apply isopropyl alcohol to connectors, align arrows, and push together. 2. Apply isopropyl alcohol to the terminal cavity.

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3. Place connectors against solid surface. To avoid injury, hold tip of tool @ securely against shoulder of terminal ® while inserting terminal . Push terminal into connector until step @ of insert tool touches connector body.

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4. Check your work. Separate the connectors and check to see that terminals are inserted the proper distance.

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Safety Related

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Packard Connector Servicing Terminal Removal

A tab on the back side of the terminal engages a shoulder in the connector's body to hold the terminal in place .

rn 1. Pry seal out of connector.

rn

2. Slightly pull on wire to move tab

®

away from shoulder.

rn W 3. Insert a tool , such as the one shown, connector above the terminal to push the tab down. W

into the

1

4. Push the tool and wire out of the connecto r.

Terminal Installation

The terminal must be pulled into the connector to lock it in place. Before installing a new terminal on a w ire, insert the wire through the seal and connector.

rn 1. The tab on the terminal must extend enough to lock the terminal in place inside the connector. If the tab isn 't extended,

2 DRC5940

use a thin tool and bend it outward slightly.

, in . (25 mm )

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2. Pull terminal into connector. 3. Push seal into connector until seated.

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mmD jl .090 in . 12.3 mml

mID&, DRC594 1

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Troubleshooting Test Equipment

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I Note The following equipment is available from various manu-

facturers to support your ignition and electrical system troubleshooting. Manufacturer ordering addresses are on the rear inside cover of this manual.

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Spark testers: • Stevens No. S21, S13C, or S48 • Merc-O- Tronic No. 55-4S or 55-6S Peak-reading voltmeters: • Merc-O-Tronic No. 781 • Stevens No. CD-77 • Electro-Specialties No. PRV-1 Ohmmeter capable of reading low and high ranges: • Merc-O- Tronic No. 700 VOA • Stevens No. AT-101

INotel Component temperature can affect resistance values at a

rate of 10 ohms per 1° F. All resistance values listed in this manual are correct at (70° F or 21 ° C).

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Ignition module load adapter: • Stevens No. PL-88

[ [ ] Ignition coil terminal extenders: • Stevens No. TS-77

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Jumper wire for Amphenol connectors. Can be made with: ® No . 16 wire, 8 in. (200 mm) © Pin, OMC PIN 511469 @ Socket, OMC PIN 581656 ® Shrink tube, OMC PI N 510628

73158

Wiring harness adapter, OMC PI N 342228

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QuikStart Electronic Starting This ignition system incorporates QuikStart electronic starting, which automatically advances ignition timing when engine temperature is less than 1050 F (41 0 C) and for approximately 7 seconds each time the engine is started, independent of temperature. Once QuikStart electronic starting has been canceled by engine temperature, the engine must be turned off before the ignition advance cycle can be repeated. QuikStart electronic starting also incorporates an RPM limit that cancels the ignition advance when the engine speed exceeds approximately 1500 RPM.

Functional Test

1. Install correct test propeller and start engine in test tank. Engine temperature must be above 1050 F (41 0 C) before proceeding . Stop the engine. INotel All engine linkage adjustments must be correct and idle RPM must be normal before proceeding. Refer to Synchronization and Linkage Adjustments, Section 1.

m 2. Disconnect temperature switch 2-pin tor.

Amphenol connec-

3. Connect timing light to No. 1 cylinder spark plug lead. Start engine and set idle speed at no more than 900 RPM in FORWARD.

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4. Timing light must show timing pointer near 10 BTDC . • If QuikStart fails to advance the ignition timing, replace the ignition module.

5. Reconnect the temperature switch to engine harness and wait 7 seconds, timing light must show timing pointer near 40 ATDC. This indicates ignition timing has been released to "normal" setting . • If QuikStart fails to release ignition timing, check for proper operation of temperature switch, associated wiring, and ignition module.

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S.L.o. W. Warning System This ignition system incorporates the 5.L.0. W. warn ing system, which gradually limits engine speed to approximately 2500 RPM when one of the following conditions occur : • Engine temperature exceeds 240 0 F (116 0 CI. • Oil level in the oil tank drops below a predetermined level. The 5.L.0. W. warning system depends on input from: • The temperature switch tan/blue lead for an engine overheat. • The no oil sender tan/yellow lead for no oil in the oil tank. To resume normal operation after the 5.L.D. W. warning system has activated, the engine must be operated below 1500 RPM and: • Engine temperature must cool to 20r F (9 r engine overheat.

CL for an

• Outboard lubricant must be added to the oil tank. Temperature Switch 1. Disconnect temperature switch tan/blue lead . 2. Install correct test propeller. Start engine in test tank and run at 3500 RPM.

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3. Attach engine harness tan lead to a clean engine ground . • If engine slows to approximately 2500 RPM, test temperature switch . Refer to Temperature Switch Test, Section 4. • If engine does not slow to approximately 2500 RPM, check wiring or replace ignition module.

No Oil Sender 1. Install correct test propeller. Start engine in test tank and run at 3500 RPM .

rn 2. Using a jumper wire, connect the tan/yellow lead to the black lead in the 3-pin Ampheno/ connector. • After four seconds, if engine slows to approximately 2500 RPM, check oil level in the oil tank. • After four seconds, if engine does not slow to approximately 2500 RPM, check wiring or replace ignition module.

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Go To Step 4

y Visually Check Sensor & Encoder

PCE0004-DR 601 8

Substitute Sensor, Check Encoder

y

Substitute Ignition Module

y

y

y

Go To Step 2

Go To Step 3

Visually Check Sensor & Encoder

No Spark On Any Cylinder

Substitute Ignition Module

Test Ignition Coil, Page 3-10

No Spark On Two Cylinders

Verify S.L.O. w., Page 3-20

Check Timing

No Spark On One Cylinder

y

Go To Step 6

Check Other Systems

Good Spark, Motor Doesn't Run

Total Output Test, Step 1

y

Good Spark, High Speed Misfire

Good Spark, Motor Runs

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Output Tests

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All cranking output tests must be performed with spark plugs installed and torqued in the cylinder head. If necessary to remove the spark plugs, be sure to keep the spark tester away from open spark plug holes.

STEP 1 - TOTAL OUTPUT TEST

&

To avoid electrical shock, do not handle ignition coil or spark tester during cranking tests. 1. Twist and remove all spark plug leads.

OJ

2. Adjust the gap on the spark tester to 3/8 in. (9 mml. Connect tester leads to the spark plug leads. Secure tester clip to a clean engine ground.

\Notel

To prevent high voltage arc, route tester leads at least 2 in . (51 mml from any metal surface.

3. If equipped, install the clip onto the emergency stop switch. Crank the engine. Spark should jump each tester gap in sequence. 4. Refer to Troubleshooting Sequence Chart, Page 3-21. Start with your specific fault symptom and continue troubleshooting in sequence.

INote I It is possible for the ignition system to have a problem but still produce good output. If the engine "pops" or "backfires" during starting, the ignition may be out of time . Check the following: • Coil primary wire routing • Spark plug lead routing • Sensor • Encoder

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STEP 2 - STOP CIRCUIT TEST

&

To avoid possible shock hazard, do not handle ignition coil or spark tester during cranking tests.

Elimination Test - Rope

rn

1. Disconnect the 4-pin Amphenol connector between start button and ignition module.

2. Connect jumper wires between terminals "A", "C", and "0" of the 4-pin connector. 3. Pull the engine over and observe results at spark tester : • If spark now jumps sequentially at each gap, the problem is in the stop circuit. Go to Ohmmeter Test - Stop Button. • If there is still no spark, go to STEP 3 - POWER COIL TEST. Elimination Test - Tiller Electric

rn rn

1. Disconnect 4-pin Amphenol connector between start button and key switch , and ignition

module.

2. Connect jumper wires between terminals "A", "C", and "0" of the 4-pin connector. 3. Crank the engine over and observe results at spark tester: • If spark now jumps sequentially at each gap, the problem is in the stop circuit. Go to Ohmmeter Test - Stop Button and Ohmmeter Test - Key Switch . • If there is still no spark, go to STEP 3 - POWER COIL TEST.

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Safety Related

3-23

DR6492

Elimination Test - Remote Start

[f]

1. Disconnect 4-pin Amphenol connector between key switch and ignition module.

2. Connect jumper wires between terminals "A", "C", and "0" of the 4-pin connector. 3. Crank the engine over and observe results at spark tester: • If spark now jumps sequentially at each gap, the problem is in the stop circuit. Go to Ohmmeter Test - Key Switch . • If there is no spark, go to STEP 3 - POWER COIL TEST.

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3 Ohmmeter Test - Stop Button INotel All ohmmeter tests must be performed with the engine NOT running.

W

1. The steering handle contains a combination stop button/emergency stop device. • When the clip and lanyard assembly is removed, the emergency stop device is in the STOP position. • When the clip and lanyard assembly is installed, the emergency stop device is in the RUN position. • To stop the engine when the clip and lanyard assembly is in place, press the stop button until the engine stops.

2. Install the clip and lanyard .

rn

3. Calibrate an ohmmeter on appropriate scale. Disconnect 4-pin Amphenol connector between stop button and ignition module. Connect meter leads between stop button terminal "8", and a clean engine ground. • The meter must show a high reading. 4. Momentarily, press inward on the stop button. • The meter must show a low reading. 5. Remove the clip and lanyard . • The meter must show a low reading.

fA

To avoid sudden loss of control, replace the stop button assembly if your test results vary.

6. Complete all circuits disconnected during this test.

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'@

1

DR6225

Ohmmeter Test - Key Switch

INote I All ohmmeter tests must be performed with the engine NOT running. 1. Insta ll the emergency stop switch clip. 2. Disconnect the 4-pin Amphenol connector between the ignition module and key switch.

IT]

3. Calibrate ohmmeter on appropriate scale . Co nnect meter leads between key switch end of 4-pin connector, terminal "8", and a clean engine ground . • Key OFF, meter must show a low reading. • Key ON, meter must show a high reading. 4. If Step 3 key ON reading is a low one, disconnect harness black/yellow lead from key switch "M" terminal. • If meter now shows a high reading, replace key switch. • If meter shows a low reading, go to Step 5. 5. Disconnect the key switch 6-pin connector @. • If meter now shows a high reading, repair or replace key switch harness. • If meter shows a low reading, go to Step 6.

6. Disconnect the engine harness to instrument harness 6-pin connector ® that contains the black/yellow lead. • If meter now shows a high reading, repair or replace instrument harness. • If meter shows a low reading, repair or replace engine harness. 7. If the engine fails to shut off, test for open black/yellow lead, black/white lead , damaged key switch, or damaged ignition module. 8. Complete all circuits disconnected during this test.

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STEP 3 - POWER COIL TEST Ground Test 1. Disconnect 4-pin Packard connector between stator and ignition module. 2. Set peak-reading voltmeter to

"pas"

and "500".

W

3. Connect the meter black lead to a clean engine ground. Alternately connect meter red lead between the orange and orange/black stator leads. Crank engine and observe meter at each connection: • Any reading indicates power coil is grounded. • Locate and repair ground, or replace stator assembly.

4. If no reading is indicated in Step 3, go to Output Test. Output Test 1. Set peak-reading voltmeter to "POS" and "500".

W

2. Attach meter black lead to orange/black stator lead . Attach meter red lead to the orange stator

lead. 3. Crank engine and observe meter : • If meter shows 30 volts or higher, go to STEP 4 - CHARGE COil TEST. • If meter shows less than 30 volts, check condition of wiring and connectors. • If wiring and connector condition is good, go to Ohmmeter Test. Ohmmeter Test

INote I All ohmmeter tests must be performed with engine NOT running. 1. Calibrate ohmmeter on appropriate scale.

W

2. Connect meter between the orange and orange/black stator leads. Meter must show: Rope and Electric Start

57 ± 5 Ohms

3. To test for a grounded condition, connect ohmmeter black lead to a clean engine ground. Alternately connect ohmmeter red lead between the orange and orange/black stator leads: • Any needle movement indicates power coil or leads are grounded. • Locate and repair ground, or replace stator assembly. 4. Complete all circuits disconnected during this test.

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3-27

E

STEP 4 - CHARGE COIL TEST Ground Test 1. Disconnect 4-pin Packard connector between stator and ignition module. 2. Set peak-reading voltmeter to "POS" and "500".

[IJ

3. Connect the meter black lead to a clean eng ine ground. Alternately connect meter red lead between the brown and brown/yellow stator leads. Crank engine and observe meter at each connection: • Any reading indicates charge coil is grounded . • Locate and repair ground, or replace stator assembly. 4. If no reading is indicated in Step 3, go to Output Test.

Output Test 1. Set peak-reading voltmeter to "POS" and "500".

m

2. Attach meter black lead to brown/yellow stator lead . Attach meter red lead to the brown stator

lead.

3. Crank engine and observe meter : • If meter shows 220 volts or higher, go to STEP 5 - IGNITION MODULE TEST. • If meter shows less than 220 volts, check condition of wiring and connectors. • If wiring and connector condition is good, go to Ohmmeter Test.

Ohmmeter Test

INotel

All ohmmeter tests must be performed with engine NOT running.

1. Calibrate ohmmeter on appropriate scale.

W

2. Connect meter between the brown and brown/yellow stator leads. Meter must show: 800 ± 80 Ohms

Rope and Electric Start

3. To test for a grounded condition, connect ohmmeter black lead to a clean engine ground. Alternately connect ohmmeter red lead between the brown and brown/yellow stator leads: • Any needle movement indicates charge coil or leads are grounded. • Locate and repair ground, or replace stator assembly. E

4. Complete all circuits disconnected during this test.

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DRC6002

STEP 5 - IGNITION MODULE TEST

In.

1. Prevent accidental starting of engine while testing; twist and remove all spark plug leads.

2. Twist and remove primary lead from ignition coil.

rn

3. Connect primary lead to Stevens PL-88 load adapter red lead. Connect adapter black lead to a clean engine ground.

/Notellf Stevens No. PL-88 is not available, you can make an adapter using a 10-ohm, 10-watt resistor, Radio Shack No. 271-132, or equivalent. 4. Set peak-reading voltmeter to "POS" and "500".

rn

5. Connect meter red lead to adapter red lead, and meter black lead to a clean engine ground.

6. Crank engine and observe meter: • Meter must show 100 volts or higher. 7. Repeat Steps 2 thru 6 for remaining ignition coil primary leads. • If primary leads have good output, test ignition coil. Refer to Ignition Coil Tests. • If one primary lead has no output, substitute the ignition module and sensor with known good components one at a time . Also check encoder for substitute damage. Repeat the test. 8. Remove load adapter and install ignition coil primary lead.

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DRC6001

STEP 6 - RUNNING OUTPUT TEST 1. Twist and remove primary lead from ignition coil.

IT]

2. Use a clockwise twist to install a Stevens No. TS-77 terminal extender, or equivalent, to ignition coil primary post.

IT]

3. Install primary lead on terminal extender.

INote I Route aII tester leads so they do not interfere with movi ng eng i ne pa rts . 4. Set peak-reading voltmeter to " POS" and " 500" .

IT]

5. Connect meter red lead to terminal extender. Connect meter black lead to a clean engine ground .

6. Start engine and run under load at RPM where ignition problem exists : • Meter must show 240 volts or higher. • If test shows low output, go to STEP 4 - CHARGE COIL TEST. • If test shows no output, go to STEP 5 - IGNITION MODULE TEST. 7. Remove terminal extender. Install ignition coil primary lead.

3-30

M irage eng

Powerhead Table of Contents

In.

General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . Service Specifications ......... . ................... Engine Temperature Check. . . . . . . . . . . . . . . . . . . . . . . . . Retaining Ring Pliers ...... . . . . . . . . . . . . . . . . . . . . . . . Temperature Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . Powerhead Servicing ............................. Removal Tiller Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning ..................................... Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly ........................... ... ....... Installation Tiller Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Models ...................... .. ...... Thermostat Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powerhead Reference Pictures. . . . . . . . . . . . . . . . . . . . . .

444444-

2 3 5 6 7 8

4- 8 4-10 4-12 4-16 4-17 4-19 4-27 4-31 4-33 4-36

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General Safety Warnings

Before working on any part of the powerhead, read the section called Safety at the end of this manual. The flywheel cover is a machinery guard . Use caution when servicing a running engine. Do not wear jewelry or loose clothing. To prevent possible fire or explosion under the engine cover after servicing: • Check entire fuel system for leaks. • Make sure all electrical and ignition leads are routed and clamped in their original positions away from rotating engine parts which could cut or abrade wire insulation. To avoid accidental starting of engine while servicing, take adequate precautions to disarm the ignition system: • Connect engine wiring harness to a boat wiring harness with key switch in OFF position. • Twist and remove all spark plug leads from spark plugs. • Disconnect the battery cables from the battery. 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. To prevent sudden movement when starting engine and possible tIman overboard" situations, test the "start-in-gear-prevention" system before returning the engine to customer.

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M irag e eng

Service Specifications Special Torque Chart

Description

Cylinder Head Screws

CD

Connecting Rod Cap Screws

®

Main Bearing Screws Crankcase Flange Screws Exhaust Housing to Cylinder Block Screws

CD

In. Lbs.

Ft. Lbs.

N'm

Adhesive

180-204

15-17

20-23

•

170-190

•

19-21

Outboard Lubricant

216-240

18-20

24-27

®

60-84

5-7

7-9

216-240

18-20

24-27

OMC Ultra Lock OMC Gasket Sealing Compound

Install screws dry. Do not use sealant on threads.

®

To ensure maximum bearing life, use OMC Rod Cap Alignment Fixture, PIN 396749, with OVIC Connecting Rod Alignment Jaw Kit, PIN 437273.

® Apply OMC

Ultra Lock to the threads. Apply OMC Gel-Seal/l'M underside of washer face.

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OVIC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

PIN

Tool Panel

342223 396749 437273 342218 342220 342219 342221 342217 342222 342225 342226 342658 396748 432128 432130 342657 391008 322697 342664 771311

G H H I I

• •H H F F

G B A A

G A E H

•

Description

Wrist Pin Retainer Installer Rod Cap Alignment Fixture Connecting Rod Alignment Jaw Kit Ring Compressor - Standard 500 cc Ring Compressor - Standard 565 cc Ring Compressor - Oversize 500 cc Ring Compressor - Oversize 565 cc Wrist Pin Bearing Alignment Tool Crankshaft Bearing/Sleeve Installer Ball Socket Installer Ba II Socket Remover Retaining Ring Installer Lifting Eye Slide Hammer Bearing Puller Jaws Wrist Pin Remover Slide Hammer Insert Tool Rod Screw Torquing Socket Flywheel Holder

Service Aids _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OVIC Temperature Gun, PIN 772018, or Markal Thermomelt Stik (125 0 F and 1630 F) or Digital Pyrometer Industrial Thermometer Rawhide Mallet Micrometer Set Feeler Gauges Machinist's Straightedge Cylinder Hone Torque Wrench OVIC Cylinder Bore Gauge, PIN 771310 Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OVIC OVIC OVIC OIVIC

Cleaning Solvent Gasket Sealing Compound Gel Seal and Gasket Remover Gel-Seal /I ™ Johnson or Evinrude TC-W3@ Outboard Lubricant OVIC Moly Lube OVIC Needle Bearing Assembly Grease OVIC Locquic Primer RTV Silicone Rubber Adhesive OVIC Triple-Guard@ Grease Wakefield Heat Sink Compound OVIC Ultra Lock OVIC Nut Lock OIVIC Black Neoprene Dip

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Engine Temperature Check The Markal Thermomelt Stik is a heat-sensitive marker that melts on contact with a surface of a specific temperature. One source of Thermomelt Stiks is Stevens Instrument Company.

IT]

At least two Thermomelt Stiks or OMC Temperature Gun, PIN 772108, or a digital pyrometer should be used to accurately determine the engine's operating temperatures.

The Thermomelt Stik mark will appear dull and chalky when the surface marked is below the Stik's rated temperature. When the surface exceeds the Stik's rated temperature, the mark will appear liquid and glossy.

[IJ

To achieve accurate and consistent readings, engine temperature must be gauged at the top of the thermostat pocket.

INote I For the following engine operating temperatures and RPM figures to be correct, the inlet water temperature must be 70 0 ± 10 0 F (21 0 ± 30 C).

Pyrometer Procedure

OR6825

&

Twist and remove spark plug leads before changing propellers to avoid accidental starting of engine. 1. Install correct test propeller and place engine in a test tank. 2. Start engine and run at 3000 RPM for at least five minutes.

[IJ

3. Reduce engine speed and run engine at 900 RPM for five minutes. At 900 RPM the digital pyrometer or OMC Temperature Gun should indicate 1400 ± 15 0 F (60 0 ± r C) when checking the cylinder head. 39169

• If engine temperature is not within this range, troubleshoot cooling system to determine problem .

[IJ

4. Increase engine speed to 5000 RPM . At 5000 RPM the digital pyrometer must not indicate more than 160 0 F (71 0 C) . • If engine temperature exceeds 160 0 F (71 0 Cl, troubleshoot cooling system to determine problem.

INotel When using the digital pyrometer, you get low or inaccurate readings during these tests, coat the probe location with a liberal amount of Wakefield Heat Sink Compound, OMC PIN 322170.

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Retaining Ring Pliers

DR 2523

Thermomelt Stik Procedure

&. Twist and remove spark plug leads before changing propellers to avoid accidental starting of engine. 1. Install correct test propeller and place engine in a test tank. 2. Start engine and run at 3000 RPM for at least five minutes. [ ] ] 3. Reduce engine speed and run engine at 900 RPM for five minutes. Mark the cylinder head with 1250 F (52 0 C) and a 1630 F (73 0 C) Thermomelt Stik.

4. At 900 RPM, the 1250 F (52 0 C) mark should be liquid and glossy. The 1630 F (73 0 C) mark should remain dull and chalky. • If the 1250 F (52 0 C) mark does not remain liquid and glossy, troubleshoot the cooling system for causes of over cooling . • If the 1630 F (73 0 C) mark becomes liquid and glossy, troubleshoot the cooling system for causes of overheating. [ ] ] 5. When the engine speed is increased to 5000 RPM, the 1630 F (73 0 C) mark should remain dull and chalky. • If the mark becomes liquid and glossy, troubleshoot the cooling system for causes of overheating. E

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Temperature Switch Test Purpose A heat sensitive switch is installed in the cylinder head to monitor engine temperature. The switch is connected in series with the warning system. If the switch senses temperature in excess of a predetermined limit, contacts close and cause the System Check gauge "WATER TEMP" light to turn on, and the warning horn to sound for ten seconds.

INote I To ensure that the temperature sensing

system can alert the operator during an overheating condition, test the warning system as described in OIVK: Accessories Service Manual, System Check Engine Monitor.

Testing

W

1. Disconnect the temperature switch connector. Remove the temperature switch from the cylinder head. 2. Using a continuity light or ohmmeter, make positive connections to the switch - one lead to the switch lead and one lead to the metal portion of the switch.

W

3. Place the switch and an accurate industrial thermometer in warm 4-stroke crankcase oil.

4. Slowly increase the oil temperature using an external heat source.

& To avoid possible fire or explosion: • Use a suitable container for the oil. • Use an oil that has a flash point above 3000 F (150 0 C), such as Johnson or Evinrude Ultra 4-Stroke Crankcase Oil. • Do not use open flame as a heat source. 5. The switch must react to the changing temperature as follows:

Wire Color

Switch Closed

Switch Open

Tan/Blue

240 ± 6° F (114 ± 4° C)

207 ± 15° F (97 ± r C)

White/Black

105 ± 3° F (41 ± 2° C)

90 ± 3° F (32 ± 2° C)

6. Replace the switch if your test results vary.

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Safety Related

4-7

Powerhead Servicing Removal - Tiller Models

&.

To avoid accidental starting of engine, twist and remove all spark plug leads before beginning service.

INote I Because of the number and types offasteners (screws and nuts), it might be appropriate to reinstall fasteners in their holes as engine components are removed. This will simplify identification and assembly. [ ] ] 1. Turn the retainer knob located in the middle of the air silencer and remove the silencer from the engine. Disconnect the drain hose from the nipple at the bottom of the silencer.

W clip

W

2. Remove the choke cable pin from the retainer. Remove securing the choke cable to the bracket.

®

3. Remove the cable from the bracket.

W 4. Unscrew six lower motor cover retaining screws @. W &.

5. Remove the port side lower motor cover enough to cut the tie strap securing the fuel hose to the fuel connector. Remove the fuel hose. Use caution as there might be fuel under pressure in the hose. Catch any fuel in the hose in a suitable container.

[ [ ] 6. Remove the J-clamp and screw © securing the electrical wires to the starboard side lower motor cover.

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[ [ ] 7. Tiller Electric Models: Remove the two screws @ securing the electrical connector cover to the engine. Remove the cover.

W

8. Disconnect the stop switch wire connector@. Remove the stop switch wire from the ground stud ® .

W

9. Tiller Electric Models: Disconnect the 6-pin connector @.

rn 10. Tiller Electric Models: Remove the two neutral start switch wires (yellow/red) from the connector. Make sure to identify the pin locations (2 and 6) for installation during reassembly.

ITQ]

11. Remove the throttle cable ball socket ® from the ball on the throttle lever using OIVIC Ball Socket Remover, PI N 342226. Remove the clip securing shift rod CD to shift lever. Remove shift rod from lever.

I1Q]

12. Remove the two screws Q) securing the trunnion anchor block ® to the engine.

!II]

13. Remove the two screws © securing the steering arm to the tiller arm . Remove the steering arm, shift and throttle cables, electrical cables, and grommet from the engine as an assembly. 14. Remove starboard side lower motor cover.

~

15. Remove the screw @j) securing the shift lever to the engine.

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16. Unplug the low oil light 2-pin Amphenol connector @.

rn

17. Remove the three screws ® securing the manual starter assembly to the powerhead. Remove the assembly.

III &

18. Attach OMC Lifting Eye, PIN 396748, to the flywheel and tighten the screws only enough to ensure thread engagement.

\Notel Threading the lifting eye screws in too far into the flywheel

will damage components mounted to the underside of the flywheel.

39201

rn 19. Remove the seven screws © securing the powerhead to the exhaust housing. W

20. With the weight of the powerhead supported by a hoist, pry the powerhead from the exhaust housing . Remove the powerhead. Discard the gasket and clean both gasket surfaces.

Removal - Remote Models

&

To avoid accidental starting of engine, twist and remove all spark plug leads before beginning service.

INotel Because ofthe number and types offasteners (screws and

nuts), it might be appropriate to reinstall fasteners in their holes as engine components are removed. This will simplify identification and assembly.

W

1. Turn the retainer knob located in the middle of the air silencer and remove the silencer from the engine. Disconnect the drain hose from the nipple at the bottom of the silencer.

IIJ

2. Disconnect the trimltilt three bullet connectors @from the wiring harness.

Safety Related

4-10

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[ [ ] 3. Unscrew the six lower motor cover screws @.

rn &. 4. Remove the port side lower motor cover enough to cut the tie strap securing the fuel hose to the fuel connector. Remove the fuel hose. Use caution as there might be fuel under pressure in the hose. Catch any fuel in the hose in a suitable container.

[1Q]

5. Remove the J-clamp and screw ® securing the electrical wires to the starboard side lower motor cover.

I1II 6. Remove the two screws © securing the electrical connector cover to the engine. Remove the cover.

[]l]

7. Unplug all six electrical connectors. Mark their location for installation. Remove any ground wires ofthe engine harness from the ground stud @. 8. Remove the engine harness and grommet from the lower motor cover. Remove the starboard side lower motor cover from the engine.

G1]

9. Remove the screw CD securing the shift leverto the engine.

~

10. Remove three screws Q) securing the flywheel cover to the powerhead.

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39201

39203

[IJ fA

11. Attach avIC Lifting Eye, PI N 396748, to the flywheel and tighten the screws only enough to ensure thread engagement.

INote I Threading the lifting eye screws in too far into the flywheel will damage components mounted to the underside of the flywheel.

W

12. Remove the seven screws the exhaust housing .

® securing

the powerhead to

\ ] ] 13. With the weight of the powerhead supported by a hoist, pry the powerhead from the exhaust housing . Remove the powerhead. Discard the gasket and clean both gasket surfaces. Disassembly 1. Remove all electrical, ignition, and carburetion components from the powerhead.

W m 2. Disconnect one crankcase oiling recirculating hoses

hose

® and three

©.

39273

[ ] ] 3. Remote Models: Remove two screws @ securing the trunnion block ® to the crankcase.

rn CD,

4. Remove locknut ®, flat washer ©, throttle lever ®, spacer shaft Q), and two bushings ® from the crankcase.

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[ ] ] 5. Remove shoulder bolt Cb), two washers, and throttle linkage @ from the crankcase. [ ] ] 6. Remove eight intake manifold retaining screws. Remove the intake manifold. Refer to the Fuel System section and remove the leaf plate assemblies from the intake manifold. Discard the gasket.

[!Q]

7. Remove twelve crankcase flange screws.

[!!]

8. Loosen in stages and remove the eight main bearing screws.

~

9. Separate crankcase and cylinder block. It may be necessary to tap on crankshaft with a rawhide or rubber mallet to . loosen.

[Jl]

10. Loosen in stages and remove cylinder head retaining screws, then remove the cylinder head. Remove the O-rings and discard them.

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39286

IT]

11. Using an indelible marker, identify each connecting rod cap by cylinder number. Rod No. 1 is closest to the flywheel.

rn

12. Use OIVIC Rod Screw Torque Socket, PI N 342664, to loosen the rod cap retaining screws. Loosen the screws in stages. Do not remove the screws.

rn 13. Use one hand to support the piston . Remove the rod cap screws with your other hand. Remove the piston . Do not allow the rod to contact the cylinder wall.

INote I Reattach each

rod cap to its rod as soon as the piston is removed. Each cap is unique and can only be installed on its mated rod. Do not allow rod to contact inside edge of piston.

39303

INote I Identify all internal components so that if reused they can be reinstalled in their original positions. 14. Repeat the preceding steps for each remaining piston and connecting rod.

W

15. Carefully lift crankshaft straight up and remove from crankcase.

[[J

16. If the lower crankshaft is to be resealed or the lower bearing replaced, remove the lower bearing seal housing assembly.

W W

17. Remove the housing O-ring @. Discard O-ring .

18. To remove the housing seal, use a drift punch as shown . Discard seal.

4-14

39307 M irage en y

fi o 19. Inspect housing and replace if necessary. [ ] ] 20. Remove the upper crankshaft bearing and seal assembly. Remove and discard the a-ring ® from the assembly.

rn 21 . Support the bearing assembly. Use a punch to remove the seal. Discard the seal. [1Q]

22. Remove a-ring © from crankshaft sleeve and inspect it. Replace the a-ring if it is not in good condition.

[!IJ

23. Inspect the crankshaft sleeve and replace, if necessary. To remove, use OMC Slide Hammer, PI N 432128, and OMC Bearing Puller Jaws, PIN 432130.

[1l]

24. Remove the lower main bearing only if it needs to be replaced. Using external retaining ring pliers, remove the lower bearing retaining ring.

[11]

25. Using an appropriate bearing separator, support the bearing, place separator flats against the bearing, and press off the crankshaft.

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[II

26. Remove both center main bearings and split sleeves from the crankshaft for inspection.

W

27. Remove crankcase seal rings for inspection.

rn

28. Using an appropriate ring expander, remove all piston rings from pistons. Discard the rings.

W

29. Using a tool as drawn on Page 4-6, remove all wrist pin retaining rings. Discard retaining rings.

rn 30. The wrist pin fit is loose on both sides. Push the wrist pin through to free the piston from the connecting rod. If necessary, use OMC Wrist Pin Remover, PI N 342657, to remove the wrist pin. 31. Be careful not to lose any of the 24 needle bearings or the two wrist pin washers. If any of the bearings are worn or lost, replace all 24 bearings during reassembly. [ ] ] 32. Remove the neutral detent retaining ring using a small screwdriver. Remove the detent ball and spring.

5 40273

Cleaning

INote I Before

inspecting or assembling powerhead, all internal components must be perfectly clean and free of contaminants. 1. Remove any carbon accumulation from exhaust port areas. 2. Remove any carbon accumulation from cylinder head combustion chambers. 3. If cylinder walls are glazed from extended use, use a medium grit cylinder hone to resurface walls. Use slow RPM to achieve a strong "crosshatch" pattern for best oil retention and ring seal ing.

40314

INote I To

avoid piston or cylinder block damage, restore the chamfer to all port edges using a ball hone or other suitable tool.

In

To avoid personal injury, wear eye protection and rubber gloves when using CIVIC Gel Seal and Gasket Remover. E

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[I]

4. Use OVIC Gel Seal and Gasket Remover to remove all traces of gaskets, adhesives, and OMC Gel-Seal II sealant from the cylinder block and crankcase. 5. Carefully remove any carbon accumulation from the tops and ring grooves of the piston. A ring groove cleaning tool can be made by breaking an old ring and grinding an angle on its end. Do not damage ring grooves while cleaning. 6. Thoroughly wash entire cylinder block and crankcase with warm, soapy water to remove all traces of contaminants. 7. Air dry cylinder block and crankcase. Blow all holes and passageways with compressed air.

&

To avoid person injury, wear eye protection and set compressed air pressure at less than 25 PSI (172 kPa).

8. Cover the cylinder walls with a liberal amount of Johnson or Evinrude Outboard Lubricant to protect them from corrosion. Inspection

1. Before any inspection process can begin, all internal components must be clean and free of excess oil. 2. Make a visual inspection of all internal components. Check for unusual wear patterns, scuffing or deterioration of aluminum parts, heat-related discoloration of bearings and bearing surfaces, and broken components.

W

3. Check for cylinder head warpage using a piece of bar stock or machinist's straightedge and a feeler gauge set . • Cylinder head warpage must not exceed 0.003 in. (0,08 mm) per inch of measurement. Replace head if warpage exceeds this dimension.

[]J

4. Use a micrometer to measure the diameter of each crankpin and main bearing journal. The lower main bearing journal would only be measured if the bearing was removed for another reason. Refer to Engine Specifications, Section 1, for dimensions.

[IQ]

5. Visually inspect crankcase seal rings for a worn, grooved, or chipped condition. If they appear worn, use a micrometer to measure their thickness . • Replace any ring that is less than 0.100 in. (2,5 mm) thick. Install seal rings in their original positions on crankshaft after inspection.

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4-17

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ave

6. Use Cylinder Bore Gauge, PI N 771310, to inspect each cylinder bore for an out-of-round, oversize, or tapered condition. Be sure the gauge or micrometer is perfectly square in the bore when measuring .

rn 7. Measure each cylinder in at least two areas as shown. Each area should be measured twice. The difference between the two measurements in each area is the cylinder out-of-round dimension. • The cylinder must not be out-of-round by more than 0.004 in. (0,10 mml.

rn 8. The dimension cylinder taper.

39 321

difference between the two areas is

• The cylinder taper must not exceed 0.002 in. (0,05 mml.

rn 9. The difference between your measurements and standard bore dimension is cylinder oversize. Refer to Engine Specifications, Section 1, for dimensions. • The cylinder must not be oversized by more than 0.003 in . (0,08 mml.

2

L...---L._ _ _ _ _ _ _ _---=~

INote I If any cylinder is outside these tolerances, it must be bored oversize. It is permissible to have one or more oversize pistons in an engine. Refer to Engine Specifications, Section 1.

m

10. Use a micrometer to check piston condition. Make at least two measurements, 90 0 from each other. Measure the piston diameter 1/4 in. (6,4 mml above the bottom edge ofthe piston skirt. • The difference between the two piston measurements must not exceed 0.003 in . (0,08 mml .

W

11. Make the following inspections for new ring sets. Place each ring, separately, in its respective bore. Use a piston to square the ring in the cylinder. Use a feeler gauge to measure the ring end gap. • The ring end gap must be within 0.005 - 0.020 in. (0,130,51 mml.

[ [ ] 12. Use a machinist's straightedge to check clearance on the tapered rings . Install one tapered ring in the piston's upper ring groove. When checked with the straightedge, there should be enough ring clearance to allow the straightedge to touch the piston on both sides of the ring groove. Make several checks around the piston . • If straightedge does not touch piston , remove the ring and clean ring groove. Remove upper ring from piston. Install remaining tapered ring in piston 's lower ring groove and check for clearance.

4-18

Mirage/eng

[ ] ] 13. Inspect center main bearing and split sleeves for excess wear, nicks, or scratches. Replace if necessary. [ [ ] 14. Inspect crankshaft rod bearings for excess wear, nicks, or scratches. Replace if necessary.

Assembly

INotel

Proceed slowly. Make no forced assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with Johnson or Evinrude Outboard Lubricant. Use new wrist pin retaining rings, gaskets, seals, and a-rings during assembly.

~

Co

2438 1

[ ] ] 1. Install the neutral detent ball and spring into the pocket in the crankcase. Use OMC Retaining Ring Installer, PI N 342658, to install the retaining ring. [ [ ] 2. Oil the end of the crankshaft. Place a new lower main bearing onto the crankshaft with the lettered side of the bearing facing away from the crankshaft. Use OMC Crankshaft Bearingl Sleeve Installer, PIN 342222, to press the bearing onto the crankshaft until it seats.

[!Q]

3. Oil the end of the crankshaft. Place a new sleeve in OMC Crankshaft Bearingl Sleeve Installer, PI N 342222, and drive the sleeve onto the crankshaft until the installer contacts the lower main bearing . • If the installer sticks on the sleeve after installation, thread OMC Slide Hammer, PI N 391008, into installer and pull off.

INotellnspect sleeve surface after installing. Sleeve must not be used if surface is damaged .

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4-19

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1 [JJ

4. Lubricate a new driveshaft a -ring and lightly lubricate crankshaft splines with OMC Moly Lube. Install a-ring in sleeve.

[I]

5. Using external retaining ring pliers, install bearing retain ing ring with sharp edge facing away from bearing .

6. Lubricate the two center main bearings and split sleeves with outboard lubricant and install them in their original positions. The split sleeve ring grooves must face away from flywheel when installed .

rn

39317

7. Install the crankshaft seal rings. Make sure the ends @ of the seal rings overlap properly.

W

8. Lightly apply OMC Gasket Sealing Compound on the metal case of a new lower housing seal. Position the exposed lip of the seal into the lower housing. Press against outer metal case of the seal until the edge of the metal case is flush with the inside surface of the lower housing.

W

9. Coat the lower housing a-ring, a-ring groove, and flange with OMC Gasket Sealing Compound. Place the a -ring on the lower housing.

W

10. Lubricate seal lip with outboard lubricant and place lower bearing seal housing on crankshaft.

INote I It

is very important to notice that there is a top to the pistons in this engine . All pistons are marked with the word "UP". This side of the piston must face the flywheel, when the pistons are placed in the cylinder block.

[l]

11. Apply OMC Gasket Sealing Compound to the outside casing of a new seal. Place the seal into the upper bearing housing. Press the seal into place until it seats. Coat the seal lip w ith outboard lubricant.

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8 40342

39320

[ ] ] 12. Lightly oil a new a-ring with outboard lubricant. Install the a-ring onto the upper bearing and seal assembly.

rn 13. Install the upper bearing and seal assembly onto the crankshaft. [IQ]

14. It is very important that the original connecting rods be installed in the powerhead in the same orientation as when they were removed. This will promote longer life for the rod, bearings, and pistons. Install new connecting rods as follows . • Alignment marks flywheel.

® or OMC part numbers © facing the

[!!]

15. Apply OMC Needle Bearing Assembly Grease to the 24 wrist pin bearings. Install the bearings in the wrist pin bore. Align the bearings in the bore using OMC Wrist Pin Bearing Alignment Tool, PI N 342217 @.

[1l]

16. Place the two wrist pin thrust washers on the tool.

INote I The piston and wrist pin have a loosel loose fit.

No tool is required to install the wrist pin. DO NOT install a wrist pin that will not easily go into place in the piston. Remove any burrs or carbon deposits from around the wrist pin bore that could cause difficulty installing the wrist pin.

2 4902

[1l]

17. Position the piston with the word "UP" on the piston dome facing up. Oil the wrist pin bore and wrist pin. Install the connecting rod with the alignment marks or OMC part number facing up. Install the wrist pin through the piston and connecting rod, pushing the alignment tool out through the piston.

~

18. Using OMC Wrist Pin Retainer Installer, PI N 342223, install new wrist pin retaining rings in each wrist pin hole. Gap ® of retaining ring faces 180°, away from notch ® in piston. 19. Repeat Steps 11 thru 14 for each piston .

14 Mi rag e 'eng

4-21

402 79

DR3481

[IJ

20. When all pistons and connecting rods are assembled, install piston ring sets. Install each piston ring set on the piston that was used to test the ring clearances.

rn I Note I Be sure gap of ring fits squarely around dowel pin. INotel Before continuing, be certain all OMC Gel-Seal I! sealant has been removed from the cylinder block and crankcase mating flanges. If traces of hardened OMC Gel-Seal I! sealant are left, main bearing misalignment might occur. Refer to Cleaning, this section. 21 . Rotate cylinder block so that the cylinder head surface is facing up and horizontal to the floor.

INotel Use one the following ring compressor tools for inserting the pistons into the block: • • • •

500 500 565 565

cc cc cc cc

Standard: OMC PIN 342218 Oversize: OMC PI N 342219 Standard: OMC PI N 342220 Oversize: OMC PIN 342221

22. Coat pistons, rings, cylinder walls, and ring compressor with outboard lubricant.

rn 23. Center connecting rod in piston and locate piston rings on dowel pins. Slide No.1 piston assembly into top cylinder while guiding connecting rod through cylinder block. Make sure the word "UP" on the piston dome, is facing toward the flywheel. 24. Repeat Steps 22 and 23 for remaining pistons.

W

25. Lightly lubricate new cylinder head a-rings with OMC Triple-Guard grease. Install a -rings in cylinder block.

5 DRC5942

W

26. Apply a 1/16 in. (2 mm) bead of GE RTV adhesive around each water passage on the cylinder. Install the cylinder head and retaining screws. Do not use sealer on screws. Torque all screws in stages and in a circular pattern starting in the middle, to 180-204 in. Ibs. (20-23 N·m).

INotel Keep adhesive away from the a-rings. E

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27. Rotate cylinder block so that crankcase mating flange is facing up. 28. Push all pistons to Top Dead Center. Remove numbered connecting rod caps.

W

29. Gently lower crankshaft assembly into place. • Orient all crankcase seal ring gaps facing up. • Locate tab on lower bearing seal housing in recess in crankcase.

• Locate each center main bearing split sleeve on its dowel pin. [ ] ] 30. Lubricate No.1 crankpin and bearing assemblies with outboard lubricant. Slowly pull No. 1 connecting rod up to crankshaft and install bearings. [ ] ] 31. Lubricate threaded portion of No.1 rod cap screws with outboard lubricant. Align dot on rod cap with dot on the connecting rod. Install rod cap screws finger tight.

I

I Note Be sure alignment dot on rod cap matches dot on rod and that both dots face flywheel. INotel Torquing the screws without OMC Rod Cap Alignment Fixture, PI N 396749, and OMC Connecting Rod Alignment Jaw Kit, PI N 437273, or using an incorrect procedure could cause permanent damage to the connecting rod and crankshaft. To maintain accurate torque values, keep torque wrench extension length to a minimum.

[ [ ] 32. Torque the rod cap screws using OMC Rod Cap Aligning Fixture, PI N 396749, OMC Connecting Rod Alignment Jaw Kit, PI N 437273, and OMC Rod Screw Torque Socket, PI N 342664. Align the flat marked "set" on the rod engagem ent stop with the arrow on the frame. Move the adjustment knob to setting @. Rotate adjustment knob 180 0 to lock position.

I

I Note Outside taper of OMC Rod Screw Torque Socket, PI N 342664, must be ground down for proper engagement of connecting rod screw.

Mirage/eng

4-23

21591

IT]

rn 33. Secure restraining jaw "G" and forcing jaw "H" to

frame.

rn

34. Tighten the rod cap screws to a torque of 25-30 in. Ibs. (2-3 N·m) . 35. Apply a light coat of outboard lubricant to the corners of the connecting rod and rod cap. Place frame on connecting rod using the following procedure:

rn •

Position frame onto the connecting rod so the contact area @ of the jaw is centered in the side of the rod @ .

• Tighten forcing screw until jaws contact connecting rod. [[]

• Slide frame down until adjustment stop contacts the connecting rod. The groove lines on the jaws must be centered on the rod/crankpin diameter.

INote I The above procedure must be followed to assure frame is squarely in position. [ ] ] 36. Tighten the forcing screw to a torque of 23 in. Ibs. (2,5 N·m). 37. Loosen both rod cap screws 114 turn.

[I]

38. Apply a preliminary torque of 40-60 in. Ibs. (5-7 N·m) to both rod cap screws. 39. Apply a final torque of 170-190 in. Ibs. (19-21 N·m) in two alternate increments to both rod cap screws.

40. Loosen forcing screw and remove the frame . Repeat Steps 36 thru 39 for remaining connecting rods.

4-24

Mirayc eng

40350

W

41 . Thoroughly clean and degrease the crankcase mating flange of the cylinder block with OMC Cleaning Solvent and let air dry.

[ [ ] 42. Apply OMC Locquic Primer to the mating flange of the crankcase and let air dry.

[IQ]

43. Apply OMC Gel-Seal II sealant to the crankcase mating flange of the cylinder block. The application must cover the flange evenly and consistently without being excessive. The application must not come within % in. (6,4 mm) of crankcase seal rings or bearing.

INotel OMC Gel-Seal II sealant has a shelf life of at least one year when stored at room temperature. Test the CIVIC Gel-Seal II sealant or replace it if the age of the tube cannot be determined. Using old OMC Gel-Seal /I sealant could cause crankcase air leaks.

III]

44. Lower the crankcase into place.

~

45. Apply OMC Locquic Primer to the eight main bearing screws and allow to air dry. Apply CIVIC Ultra Lock adhesive to the screws. Apply OMC Gel-Seal II to underside of the washer face. Install the screws finger tight. The two longer screws are used on the top end of the crankcase.

[J]]

46. Torque main bearing screws in stages to 216-240 in. Ibs. (24-27 N·m). Begin with the center screws and work outward in a spiral pattern.

47. Attach lower drain nipple.

[1!]

48. Apply OMC Locquic Primer to the twelve crankcase flange screws and allow to air dry. Apply OMC Ultra Lock adhesive to the screws. Install the twelve screws and tighten to 60-84 in . Ibs. (7-9 N·m).

Mirage/eng

4-25

1 40376

rn

49. Remove the backing from a new intake manifold gasket and install it in place on the reed box side ofthe manifold . Refer to the Fuel System section and install the leaf plate assemblies.

rn

50. Apply OVIC Locquic Primer to the eight intake manifold screws and allow to air dry. Apply OVIC Ultra Lock adhesive to the screws. Install the intake manifold and secure with the screws. Tighten the screws to 60-84 in. Ibs. (7-9 N·m).

rn 51. Install the throttle/spark lever ® to the crankcase and secure with two flat washers and shoulder bolt. Tighten the bolt to 60-84 in. Ibs. (7-9 N·m).

INote I The larger of the two flat washers must be placed between the throttle/spark lever and the crankcase.

W

52. Apply OVIC Triple-Guard grease to the inside and outside of the two throttle lever bushings @ . Install the bushings into the bosses on the crankcase.

[ ] ] 53. Apply OVIC Triple-Guard grease to the throttle lever shaft © and install it in the bushings. Place the spacer @ on the end of the shaft. Place the throttle lever ® on the end of the shaft and secure with flat washer and nut ®. Tighten the nut to 60-84 in . Ibs. (7-9 N·m) . [ ] ] 54. Remote Models: Apply OVIC Locquic Primer to the two trunnion anchor screws and allow to air dry. Apply OVIC Nut Lock adhesive to the screws. Attach the trunnion anchor block to the crankcase and secure with the two screws @. Tighten the screws to 84-106 in. Ibs. (9-12 N·m).

39278

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m rn 55. Install one crankcase oiling recirculating hoses CD to the powerhead.

hose

® and three

56. Install all carburetion, ignition, and electrical components on the powerhead following instructions found in their respective sections. Installation - Tiller Models

rn 1. Coat both sides of a new powerhead base gasket with OMC Gasket Sealing Compound and install it on the exhaust housing. rn 2. Coat the driveshaft splines Q) with OMC MolV Lube. Do not apply lubricant to the end of the driveshaft as lubricant here may prevent seating of driveshaft in crankshaft.

[1QJ &.

3. Attach OMC Lifting Eye, PI N 396748, to the flywheel and tighten the screws only enough to ensure thread engagement.

INote I Threading the lifting eye screws in too far into the flywheel will damage components mounted to the underside of the flywheel.

[I!]

4. Using a hoist, carefully lower the powerhead onto the exhaust housing. Secure with seven screws coated with OMC Gasket Sealing Compound. Tighten the screws to 180-204 in. Ibs. (20-23 N·m). Remove the lifting eye.

[JII

5. Attach shift arm ® to shift lever shaft and secure with screw and washer. Tighten the screw to 84-106 in. Ibs. (9-12 N·m).

IJl]

6. Position the manual starter on top of the powerhead. Apply CIVIC Locquic Primerto the three manual starter screws and allow to air dry. Apply CIVIC Nut Lock adhesive to the screws. Install the screws and tighten to 60-84 in . Ibs. (7-9 N·m).

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Safety Related

4-27

IT]

7. Connect the low oil light lead @ to the engine harness. Secure the connector to the ignition module @.

rn 8. Install the starboard lower motor cover. II]

9. Attach the steering arm to the tiller arm . Secure with two screws and washers. Tighten the screws to 216-240 in. Ibs. (24-27 N·m) . Thread two locknuts © onto the threaded end s to the two tiller arm screws and tighten to 216-240 in. Ibs. (24-27 N·m).

W

10. Place the shift and electrical cables in the lower motor cover grommet and secure in place in the lower motor cover.

W

11. Apply OVIC Locquic Primer to the two trunnion anchor screws and allow to air dry. Apply OVIC Nut Lock adhesive to the screws. Attach the trunnion anchor block to the crankcase and secure with the two screws @. Tighten the screws to 84-106 in. Ibs. (9-12 N·m).

[]] In

12. Attach the throttle cable ball socket ® to the throttle lever using OVIC Ball Socket Installer, PI N 342225. Attach the shift cable to the shift lever and secure with clip ®.

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4-28

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13. Tiller Electric Models: Install the neutral start switch leads into the 6-pin connector.

[ [ ] 14. Tiller Electric Models: Connect both 6-pin and 1-pin connectors together and secure to the electrical connector block. [ [ ] 15. All Models: Secure all ground leads and cables with nut tightened to 60-84 in. Ibs. (7-9 N·m). Coat the connections with OMC Black Neoprene. [ ] ] 16. Install the electrical connector cover and secure with two screws. Tighten the screws 24-36 in. Ibs. (3-4 N·m).

&

17. Tiller Electric Models: Connect the positive battery cable to the starter solenoid. Tighten the nut securely. Position the plastic cover over the terminal.

Mirage1eng

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Safety Related

4-29

[I]

19. Secure the tiller arm electrical cables (and battery cables if equipped) to the starboard lower motor cover with a J -clamp and screw. Tighten the screw to 84-106 in. Ibs. (9-12 N·m).

W&

20. Attach the fuel line to the fitting in the port lower motor cover. Secure with a tie strap.

rn 21. Install the port lower motor cover and secure with six screws. Tighten the screws to 84-106 in. Ibs. (9-12 N·m).

rn

22. Position choke cable in the bracket and secure with clip

@. Attach choke cable to retainer in linkage.

[ [ ] 23. Attach the drain hose to the nipple on the bottom of the air silencer. Attach the air silencer to the powerhead and secure by twisting the silencer lock.

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Installation - Remote Models

[]J

1. Coat both sides of a new powerhead base gasket with OMC Gasket Sealing Compound and install it on the exhaust housing.

[]J

2. Coat the driveshaft splines

©

with OMC Moly Lube. DO

NOT apply lubricant to the end of the driveshaft as lubricant here may prevent seating of driveshaft in crankshaft.

rn fA 3. Attach OMC lifting Eye, PI N 396748, to the flywheel and tighten the screws only enough to ensure thread engagement.

INote I Threading the lifting eye screws in too far into the flywheel will damage components mounted to the underside of the flywheel. [ [ ] 4. Using a hoist, carefully lower the powerhead onto the exhaust housing. Secure with seven screws coated with OMC Gasket Sealing Compound. Tighten the screws to 180-204 in. Ibs. (20-23 N·m). Remove the lifting eye. [ ] ] 5. Attach shift arm @ to shift lever shaft and secure with screw and washer. Tighten the screw to 84-106 in.lbs. (9-12 N·m) .

I1Q]

6. Install the flywheel cover to the powerhead. Apply OMC Locquic Primer to the three cover screws and allow to air dry. Apply OMC Nut Lock adhesive to the screws. Install the screws and tighten to 60-84 in. Ibs. (7-9 N·m).

[!j]

7. Install the starboard lower motor cover.

39200

Mirage/eng

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Safety Related

4-31

8. Place the main engine cables into the motor cover grommet and install in the starboard lower motor cover. Route the cables along the side of the cover back to the electrical bracket.

IT]

9. Connect all connectors and secure to the electrical bracket. Connect all ground wires to the ground stud. Secure with nut tightened to 60-84 in. Ibs. (7-9 N·m) and coat the connection with OMC Black Neoprene.

W

10. Install the electrical connector cover and secure with two screws. Tighten the screws 24-36 in. Ibs. (3-4 N·m).

rn 11. Secure the main engine cable to the starboard lower motor cover with a J-clamp and screw. Tighten the screw to 84-106 in. Ibs. (9-12 N·m).

W In. 12. Attach the fuel

line to the fitting in the port lower motor cover. Secure with a tie strap.

[ ] ] 13. Install the port lower motor cover and secure with six screws. Tighten the screws to 84-106 in. Ibs. (9-12 N·m). [ ] ] 14. Connect the trim/ti't three bullet connectors and route out of the way.

W

15. Attach the drain hose to the nipple on the bottom of the air silencer. Attach the air silencer to the powerhead and secure by twisting the silencer lock.

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Thermostat Servicing Disassembly

[ ] ] 1. Remove the thermostat assembly from the cylinder head.

rn 2. Unscrew the thermostat cover @ from the thermostat housing @. Remove the relief spring ©, diaphragm and cup @,

washer ®, vernatherm ®, and spring @. Remove the thermostat housing O-ring ® and thermostat cover O-ring CD.

11 40387

[!Q]

3. Inspect the thermostat seal area in the cylinder head . Repair any damaged surfaces before assembly.

4. Inspect the housing for cracks or heat damage . Replace if necessary. 5. Inspect the vernatherm, diaphragm and cup, and spring for signs of corrosion or heat damage. Replace if necessary. Assembly

12

I1II

1. Place the short spring @ onto the end of the thermostat ®. Place the washer ® on the diaphragm and cup @.

[J1] ~

2. Position the vernatherm and spring in the diaphragm and cup . Position the relief spring © on the opposite side of the diaphragm and cup. Assemble the thermostat housing.

M irage/eng

4-33

40388

IT]

3. Tighten the thermostat housing and cover securely.

rn 4. Install a new thermostat housing O-ring ® and cover O-ring @ onto the thermostat assembly. W

5. Install the thermostat assembly in the cylinder head. Tighten to 60-84 in . Ibs. (7-9 N·m).

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4-34

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NOTES

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4-35

::::: i:i.

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Rope Models

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Rope Models

Mirage/eng

4-37

DP0097

Tiller Electric Models

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Tiller Electric Models

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Remote Models

DP0102

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Remote Models

M irage/eng

4-41

Midsection Table of Contents

&

General Safety Warnings . . . . . . . . Service Specifications. . . . . . . . . . . Cleaning and Inspection. . . . . . . . . Steering Handle Service. . . . . . . . . Twist-Grip Throttle Service . . . . . . Exhaust Housing Service . . . . . . . . Swivel Bracket Service. . . . . . . . . . Midsection Adjustments .........

... ... ... ... ... ... ... ...

....... ....... ....... ....... ....... ....... ....... .......

. . . . . . . .

....... ....... ....... ....... ....... ....... ....... .......

5- 2 5- 3 5- 4 5- 5 5- 7 5-11 5-14 5-21

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5- 1

i::i.

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In

General Safety Warnings

Before working on any part of the midsection, read the section called Safety at the end of this manual. To avoid accidental starting of engine while servicing, take adequate precautions to disarm the ignition system: • Connect the engine's wiring harness to the boat's wiring harness with the key switch in OFF position. • Twist and remove all spa rk plug leads from the spark plugs. • Disconnect the battery cables at the battery. To prevent possible fire or explosion under the engine cover after servicing: • Check entire fuel system for leaks. • Make sure all electrical and ignition leads are routed and clamped in their original positions away from rotating engine parts. 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. To prevent possible injury, test the engine's entire shift system and "start-in-gear-prevention" feature before returning engine to the customer.

5-2

M irage eng

Service Specifications Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Description

Torque

Adhesive

Upper Mount

312-336 in. Ibs. (35,3-38 N·m)

orJIC Nut Lock

Lower Mount

180-204 in. Ibs. (20-23 N·m)

orJIC Nut Lock

Lower Mount Bracket

180-204 in. Ibs. (20-23 N·m)

orJIC Nut Lock

50-54 ft. Ibs. (68-73 N·m)

•

180-240 in. Ibs. (20-27 N·m)

orJIC Nut Lock

Tilt Tube Nut* Ti It Lock Pi n Nuts

* Back off nut 1f4 turn after tightening.

orJIC Special Tools Required

PIN

Tool Panel

390767 322699 322697 342226 342225

K E E F E

Description

Twist-Grip Remover Socket Removal Tool Insert Tool Ball Socket Remover Ball Socket Installer

Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

orJIC orJIC orJIC orJIC orJIC orJIC orJIC

Locquic Primer Ultra Lock Nut Lock Moly Lube Gasket Sealing Compound Triple-Guard@Grease Black Neoprene Dip Isopropyl Alcohol Loctite Depend 300 Adhesive

Mirage.eng

5-3

Cleaning and Inspection 1. Inspect clamp screw assembly. Replace swivel plate and retainer if bent or loose . To install a new swivel plate, remove screw and old plate. Apply OMC Locquic Primer to the threads of the screw and allow it to dry four to five minutes. Then apply OMC Ultra Lock to threads. Install a new swivel plate with screw and tighten securely. 2. Clean all parts with parts cleaning solvent and dry with compressed air. All nut and screw threads coated with OMC Ultra Lock or OMC Nut Lock must be thoroughly cleaned before reassembly. When using a thread locking product, be sure to prime the threads with OMC Locquic Primer. 3. Discard all oil seals, a-rings, and gaskets. 4. Examine the rubber motor mounts and replace if deteriorated or damaged. 5. Before checking the exhaust housing for distortion, thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion.

OJ

6. Check the exhaust housing for distortion. Place the housing on a surface plate. Using a dial indicator, check flatness by measuring the run-out on the top edge of the housing. The maximum allowable run-out is 0.009 in. (0,228 mm). If you do not have access to a dial indicator and surface plate, seek the services of a machine shop. DO NOT attempt to straighten a distorted housing; replace it.

INote I A

bent exhaust housing will cause upper driveshaft splines to wear excessively, and will also damage crankshaft splines.

7. Inspect shift components for wear. Replace if deteriorated or damaged.

5-4

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Steering Handle Service Removal

11

1. To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.

m 2. Remove the throttle cable ball socket @ from the ball on the throttle arm ® using OMC Ball Socket Remover, PI N 342226. rn 3. Remove the shoulder screw © and spacer securing throttle cable to bracket. W

® to allow throttle cable

[[J

® securing the electrical cover

4. Loosen screw @ and pivot cover removal.

5. Remove two cover screws to the engine.

6. Remove screw and J-clamp securing wires to lower engine cover.

[§]

7. Separate the 1-pin Amphenol connector. Remove the ground stud nut @, then remove the stop button ground lead from the stud. 8. Remove the stop button lead from the Amphenol connector, using OMC Socket Removal Tool, PIN 322699. 9. Remove protective sleeve from stop button leads and throttle cable .

[I]

10. Remove the steering handle screw. Pull the throttle cable and stop button leads through the grommet in the lower engine cover. 39083

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Installation

[ ] ] 1. Slide the protective sleeve over the stop button leads. Insert the stop button leads ® and the throttle cable ® through the lower engine cover grommet.

W

2. Apply OMC Triple-Guard grease to the two steering handle bushings. Place the bushings into the steering bracket. Attach the steering handle to the steering bracket. Tighten the screw so the steering handle can be pivoted and maintain any position.

rn

3. Secure stop button ground lead to the ground stud @. Tighten the nut securely. Apply CIVIC Black Neoprene Dip to the stud and nut.

[!]

4. Using OMC Insert Tool, PIN 322697, install the stop button lead into the plug. Connect the 1-pin Amphenol connector @. Secure connector in the bracket.

5. Secure wires to lower engine cover with J-clamp and screw. Tighten screw securely. [[] 6. Install the electrical connector cover and secure with two screws @. Tighten the screws securely. []] 7. Thread the connector onto the cable housing 13/4 in. (44 mm) from end of the cable sleeve.

13f4in. (44mm)-

[ [ ] 8. Attach connector to bracket and secure with shoulder bolt and spacer ®. Tighten bolt securely. [ [ ] 9. Pivot bracket cover @ and tighten retaining screw securely.

:J;.;

'=

®

[ [ ] 10. Attach throttle cable ball socket Q) to the ball on the throttle arm Q) using CIVIC Ball Socket Installer, PIN 342225. 11 . To adjust the throttle cable, refer to Synchronization and Linkage Adjustment, Section 1.

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9 Twist-Grip Throttle Service Disassembly

rn 1. Using OMC Twist-Grip Throttle Remover, PIN 390767, depress the grip detents. Tighten screw ® and remove the grip by pulling grip and turning the idle adjustment knob

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CD

W

2. Remove the helix halves

[!Q]

3. Pull the throttle pin out of the cable .

[!1]

4. Remove throttle end cap from inner handle.

clockwise.

rollers @, and guides @.

[J1]

5. Remove stop switch cover screws and cover/stop switch assembly.

[lID

6. Remove the throttle control plate.

~

7. Remove the throttle cable retainer clip ®. Pry the throttle cable trunnion @ out ofthe steering handle and remove the cable.

12 24288

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24286

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112 In. (12 mm)

3 [ ] ] 8. Using a punch and mallet, drive the steel pin that retains the inner handle from the steering handle. INotel Do not remove the inner handle except to replace it.

W

9. Remove the plastic inner handle from the metal outer handle by driving the outer handle off with a mallet and a punch. Inner handle is bonded to the outer handle. After removing, chip away remnants of inner handle. 10. Remove the throttle cable seal from the inner handle.

Inspection 1. Inspect the throttle cable for kinks and wear. Replace if necessary. 2. Inspect the steering handle components for wear, cracks, or damage. Replace parts if necessary. 3. Refer to Ignition System, Section 3, to test stop switch.

.---.a....4.~'-------5 24282

Assembly 1. Install the throttle cable seal in inner handle.

rn 2. If removed, apply Loctite Depend 300 adhesive to inner handle at areas shown.

m

3. Install the metal outer handle over the plastic inner handle and drive the outer handle into place.

[ ] ] 4. Secure tab of the inner handle into recess of the outer handle with the steel pin.

[[] W

5. Install the handle end of the throttle cable. Snap the throttle cable trunnion into the recess in the handle. Install the retainer clip.

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[ [ ] 6. Install the throttle control plate on outer handle. [ ] ] 7. Place the throttle end cap into inner handle. The tab on the cap goes into the recess of the inner handle.

W

8. Push the throttle cable pin through the end of the throttle cable.

~

9. Lubricate end ofthe pin, guides, rollers, helix grooves, and inner handle guide slot with OMC Moly Lube. Place the guides over the roller pin and into the slots of the inner handle. Place the rollers on the ends of the roller pin .

24293

~ [!!]

10. Assemble the helix halves on the handle and slide the grip over the helix. Be sure the twist-grip's speed indicator line is positioned with the speed range symbol on the handle. Snap the grip into place.

[!!]

11. Turn the idle speed adjustment knob counterclockwise to the minimum slow speed position.

[11] [j]]

12. Slide the protective sleeve over the stop switch leads and throttle cable. Slide grommet over the protective sleeve until '/2 in. (12 mml of the sleeve is exposed. Place grommet in position and install stop switch bracket.

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NOTES

5-10

Mirage eng

Exhaust Housing Service Removal and Disassembly

1. Remove the powerhead as described in Section 4. 2. Remove the gearcase as described in Section 6.

rn 3. Move the shift lever ® to allow access to the shift rod and bellcrank. Remove the bellcrank clip @.

rn

4. Slide the shift rod © off the bellcrank pin @. Make a note of which way the offset in the shift rod faces for reassembly (offset to the rear). Remove the shift rod from the exhaust housing.

rn 5. Remove the screw ® securing the shift lever ® to the bellcrank. Remove the shift lever from the bellcrank. W

6. Remove the bellcrank @ and inner bushing exhaust housing.

® from the

CD from

the exhaust

[ ] ] 7. Remove the outer bellcrank bushing housing .

W

8. Remove the lower motor mounts screw, two washers, and locknut.

6 38882

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5-11

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[ ] ] 9. Remove the two upper motor mount screws ® (one on each side of the housing). Remove the exhaust housing from the swivel bracket.

rn 10. Remove the upper and lower motor mounts by prying them out of the pockets in the exhaust housing with a screwdriver.

W

11. Remove the lower motor cover mounts by twisting and pulling them off the roll pins.

rn 12. Remove the upper and lower motor cover seals by pulling them out of their grooves and off the exhaust housing. 13. Refer to Cleaning and Inspection at the beginning of this section. Assembly and Installation

W

1. Install the upper and lower motor cover seals into their grooves. No adhesive is required.

[ ] ] 2. Install the two lower motor cover mounts onto their roll pins. Push them into position until they seat.

5-12

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[IJ

3. Apply soapy water to the outside surface of the upper and lower motor mounts. Push them into the mount pockets in the exhaust housing until they seat.

[ ] ] 4. Apply OIVIC Nut Lock to the two upper motor mount screws. Attach the exhaust housing to the swivel bracket and secure with the two upper motor mount screws. Tighten the screws to 312-336 in. Ibs. (35,3-38 N·m) . [ ] ] 5. Apply OIVIC Nut Lock to the threaded end of the lower motor mount bolt. Secure the lower motor mount to the swivel bracket with the mount bolt, two flat washers, and locknut. Tighten the bolt and nut to 180-204 in. Ibs. (20-23 N·m).

[1Q]

6. Apply OIVIC Triple-Guard grease to the inside and outside surfaces of an outside shift bellcrank bushing @. Push the bushing into position in the exhaust housing until it seats.

[!1J

7. Apply OIVIC Triple-Guard grease to the inside and outside of the inside bellcrank bushing © and to the bellcrank.

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5-13

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OJ 8. Install the shift bellcrank into the exhaust housing. Make sure the inside @ and outside

® bushings are seated.

rn rn

9. Attach the shift lever to the bellcrank. Secure with screw and washer @ . Tighten the screw to 60-85 in. Ibs. (7-10 N·m).

10. Verify that the shift rod connector @ is threaded down onto the rod until seated. Back off the connector until the connector is in line with the offset in the rod . Install the shift rod into the exhaust housing . Position the rod with the offset facing to the rear.

m & clip@.

11 . Attach the shift rod to the bellcrank and secure with

12. Install the gearcase as described in Section 6. 13. Install the powerhead as described in Section 4. 14. Adjust shift detent as described in Section 1.

Swivel Bracket Service Disassembly

1. Remove the powerhead as described in Section 4. 2. Remove the gearcase as described in Section 6. 3. Remove the exhaust housing as described in this section . [ ] ] 4. Remove two screws, locknuts, and four flat washers securing the lower motor mount bracket @ to the pivot tube.

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5. Remove the lower motor mount bracket @ and thrust washer @.

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6. Remove the steering arm assembly Q) from the swivel bracket.

CD and thrust washer

[ ] ] 7. Remove the upper seal by prying it out with a screwdriver. [ ] ] 8. Back off the steering friction screw ®, if equipped, to allow removal of the friction block or upper bushing ©. Remove the friction block or upper bushing.

[1Q]

9. Remove the lower seal by prying it out with a screwdriver.

[II]

10. Remove the lower bushing from the swivel bracket.

[1l]

11. Tilt the swivel bracket into the UP position and lock it in place. Remove the port and starboard tilt lock pins and locknuts

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5-15

38939

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38940

IT]

12. Unscrew one of the two locknuts

®

from the tilt tube .

m ©

13. Carefully remove the tilt tube @ and two thrust washers from the swivel and stern brackets.

W

14. Remove the two tilt tube bushings @ from the swivel bracket.

Assembly

W []] []]

1. If any of the swivel bracket components were removed, refer to the three reference pictures for correct assembly.

5-16

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5 38941

6 38942

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5-17

/ 0.62 in . (15,7 mm)

®

--39044

38944

ITJ 2. Apply OMC Triple-Guard grease to the inside and outside surfaces of two new tilt tube bushings @. Insert the bushings into the swivel bracket.

W

3. Apply OMC Triple-Guard grease to the two tilt tube thrust washers @. Install the swivel bracket © in between the port and starboard stern brackets @. Place a thrust washer in between the swivel bracket and each stern bracket.

W

4. Verify one tilt tube locknut ® is threaded a minimum of 0.62 in. (15,7 mm) from the end of the tilt tube . This is required for proper steering cable installation .

m

5. Apply OMC Triple-Guard grease to the tilt tube. Install the tilt tube from the starboard side of the stern bracket. Make sure the tilt tube passes through both thrust washers @.

[]] 6. Install a second locknut ® on the other end of the tilt tube . Hold the starboard locknut with a wrench. Tighten the port locknut to 50-54 ft. Ibs. (68-73 N·m), then back the nut off 1fs to % turn .

W

m

7. Tilt the swivel bracket up. Position the port and starboard tilt lock assemblies into position. Install the tilt lock pins @. Apply OMC Nut Lock to the threaded end of the t ilt lock pins and secure with two locknuts @. Tighten the locknuts to 180-240 in. Ibs. (20-27 N·m).

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[ ] ] 8. Apply OMC Triple-Guard grease to the inside and outside of the lower bushing CD and install it into the bottom of the swivel bracket. [ ] ] 9. Apply OMC Gasket Sealing Compound to the outside case of a new lower seal Q). Use a suitable tool and drive the seal into place until flush with the outside surface. Apply OMC Triple-Guard grease to the seal lips.

I1Q]

10. Apply OMC Triple-Guard grease to the inside and outside surfaces ofthe friction block or upper bushing @. If equipped with a friction screw, install the block with the metal plug © facing toward the steering friction screw @. Tighten the friction screw, if equipped, just enough to keep the block in place. Overtightening the friction screw will make installing the steering arm assembly difficult.

[!1]

11. Apply OMC Gasket Sealing Compound to the outside case of a new upper seal @. Use a suitable tool and drive the seal into place until flush with the outside surface. Apply OMC TripleGuard grease to the seal lips.

[!!I

12. Apply a light coat of OMC Triple-Guard grease to the outside of the steering arm assembly @ and thrust washer ®. Place washer onto the assembly. Install the steering arm through the seals, block, and bushing in the swivel bracket. Push down to seat the washer.

38960

M irage/eng

5-19

[JJ

13. Apply a light coat of OMC Triple-Guard grease to thrust washer @ and place it on the lower end of the steering arm. Place the lower motor mount bracket ® onto the steering arm and align the mounting bolt holes.

W

14. Apply OMC Nut Lock to the threaded ends of the two mounting bolts @. Install the two bolts, four flat washers, and two locknuts in the lower motor mount bracket. Tighten the bolts and locknuts to 180-204 in . Ibs. (20-23 N·m). 15. Install the exhaust housing as described in this section.

16. Install the gearcase as described in Section 6. 17. Install the powerhead as described in Section 4.

5-20

Mirage eng

Midsection Adjustments Steering Friction Adjustment

W&

Adjust steering friction with motor mounted to boat by loosening or tightening screw with a screwdriver, as shown . Steering friction should be adjusted so that a slight drag is felt when turning. Minimum friction is required when remote steering is used . The steering friction screw is not intended to allow "hands off" steering. Idle Speed Adjustment

rn The idle speed knob is located on the steering handle. Turning clockwise on the knob increases idle speed, turning counterclockwise decreases idle speed. Make certain that throttle is in slow position and the motor is at normal operating temperature before making the idle speed adjustment. Motor should idle at recommended RPM in gear.

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Safety Related

5-21

Gearcase Table of Contents General Safety Warnings ......................... . Service Specifications ............................ . Water Pump Servicing ........................... . Service Chart .................................. . Gearcase Servicing .............................. . Removal .................................... . Disassembly ................................. . Cleaning and Inspection ........................ . Assembly .................................... . Installation ................................... . Trim Tab Adjustment ............................ . Gearcase Extension Servicing ..................... . Removal .................................... . Disassembly ........................... . ..... . Assembly .................................... . Installation ............ . ...................... .

6666666-

2 3 5 7 8 8 9

6-12 6-13 6-19 6-20 6-21 6-21 6-22 6-22 6-22

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General Safety Warnings

Before working on any part of the gearcase, read the section called Safety at the end of this manual. To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. When using shop air for cleaning or drying parts: • Be sure air supply is regulated to not more than 25 PSI (172 kPa). • Be sure you use appropriate eye protection to avoid personal injury. 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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Service Specifications Special Torque Chart

Torque

Adhesive

Water Pump Screws

60-84 in. Ibs. (7-9 N·m)

Q\IIC Gasket Sealing Compound

Oil Level & Fill/Drain Plug

84-86 in. Ibs. (9-10 N·m)

•

192-216 in. Ibs. (22-25 N·m)

Q\IIC Gasket Sealing Compound

60-84 in. Ibs. (7-9 N·m)

Q\IIC Gasket Sealing Compound

192-216 in. Ibs. (22-25 N·m)

Q\IIC Gasket Sealing Compound

48-84 in . Ibs. (5-9 N·m)

Q\IIC Nut Lock

Description

Gearcase Retaining Screws Propeller Shaft Bearing Housing Screws Gearcase Extension Screws Pivot Pin

Q\IIC Special Tools Required

PIN 331045 391257 330067 330068 327693 335820 321428 335821 319929 304515 322923 326552 328081 383175 318122

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Tool Panel

B C C C N P

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Description

Retaining Ring Pliers Universal Pinion Bearing Remover and Installer Lower Pinion Bearing Spacer Upper Pinion Bearing Spacer Shift Rod Bushing Remover Propeller Housing Rear Bearing Installer Propeller Housing Forward Bearing Installer Propeller Housing Seal Installer Forward Gear Bearing Cup Installer Shift Rod Bushing Installer Driveshaft Bearing Installer Driveshaft Seal Installer Shift Detent Sleeve Guide Pin Plate

6-3

Sealants and Lubricants Required OMC OMC OMC OMC OMC OMC OMC

Adhesive M ™ Gasket Sealing Compound Ultra-HPF'MGearcase Lube Moly Lube Nut Lock Triple-Guard@Grease Needle Bearing Assembly Grease

Service Aids Required Magnetic Tool Gearcase Pressure Tester Gearcase Vacuum Tester

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Water Pump Servicing Disassembly

1. Remove gearcase assembly as described in Gearcase Servicing, this section.

[I]

m

2. Remove and discard seal. 3. Remove the six impeller housing screws.

4. Pull up on the driveshaft and remove the driveshaft with the water pump assembly from the gearcase. Remove the water pump assembly from the driveshaft.

rn

5. Remove the impeller plate ® and gasket @. Discard the gasket. 6. Scrape all gasket material from the plate and gearcase. 7. Remove the water pump grommet, all a-rings, and the shift rod bushing from the impeller housing . 21219

8. Inspect all components for excessive wear. Assembly

W

1. ail and install the shift rod bushing © into the impeller housing.

[[J

2. Apply OIVIC Triple-Guard grease to the two impeller housing a-rings. Install the small, thick shift rod a-ring @. Place the large a-ring ® into the impeller housing .

[ ] ] 3. Lightly coat the exterior of the impeller cup with OMC Gasket Sealing Compound. Align tabs ® of the impeller cup with location holes @ of the impeller housing and install the impeller cup into the impeller housing.

W

4. Lightly coat the impeller cup with oil. Install the impeller into the impeller cup with a counterclockwise rotation. Sharp edge of cam slot in the impeller is leading edge during rotation.

®

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5. Apply OIVIC Adhesive Mto groove of the impeller housing . Install a new seal CD into the groove.

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1 38644

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6. Apply avIC Adhesive M to the groove on the underside of the grommet @. Install grommet onto the impeller housing.

W

7. Lightly oil pinion splines of the driveshaft. Slide the driveshaft through the impeller housing and impeller until drive pin flat of the driveshaft is below the impeller.

W

8. Align drive cam flat with groove of the impeller. Install the impeller drive cam.

rn • driveshaft Sharp edge ® of the cam is leading edge during rotation @. Slide the impeller housing down

38630

the driveshaft. Engage the impeller with the cam .

INote I Verify that the impeller engages the impeller cam properly. Serious powerhead damage will result if impeller cam is displaced.

W

9. Lightly coat both sides of a new impeller plate gasket @ with avIC Gasket Sealing Compound. Place gasket on the gearcase.

W

10. Place the impeller plate

® over the gasket.

[ ] ] 11 . Slide the driveshaft down into the gearcase and engage the pinion.

W

12. Turn the driveshaft until holes ofthe impeller housing are aligned with holes of the gearcase. Place the washers on the six impeller housing screws. Apply avIC Gasket Sealing Compound to the threads of the screws. Install and tighten the screws to 60-84 in . Ibs. (7-9 N·m).

[ [ ] 13. Apply OMC Adhesive M to the bottom of the seal and install it into the slot in the gearcase.

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Service Chart

CD OMC Triple-Guard Grease ® OMC Gasket Sealing Compound ® OMC Adhesive M

o

OMC Moly Lube

® OMC Nut Lock OMC Ultra-HPF Gearcase Lubricant: 11 fl. oz. (330 ml)

CD

®

/

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CD /

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192-216in.lbs.®~/~ 2 /i

~I----====f"

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(22-25 Nom)

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2

®

®

60-84 in. Ibs. (7-9 N.m)

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•

84-86 in. Ibs. (9-10 N.m) _ _ ~

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48-84 in. Ibs. (5-9 N·m)

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6-7

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Gearcase Servicing Removal

In.

1. To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.

2. Mark the trim tab position for reference, then remove the trim tab. Remove the propeller from the gearcase. Inspect the condi tion of t he propeller hub.

[]J

3. Drain the gearcase by first removing the oil level plug @, then the oil fill/drain plug @.

[]J

4. Remove both water intake screens.

INotel Remove any paint from the upper shift rod before disassembling the shift rod connectors.

W 5. Disengage the shift rod using two open-end wrenches. W 6. Remove and discard the upper plastic keeper @. Remove the upper connector @.

[ [ ] 7. Remove the six gearcase to exhaust housing screws @. 8. Remove the gearcase from the exhaust housing and place in a suitable holding fixture.

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Disassembly

[ ] ] 1. Remove the six impeller housing screws. 2. Pull up on the driveshaft and remove the driveshaft with the water pump assembly from the gearcase. Disassemble the water pump assembly from the driveshaft.

[IJ

3. Remove the impeller plate gasket.

® and gasket @. Discard the

[ ] ] 4. Remove the two propeller shaft bearing housing screws.

rn

5. Assemble the following components from OMC Universal Puller, PIN 378103. Remove the propeller shaft bearing housing from the gearcase.

®

PI N 307636 Body PI N 307637 Pressing Screw Q) 2 Screws, %-20 X 6 in. (obtain locally) ® PIN 307639 Flat Washers © PI N 307638 Handle

CD

I1Q]

In.

6. Remove the retaining ring using OMC Retaining Ring Pliers, PIN 331045. The retaining ring is under extreme pressure during removal and installation. Wear safety glasses and proceed with care to avoid unsnapping the ring from the pliers. After the retaining ring is removed far enough from the gearcase to clear the housing, release the tension on the pliers while the retaining ring is still around the propeller shaft.

7. Remove the retainer plate and reverse gear thrust washer from gearcase.

[1IJ

8. Unthread the lower shift rod from the shifter yoke and remove the shift rod from the gearcase. Remove and discard lower plastic keeper ~, then remove the nut @.

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9. Remove the shift yoke with long-nose pliers.

rn 10. Remove the shifter lever pivot pin. Discard the pivot pin O-ring. rn 11. Remove the propeller shaft and reverse gear components from the gearcase. INotel

Shifter detent balls and spring will pop out of the clutch dog when the propeller shaft is removed.

m

12.Using a magnetic tool, locate and remove the two shifter detent balls and one detent spring from the gearcase.

[]J

13. Use long-nose pliers to remove the clutch dog and shifter lever assembly. Use no force . Tilting the shifter lever slightly will allow you to remove it from the gearcase.

W

14. Remove the forward bearing, forward gear, pinion, pinion thrust bearing, and two pinion thrust washers .

6-10

Mirage eng

[I]

15. Use OMC Bearing Puller, PI N 432130, attached to OMC Slide Hammer, PIN 432128, to remove the forward bearing cup. Secure the puller jaws into grooves behind the cup with jaws facing port and starboard. Use OMC Wrench, PIN 334359 @, to hold the puller while tightening the jaws.

[ ] ] 16. Use OMC Puller Bridge, PIN 432127, and OMC Small Puller, PI N 432131, to remove the driveshaft seals from the

gearcase.

\

INotellnspect bearings in place. If a bearing is removed for any reason, it must be replaced.

2 1789

® and bearing sleeve © from the gearcase using the same two tools. Discard the bearing.

[ ] ] 17. Remove the upper driveshaft bearing

ITQ]

18. To remove the pinion bearings, assemble the following components from OMC Universal Pinion Bearing Remover and Installer, PIN 391257:

@ PIN 326582 Rod ® PIN 326583 Pilot Plate ® PIN 326577 Remover and Installer @ %-20 x 1/2 in . Hex Head Screw ® %-20 x 1% in. Hex Head Screw

CD

1 in. 0 .0. Flat Washer

Place the tool in the gearcase. Using a mallet, drive the pinion bearings into the gearcase propeller shaft cavity. Discard the bearings.

[I!]

19. Remove the shift rod bushing as follows:

• Position OMC Shift Rod Bushing Remover, PI N 327693 Q), under the shift rod bushing. • Thread the adapter ® of the universal slide hammer in the slide hammer. Place the adapter through the shift rod bushing © and thread into the remover tool Q). • Remove the handle from the remover tool. Then remove the bushing from the gearcase . • Once the bushing has been removed from the gearcase, examine the bushing for damage. If damaged, replace the bushing . Remove and discard the a-rings and washer from the bushing.

@~~CD

®.

~.-@

10

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6-11

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DR1505

ii

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20. Remove and discard the propeller shaft bearing housing O-ring.

INote I Inspect bearings in place. If a bearing is removed for any reason, it must be replaced.

IJJ 21.

Using OMC Puller Bridge, PI N 432127, and OMC Small Puller, PI N 432131, remove and discard the bearings and two seals from the propeller shaft bearing housing.

Cleaning and Inspection

21795

&.

Replace damaged components. Shift system failure could cause loss of control over direction of engine thrust. 1. Discard all seals, O-rings, gaskets, and clutch dog spring.

&.

2. Clean all gearcase components in solvent and dry with compressed air. To avoid personal injury, wear eye protection and regulate air pressure to not more than 25 PSI (172 kPa). After cleaning, coat all internal components with OMC Ultra-HPF gearcase lube to prevent rusting. 3. Perform the following inspections. • Gearcase housing - all gasket surfaces must be free of gasket material. All threaded holes must be free of corrosion and sealer. • Gearcase anode - if anode has been reduced to twothirds of its original size, it must be replaced. Refer to Section 1 for testing procedure. • Driveshaft - check splines for chips, wear, and cracks. Bearing and gear surfaces must not show signs of metal transfer, corrosion, or discoloration. Severe spline wear might indicate an exhaust housing or gearcase has been distorted by impact damage. • Water intake screen - must be clear. If screen can't be cleaned, it must be replaced. • All internal components - must be visually inspected for signs of wear, distortion, chipping, metal transfer, pitting, galling, and discoloration due to improper lubrication. • Water pump - check impeller for wear, crumbling, and hub bonding. Check liner and wear plate for scoring and distortion .

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6-12

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DR2061

Assembly

INotel

Make no dry assemblies. Lubricate bearings, shafts, and gears with OMC Ultra-HPF gearcase lube.

rn

1. Oil and install a new bearing in aft end of the bearing housing using OMC Bearing Installer, PIN 335820. Press against the lettered side of the bearing to prevent damage to the bearing when installing. Press the bearing into the housing until the tool is seated on the housing.

rn 2. Oil and install a new bearing in the forward end of the bearing housing using OMC Bearing Installer, PIN 321428. Press against the lettered side of the bearing until the tool is seated on the bearing housing.

W

rn

3. Install new seals back to back in aft end ofthe bearing housing using OMC Seal Installer, PI N 335821. Apply OMC Gasket Sealing Compound to the metal casing of the seals before installing. Install the inner seal ® with lip facing into the bearing housing and install the outer seal ® with lip facing away from the bearing housing. Apply OMC Triple-Guard grease to the seal lips after installing .

4. Lightly apply OMC Triple-Guard grease to a new bearing housing a-ring. Place the a-ring in groove ofthe bearing housing.

[]J

5. Oil and install the forward bearing cup © into the gearcase. Use OMC Drive Handle, PI N 311880, and OMC Bearing Cup Installer, PIN 319929. Support nose of gearcase on the floor and seat the cup firmly in the gearcase.

6. Coat the shift rod a-ring with OMC Triple-Guard grease and install in shift rod bushing. [ ] ] 7. Apply OMC Gasket Sealing Compound to the outside diameter of the bushing. Install the bushing and washer @ using OMC Shift Rod Bushing Installer, PI N 304515.

7 COA3319

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6-13

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®@.: @ . @ .. DR2088

IT]

8. Install the pinion bearings using the following components of OMC Universal Pinion Bearing Remover and Installer, PIN 391257, and two tool spacers:

® ® ©

PIN 326582 Rod PI N 326583 Plate PI N 326577 Removerl lnstaller @ %-20 x 1/ 2 in. Screw ® %-20 x 1% in. Screw ® 1 in. Flat Washer @ PIN 330067 Spacer, Short @ PIN 330068 Spacer, Long

4 DR2061

IT] •

Assemble the tools using short spacer, PIN 330067, to install the lower pinion bearing. Press against the bearing's lettered side until washer ® contacts short spacer @.

IT] •

Assemble the tools using long spacer, PIN 330068, to install the upper pinion bearing . Press against the bearing's lettered side until washer ® contacts long spacer

@.

IT]

INotel To ensure accurate bearing location, washer be flat and screw @ must be tight.

® must

DR2062

rn rn 9. Oil and install a new driveshaft bearing CD in the bearing sleeve Q) using OMC Bearing Installer, PI N 322923. Press against the lettered side of the bearing until the tool is seated on the bearing sleeve. Using the same tool attached to OMC Plate, PIN 318122, press the bearing sleeve assembly into the gearcase until the plate contacts the gearcase. Press against the lettered side of the bearing when installing it into the gearcase.

W []]

10. Apply OMC Gasket Sealing Compound to the metal casing ofthe seals. Install new seals back to back in the driveshaft bore using OMC Seal Installer, PI N 326552. Install the inner seal with flush lip ® facing into the gearcase, then the outer seal with extended lip © facing out of the gearcase. Apply OMC Trip leGuard grease to the seal lips after installing.

COA3216

[ ] ] 11 . Coat the forward bearing with oil and place it in the bearing cup. E

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6-14

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7 8 9 DR5939

COA3290

L . . . - - - - L - - - - - - --

----;:C""OS;:::"30== 57=-'

rn 12. Assemble the small pinion thrust washer ~ with the inside chamfered diameter facing the pinion, onto the pinion . Oil and install the thrust bearing @. Install the large thrust washer @ with chamfered outside edge facing up. [ ] ] 13. Using a right angled rod , install the pinion assembly in the gearcase. [ ] ] 14. Place the forward gear into the gearcase.

[IQJ

15. Apply CIVIC Needle Bearing Assembly Grease to clutch dog and shifter cradle. Install the shifter cradle on clutch dog. Grooved end of clutch dog must face forward gear end of the propeller shaft.

[!!]

16. Install the shifter cradle and clutch dog in the gearcase using long-nose pliers.

~

17. Apply CIVIC Triple-Guard grease to a new pivot pin a-ring. Install the a -ring on the pivot pin. Apply CIVIC Nut Lockto threads of the pin. Align hole of the shifter lever with hole in the gearcase. Install and tighten the pivot pin to a torque of 48-84 in. Ibs. (5-9 N·m).

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6-15

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1 26727

26728

11 Wear safety glasses for eye protection. Detent balls can pop out with great force.

OJ

18. Slide ONIC Shift Detent Sleeve, PI N 328081, over the propeller shaft. Align slot in the tool with hole in the propeller shaft.

W

19. Insert one detent ball, then the spring, then the other detent ball. Push down on the ball and slide the tool back until you feel the ball slip into the detent.

rn 20. Install the propeller shaft and detent tool in gearcase: • • • •

Propeller shaft must engage forward bearing. Tool ramps must engage clutch dog ramps. Hold tool firmly against clutch dog. Gently tap propeller shaft with a rawhide mallet to seat detent assembly.

21. Remove detent tool.

W

22. Slide the reverse gear down the propeller shaft and into the gearcase.

W

23. Coat the reverse gear bushing with oil. Slide the bushing down the propeller shaft, seating the bushing into the reverse gear.

W

24. Holding the shifter yoke ® with long-nose pliers, install the yoke at a tilted position, locating top ® of yoke into upper gearcase cavity.

W

25. Engage the shifter yoke hook onto the shifting lever clevis pin in bottom of the gearcase cavity.

&

Safety Related

6-16

6

M ir age/eng

[ ] ] 26. Install a new plastic keeper © and the lower shift rod nut @ onto the lower shift rod @. Apply OMC Triple-Guard grease to threads of lower shift rod. Install the shift rod into gearcase through the water intake opening and engage the shifter yoke. Thread the shift rod into the shifter yoke until the rod bottoms in the yoke. [ ] ] 27. Slide the retainer plate down the propeller shaft and into the gearcase with tab facing down.

rn &

28. Using OMC Retaining Ring Pliers, PI N 331045, install the retaining ring into groove in gearcase with sharp outside edge facing aft. The retaining ring is under extreme pressure during installation . Wear safety glasses and proceed with care to avoid unsnapping the ring from the pliers. Look inside the gearcase and make sure that the ring is seated in groove.

I1Q]

29. Thread one OMC Guide Pin, PI N 383175 retainer plate.

®,

COA3240

into the

[11]

30. Stick the reverse gear thrust washer © to the back side of the propeller shaft bearing housing with OMC Needle Bearing Assembly Grease. COA3309

[]1]

31. Lightly apply OMC Gasket Sealing Compound to the aft support flange of the bearing housing. Align the propeller shaft bearing housing on the guide pin with the word "UP" toward the top .

COA3241

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[I]

32. Using a brass punch and a mallet, seat the bearing housing in the gearcase.

rn 33. Place new O-rings on the bearing housing retaining screws. Apply OMC Gasket Sealing Compound to the O-rings and threads of the screws. 34. Install one screw in the bearing housing. Remove the guide pin and install the second screw. Tighten the screws to a torque of 60-84 in. Ibs. (7-9 N·m).

W

35. Coat the lower driveshaft splines with OMC Ultra-HPF gearcase lubricant. Install the driveshaft into the gearcase with the water pump key end down. Be careful not to damage the seals with the splines. Turn the driveshaft to engage the pinion .

W

36. Pressure and vacuum test the gearcase as follows:

INote I Pressure and vacuum test gearcase before filling . • Remove the oil level plug and install a pressure test gauge. • Hold down firmly on the driveshaft and pump pressure up to 3-6 PSI (21 -41 kPa). If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leakage as evidenced by bubbles. If the gearcase pressure does not indicate leakage, increase pressure to 16-18 PSI (110-124 kPa).lf pressure does not hold, submerge the gearcase in water and check for source of leakage. Make necessary repairs and repeat t he test. • Install a vacuum test. Pump out 3-5 inches (76-127 mm) Hg and see if vacuum holds. Then pump out 15 inches (381 mm) Hg and check. If the gearcase fails to hold on either test, put lubrication around suspected seal. If the leak stops or lubricant is drawn in, that seal is defective. When the gearcase checks out properly, fill the gearcase with OMC Ultra-HPF gearcase lubricant.

6-18

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37. Fill the gearcase with 9-11 fl. oz. (264-330 ml) lubricant as follows: • Secure the gearcase in an upright position. • Remove the oil level and oil fill /drain plugs. Replace the seals if damaged. • Fill the gearcase with OIVIC Ultra-HPF gearcase lube until lubricant appears at the oil level hole. Insert the oil level plug first. Install the fill /drain plug. Tighten the oil level and fill/drain plugs to 84-86 in. Ibs. (9-10 N·m). • Inspect the gearcase oil level after the motor test has been performed. 38. Install water pump assembly as described in Water Pump Servicing, this section. Installation 1. Coat the driveshaft splines with OIVIC Moly Lube. Do not coat top surface of the driveshaft as the lubricant here may prevent seating of the driveshaft in the crankshaft. Coat upper shift rod with OIVIC Triple-Guard grease. 2. Temporarily install the upper shift rod connector on the gearcase lower shift rod. Installation of the gearcase will not allow the upper shift rod connector to be installed at a later time. 3. Install the gearcase onto the exhaust housing. See that the driveshaft engages the crankshaft. Rotate the flywheel, if necessary.

I}]

4. Apply OIVIC Gasket Sealing Compound to the threads of the gearcase retaining screws. Install and tighten the six screws ® to 192-216 in. Ibs. (22-25 N·m) .

[ ] ] 5. Slide the upper connector half © and install the plastic keeper @ .

® onto the upper shift rod

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6-19

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IT]

6. Move the shift lever until the upper shift rod engages the lower shift rod connector. While holding the lower shift rod connector, tighten the upper shift rod connector securely.

W

7. Install the port and starboard water intake screens with water intake holes facing rear of gearcase. Tighten the two screen retaining screws securely.

W

8. Install the propeller as follows: • Apply OMC Triple-Guard grease to entire length of the propeller shaft. • Install the large thrust bushing ® onto the propeller shaft with fish line groove facing gearcase. • Install the propeller. Propeller should seat onto the thrust bushing. • Install the spacer @, engaging the propeller shaft splines. • Install the propeller nut © and tighten to 120 in. Ibs. (14 N·m). Continue to tighten the nut to align next cotter pin hole.

@

• Install and secure the cotter pin @. 9. Install and position the trim tab as referenced during disassembly. Install and tighten the screw to 60-84 in. Ibs. (7-9 N·m). If position is not known, see Trim Tab Adjustment in this section. 10. Adjust the shift lever and neutral start switch.

Trim Tab Adjustment C02385

&.

Improper trim tab adjustment can cause difficult steering.

A propeller will generate steering torque when the propeller shaft is not running parallel to the water's surface. The trim tab is adjustable to compensate for this steering torque.

Important A single trim tab adjustment will relieve steering effort under only one set of speed, motor angle, and load conditions. No single adjustment can relieve steering effort under all speed, motor angle, and load conditions. If the boat pulls to the left or right when its load is evenly distributed, adjust the trim tab as follows:

&

Safety Related

6-20

Mirag e/eng

m•

With the motor shut OFF, loosen the trim tab screw@. If the boat pulled to the right, move the rear of the trim tab slightly to the right. If the boat pulled to the left, move the rear of the trim tab slightly to the left .

• Tighten the trim tab screw to 60-84 in. Ibs. (7-9 N·m) . • Test the boat and, if needed, repeat the procedure until steering effort is as equal as possible. High motor installations - The trim tab might be above the water when the motor is trimmed out. Steering effort might increase. Steering effort will be reduced if you trim the motor in and submerge the trim tab. Dual motors - Move both trim tabs equally and in the same direction.

Gearcase Extension Servicing Removal

&

1. To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. [ ] ] 2. Remove both water intake screens.

[§]

3. Disengage the shift rod using two open-end wrenches.

rn 4. Remove and discard the upper plastic keeper ®. Remove the upper connector @. []J

5. Remove the six gearcase extension to exhaust housing screws. The anti-ventilation plate will not allow the two middle screws ® to be completely removed.

6. Remove the gearcase from the exhaust housing and place in a suitable holding fixture.

Mirage/eng

&

Safety Related

6-21

38648

OJ 7. Remove the last extension mounting bolt ® located in the exhaust passage of the extension. Remove the extension from the exhaust housing. Disassembly

m

1. Remove the spacer assembly @ from the extension.

[ ] ] 2. Remove and discard the grommet

© from

the spacer.

Assembly

rn 1. Install the spacer @ onto the extension. No sealer is required. [ ] ] [ ] ] 2. Apply CIVIC Adhesive M to the groove on the underside of the grommet ©. Install the grommet on top of the spacer @. Installation

IT]

1. Using two of the long extension mounting screws install the extension onto the exhaust housing.

®,

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6-22

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2. Apply OMC Gasket Sealing Compound to the threads of the single shorter mounting screw @. Install the screw into the hole in the exhaust passage of the extension. Tighten the screw to 192-216 in. Ibs. (22-25 N·m). Remove the two alignment screws. 3. Coat the driveshaft splines with OMC Moly Lube. Do not coat top surface of the driveshaft as the lubricant here may prevent seating of the driveshaft in the crankshaft. Coat upper shift rod with OMC Triple-Guard grease. 4. Temporarily install the upper shift rod connector on the gearcase lower shift rod. Installation of the gearcase will not allow the upper shift rod connector to be installed at a later time.

rn 5. Apply OMC Gasket Sealing Compound to two of the long gearcase extension screws. Install these screws into the two middle screw holes ® of the gearcase before the gearcase is installed. Their length will not allow access past the anti-ventilation plate once the gearcase is installed. Install the gearcase onto the extension. See that the driveshaft engages the crankshaft. Rotate the flywheel, if necessary.

m

6. Apply OMC Gasket Sealing Compound to the threads of the two remaining long @ and two short ® gearcase extension retaining screws. Install these screws. Tighten all six screws to 192-216 in. Ibs. (22-25 N·m).

[IQ]

7. Slide the upper connector half CD onto the upper shift rod

Q) and install the plastic keeper @.

lI!1

8. Move the shift lever until the upper shift rod engages the lower shift rod connector. While holding the lower shift rod connector, tighten the upper shift rod connector securely.

[1!]

9. Install the port and starboard water intake screens with water intake holes facing rear of gearcase. Tighten the two screen retaining screws securely. 10. Adjust the shift lever and neutral start switch .

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Manual Starter Table of Contents General Safety Warnings ....... . ......... . ......... Service Specifications .............................. Starter Servicing ................................. Removal ...................................... Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly ................................... Cleaning and Inspection ............... . .......... Assembly ...................................... Installation ....................................

7-2 7-3 7-4 7-4 7-4 7-5 7-5 7-6 7-7

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/1

General Safety Warnings

Before working on any part of the manual starter, read the section called Safety at the end of this manual. Wear safety glasses while servicing the manual starter. To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. When using shop air for cleaning or drying parts: • Be sure air supply is regulated to not more than 25 PSI (172 kPa) • Be sure you use appropriate eye protection to avoid personal injury. 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. To prevent sudden movement when starting engine and possible "man overboard" situations, test the "start-in-gear-prevention" feature before returning engine to customer.

7-2

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Service Specifications Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Description

Starter Retaining Screw Starter Spindle Screw and Nut

In. Lbs.

Ft. Lbs.

N'm

60-84

5-7

7-9

120-145

10-12

14-16 PCE0070

Starter Rope Length _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

59 in. (150 cm) PCE0068

Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OMC Trip/e-Guard® Grease OMC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

PIN

Tool Panel

342682

F

Description

Starter Spring Winder/Installer

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46664

Starter Servicing

m Important

Use PIN 342682, is required.

of

Starter

Spring

Installer

Kit,

Removal

&

1. Avoid accidental starting of engine while servicing; twist and remove all spark plug leads.

W

2. Disconnect low oil lead two-pin connector harness.

W W

® from engine

3. Remove the three starter retaining screws and washers @.

4. Remove powerhead.

link from

lockout cam.

Lift starter from

Rope Replacement

& Wear safety glasses to perform this procedure.

46681

[[] 1. Pull rope out completely and retain pulley in position with stop tool (Kit, PI N 342682). 2. Remove rope from pulley channel, untie knot and remove rope from starter assembly. []] 3. Remove rope from anchor and replace with new rope. Cut new rope 59 in. (150 cm) long. Fuse 1/2 in. (12 mm) of both ends.

m

6 37454

4. Route rope through housing into pulley. Tie knot in rope and install in pulley channel.

5. Hold rope taut and pull stop tool out. Allow rope to slowly wind into starter.

&

Safety Related

7-4

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Disassembly

m

1. To service lockout assembly, remove the retaining pin

©.

[ ] ] 2. Remove the plunger, spring, tappet, and cam from the housing.

& Wear

safety glasses while disassembling and assembling manual starters because of rewind spring tension.

[ ] ] 3. Pull rope out completely and retain pulley in position with stop tool (Kit, PIN 342682). 4. Remove rope from pulley channel, untie knot and remove rope from starter assembly. 5. Remove stop tool and slowly unwind pulley until tension is released . [ [ ] 6. Remove retaining ring, pawl, and linkage.

[!Q] &

7. Remove the starter spindle screw and locknut. Hold the pulley down in housing and lift out spindle. Carefully lift out pulley, leaving spring in housing.

& Do not remove spring with

housing facing up. Do not lift spring out of housing by hand or with pliers. Spring is under tension and will cause injury if accidentally released.

&

8. Keep fingers away from uncoiling spring. Turn starter housing over and jar on bench to remove spring. Cleaning and Inspection 1. Wash metal parts in solvent and dry with compressed air.

2. Inspect the rewind spring for cracked or broken end loops. 3. Inspect the pawl and links for wear. 4. Examine the pulley and starter housing. Look for sharp edges and surfaces that could fray rope. Smooth all rough edges. 5. Inspect lockout parts.

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Assembly

& Wear

safety glasses while disassembling and assembling manual starters because of rewind spring tension .

IT]

1. Install mandrel (Kit, PI N 342682) in vice and place spring around mandrel as shown.

W

2. Place housing over mandrel and route hook end of spring through housing opening.

W

3. Place pulley over mandrel and secure with pulley retainer (taper toward pulley) and left hand thread nut (Kit, PIN 342682).

rn 4. Pull lightly on spring to eliminate slack and turn pulley counterclockwise with handle (Kit, PI N 342682) until spring hook engages pulley hub slot. 5. Turn pulley counterclockwise to pull spring all the way into housing . 6. Allow pulley to slowly unwind until tension is relieved.

W

7. Turn pulley counterclockwise approximately 3% turns until opening for rope in housing aligns with rope channel in pulley. Secure pulley in place with stop tool in pulley and housing holes.

8. Route rope through housing into pulley. Tie knot in rope and place in channel. [ ] ] 9. Hold rope taut and pull stop tool out. Allow rope to slowly wind into starter.

Safety Related

7-6

M irage/eng

!! 10. Remove nut and pulley retainer from mandrel and remove starter assembly.

[1J

11. Install spindle, screw and locknut. Tighten locknut to 120-144 in. Ibs. (14-16 N·m).

[]J

12. Install pawl, linkage, and retaining ring (sharp edge up).

[ [ ] 13. Reinstall lockout cam, tappet, spring, and plunger in housing. Installation

[!Q]

1. Position starter on motor. Connect starter lockout link to

cam.

[II]

2. Reinstall starter screws. Tighten screws to 60-84 in. Ibs. (7-9 N·m).

~

3. Connect low oil light 2-pin connector to engine harness. Secure connector in holder on the power pack.

11 4.

Check operation of starter and starter lockout. Starter should crank motor in NEUTRAL gear. Starter MUST NOT crank motor in FORWARD or REVERSE gear.

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Safety Related

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Electrical System Table of Contents

In.

General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Circuit Check - All Models ... . ............... Starter System Voltage Drop Test . . . . . . . . . . . . . . . . . . . Start Switch Ohmmeter Tests - TE Models. . . . . . . . . . . . Solenoid Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Load Current Draw, Electric Starter ............... Electric Starter Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Charging System . ... .. ............... Charging System Check Chart . .. ................... Running Test, Alternator Output ..................... Stator Resistance Tests . . .. . . . . . . . . . . . . . . . . . . . . . . . Rectifier/Regulator Tests . .. . .................... . . AC Lighting Coil Resistance Tests ............ . ....... Tachometer Circuit Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier/Regulator Service. . . . . . . . . . . . . . . . . . . . . . . . .

8- 2 8- 3 8- 4 8- 6 8- 7 8- 8 8- 8 8- 9 8-16 8-17 8-18 8-19 8-20 8-23 8-24 8-26

Refer to QVIC Accessories Service Manual for battery, battery cable, and System Check service procedures.

Mirage/eng

8-1

In.

General Safety Warnings

Before working on any part of the electrical system, read the section called Safety at the end of this manual. The engine cover is a machinery guard. Use caution when conducting tests on running engines. Do not wear jewelry or loose clothing. Before working on or removing any electrical parts, disconnect the battery cables at the battery to prevent electrical sparks. Before returning the outboard motor to the owner, make sure: • all electrical connections are tight, • insulator boots and sleeves are in place, and • electrical wires are routed and clamped in their original positions. Do not use jumper cables and a booster battery to start engine. Do not charge a battery in the boat with an external charger. Fumes vented during either operation can lead to an explosion. 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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Service Specifications Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

In. Lbs.

Ft. Lbs.

N·m

Adhesive

•

100-105

136-142

OMC Gasket Sealing Compound

Stator to Cylinder Block Screws

84-106

9-12

OMC Nut Lock

Rectifier/Regulator to Cylinder Block Screws

60-84

• •

7-9

•

15-17

20-23

OMC Nut Lock

Description Flywheel Nut

•

Starter Motor to Cylinder Block Screws

No Load Current Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Voltage

Amps (Maximum)

RPM

12 - 12.4

30

6500 - 7500

Stator Resistance Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

12 Amp 0.45 - 0.54

n

Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OMC OMC OMC OMC OMC OMC OMC OMC

Electrical Grease Black Neoprene Dip Starter Pinion Lube Locquic Primer Triple-Guard@Grease Screw Lock Nut Lock Wheel Bearing Grease

OMC Special Tools Required

PIN

Tool Panel

342667 322696

F E

Mirage/eng

Description Connector Tool Crimping Pliers

8-3

Starter Circuit Check - All Models INotel Battery must be fully charged.

Step

II Check voltage and

Procedure

between ground

CD.

In

D

iii -

Steps thru Remove starter to solenoid cable from to prevent starter engagement while making checks.

o

II Check voltage between ground and

0.

Result

Remove black lead from ground at CD. Connect voltmeter between CD and common engine ground. Turn key to START position. Voltmeter should show battery voltage. Connect meter at START position.

0. Turn

key to

INote I Steps fJ thru iii - Turn

Check voltage between ground and@.

iii.

a. If meter reads battery voltage, lead is open between CD and b. If no reading, go to Step

Connect meter at @. Turn key to START position.

between ground

and@.

Connect meter at @. Turn key to START position.

between ground

and@.

Connect meter at @. Turn key to OFF position .

II.

a. If meter reads battery voltage, lead is open between @ and @ or neutral start switch @ is open or improperly adjusted . b. If no reading, go to Step

II Check voltage

II.

a. If meter reads battery voltage, solenoid is faulty. b. If no reading, go to Step

II Check voltage

fJ.

b. If meter reads battery voltage, reconnect black lead to ground and go to Step

0·

key OFF before connecting and disconnecting meter. Turn key to START position after connecting.

D

a. If no reading, go to Step

Ell.

a. If meter reads battery voltage, check key switch. b. If no reading at @, check for open lead or open fuse between @ and @. c. Connect meter at @. If no reading, check for open lead between @ and battery "+" terminal. If meter reads battery voltage, go to Step

IJ.

PCE0054

Safety Related

8-4

Mirage eng

III Check voltage

between ground

and (]).

Connect voltmeter at (]). Turn key to START position.

a. If no reading, solenoid is faulty. b. If solenoid clicks and meter reads battery voltage, go to Step

II.

II Check voltage and@.

between ground

Reconnect starter to solenoid cable at (]). Connect meter at @ . Turn key to START position.

a. If meter reads battery voltage and starter motor does not turn, check starter motor. b. If no reading, check for broken cable or poor connection . PCE0054

+

I

DR C6 169

M irage eng

8-5

Starter System Voltage Drop Test By making a systematic check of the starter system, any component or electrical connection having excessive resistance can be located.

&

Avoid accidental starting of engine while servicing; twist and remove all spark plug leads.

Clean and retighten, or replace, any connection, cable, or component having greater than specified voltage drop. [}] 1. Connect voltmeter positive lead to battery positive post. Connect voltmeter negative lead to starter solenoid positive terminal. Turn key switch to START to crank engine. Voltage reading should not exceed 0.3 volt.

INotel

In Step 2, connect the voltmeter leads only while the engine is cranking, or damage to the voltmeter can occur.

rn 2. Connect voltmeter negative lead to the starter side of the starter solenoid terminal. While cranking engine, connect voltmeter positive lead to starter solenoid opposite terminal. Voltage reading should not exceed 0.2 volt. Remove voltmeter positive lead from starter solenoid and stop cranking engine.

DR4030

W

3. Connect voltmeter positive lead to starter solenoid, starter lead terminal. Connect voltmeter negative lead to starter motor terminal. Turn key switch to START. Voltage reading should not exceed 0.2 volt.

W

4. Connect voltmeter positive lead to battery negative lead common powerhead ground screw. Connect voltmeter negative lead to battery negative post. Turn key switch to START. Voltage reading should not exceed 0.3 volt.

&

Safety Related

8-6

Mirage eng

Start Switch Ohmmeter Tests - TE Models Disconnect the two switch leads from the starter solenoid. Calibrate ohmmeter on appropriate scale. Connect one meter lead to switch yellow/red lead, the other meter lead to switch red lead. Depress switch. Meter should show: • Low reading when the switch is depressed • High reading when the switch is released Replace the start switch if your test results vary.

8-7

Solenoid Tests

INotel

All engine wiring must be disconnected from the solenoid before proceeding with this test.

II]

1. Calibrate ohmmeter on appropriate scale. Connect one lead to terminal @ and the other lead to terminal @. • Ohmmeter should show a high reading. • If ohmmeter shows a low reading, replace the solenoid.

II]

2. With the ohmmeter still connected as described in Step 1, attach a positive battery jumper to terminal © and a negative battery jumper to terminal @. The solenoid should close with an audible click. • Ohmmeter should show a low reading . • If ohmmeter shows a high reading, replace the solenoid.

3. After installing the solenoid, coat all wires and terminals with

CIVIC Black Neoprene Dip.

No Load Current Draw, Electric Starter

INotel

Securely fasten starter in a vise or other suitable fixture before proceeding with this check. 1. Locate a battery rated at 500 CCA (60 amp-hr) or higher that is in good condition and fully charged.

rn

2. Connect a 0-100 amp ammeter in series with a heavy jumper between the battery "+" terminal and the starter "+" terminal.

3. Attach or hold a vibration tachometer, such as a Frahm Reed tachometer, to the starter.

rn

4. Complete the circuit with a heavy jumper between the battery "-" terminal and the starter frame.

5. Monitor the starter RPM and current draw and refer to the chart below for the correct specifications. No Load Current Draw Specifications

Voltage

Amps (Maximum)

RPM

12 - 12.4

30

6500 - 7500 E

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8-8

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Electric Starter Service Removal

INotel

1. Disconnect the battery cables at the battery.

rn rn

2. Disconnect all ground cables and wires from the ground stud @. 3. Disconnect positive battery cable from large post the solenoid.

® on

[!]

4. Disconnect the neutral start switch yellow/red wire © and the ground wire @ from the bottom solenoid posts. Remove red lead from large solenoid terminal @.

[ ] ] 5. Remove the screw ® and ground stud @ securing the electrical bracket to the engine. Move the bracket out of the way.

[]J

6. Remove the top oil reservoir mounting screw@. Move the oil reservoir slightly to allow access to the aft starter motor mounting screw.

rn

7. Remove the two screws ® securing the starter to the engine block. Remove the starter and solenoid assembly from engine.

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8-9

ii

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40092

Disassembly

W W

1. Remove nut securing solenoid strap to starter post.

2. Remove the two screws ® securing bracket and solenoid to starter. Remove bracket and solenoid.

rn 3. Check the end cap and brush holder cap orientation marks for reassembly reference. If there are no marks, make some. Remove the two thru bolts @.

W

4. Remove the brush holder cap. DO NOT lose the brush springs.

[ ] ] 5. Remove end cap and armature assembly from the frame.

W

6. Remove the plastic cover from the Bendix shaft.

8-10

M ir age eng

@

©

I

J

e

o 9 40111

40112

rn

7. Remove retaining ring securing starter Bendix components to shaft using modified needle-nose pliers found in the Powerhead section.

[ [ ] 8. Remove all Bendix components from armature shaft. [ ] ] 9. Remove end cap

© and thrust washer @.

10

Cleaning and Inspection

~

ITQ]

1. Inspect the brushes; replace if damaged, cracked, or one-half worn. Replace brush springs, if weak.

2. Clean the commutator with 300-grade emery cloth. If commutator surface is unevenly worn or pitted, turn it on a lathe. Remove any trace of oil or metal dust from commutator.

I11J IE] 3. Check the armature on a growler for shorted turns. Check for grounding by using a test light or meter. Inspect armature insulation for indications of overheating or damaged windings. Clean off any carbon deposits or foreign matter which may contribute to later windings failure.

[IT]

4. Check permanent magnets. Magnets should strongly attract any steel or iron object held inside frame. Weak magnets could cause excessive RPM on No load Current Draw, Electric Starter test.

M irage/eng

8-11

_ _L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

~~

5. If the pinion does not properly engage the flywheel, the pinion and shaft may be worn, distorted, or dirty. 6. Inspect and replace end cap thrust washer if distorted or worn excessively.

7. Inspect and replace armature shaft snap ring if worn or distorted. Assembly

m

1. Lubricate the armature shaft bearing surface with one drop of SAE No. 10 oil. Lubricate the armature shaft on and above the pinion helix with ave Starter Pinion Lube, PIN 337016. Place thrust washer @ on armature shaft.

rn 2. Place end cap ® onto armature shaft. W

3. Install the Bendix drive components shaft.

© onto the armature

m

4. Install the lower spring holder @ onto the armature shaft, with the recessed end facing the end of the shaft. Install the spring @. Install the upper spring retainer ® onto the shaft, with the deeper recess facing the end of the shaft. 5. Place a small amount of ave Triple-Guard grease on the end of the armature shaft. Snap the retaining ring © into the groove at the end of the armature shaft. Move the upper spring retainer ® into position to cover the retaining ring. Wipe away any excess OVIC Triple-Guard grease.

[]J

m

6. Install the plastic cover onto the armature shaft. Push the cover until it snaps into place.

W

7. Install armature and end frame into starter housing. Align marks on the housing @ and end frame alignment 0·

/Note/lf removed, apply ave Locquic Primer and Lock to the brush card screws before installing.

ave

Screw

7 8-12

40124 M ir age eng

8 401 2 7

[ [ ] 8. Apply OMC Wheel Bearing Grease to the brush holder cap armature bearing. 9. Correctly route the brush leads and install the springs and brushes.

INote I Incorrect

orientation of the brushes cou Id damage the starter or cause reverse rotation .

[ ] ] 10. Compress the brushes and springs with a modified putty knife .

40 128

[lID

11. Align marks Q) and ® and place brush holder cap firmly on armature and slide putty knife out, making sure the brushes are retained properly.

ITIJ

12. Apply OMC Locquic Primer and OMC Screw Lock to the threaded portion, and install the two thru bolts. Tighten to 50-60 in . Ibs. (5,6-9 N·m).

lm [11]

13. Attach solenoid with bracket to starter. Attach solenoid strap CD to starter post. Tighten screws and nut securely. Coat strap, post, and nut with OMC Black Neoprene Dip. 40119

13 4 01 2 0

M irage/eng

8-13

Installation

1. Apply ONIC Locquic Primer and OMC Nut Lock to the threads of the two starter mounting screws.

IT]

2. Position the starter and install the mounting screws @. Tighten to 15-17 ft. Ibs. (20-23 N·m).

rn rn

3. Install top oil reservoir mounting screw. Tighten screw to 6-9 ft. Ibs. (8-12 N·m). 4. Attach electrical connector bracket to the engine and secure with screw@ and ground stud @. Tighten both to 60-84 in. Ibs. (7-9 N·m).

W

5. Attach ground wire @ and yellow/red wire ® from neutral start switch to small posts on the bottom of the solenoid. Tighten nuts securely.

[ [ ] 6. Attach red lead securely.

® to large solenoid post. Tighten nut

W

7. Connect positive battery cable © to large solenoid terminal. Tighten nut securely. Position protective cover ® over the connection.

W

8. Attach two ground leads CD and negative battery cable Q) to ground stud. Tighten nut securely. Coat all finished connections with ONIC Black Neoprene Dip.

8-14

M irage eng

NOTES

Mirage/eng

8-15

Description of Charging System The charging system consists of a battery, a flywheel, an alternator stator, and a rectifier/regulator. The engine's battery can affect the charging system operation. The battery should be of heavy-duty marine construction, should be the correct capacity for the application, and should be in good condition with a normal charge .

[I]

The engine's flywheel contains the permanently charged magnets which provide the energy to power the stator windings. The magnets must be at their original design strength for full alternator output.

1 =::-'

0...-___'_ _ _ _ _ _ _ _ _ _

rn

The alternator stator consists of many windings of wire wrapped around metal laminations. The stator is attached to the ignition plate. The flywheel's magnetic lines of force, cutting through the stator windings, produce alternating current. The stator or its leads could be damaged, which could result in reduced or no alternator output.

rn

The rectifier/regulator changes the stator's alternating current to the direct current used to charge the engine's battery and support the boat's electrical system. The unit also provides full wave regulation of the charging system. An additional circuit, represented by the gray lead, provides a tachometer signal for the Quartach @and 7K tachometers.

8-16

Mirage/eng

Charging System Check Chart

Where to Look Battery

Procedure

Cause 1. Battery defective or worn out 2. Low electrolyte level 3. Terminal connections loose or corroded 4. Excessive electrical load

Wiring

Alternator stator

Rectifier

1. Check condition and charge 2. Add water and recha rge 3. Clean and tighten

Reference

OMC Accessories Service Manual

4. Evaluate accessory loads

1. Connections loose or corroded 2. Stator leads shorted or grounded 3. Circuit wiring grounded

1. Clean and tighten

3. Perform ohmmeter tests

1. Damaged stator windings

1. Perform ohmmeter tests

2. Weak flywheel magnets 3. Damaged stator leads

2. Perform running output tests 3. Perform ohmmeter tests

1. Inoperative rectifier/regulator

1. Perform variable load tests

2. Perform ohmmeter tests

• 2. Page 8-19 3. Page 8-19 1. Page 8-19 2. Page 8-18 3. Page 8-19 1. Page 8-20 PCE0089

Mirage/eng

8-17

12 AMP 14 12 10

",

8

4

-

/ /

6

2

-""'"

~

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I

1000

2000

3000

4000

5000

6000

1 DRC5871

Running Test, Alternator Output

INote I Disconnect

battery cables before proceedin g with this

check. 1. Disconnect the rectifier red lead. 2. Wire a 0-40 amp ammeter in series with the rectifier red lead and the wiring harness red lead .

&.

Guard against any red wire, its terminals, or the ammeter coming in contact with engine ground while the engine is running. Contact may cause arcing.

[IJ

3. The engine's battery should not be fully charged when beginning this test. Connect the battery cables and run the engine in a test tank. Refer to the output curves to determine the correct output-to-RPM ratio for your engine . • If there is no output or the output is not correct, refer to the stator and rectifier ohmmeter tests in this section.

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Safety Related

8-18

Mi r age 'eng

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2

3 DR5882

DR5883

Stator Resistance Tests INotel Disconnect the battery cables before proceeding with this check.

1. Separate the stator yellow and yellow/gray lead's connector.

W

2. Calibrate an ohmmeter on the appropriate scale. Connect one meter lead to the stator yellow lead and the other meter lead to the stator yellow/gray lead. • 12 Amp resistance - 0.45 - 0.54 ohms • Repair or replace the stator if your results vary.

IT]

3. Test for a grounded condition - disconnect both meter leads. Calibrate the ohmmeter on the proper scale. Connect one meter lead to a clean engine ground and the other meter lead alternately to both stator leads. • Ohmmeter should show a high reading.

• If the ohmmeter shows a low reading, the stator or its leads are grounded and should be repaired or replaced. Refer to Ignition Component Service, Section 3.

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8-19

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Rectifier/Regulator Tests Variable Load Tests To test the operation of the rectifier/regulator, you must be able to run the engine continuously at approximately 4500 RPM, such as in a test tank or on a marine dynamometer. The test consists of monitoring the system's response to a partially discharged battery. Two methods for performing this test are described below. Variable Load High Rate Discharge Method

INote I The

rectifier/regulator requires battery voltage from the purple lead to operate. Before proceeding, separate the rectifier/ regulator purple lead bullet connector. Verify battery voltage at the engine harness connector when the key is ON. Reconnect the purple lead bullet connector. 1. Disconnect battery cables.

IJJ

2. Connect a 0-40 amp ammeter in series between the rectifier/regulator red lead and the battery side of the starter solenoid .

3. Reconnect the engine's battery cables.

IJJ 4.

Following the manufacturer's directions, connect the variable load tester (carbon pile) across the battery terminals. Stevens Model No. LB-85 and Snap-on Model No. MT540D are examples of testers available.

11 Excessive

battery discharge rates might overheat battery causing electrolyte gassing. This might create an explosive atmosphere.

rn

5. Start the engine and run it at approximately 4500 RPM. Use the variable load tester to draw the battery down at a rate equivalent to the stator's full output. • The ammeter should indicate nearly full output - 12 amps.

rn

6. Decrease the battery load toward zero amps. • Ammeter should show a reduced output. As the current draw decreases, the battery voltage should stabilize at approximately 14.5 volts. • If your results vary, check the stator's condition before replacing the rectifier/regulator.

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Safety Related

8-20

MlfayC e n g

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® Stator ® Rectifier/Regulator Assembly © Red Wire @ Ammeter (0-40)

® Jumper Wire ® Starter Solenoid @ Red Battery Cable

® Carbon Pile

~®

7

---©

®

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8-21

~

Cranking Discharge Method

1. Check battery voltage. • If voltage is greater than 12.5 volts, go to Step 2. • If voltage is less than 12.5 volts, go to Step 3. 2. Twist the spark plug leads and remove them from the spark plugs. Crank the engine in short bursts until battery voltage is less than 12.5 volts. Check battery voltage with key OFF. 3. Disconnect the battery cables. 4. Connect a 0-40 amp ammeter in series between the rectifier/ regulator red lead and the battery side of the starter solenoid. 5. Reconnect the battery cables and the spark plug leads.

INotel

The rectifier/regulator requires battery voltage from the purple lead to operate. Before proceeding, separate the rectifier/ regulator purple lead bullet connector. Verify battery voltage at the engine harness connector when key is ON . Reconnect the purple lead bullet connector. 6. Start the engine and run it at approximately 4500 RPM. The ammeter should indicate nearly full output - 12 amps. While continuing to run at 4500 RPM, the voltage should stabilize at about 14.5 volts and the alternator output should begin to decrease. • If your results vary, check the stator's condition before replacing the rectifier/regulator.

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8-22

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1 DR5882

DR5883

AC Lighting Coil Resistance Tests

[JJ

1. Calibrate an ohmmeter on appropriate scale. Connect it between yellow/gray ® and yellow ® leads. • Meter must show 1.38 - 1.68

n.

W

2. Calibrate ohmmeter on appropriate scale. Connect one lead to a clean engine ground @. Probe each of the connector pins with the other ohmmeter jumper wire. • The ohmmeter should show a high reading . • If the ohmmeter reading is low, repair the grounded coil lead or replace the stator assembly. Refer to Section 3 for ignition plate servicing.

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8-23

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Tachometer Circuit Tests

Perform the following tests if the tachometer does not operate.

INote I The tachometer circuit is driven by the stator output. Before proceeding, check condition of the stator following Stator Resistance Tests, this section.

Important

Verify that all engine and boat wiring and connectors are in good condition.

INote I Do not energize the primer while performing these tests. 1. Set your peak-reading voltmeter to "POS" and "50". Check voltage at the battery. Use this reading as your reference for battery voltage. 2. Use peak-reading voltmeter to check for battery voltage between the tachometer purple lead black lead ® at the dash with the engine NOT running and the key switch ON.

® and

• If the voltmeter shows battery voltage, go to Step 3. • If the voltmeter shows less than battery voltage, check the purple, purple/red, and black circuits, engine fuse, key switch, and the battery connections. 3. With the engine NOT running and the key switch ON, check for battery voltage between the instrument harness gray lead © and black lead ® at the dash. • If voltmeter shows 0 volts, go to Step 4. • If voltmeter shows any voltage, replace the rectifier/regulator. 4. With the engine running at 1000 RPM, check for voltage between the instrument harness gray lead and black lead ® at the dash.

©

• If voltmeter shows 0 volts, go to Step 5. • If voltmeter shows more than 8 volts, replace the tachometer. 5. Disconnect the purple lead connector @ between engine harness and rectifier/regulator. With the engine NOT running and the key switch ON, check for battery voltage at the engine harness purple lead. • If voltmeter shows battery voltage, replace the rectifier/regulator. • If voltmeter shows NO battery voltage, check instrument harness and engine harness purple and purple/red circuits, engine fuse and key switch.

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8-24

Mirage/eng

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8-25

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::::: ii

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Rectifier/Regulator Service Removal

1. Remove the battery cables from the battery.

[IJ

2. Separate the stator yellow and yellow/gray lead connector

@.

rn

3. Disconnect the engine wiring harness red and gray @ leads' bullet connectors.

®, purple ©,

rn 4. Remove the two screws ® retaining the rectifier/regulator to the cylinder block. Installation

W

1. Position the rectifier/regulator on the cylinder block. Install the two retaining screws ® and tighten to 60-84 in. Ibs. (7-9 N·m).

W

2. Connect the rectifier/regulator red, purple, and gray bullet connectors ®.

W

3. Connect the stator yellow and yellow/gray connector @.

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8-26

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Safety Section Table of Contents Part A Marine Products and the Safety of People Who Use Them . . . . . . . . . . . . . . . . . . . . . Outboard Shift System and Persons Safety. . . . . . . . . . . . Outboard Speed Control System and Persons Safety .... Outboard Steering System and Persons Safety. . . . . . . . . Outboard Fuel, Electrical System and Persons Safety . . . . Outboard Mounting System and Persons Safety. . . . . . . . Outboard Hydraulic Tilt/Trim Shock Absorption System and Persons Safety . . . . . . . . . . . . . . . . . Outboard Emergency Stop System and Persons Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . Part B Marine Products and the Safety of People Who Fix Them. . . . . . . . . . . . . . . . . . . . . . Handling Lead/Acid Batteries ....................... Gasoline! Handle With Care ........................ Hazardous Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S-1

S- 2 S- 3 S- 4 S- 5 S- 7 S-10 S-12 S-13 S-16 S-19 S-20 S-21

Part A Marine Products and the Safety of People Who Use Them Enjoyable boating is the Goal of people who design and build marine products. To reach this Goal, manufacturers are careful to make sure .... •

Product User is Informed .....

•

Products are Safe and Reliable .....

It's up to You, the people who ..... •

Rig Boats

•

Fix Machinery

•

Maintain Equipment .... to Keep the products safe and reliable.

This section talks about safe boating and how You can help make it safe. Some items you may know ..... but others you may not.

First!

A word about parts ..... Plain parts ..... Special parts . .... AU. parts! DO NOT SUBSTITUTE PARTS "They look the same, but . .... are they the same?

Same Size? Same Strength? Same Material? Same Type?

Don't Substitute unless You Know they are the Same in ~ characteristics.

Second!

• • •

Special Locking bolts and nuts are often used to hold steering, shift, and throttle remote control cables to the motor . When you take any motor off a boat, Keep Track of Special Nuts and Bolts. Don't mix with other parts. When motor is returned to boat, Use Only the Special Nuts and Bolts to hold remote Steering, Shift, and Throttle cables to the motor.

S-2

Outboard Shift System and Persons Safety The outboard Shift System starts here at the remote control lever ... ..

and ends here ..... at the propeller.

What's Most Important? When control lever is in "Forward," "Neutral" or "Reverse" position,

Shift linkage must 0 ..- - - - match control lever position. What Could Happen? . I f .....

• If .....

Forward or Reverse

Reverse

. . ... propeller still powered (turning) unknown to operator, or motor will Start in Gear, boat will move suddenly.

..... boat will move Opposite to direction wanted by operator.

How Can Loss of Shift Control be Minimized?

when Rigging or after Servicing

• • ••• •

Read, Understand, and Follow manufacturers Instructions. Follow warnings marked"

& " closely.

Assemble Parts Carefully. Make Adjustments Carefully. Test Your Work. Don't Guess. Make Sure Propeller Does Just What the Operator Wants and Nothing Else. Do Not Shift Gears When Motor is Stopped. Adjustments Can be Lost and Parts Weakened .

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S-3

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Outboard Speed Control System and Persons Safety The outboard Speed Control System starts here at the remote control lever ..... (single lever remote control)

and ends here on the powerhead.

What's Most Important?

powerhead speed must slow down enough to allow operator to shift into Neutral Operator must be able to Stop propeller.

What Could Happen? If Operator can't slow down the motor Or shift into Neutral gear (stop propeller), Operator could panic and lose control of boat. How Can Loss of Speed Control be Minimized? •

Read, Understand, and Follow manufacturers Instructions.

•

Follow warnings marked"

when Rigging or after Servicing

• • • •

&"

closely.

Assemble Parts Carefully Make Adjustment Carefully Test Your Work. Don't Guess. Make Sure Motor Changes Speed Smoothly, Quickly. Make Sure Full Throttle Can be Obtained so Operator Won't Overload Parts.

S-4

Outboard Steering System and Persons Safety The outboard steering system starts here at the steering wheel .....

. . . . . and ends ... ..

What's Most Important?

here at the Trim Tab on the outboard motor .....

The Steering System ..... •

must not come apart

•

must not jam

•

must not be sloppy or loose

What Could Happen? •

I f steering system comes apart, boat might tu rn suddenly and circle ..... persons thrown into water could be hit.

•

If steering jams, operator may not be able to avoid obstacles. Operator could panic.

•

If steering is loose, boat may weave while operator tries to steer a straight course. With some rigs (at high speed) loose steering could lead to loss of boat control.

5-5

How Can Loss of Steering Control be Minimized?

• • •• •••

When Rigging or after Servicing

•

Use a steering system recommended by the motor manufacturer which meets Marine Industry Safety Standards (ABYC). Read, Understand, and ·F ollow manufacturers Instructions.

&"

Follow warnings marked" closely. Assemble Parts Carefully Make Adjustments Carefully Keep Parts Moving Freely .. .. . Lubricate Parts as Shown in Manuals Use the bolts, nuts, and washers supplied with steering attachment kits .... they're a Special Locking Type That Won't Loosen, Rust, or Weaken.

When Transom Mounted steering systems (see picture) are used, check to uncover possible Trouble! During this procedure, steering parts

/

transom mounted steerer

"

-

"

•

Must Not Bind

•

Must Not Touch Other boat, motor or accessory Parts in Transom Area.

Why? A hard blow to the motor's - - gearcase can result in damage to steering parts here

I

,

'. '

- - /"

~ stop

~...---~

to

•

Be aware that Raising or Lowering motor on transom can change a set up which was O.K. earlier. If moved up or down even 1/2 inch, run test again to make sure steering parts are free and clear.

•

Check for Damaged parts .. . .. Blows to the Motor like this

•

Replace damaged parts. If weakened, parts could fail later . ... on the water .... when least expected.

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Outboard Fuel, Electrical System and Persons Safety The Electrical System begins here ..... at the battery .....

The Fuel System starts here at the fuel tank .....

. . . . . and ends here ..... ~_ _~ at the carburetor .. . .. and ends here on the powerhead. What's Important? •

Fuel Leakage must be eliminated.

•

Stray electric sparks must be avoided.

What Could Happen? Gasoline can ignite and burn easily. Gasoline vapors can ignite and explode.

• •

When not boating, fuel leaking in car trunk or van, or a place where portable tank is stored (basement, cottage) could be ignited by any open flame or spark (furnace pilot light, etc.). When boating, fuel leaking under the motor cover could be ignited by a damaged or deteriorated electrical part or loose wire connection making stray sparks.

How Can Fire and Explosion Be Minimized? •

Read, Understand, and Follow manufacturers Instructions.

•

Follow warnings marked"

•

Do not substitute fuel or electrical system parts with other parts which may look the same. Someelectrical parts, like starter motors, are of special design to prevent stray sparks outside their cases. Replace wires, sleeves, boots which are cracked or torn or look in poor condition.

• •

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closely.

Always fill the tank Outside the boat.

When Mixing and Refueling .... . Always Mix gas and oil Outside .. . . .

Fumes are hard to control ..... . . . . . they collect and Hide in the bottom of the boat. To avoid those Static Electric Sparks .....

And remember

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If you use a Funnel .....

Ground (touch) the spout against the tank

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•

After Repair on any part of the fuel system, pressure test engine portion of fuel system as shown: (See Section 2 for testing the fuel tank portion.) Squeeze till bulb feels hard

~::::::iiiiiiiii~~~\ /

I~~I

•

When Storing:

Whenever possible, ... remove Hose from motor And from tank . . . . . . and store arou nd ears of tank.

I f tank cap has an air vent valve, make sure it's closed.

This way gasoline is trapped in tank and not in the hose where it might leak onto the floor if hose deteriorates.

If stored indoors, do not put in room having an appliance with Pilot Light or where electrical appliances or switches (which may spark) will be used. •

When Running:

Carburetor air intake silencer will catch and hold fuel which may Flood into motor if carbu retor float sticks.

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So make sure Silencer and all its Gaskets are on motor And Drain Hose is in place.

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Air silencer mounting Screws are special lock screws. Use only the special Screws.

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•

If electrical parts are replaced or even removed from the motor, check the following: Wire and High Voltage Lead Routing • as shown in service manual away from moving parts which could cut wires or wire insulation away from motor cover latches which can catch and cut insulation from High Voltage spark plug leads.

••

Sleeves, Boots, Shields • in position (to avoid shock hazard) not torn or cracked

Wire Clamps - Tie Straps • position as shown in manuals • use only coated clamps Screws, Nuts, Washers ............- . tighten firmly. They keep clamps in position and ends of wires from sparking • where lockwashers are called for .... . use them.

Spark Plug Boots • not torn or cracked • fully pushed onto spark plug

Spark Plugs • avoid rough handling that could crack Ceramic part of plug. (Sparks may jump across outside of plug.)

40764

•

I n transom area .....

All Connections • clean • Tight (Prevents sparks)

Electrical Cable •

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•

Not rubbing on sharp objects ..... enough slack to allow full turning without pull loads on cable (Prevents Sparks)

• • •

Secure in approved battery box or battery tray. Battery terminals insulated. No strain on cables.

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Outboard Mounting System and Persons Safety

The Mounting System includes --~

______ motor parts """ bo Its, nuts, washers, and

~-...:.----

_ _----- boat's transom

What's Important? Motor must stay in position on boat's transom

What Could Happen?

•

SL . . . I .. . 0 . . . E on transom

Motor may

. . . . . Boat may turn and be hard to steer. •

T . . . I . . . L . . . T on transom . .. Boat may turn

• If motor hits some- ' thing solid and does not stay on the transom, boat ' occupants may be injured from the motor or its parts , entering the boat ..

Motor may and be hard to steer. ... .or boat's transom could break away.

·_-_:_-_-_-~_-_-_-_~-_--_-~"~~+-·--jl--m-in;l

Motor may be lost overboard. Boat may S

How Can Loss of Mounting Be Minimized? •

Read, Understand, and Follow manufacturers mounting Instructions.

•

Follow warnings marked"

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If Boat Plate shows .....

U .S. COAST GUARD CAPACITY IN FORMAn ON _ MAX HP ... . MAX PERSONS MAX WE IGHT

..... use

[§]

Only .....

~------'

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Or Smaller!

•

When Rigging or Fixing any boat .... if transom looks Weak, tell the owner .... . If transom is Curved, motor may come Loose .....

Mount on Flat Surface only. , ~ ..... Use Shims to make surface flat.

/ /

Flat

.&_---..

•

Use Bolts, Nuts, and Washers sent with Motor They're usually Special ..... won't Rust ... or Weaken.

•

I f owner tells you "1 hit something rea lIy hard ..... .

-..~

~~~ -: . "":" . : -::.:...

- - ::- .- -.-

..... High speed blow to lower unit ... or, ..... "1 was backing up ... think motor may have hit the tree ... or something"

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1../ slow, heavy squash to motor .....

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. .. . . look for Damaged Parts and Loosened Nuts and Bolts in both the Steering and Mounting Systems. Replace damaged parts.

l \1 weakened, parts could fail later . . . . . on the water . . . . . when not expected.

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Outboard Hydraulic Tilt/Trim Shock Absorption System and Persons Safety What' s Important? •

Shock Absorption system must always be ready to Absorb some Blows to the lower parts of the motor.

•

Motor must not Trim "In"

~~uuu: ____ '_~_

too far Suddenly

What Can Happen? •

Without Shock protection,a Blow like this could cause serious damage to the motor and injury to boat occupants from the motor or its parts entering the boat ... . or Transom could break away .... Motor may be lost overboard, .... and Boat may .. .. S n

k

•

At high boat speeds, Sudden trimming "in" too far and boat may dive under water or spin around.

How Can Possible Conditions Be Minimized? •

Read, Understand, and Follow manufacturers Instructions.

•

Follow warnings marked"

• •

Test your work whenever Possible. If oil Leaks seen in area, determine Source. Keep reservoir filled. If motor is Hydraulic Tilt/Trim Model,

•

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closely. Trimming "I n" too Far can happen when Angle Adjusting Rod isn 't in the Right hole ... Or is Not in Any H~ . (Lost)

Always return Rod to Hole Position determined earlier by Boat Operator . .. and make sure Angle Adjusting Rod Retainer is in locked position.

S- 12

Outboard Emergency Stop System and Persons Safety

the Emergency Stop system begins here at the Buckle ... ..

. . . here in the ignition system on the power head . . ..

,----,.",,~~~ What's Most Important? The Emergency System ..... •

must STOP the engine when the emergency stop switch's cap is pulled from switch .

What Could Happen? •

Ifswitchfails .. .. .

. . . . engine will keep running when cap is pulled from switch . •

If lanyard is caught ....

. .. engine will keep running.

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•

If lanyard is cut or frayed . .. ~ ,..-==::::-.

. . . lanyard or cap may break when pu lied .. . .

and engine will continue running.

~--- ...........

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If engine does NOT stop when lanyard is ;/)' an operator thrown from boat could be hit as ~ ~ boat circles area .. . . or boat may not turn but ---. ~ leave area as a runaway . .. . operator may drown and boat WI LL run into something.

•

How can failure of the Emergency Stop system be minimized? •

Read , Understand, and Follow manufacturers Instr uctions.

•

Follow warnings marked

When Rigging or after Servicing

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closely.

•

Assemb Ie parts carefu Ily

•

Inspect lanyard for cuts or fraying, rubber cap for wear. Replace with orig inal parts. Do not substitute.

•

Locate control box and other items in area to keep lanya rd from being caught.

•

ALWAYS TEST EM ERGENCY STOP SYSTEM. PULL LANYARD. ENGIN E MUST STOP. IF IT DOESN 'T, REPAIR BEFORE NEXT USE .

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Summing Up Now You know some things that can take the Joy out of enjoyable boating . No doubt about it ... . . It Takes Time!

~ Reading and Understanding Instructions,

~

Re-Reading Warnings Marked"

~

Putting Parts Together Right.

~

Making Adjustments Right,

~

Testing Your Work,

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and making sure

~ Worn or Damaged Parts are Replaced,

~

Replaced Parts are Like Originals ..... in Every Way,

~

Customer is Told of Things Which Need Attention .....

But, Do You Really Want the Alternative?

S-15

Part B Marine Products and the Safety of People*Who Fix Them Part A talked about Safe boating and how You, the mechanic, can help keep it Safe for the boater. But What About You? Mechanics Can be Hurt While .... .

~

~ Fixing Things

Rigging Boats ~ Trouble Shooting Problems

~ Testing Their Work

Some items you'll know ... . . others you may not.

Handling Motors When Lifting Motors

•

Some motors have a fixed lift bracket bolted to the powerhead. Because motor will want to "'"

~

Center of gravity-.........;;.,. •

•

hang like this when lifted off the floor ..... Stand Clear! It might hit you as it swings.

If motor does not have fixed lift bracket and you use Universal Puller (378103) and Lifting Eye (321537) or Lifting Eye and Adapter Assembly (396748) .... use only the special hardened screws and washers from the set. . .... use only the special hardened screws and washers from the set. . .. Regular screws aren't strong enough. Screws may Break and motor may drop suddenly.

Motor may also Drop suddenly if Hoist or Motor Stand are in Poor shape .... or Too small -for the job 300lbs

•

Make sure Shop Aids have Extra Capacity .. . . ... ... and keep them in Good Repair!

*Mechanics, Technicians, backyard do-it-yourselfers.

S- 16

Running Motor with Motor Cover Removed •

Motor Cover is a Guard. When you remove Cover/Guard to work on motor remember ..... Loose Clothing (open shirt sleeves, neckties) ..... Long hair .... . Jewelry (rings, watches, bracelets) . . .. . Hands and arms .... .

. . . . . can be Caught by the spinning Flywheel. Handling High Voltage Parts like spark plugs and coils can shock ~rt'r"'---- you . ... may cause you to recoil into the flywheel

•

Two People working together on a Live Motor must Look Out for each other. Never, Ever, hit the Key to Start Motor Before signaling your Partner. He may be leaning over the motor with hands on flywheel .. . . or a "hot" electrical part ..... or near the propeller.

Motors Starting at the Wrong Time •

When you do things that turn the Flywheel like

~ Off-Season Storage Fogging (oiling) of motor

~ Removing propeller with a powered tool

~ Electrical system checks ~ Servicing the flywheel ~ Or? ? ?

•

Always .... . Turn Key Switch "Off"

•

NO SPARK

Shift to Neutral Twist and remove ALL spark plug leads

NO START

S-17

shaft . .... is motor really in Neutral? NO SURPRISES

Running Motors Too Fast (Overspeeding) "Too Fast" means faster than motor normally runs on the Boat .. . . . • Running Too Fast can happen when . .. .. . . . . . using a Flushing Kit .. . ..

•

•

. .. . ... .. . . Turn on water Before starting motor and Keep motor Speed beiow 2000 RPM ... . . with no load, motor will run Too Fast very easily .. .. . and wear Ear Protectors .

running motor w ith the Wrong Test Wheel ... . .

. .... so use the

This may happen if motor runs Too Fast . ....

Right test wheel

Running Motors: Exhaust Fumes Exhaust Gases of running Motors contain Carbon Monoxide . .. . . you can't See it ... . . you can't Smell it .. . .. you can't Taste it ... but It' s There whenever a motor Runs ... . And It's Deadly! When you smell the Other gases in the Exhaust, You are inhaling Carbon Monoxide. Run motors only in Well Ventilated areas.

Eyes need Help

,~ -.

~Sprayed

'~~ :~ ' .\~IJ-\ ,

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Cleaners, Paints

~Grinding

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~Chiseling (Steel on Steel) (Tip: Use Plastic or Brass type Hammers. They don't chip off as easily as steel hammer.)

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Protect Eyes ..... Wear Safety Glasses

~ Ends of Cables

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Handling Lead/Acid Batteries

~ If spilled or splashed on Any part of Body .....

Wash with lots of Water .. ... Wash . ... . . And contact a Doctor, Fast! Charging lead Acid Batteries

(1) Attach and remove these cables with charger UNPLUGGED from 110 volt wall socket. (Prevents shocks if the charger is defective.) (2) Observe correct polarity when connecting these charger Leads. (3) Always charge in a well ventilated area. Charging causes acid solution to give off Hydrogen gas thru the Vents in the Caps .. . .. Make sure Vents are open. If :~. . . . . .".~~~---­ clogged , pressure inside may build . .. battery may EXPLODE. Battery Gas is Explosive! While Charging or Discharging, remember . .. . . Never remove charger cables from battery posts ... it's a sure way to make lots of sparks . . . surrounded by Battery Gas.

No Smoking No Flames No Sparks

Don't check battery charge by placing metal objects across posts

After Charging ( 1) Shut Off charger

You're sure to make Sparks and serious Burns are possible.

(2) Pull charger Plug out of 110V outlet . .. Then, (3) Take charger Cables off battery Posts

S-19

Gasoline! Handle With Care Gasoline vapor and air mixtures explode easily and violently when mixed as shown ....... .. .

1 Part Gasoline

When you smell ANY odor of gasoline, explosion is possible

•

Gasoline fumes are heavy and will sink to the lowest point in the boat or room ..... and will Stay there ..... Waiting

t

20 Parts Air

By Volume

I

!GAS FUMES

If the air around you is quiet. .. .. the pilot light in the heater may ignite the heavy fumes ..... before you r nose ever smells the fumes

What Can You Do?

Store in sturdy, approved sealed Gas Can ..... and ..... Keep Outside

• • • •

Always store gasoline outside in a safety can (flame arrester and pressure relief valve in pour spout). Fill portable tanks outside of boat. Spillage will collect in bottom of boat. Use fuel for Fuel ..... Not for a cleaner, degreaser If Fumes are Smelled in shop, basement or garage, Immediately .. . .. ~ Put Out open flames, cigarettes, sparking devices ~ Wipe up spill or leak. ~ Get towels, rags Outside Fast ~ Open doors or windows ~ Check Lowest area for fumes.

•

Know Items I n and Around repair area which can Ignite gasoline fumes ..... Control them if fumes are smelled.

~ ~ ~ ~

Matches, Cigarettes, Blow Torches, Welders Electric Motors (with unsealed cases) Electric Generators (with unsealed cases) Light Switches

~ Appliance Pilot Lights or electronic ignitors (furnace, dryer, water heaters)

~ Loose Wires on Running Motors

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How Many of These are in Your Area?

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Hazardous Products

~_~

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:::..---

-------::::::

--

ADDITIVE

AD~ESIVE

DANGER ---- -

--::::

~

Know How items in the Shop can hurt people . ... .

...."

•

Read

~ "How and Where to Use,"

~ ~

"How to give First Aid." Have "recommended " first aid materials on hand - should an emergency arise, "How to Dispose of Can."

It's All on the back of the Can or Bottle label. And remember ..... little children are very curious and will try to taste everything, so .... .

Keep Containers Away From Children . . . .. mummmmmmmm

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3 CYLINDER 25,35 REMOTE TNT

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I DRC7060

-

FUEL

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1 1

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PULSE

25/35 FUEL FLOW

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DRC7396

3 CYINDER 25, 35 ROPE

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DRC7057

3 CYLINDER 25,35 REMOTE

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DRC7059

3 CYLINDER 25, 35 TILLER ELECTRIC

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Special Equipment Ordering Information Some tools and equipment demonstrated in this manual are only available directly from the manufacturer. Use the following addresses when ordering: OTC 28635 MOUND ROAD WARREN MI 48092 1-800-533-0492 or 1-800-533-5338

MERC-O-TRONIC INSTRUMENTS CORPORATION 215 BRANCH STREET ALMONT MI 48003 (810) 798-8555

MEYER ENGINEERING COMPANY 1139 N LEWIS AVENUE WINTHROP HARBOR IL 60096 (847) 746-1500

STEVENS INSTRUMENT COMPANY POBOX 193 WAUKEGAN IL 60079 (847) 336-9375

Do not order this equipment from Outboard Marine Corporation. Contact the above manufacturers for pricing and ordering information.

Order OMC Service Tools from OMC® Genuine Parts.

irc 5/97

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